Toyota Tercel Sistema de Aire Acondicionado PDF

AC-1
AIR CONDITIONING SYSTEM

AC-2
AIR CONDITIONING SYSTEM - GENERAL DESCRIPTION
GENERAL DESCRIPTION
NEW AIR CONDITIONING SYSTEM WITH
R134a
Refrigerant R12(CFC12), previously used in automo-
bile air conditioning systems is believed to contribute
towards the depletion the earths ozone layer. The
ozone layer help to protect us against the harmful
ultraviolet rays of the sun.
A newly developed refrigerant, R134a (HFC 134a),

does not the destroy the ozone layer.
AN1-M
PRECAUTIONS FOR SERVICING R134a AIR

CONDITIONINGS
1. USE OF NEW REFRIGERANT R134a
The very different characteristics of refrigerants
R134a and R12 have determined the design of their
respective air conditioning systems. Under no circum-
stances allow R12 to enter an R134a system, or vice
versa, because serious damage could occur.
2. USE OF PROPER COMPRESSOR OIL

Compressor oil used in conventional R12 air condi-
tioning systems cannot be used in R134a air condi-
tioning systems.
Always use genuine Toyota R134a air conditioning oil
ND - OIL 9, made expressly for use with R134a.
If even a small amount of the wrong oil is changed, it

will result in clouding of the refrigerant.
A large amount will cause the compressor to seize up.
AC-3
3. USE OF PROPER O-RINGS AND SEALS

O-rings and seals used for conventional R12 air
conditioning systems cannot be used for R134a air
conditioning systems.
Always use genuine Toyota R134a system O-rings
and seals for R134a air conditioning systems.
If O-rings and/or seals for R12 air conditioning sys-

tems are used by mistake in the connections of an R
134a air conditioning system, the O-ring and seals
will foam and swell resulting in leakage of refrigerant.
4. TIGHTEN CONNECTING PARTS SECURELY

Securely tighten the connecting parts to prevent leak-
ing of refrigerant gas.
Apply a few drops of compressor oil to O-ring
fittings for easy tightening and to prevent leaking
of refrigerant gas.
CAUTION: Apply only ND-OIL 9 compressor oil
Tighten the nuts using 2 wrenches to avoid twist-
ing the tube.
Tighten the O-ring fittings or the bolted type
fittings to the specified torque.
5. INSERT PLUG IMMEDIATELY IN DISCONNECTED
PARTS
Insert a plug immediately in the disconnected parts to
prevent the ingress of moisture and dust.
6. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL
IMMEDIATELY BEFORE INSTALLATION
7. WHEN DISCONNECTING THE PLUG, TAKE CARE

SO THAT OIL WILL NOT AGAIN
AC-4
SERVICE TOOLS FOR R134a AIR

CONDITIONING
When servicing R134a air conditioning systems
always use the R134a dedicated manifold gauges, gas
leak detector and vacuum pump adaptor.
1. USE MANIFOLD GAUGES FOR R134a AIR CONDI-

TIONING
Always use R134a dedicated manifold gauges to pre-
vent R12 and R12 compressor oil contaminating the
R134a system.
2. USE R134a GAS LEAK DETECTOR

Similarly, always use an R134a dedicated leak detec-
tor. The R12 leak detector is not sufficiently sensitive.
3. USE VACUUM PUMP ADAPTER

By connecting a vacuum pump adapter, the vacuum
pump can be used for both R134a and R12 air conditioning
systems.
The vacuum pump adaptor has an internal magnetic
valve.
When evacuation is completed and the vacuum pump
switch is turned off, the magnetic valve opens allow.
ing the introduction of atmospheric air into the manifold
gauges to prevent the back flow of oil from the
vacuum pump into the gauge hose.
CAUTION:
Be sure to turn off the manifold gauge valve immediately
after evacuating the system. Then you may switch off
the vacuum pump. If this order is reversed, the line wilI
be temporarily open to atmosphere.
AC-5
HANDLING PRECAUTIONS FOR

REFRIGERANT
1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED
AREA OR NEAR AN OPEN FLAME
2. ALWAYS WEAR EYE PROTECTION
3. BE CAREFUL THAT LIQUID REFRIGERANT DOES

NOT GET IN YOUR EYES OR ON YOUR SKIN
If liquid refrigerant gets in your eyes or on your skin:
(a) Wash the area with lots of cool water.
CAUTION: Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) GO immediately to a physician or hospital for profes-
sional treatment.
HANDLING PRECAUTIONS FOR

REFRIGERANT CONTAINER
1. NEVER HEAT CONTAINER OR EXPOSE IT TO
NAKED FLAME
2. BE CAREFUL NOT TO DROP CONTAINER AND NOT
TO APPLY PHYSICAL SHOCKS TO IT
CHARGING AND LEAK-CHECK METHODS

Evacuate the refrigeration system according to the
following procedures.
10 min. Leave for 5 min.
Start Stop Airtight Refrigerant Gas Leak Refrigerant

Evacuation Evacuation Check Charge Check Charge
Check and correct Fill refrigerant in gas state until

pipe joints gauge pressure reads 1 kg/cm2
Abnormal indication of
manifold gauges
AC-6
CAUTION:
Be sure to connect both the high and low pressure
quick-connectors onto the A/C system when eva-
cuating. If only one side is connected, the system
would be open to atmosphere through the other
connector, making it impossible to maintain
vacuum.
Be sure to turn off the manifold gauge valve imme-
diately after evacuating the system. Then you may
switch off the vacuum pump.
PRECAUTIONS WHEN CHARGING
REFRIGERANT
1. DO NOT OPERATE COMPRESSOR WITHOUT
ENOUGH REFRIGERANT IN REFRIGERANT CYCLE
If there is not enough refrigerant in the refrigerant
system, oil lubrication will be insufficient and com-
pressor burnout may occur, so take care to avoid this.
2. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE
WHILST COMPRESSOR IS OPERATING
If the high pressure valve is opened, refrigerant flows
in the reverse direction and could cause the charging
cylinder to rupture, so open and close the low pres-
sure valve only.
3. BE CAREFUL NOT TO OVERCHARGE WITH RE-
FRIGERANT IN SYSTEM
If refrigerant is overcharged, it causes problems such
as insufficient cooling, poor fuel economy, engine
overheating etc.
ELECTRICAL PARTS
Before removing and inspecting the electrical parts,
set the ignition switch to the LOCK position and
disconnect the negative (-) terminal cable from bat-
tery.
CAUTION: Work must be started after 90 seconds from
the time the ignition switch is turned to the LOCK
position and the negative (-) terminal cable is discon-
nected from the battery.
AC-7
SUPPLEMENTAL RESTRAINT SYSTEM

(SRS)
Failure to carry out service operations in the correct
sequence could cause the airbag system to deploy,
possibly leading to a serious accident.
During removal or installation of the parts and the
yellow wire harness and connector for the airbag is
necessary, refer to the precautionary notices in the RS
section before performing the operation.
AC-8
AIR CONDITIONING SYSTEM - DESCRIPTION
DESCRIPTION
PARTS LOCATION
AC-9
WIRING DIAGRAM
USA
AC-10
Canada
AC-1 1
DAMPERS POSITION
AC-12
AIR CONDITIONING SYSTEM - PREPARATION
PREPARATION
SST (SPECIAL SERVICE TOOLS)
07110-58060 Air Conditioner Service Tool Set
(07117-58060) Refrigerant Drain Service Valve
(07117-58070) T-Joint
(07117-58080) Quick Coupler Discharge (diam. 16 mm)
(07117-58090) Quick Coupler Suction (diam. 13 mm)
(07117-78050) Refrigerant Charging Gauge
(07117-88060) Refrigerant Charging Hose Discharge (Red)
(07117-88070) Refrigerant Charging Hose Suction (Blue)
(07117-88080) Refrigerant Charging Hose Utility (Green)
07112-66040 Magnetic Clutch Remover
07112-76060 Magnetic Clutch Stopper
07114-84020 Snap Ring Pliers
07116-38360 Gas Leak Detector Assembly

AC-13
AIR CONDITIONING SYSTEM - PREPARATION
RECOMMENDED TOOLS
09082-00050 TOYOTA Electrical Tester Set
LUBRICANT
Item Capacity Classification
Compressor oil ND-OIL 8
When replacing receiver 10 cc (2.9 fl.oz.)
When replacing condenser 40 cc (1.4 fl.oz.)
When replacing evaporator 40 cc (1.4 fl.oz.)
When replacing compressor 120 cc (4.1 fl.oz.)
AC-14
AIR CONDITIONING SYSTEM - USE OF MANIFOLD GAUGE SET
USE OF MANIFOLD GAUGE SET

MANIFOLD GAUGE SET INSTALLATION
1. CONNECT CHARGING HOSES TO MANIFOLD
GAUGE SET
Tighten the nuts by hand.
CAUTION: Do not connect the wrong hoses.
2. CONNECT QUICK CONNECTORS TO CHARGING
HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD
GAUGE SET
4. REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINE
5. CONNECT QUICK CONNECTORS TO SERVICE

VALVES
HINT: Push the quick connector onto the service
valve, then slide the sleeve of the quick connector
downward to lock it.
MANIFOLD GAUGE SET REMOVAL

1. CLOSE BOTH HAND VALVES OF MANIFOLD
GAUGE SET
2. DISCONNECT QUICK CONNECTORS. FROM SER-
VICE VALVES ON REFRIGERANT LINE
HINT: Slide the sleeve of the quick connector upward
to unlock the connector and remove it from the ser-
vice valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIG-
ERANT LINE
AC-15
AIR CONDITIONING SYSTEM - TROUBLESHOOTING
TROUBLESHOOTING
You will find the troubles easier using the table well shown below. In this table, each number
shows the priority of causes in troubles. Check each part in order. If necessary, replace these
parts.
AC-22
AC-61
AC-51
AC-23
AC-64
AC-46
AC-47
AC-52
AC-54
AC-55
AC-54
AC-55
See Page
Inspect cooling system for refrigerant

Inspect A/C control lever adjustment
Blower speed control switch
Condenser fan relay No. 2
Condenser fan relay No. 3

Inspect engine coolant volume
Part Name
Radiator fan main relay

Inspect volume of refrigerant
Condenser fan motor

Condenser fan fuse
Inspect drive belt tension
Inspect outlet air control
Heater main relay
Blower resistor
Blower motor
Trouble
No blower operation
No air temperature control
No compressor operation
Compressor operates immediately
No condenser fan operation
No cool air cones out
Cool air comes out immediately
Cool air comes out only at high

engine rpm
Insufficient cooling
No engine idle up when A/C

switch on
No warm air comes out

AC-16
High pressure switch AC-60
Engine coolant temperature switch
Inspect refrigerant lines
Compressor AC-34
Magnetic clutch AC-34
Condenser AC-42
AIR CONDITIONING SYSTEM

Receiver AC-41
Evaporator AC-44
Expansion valve AC-48
Inspect refrigeration control
A/C fuse
-
A/C switch AC-63
TROUBLESHOOTING
Magnetic clutch relay AC-53
Dual pressure switch AC-60
Thermistor AC-57
A/C amplifier AC-66
Wiring and wiring connections
Vacuum switching valve (VSV) AC-49
Heater radiator
AC-17
REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET

This is a method in which the trouble is located by using a manifold gauge set.
(See USE OF MANIFOLD GAUGE SET on page AC-14 )
Read the manifold gauge pressure when the following conditions are established:
(a) Temperature at the air inlet with the switch set at RECIRC is 30 - 35C (86 - 95F)
(b) Engine running at 1,500 rpm
(c) Blower speed control switch set at high
(d) Temperature control set at max. cool
HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature
conditions.
1. NORMALLY FUNCTIONING REFRIGERATION SYSTEM
Gauge reading:
Low pressure side:
0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm2)
High pressure side:
1.37 - 1.57 MPa (14 - 16 kgf/cm2)
AC-18
2. MOISTURE PRESENT IN REFRIGERATION SYSTEM
Condition: Periodically cools and then fails to cool
Symptom seen in
Probable cause Diagnosis Remedy
refrigeration system
During operation, pres- Moisture entered in re- Drier in oversaturated (1) Replace receiver/drier
sure on low pressure frigeration system state (2) Remove moisture in
side sometimes freezes at expansion cycle through repeat-
becomes a vacuum valve orifice and tempo- Moisture in refrigeration edly evacuating air
and sometimes normal rarily stops cycle, but system freezes at expan- (3) Charge new refrigerant
normal state is restored sion valve orifice and to proper amount
after a time when the ice blocks circulation of re-
melts frigerant
3. INSUFFICIENT REFRIGERANT
Condition: Insufficient cooling
Symptom seen in
Pressure low on both Gas leakage at some Insufficient refrigerant (1) Check for gas leak-
low and high pressure place in refrigeration in system age with leak detector
sides system and repair if necessary
Bubbles seen in sight Refrigerant leaking (2) Charge refrigerant to
glass continuously proper amount
Insufficient cooling (3) If pressure indicated
performance value is near 0 when
connected to gauge,
create the vacuum
after inspecting and
repairing the location
of the leak
AC-19
4. POOR CIRCULATION OF REFRIGERANT
Symptom seen in
Pressure low on both Refrigerant flow ob- Receiver clogged Replace receiver
low and high pressure structed by dirt in re-
sides ceiver
Frost on tubes from
receiver to unit
5. REFRIGERANT DOES NOT CIRCULATE
Condition: Does not cool (Cools from time to time in some cases)
Symptom seen in
Vacuum indicated on Refrigerant flow ob- Refrigerant does not cir- (1) Check heat sensing
low pressure side, very structed by moisture or culate tube, expansion valve
low pressure indicated dirt in refrigeration sys- and EPR
on high pressure side tem (2) Clean out dirt in expan-
Frost or dew seen on Refrigerant flow ob- sion valve by blowing
piping before and after structed by gas leakage with air
receiver/drier or expan- from expansion valve If not able to remove
sion valve heat sensing tube dirt, replace expansion
valve
(3) Replace receiver
(4) Evacuate air and
charge new refrigerant
to proper amount.
For gas leakage from
heat sensing tube, re-
place expansion valve.
AC-20
6. REFRIGERANT OVERCHARGE OR INSUFFICIENT COOLING OF CONDENSER
Condition: Does not cool sufficiently
Symptom seen in
Pressure too high on Unable to develop suffi- Excessive refrigerant in (1) Clean condenser
both low and high cient performance due to cycle refrigerant over- (2) Check fan motor oper-
pressure sides excessive refrigerant in charged ation
No air bubbles seen system Condenser cooling insuf- (3) !f (1) and (2) are in nor-
through the sight glass Insufficient cooling of ficient condenser fins mal state, check
even when the engine condenser clogged or fan motor amount of refrigerant
rpm is lowered. faulty Charge proper amount
of refrigerant
7. AIR PRESENT IN REFRIGERATION SYSTEM
Condition: Does not cool down sufficiently
NOTE: These gauge indications are shown when the re-

frigeration system has been opened and the refrig-
erant charged without vacuum purging.
Symptom seen in
Pressure too high on Air entered in refrigera- Air present in refrigera- (1) Check compressor oil
both low and high tion system tion system to see if dirty or insuffi-
pressure sides cient
The low pressure piping Insufficient vacuum (2) Evacuate air and
is hot to the touch purging charge new refrigerant
Bubbles seen insight
glass
AC-21
8. EXPANSION VALVE IMPROPERLY

MOUNTED/HEAT SENSING TUBE DEFECTIVE
(OPENS TOO WIDE)
Symptom seen in ^
refrigeration system Probable cause Diagnosis Remedy
Pressure too high on Trouble in expansion Excessive refrigerant in (1) Check heat sensing
both low and high valve or heat sensing low pressure piping tube installed condition
pressure sides tube not installed cor- (2) If (1) is normal, check
Frost or large amount rectly Expansion valve opened expansion valve
of dew on piping on low too wide Replace if defective
pressure side
9. DEFECTIVE COMPRESSION COMPRESSOR
Condition: Does not cooI
Symptom seen in
refrigeration system Probable cause Diagnosis Remedy
Pressure too high on Internal leak in compres- Compression defective Repair or replace com-
low pressure side sor pressor
Pressure too low on
Valve leaking or broken,
high pressure side
sliding parts
AC-22
AIR CONDITIONING SYSTEM - REFRIGERANT VOLUME
REFRIGERANT VOLUME
REFRIGERANT VOLUME INSPECTION
1. RUN ENGINE AT APPROX. 1,500 RPM
2. SET TEMPERATURE CONTROL AT MAX. COOL
3. SET BLOWER SWITCH AT HI
4. SET AIR INLET CONTROL AT RECIRC
5. TURN A/C SWITCH ON
6. FULLY OPEN DOORS
7. INSPECT AMOUNT OF REFRIGERANT
Observe the sight glass on the liquid tube.
Item Symptom Amount of refrigerant Remedy

(1) Check for gas leakage with gas leak
tester and repair if necessary
Bubbles present in sight glass Insufficient* (2) Add refrigerant until bubbles disap-
pear
No bubbles present in sight glass None, sufficient or too much Refer to items 3 and 4
(1) Check for gas leakage with gas leak
No temperature difference between tester and repair if necessary
compressor inlet and outlet Empty or nearly empty (2) Add refrigerant until bubbles disap-
pear
Temperature between compressor inlet

and outlet is noticeably different Correct or too much Refer to items 5 and 6
Immediately after air conditioning is (1) Recover refrigerant

turned off, refrigerant in sight glass Too much (2) Evacuate air and charge proper
stays clear amount of purified refrigerant
When air conditioning is turned off, re-

frigerant foams and then stays clear Correct
* Bubbles in the sight glass with ambient tempera-

tures higher can be considered normal if cooling is
sufficient.
REFRIGERANT CHARGE VOLUME

Specified amount:
700 50 g (24.69 1.76 oz.)
AC-23
AIR CONDITIONING SYSTEM - DRIVE BELT TENSION
DRIVE BELT TENSION

DRIVE BELT TENSION INSPECTION
1. MAKE SURE THAT DRIVE BELT IS INSTALLED
CORRECTLY
Check that the drive belt fits properly in the ribbed
groves.
2. INSPECT DRIVE BELT TENSION

Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge: Nippondenso BTG-20 (95506-
00020) or Borroughs No. BT-33-73F
Drive belt tension:
New belt 160 25 lbf
Used belt 100 20 lbf
HINT:
New belt refers to a belt which has been used
less than 5 minutes on a running engine.
Used belt refers to a belt which has been used
on a running engine for 5 minutes or more.
After installing the drive belt, check that it fits
properly in the ribbed grooves.
AC-24
AIR CONDITIONING SYSTEM - IDLE-UP SPEED
IDLE-UP SPEED
IDLE UP SPEED INSPECTION
1. WARM UP ENGINE
2. SET VEHICLE IN FOLLOWING CONDITION
Blower switch high position
A/C switch on
Magnetic clutch on
3. INSPECT IDLE UP SPEED
Standard:
950 50 RPM
IDLE-UP SPEED ADJUSTMENT

ADJUST IDLE-UP SPEED
Adjust idle-up speed with the idle adjusting screw of
the VSV.
AC-25
AIR CONDITIONING SYSTEM - REFRIGERANT LINES
REFRIGERANT LINES
LOCATIONS
AC-26
AIR CONDITIONING SYSTEM - REFRIGERANT LINES
ON-VEHICLE INSPECTION
1. INSPECT HOSE AND TUBE CONNECTIONS FOR
LOOSENESS
2. INSPECT HOSES AND TUBES FOR LEAKAGE
Using a gas leak tester, check for leakage of refriger-
ant.
REFRIGERANT LINES REPLACEMENT

1. RECOVER REFRIGERANT IN REFRIGERATION
SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fittings immediately to keep mois-
ture or dirt out of the system.
3. TORQUE CONNECTIONS TO SPECIFIED TORQUE
NOTICE: Connections should not be torque tighter than
the specified torque.
4. EVACUATE AIR IN REFRIGERATION SYSTEM AND
CHARGE WITH REFRIGERANT
Specified amount:
700 50 g (24.69 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak tester, check for leakage of refriger-
ant.
6. INSPECT AIR CONDITIONING OPERATION
AC-27
AIR CONDITIONING SYSTEM - COOLING UNIT
COOLING UNIT
COOLING UNIT REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BAT-
TERY
2. RECOVER REFRIGERANT FROM REFRIGERATION
SYSTEM
3. DISCONNECT SUCTION TUBE FROM COOLING
UNIT OUTLET FITTING
4. DISCONNECT LIQUID TUBE FROM COOLING UNIT
INLET FITTING
ture out of the system.
5. REMOVE INSTRUMENT LOWER FINISH PANEL
(See page BO-46 )
6. DISCONNECT CONNECTOR FROM WIRE HARNESS
7. REMOVE EARTH WIRE
8. REMOVE A/C AMPLIFIER

(a) Disconnect the connector from the A/C amplifier.
(b) Remove the 3 screws and the A/C amplifier.
9. REMOVE COOLING UNIT

Remove the 3 screws, nuts and the cooling unit.
AC-28
COOLING UNIT DISASSEMBLY
1. REMOVE UPPER AND LOWER CASE

(a) Disconnect and remove the wire harness.
(b) Remove the 2 clips and the 4 screws.
(c) Remove the upper and the lower case.
(d) Remove the A/C main relay from the upper case.
(e) Remove the blower resistor from the lower case.
AC-29
2. REMOVE THERMISTOR FROM EVAPORATOR
3. REMOVE EXPANSION VALVE, SUCTION AND

LIQUID TUBES FROM EVAPORATOR
COOLING UNIT ASSEMBLY

1. CONNECT EXPANSION VALVE, SUCTION AND
LIQUID TUBES TO EVAPORATOR
Torque the bolts.
Torque: 5.4 N-m (55 kgf-cm. 48 in.-Ibf)
2. INSTALL THERMISTOR
3. INSTALL UPPER AND LOWER CASE TO EVAPORA-
TOR
(a) Install the blower resistor to the lower case.
(b) Install the A/C main relay to the upper case.
(c) Install the upper and lower case to the evaporator.
(d) Install the 2 clips and 4 tapping screws.
(e) Connect the connectors of wire harness.
AC-30
COOLING UNIT INSTALLATION

1. INSTALL COOLING UNIT
Install the cooling unit with the 3 nuts and 4 screws.
2. INSTALL A/C AMPLIFIER
(a) Install the A/C amplifier to the cooling unit with the 2
screws.
(b) Connect the connector to the A/C amplifier.
3. INSTALL EARTH WIRE TO BODY
4. CONNECT CONNECTOR TO WIRE HARNESS OF VE-

HICLE SIDE
5. INSTALL INSTRUMENT LOWER FINISH PANEL
6. CONNECT LIQUID TUBE TO COOLING UNIT INLET

FITTING
Torque the nut.
Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf)
7. CONNECT SUCTION TUBE TO COOLING UNIT
OUTLET FITTING
Torque the nut.
Torque: 32 N-m (330 kgf-cm, 24 ft-Ibf)
8. IF EVAPORATOR WAS REPLACED, ADD COMPRES-
SOR OIL TO COMPRESSOR
Add 40 - 50 cc (1.4 - 1.7 fl.oz.)
Compressor oil:
ND-OIL 9
9. CONNECT NEGATIVE (-) CABLE TO BATTERY
10. EVACUATE AIR FROM REFRIGERATION SYSTEM
11. CHARGE SYSTEM WITH REFRIGERANT AND IN-
SPECT FOR LEAKAGE OF REFRIGERANT
Specified amount:
700 50 g (24.69 1.76 oz.)
AC-31
AIR CONDITIONING SYSTEM - BLOWER UNIT
BLOWER UNIT
BLOWER UNIT REMOVAL
(See page AC-25 )
2. REMOVE BLOWER UNIT
(a) Disconnect the connector from the blower motor.
(b) Disconnect the air inlet damper control cable from the
blower motor.
(e) Remove the nut, 2 screws and the blower unit.
BLOWER UNIT INSTALLATION
1. INSTALL BLOWER UNIT
(a) Install the blower unit with the nut and 2 screws.
(b) Connect the air inlet damper control cable to the
blower unit.
HINT: For installing the control cable, refer to Adjust-
ment of A/C Control Cables.
(c) Connect the connector to the blower motor.
2. INSTALL COOLING UNIT
(See page AC-30 )
AC-32
AIR CONDITIONING SYSTEM - HEATER UNIT
HEATER UNIT
HEATER UNIT REMOVAL
1. REMOVE SAFETY PAD
See Instrument Panel on BO section.
(See page AC-25 )
3. DRAIN ENGINE COOLANT FROM RADIATOR
HINT: It is not necessary to drain out all the coolant.
4. DISCONNECT WATER HOSES FROM HEATER RA-

DIATOR PIPES
(a) Grip the claws of the hose clip with pliers and slide the
clip along the hose to a place where it dose not clamp
the hose to the pipe.
(b) Disconnect the water hoses.
5. REMOVE PIPE GROMMETS
6. REMOVE A/C CONTROL ASSEMBLY
(See page AC-64 )
7. REMOVE HEATER TO REGISTER CENTER DUCT

Remove the 3 screws and the duct.
8. REMOVE INSTRUMENT PANEL REINFORCEMENT

NO. 1 BRACE
Remove the 2 nuts, 2 bolts and the No. 1 brace.
9. REMOVE INSTRUMENT PANEL REINFORCEMENT
NO. 2 BRACE
Remove the 2 nuts, a bolts and the No. 2 brace.
10. REMOVE HEATER UNIT

Remove the screw, nut and the heater unit.
AC-33
AIR CONDITIONING SYSTEM - HEATER UNIT
HEATER UNIT INSTALLATION

Install by following the removal procedure in reverse
order.
HINT:
Push the water hose onto the heater radiator pipe
as far as the ridge on the pipe.
Install the hose clip in a position, as shown to the
left.
AC-34
AIR CONDITIONING SYSTEM - COMPRESSOR
COMPRESSOR
Magnetic Clutch:
INSPECT MAGNETIC CLUTCH FOR FOLLOWING
(a) Inspect the pressure plate and the rotor for signs of
oil.
(b) Check the clutch bearings for noise and grease leak-
age.
(c) Connect the positive (+) lead from the battery to the
terminal on the magnetic clutch connector and the
negative (-) lead to the body ground.
(d) Check that the magnetic clutch is energized.
If the magnetic clutch is not energized, replace the
magnetic clutch.
Compressor:
1. INSTALL MANIFOLD GAUGE SET
3. INSPECT COMPRESSOR FOR FOLLOWING
(a) High pressure gauge reading is not lower and low
pressure gauge reading is not higher than normal.
(b) Check that the metallic sound.
(c) Check that the leakage from shaft seal.
AC-35
COMPRESSOR REMOVAL
1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR 10

MINUTES
2. STOP ENGINE
TERY
SYSTEM
5. REMOVE UNDER COVER
6. DISCONNECT CONNECTOR FROM MAGNETIC
CLUTCH
7. DISCONNECT 2 HOSES FROM COMPRESSOR SER-
VICE VALVE
Cap the open fitting immediately to keep moisture and
dust out of the system.
AC-36
8. REMOVE COMPRESSOR
(a) Loosen the compressor drive belt.
(b) Remove the compressor mounting bolts and the com-
pressor.
MAGNETIC CLUTCH DISASSEMBLY
1. REMOVE PRESSURE PLATE

(a) Using a socket and SST, remove the shaft nut.
SST 07112-76060
(b) Install SST to the pressure plate.

SST 07112 - 66040
AC-37
(c) Using SST and the socket, remove the pressure plate.
SST 07112-76060, 07112-66040
(d) Remove the shims from the shaft.
2. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114-84020
(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE: Be careful not to damage the pulley when tapp-
ing on the rotor.
3. REMOVE STATOR
(a) Using a screwdriver and disconnect the stator lead
wires from the compressor housing.
AC-38
(b) Using SST, remove the snap ring.

SST 07114-84020
(c) Remove the stator.
MAGNETIC CLUTCH ASSEMBLY

1. INSTALL STATOR
(a) Install the stator on the compressor.
(b) Using SST, install a new snap ring.
SST 07114-84020
NOTICE: The snap ring should be installed so that its

beveled side faces up.
(c) Connect the stator lead wires to the compressor hous-

ing.
AC-39
2. INSTALL ROTOR
(a) Install the rotor on the compressor shaft.
(b) Using SST, install a new snap ring.
SST 07114-84020
NOTICE: The snap ring should be installed so that its

beveled side faces up.
3. INSTALL PRESSURE PLATE

(a) Adjust the clearance between the pressure plate and
rotor by putting shims on the compressor shaft.
Standard clearance:
0.5 0.15 mm (0.020 0.0059 in.)
If the clearance is not within tolerance, change the
number of shims to obtain the standard clearance.
(b) Using SST and torque wrench, install the shaft nut.
SST 07112-76060
Torque: 14 N-m (140 kgf-cm, 10 ft-lbf)
AC-40
4. INSPECT CLEARANCE OF MAGNETIC CLUTCH

(a) Set the dial-gauge to the pressure plate of the mag-
netic clutch.
(b) Connect the magnetic clutch lead wire to the positive
(+) terminal of the battery.
(c) Check the clearance between the pressure plate and
rotor, when connect the negative (-) terminal of the
battery.
Standard clearance:
0.5 0.15 mm (0.020 0.0059 in.)
If the clearance is not within standard clearance
adjust the clearance using shims to obtain the stand-
ard clearance.
COMPRESSOR INSTALLATION
1. INSTALL COMPRESSOR WITH 4 MOUNTING
BOLTS
2. INSTALL DRIVE BELT
See Drive Belt Tension Adjustment on page AC-23 .
3. CONNECT 2 HOSES TO COMPRESSOR SERVICE
VALVES
Torque:
Discharge line
10 N-m (100 kgf-cm, 8 ft-lbf)
Suction line
10 N-m (100 kgf-cm. 8 ft-lbf)
4. CONNECT CLUTCH LEAD WIRE TO WIRING HARNESS
7. CHARGE SYSTEM WITH REFRIGERANT AND IN.
Specified amount:
700 50 g (24.69 1.76 oz.)
AC-41
AIR CONDITIONING SYSTEM - RECEIVER
RECEIVER
INSPECT SIGHT GLASS, FUSIBLE PLUG AND FIT-
TINGS FOR LEAKAGE
Use a gas leak tester. Repair as necessary.
RECEIVER REMOVAL
SYSTEM
2. DISCONNECT (-) NEGATIVE CABLE FROM BAT-
TERY
the time the ignition switch is turned to the LOCK position
and the negative (-) terminal cable is discon-
3. REMOVE FRONT GRILLE
4. DISCONNECT 2 LIQUID TUBES FROM RECEIVER
5. REMOVE RECEIVER FROM RECEIVER HOLDER
RECEIVER INSTALLATION
1. INSTALL RECEIVER IN RECEIVER HOLDER
HINT: Do not remove the blind plugs until ready for
connection.
2. CONNECT 2 LIQUID TUBES TO RECEIVER
Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-lbf)
3. INSTALL FRONT GRILLE
5. IF RECEIVER WAS REPLACED, ADD COMPRESSOR
OIL TO COMPRESSOR
Add 20 cc (0.71 fl.oz.)
Compressor oil:
ND-OIL 9
Specified amount:
700 50 g (24.69 1.76 oz.)
AC-42
AIR CONDITIONING SYSTEM - CONDENSER
CONDENSER
1. INSPECT CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, wash them with water and dry
with compressed air.
NOTICE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver
or pliers.
2. INSPECT CONDENSER FITTINGS FOR LEAKAGE
Repair as necessary.
CONDENSER REMOVAL
SYSTEM
TERY
3. REMOVE FOLLOWING PARTS

Front grille
Horn
Hood lock
Center brace
Condenser fan
4. DISCONNECT LIQUID TUBE AND DISCHARGE
HOSE FROM CONDENSER FITTING
5. REMOVE RECEIVER WITH RECEIVER BRACKET
FROM CONDENSER
6. REMOVE RADIATOR SUPPORT BRACKETS
7. REMOVE CONDENSER
(a) Remove the 2 condenser mounting bolts.
(b) Remove the 2 condenser brackets.
AC-43
(c) Pull the condenser out.
CONDENSER INSTALLATION
1. INSTALL CONDENSER
Install the condenser with the 2 condenser brackets
and the 2 mounting bolts.
2. INSTALL RADIATOR SUPPORT

3. INSTALL RECEIVER WITH RECEIVER BRACKET TO
CONDENSER
4. CONNECT LIQUID TUBE TO RECEIVER
Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)
5. CONNECT LIQUID TUBE AND DISCHARGE HOSE
TO CONDENSER
Torque the bolt.
Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf)
6. INSTALL FOLLOWING PARTS
Condenser fan
Center brace
Hood lock
Horn
Front grille
8. IF CONDENSER WAS REPLACED, ADD COMPRES-
SOR OIL TO COMPRESSOR
Add 40 - 50 cc (1.4 - 1.7 fl.oz.)
Compressor oil:
ND-OIL 9
9. EVACUATE AIR FROM AIR CONDITIONING
SYSTEM
Specified amount:
700 50 g (24.69 1.76 oz.)
AC-44
EVAPORATOR INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed
air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES
Repair as necessary.
REMOVAL AND INSTALLATION OF

EVAPORATOR
See item of cooling unit.
AC-45
AIR CONDITIONING SYSTEM - HEATER RADIATOR
HEATER RADIATOR
HEATER RADIATOR REMOVAL
1. REMOVE HEATER UNIT
(See page AC-32 )
2. REMOVE HEATER RADIATOR
(a) Remove the 2 screws and the 2 plates.
(b) Pull the heater radiator out.
HEATER RADIATOR INSPECTION

INSPECT FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed
air.
HEATER RADIATOR INSTALLATION
1. INSTALL HEATER RADIATOR
(a) Insert the heater radiator to the heater unit.
(b) Install the 2 plates with the 2 screws.
2. INSTALL HEATER UNIT
(See page AC-33 )
AC-46
AIR CONDITIONING SYSTEM - BLOWER MOTOR
BLOWER MOTOR
MOTOR REMOVAL
TERY
2. REMOVE A/C AMPLIFIER

Remove the 3 screws and the A/C amplifier with the
connector connected.
3. REMOVE BLOWER MOTOR

(a) Disconnect the connector from the blower motor.
(b) Remove the 3 screws and the blower motor.
MOTOR INSPECTION
INSPECT BLOWER MOTOR OPERATION
Connect the positive (+) lead from the battery to
terminal 1 and the negative (-) lead to terminal 2,
then check that the motor operation is smooth.
MOTOR INSTALLATION
1. INSTALL BLOWER MOTOR
(a) Install the blower motor with the 3 screws.
(b) Connect the connector to blower motor.
2. INSTALL A/C AMPLIFIER
Install A/C amplifier with the 3 screws.
AC-47
AIR CONDITIONING SYSTEM - CONDENSER FAN
CONDENSER FAN
INSPECT CONDENSER FAN MOTOR
(a) Using the wire harness, apply battery positive voltage
to the connector.
(b) Confirm smooth rotation of the motor within the spe-
cified current flow.
Standard current:
9.5 1.5 A
If current is not as specified, replace the motor.
CONDENSER FAN REMOVAL

TERY
2. REMOVE FOLLOWING COMPONENTS
Front grille
Hood lock
Center brace
3. REMOVE CONDENSER FAN
(a) Disconnect the connector from fan motor.
(b) Remove the 2 bolts and the condenser fan.
CONDENSER FAN INSTALLATION
1. INSTALL CONDENSER FAN
(a) Install the condenser fan with the 2 bolts.
(b) Connect the connector to the fan motor.
2. INSTALL FOLLOWING PARTS
Center brace
Hood lock
Front grille
AC-48
AIR CONDITIONING SYSTEM - EXPANSION VALVE
EXPANSION VALVE
1. CHECK QUANTITY OF GAS DURING REFRIGERA-
TION CYCLE
3. RUN ENGINE
Run the engine at 2,000 RPM for at least 5 minutes.
Then check that the high pressure reading is 1,275 -
1,471 kPa (13 - 15 kgf/cm2, 185 - 213 psi).
4. CHECK EXPANSION VALVE
If the expansion valve is faulty, the low pressure
reading will drop to 0 kPa (0 kgf/cm2, 0 psi), otherwise
it is OK.
HINT: When the low pressure drops to 0 kPa (0 kgf/
cm2, 0 psi), feel the receivers IN and OUT sides for no
temperature difference.
EXPANSION VALVE REMOVAL AND

INSTALLATION
AC-49
AIR CONDITIONING SYSTEM - VACUUM SWITCHING VALVE (VSV)
VACUUM SWITCHING VALVE (VSV)

VACUUM HOSE CIRCUIT
VSV INSPECTION
1. DISCONNECT VACUUM HOSES AND CONNECTOR
FROM VSV
2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY

BLOWING AIR INTO PIPES
(a) Connect the VSV terminals to the battery terminals as
illustrated.
(b) Blow into pipe A and check that air comes out of
pipe B.
(c) Disconnect the battery.

(d) Blow into pipe A and check that air does not come
out pipe B.
If a problem is found, replace the VSV.
3. CHECK FOR SHORT CIRCUIT

Using an ohmmeter, check that there is no continuity
between each terminal and the VSV body.
If there is continuity, replace the VSV.
AC-50
AIR CONDITIONING SYSTEM - VACUUM SWITCHING VALVE (VSV)
4. CHECK FOR OPEN CIRCUIT

Using an ohmmeter, the resistance between the 2
terminals.
Resistance:
30 - 34 at 20 C (68 F)
If the resistance is not within specification, replace
the VSV.
AC-51
AIR CONDITIONING SYSTEM - BLOWER RESISTOR
BLOWER RESISTOR
BLOWER RESISTOR REMOVAL
TERY
2. REMOVE BLOWER RESISTOR
(a) Disconnect the connector from the blower resistor.
(b) Remove the 2 screws and the blower resistor.
BLOWER RESISTOR INSPECTION

INSPECT BLOWER RESISTOR
Continuity
Terminal
Condition
Constant
If continuity is not as specified, replace the blower

resistor.
BLOWER RESISTOR INSTALLATION

1. INSTALL BLOWER RESISTOR
(a) Install the blower resistor with the 2 screws.
(b) Connect the connector to the blower resistor.
AC-52
AIR CONDITIONING SYSTEM - HEATER MAIN RELAY
HEATER MAIN RELAY

RELAY REMOVAL
TERY
(See page BO-46 )
3. DISCONNECT HEATER MAIN RELAY FROM A/C
RELAY BLOCK
RELAY INSPECTION
INSPECT HEATER MAIN RELAY
Continuity
Tester connection to Specified value

Condition
terminal number
Constant 1-3 Continuity

2-4
Apply B + between
terminals 1 and 3. 4-5 Continuity
If continuity is not as specified, replace the relay.
RELAY INSTALLATION
1. CONNECT HEATER MAIN RELAY TO A/C RELAY
BLOCK
AC-53
AIR CONDITIONING SYSTEM - MAGNETIC CLUTCH RELAY
MAGNETIC CLUTCH RELAY

RELAY REMOVAL
TERY
(See page BO-46 )
3. REMOVE MAGNETIC CLUTCH RELAY
Remove a screw and disconnect the relay from the
connector.
RELAY INSPECTION
INSPECT MAGNETIC CLUTCH RELAY
Continuity
Tester connection to
Condition terminal number Specified value

Apply B+ between
RELAY INSTALLATION
1. INSTALL MAGNETIC CLUTCH RELAY
Connect the relay to the connector and install it to the
cooling unit with the screw.
AC-54
AIR CONDITIONING SYSTEM - CONDENSER FAN RELAY N0.2 AND N0.3 (USA)
CONDENSER FAN RELAY NO.2 AND

NO.3 (USA)
RELAYS REMOVAL
TERY
2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 FROM RELAY BLOCK NO. 2
RELAYS INSPECTION
1. INSPECT CONDENSER FAN RELAY NO. 2
Check the relay the same way as for the heater main
relay.
2. INSPECT CONDENSER FAN RELAY NO. 3
Check the relay the same way as for the magnetic
clutch relay.
RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 TO RELAY BLOCK NO. 2
AC-55
AIR CONDITIONING SYSTEM - CONDENSER FAN RELAY NO.2 AND NO.3 (Canada)
CONDENSER FAN RELAY NO.2 AND

NO.3 (Canada)
RELAYS REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE FROM BATTERY
2. DISCONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 FROM RELAY BLOCK NO. 5
RELAYS INSPECTION
1. INSPECT CONDENSER FAN RELAY NO.2
Continuity
Condition Tester connection to

Specified value
terminal number
Constant 1-2
Continuity
3-4
Apply B + between

2. INSPECT CONDENSER FAN RELAY NO.3
Continuity
Condition Specified value
terminal number
Apply B+ between

AC-56
AIR CONDITIONING SYSTEM - CONDENSER FAN RELAY N0.2 AND N 0.3(Canada)
RELAYS INSTALLATION
1. CONNECT CONDENSER FAN RELAY NO. 2 AND
NO. 3 TO RELAY BLOCK NO.5
AC-57
AIR CONDITIONING SYSTEM - THERMISTOR
THERMISTOR
THERMISTOR REMOVAL AND
INSTALLATION
THERMISTOR INSPECTION
INSPECT THERMISTOR RESISTANCE
(a) Measure the resistance between terminals at 25C
(77F).
Resistance:
1,500 at 25C (77F)
(b) Place the thermistor in cold water. While varying the
temperature of the water, measure the resistance at
the connector and at the same time, measure the
temperature of the water with a thermometer.
(c) Compare the 2 readings on the chart.
If the resistance valve is not as specified, replace the
thermistor.
AC-58
AIR CONDITIONING SYSTEM - REVOLUTION DETECTING SENSOR (w Power Steering)
REVOLUTION DETECTING SENSOR

(w Power Steering)
SENSOR INSPECTION
MEASURE SENSOR RESISTANCE
Measure the resistance between terminals 3 and 4.
Standard resistance:
240 80 at 20C (68F)
If resistance value is not as specified, replace the
sensor.
SENSOR REMOVAL
1. REMOVE COMPRESSOR
(See page AC-35 )
2. REMOVE REVOLUTION DETECTING SENSOR
(a) Remove the bolt.
(b) Remove the revolution detecting sensor.
SENSOR INSTALLATION
1. INSTALL REVOLUTION DETECTING SENSOR
Using a torque wrench, tighten the bolt.
Torque: 11 N .m (110 kgf-cm, 8 ft-lbf)
2. INSTALL COMPRESSOR
(See page AC-40 )
AC-59
AIR CONDITIONING SYSTEM - REFRIGERANT TEMPERATURE SWITCH
REFRIGERANT TEMPERATURE
SWITCH
SWITCH REMOVAL AND INSTALLATION
See Discharge Valve Removal or Installation on page
AC-35 or 40.
SWITCH INSPECTION
INSPECT REFRIGERANT TEMPERATURE SWITCH
Check refrigerant temperature switch operation.
Oil Temperature Specified Value
120C (248F) Continuity
180C (356F) No continuity
If operation is not as specified, replace the switch.

HINT: After inspection, throughly clean the switch
before assembly.
AC-60
AIR CONDITIONING SYSTEM - TRIPLE PRESSURE SWITCH
TRIPLE PRESSURE SWITCH

1. DISCONNECT CONNECTOR FROM TRIPLE PRES-
SURE SWITCH
4. INSPECT TRIPLE PRESSURE SWITCH

(Magnetic Clutch Control)
(a) Connect the positive (+) lead from the ohmmeter to
terminal 1 and negative (-) lead to terminal 2.
(b) Check continuity between terminals when refrigerant
pressure is changed, as shown.
If operation is not as specified, replace the pressure
switch.
SWITCHES REMOVAL
SYSTEM
TERY
3. REMOVE TRIPLE PRESSURE SWITCH FROM
LIQUID TUBE
Disconnect the connector and remove the triple pres-
sure switch.
SWITCHES INSTALLATION
1. INSTALL TRIPLE PRESSURE SWITCH TO LIQUID
TUBE
Tighten the triple pressure switch then connect the
connector to it.
Specified amount:
700 50 g (24.69 1.76 oz.)
AC-61
AIR CONDITIONING SYSTEM - BLOWER SPEED CONTROL SWITCH
BLOWER SPEED CONTROL SWITCH

SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) GABLE FROM BAT-
TERY
2. REMOVE A/C CONTROL PANEL
(See page BO-47 )
3. REMOVE AUDIO AND ASH TRAY
(See page BO-46 )
4. REMOVE BLOWER SPEED CONTROL SWITCH
(a) Remove the illumination light from the A/C control
assembly.
(b) Using a screwdriver, pry loose the clip and push out
the blower speed control switch to rear of the A/C
control assembly.
(c) Disconnect the connector from the blower speed con-
trol switch.
SWITCH INSPECTION
INSPECT BLOWER SPEED CONTROL SWITCH
Continuity
Terminal Illumination
Switch position
OFF
If continuity is not as specified, replace the blower

speed control switch.
AC-62
AIR CONDITIONING SYSTEM - BLOWER SPEED CONTROL SWITCH
SWITCH INSTALLATION
1. INSTALL BLOWER SPEED CONTROL SWITCH
(a) Connect the connector to the blower speed control
switch.
(b) Install the illumination light to the A/C control assem-
bly.
(c) Install the blower speed control switch to the A/C
control assembly.
2. INSTALL AUDIO AND ASH TRAY
3. INSTALL A/C CONTROL PANEL
AC-63
AIR CONDITIONING SYSTEM - AIR CONDITIONING SWITCH
AIR CONDITIONING SWITCH

SWITCH REMOVAL
1. DISCONNECT NEGATIVE (-) CABLE PROM BAT-
TERY
2. REMOVE A/C SWITCH
Using a screwdriver, pry loose the clips and remove
the A/C switch.
HINT: Tape the screwdriver tip before use.
SWITCH INSPECTION
INSPECT A/C SWITCH
Continuity
Condition terminal number Specified value
A/C Switch OFF No continuity

4-5
A/C Switch ON Continuity
4-6
Illumination circuit 1-3 Continuity
If continuity is not as specified, check the bulb or

replace the switch.
SWITCH INSTALLATION
1. INSTALL A/C SWITCH
Push in the A/C switch to the A/C control assembly.
AC-64
AIR CONDITIONING SYSTEM - AIR CONDITIONING CONTROL ASSEMBLY
AIR CONDITIONING CONTROL

ASSEMBLY
INSPECT A/C CONTROL LEVERS OPERATION
Move the control levers left and right and check for
stiffness and binding through the full range of the
levers.
A/C CONTROL CABLES ADJUSTMENT
1. ADJUST AIR INLET DAMPER CONTROL CABLE

Set the air inlet damper on RECIRC position, install
the control cable and lock clamp.
2. ADJUST MODE DAMPER CONTROL CABLE

Set the air inlet damper on FACE position, install the
control cable and lock the clamp.
3. ADJUST AIR MIX DAMPER CONTROL CABLE

Set the air mix damper on COOL position, install the
control cable and lock the clamp.
AC-65
AIR CONDITIONING SYSTEM - AIR CONDITIONING CONTROL ASSEMBLY
A/C CONTROL ASSEMBLY REMOVAL

1. REMOVE SAFETY PAD
See Instrument Panel on BO section.
2. REMOVE A/C CONTROL ASSEMBLY
(a) Disconnect the control cables from the heater unit
and the blower unit.
(b) Remove the blower switch and remove the A/C con-
trol assembly.
A/C CONTROL ASSEMBLY

INSTALLATION
1. INSTALL A/C CONTROL ASSEMBLY
(a) Install the blower switch to the A/C control assembly.
(b) Wire the control cables, as shown the illustration.
(c) Connect the control cables to the heater unit and
blower unit.
HINT: For installing the control cables, refer to Ad-
justment of A/C Control Cables.
2. INSTALL SAFETY PAD
AC-66
AIR CONDITIONING SYSTEM - AIR CONDITIONING AMPLIFIER
AIR CONDITIONING AMPLIFIER

AMPLIFIER REMOVAL
REMOVE A/C AMPLIFIER
(a) Disconnect the connector from the amplifier.
(b) Remove the 3 screws and the amplifier.
AMPLIFIER INSPECTION
INSPECT A/C AMPLIFIER CONNECTOR ON WIRE
HARNESS SIDE
Test conditions:
Ignition switch ON
Temperature control lever to MAX COOL
Blower switch ON
w/o Power Steering
Condition Specified value (Voltage)
terminal number
1 - Ground Start the engine Approx. 10 to 14 V
1 - Ground Stop the engine No voltage
7 - Ground Blower switch ON Battery positive voltage
7 - Ground Blower switch OFF No voltage
8 - Ground A/C switch ON Battery positive voltage
8 - Ground A/C switch OFF No voltage
terminal number Condition Specified value (Resistance)
2- 13 Constant Approx. 1.5 k at 25C (77F)

9-13 Constant Approx. 240
terminal number Condition Specified value (Continuity)
5 -7 Constant Continuity
12 - Ground Constant Continuity
w/ Power Steering
terminal number Condition Specified value (Voltage)
1 - Ground Start the engine Approx. 10 to 14 V

1 - Ground Stop the engine No voltage
7 - Ground Blower switch ON Battery positive voltage
7 - Ground Blower switch OFF No voltage
8 - Ground A/C switch ON Battery positive voltage
8 - Ground A/C switch OFF No voltage
AC-67
AIR CONDITIONING SYSTEM - AIR CONDITIONING AMPLIFIER
Condition Specified value (Resistance)
terminal number
2 - 12 Constant Approx. 1.5 k at 25C (77F)
terminal number Condition Specified value (Continuity)
5-7 Constant Continuity

12 - Ground Constant Continuity
If continuity is not as specified, replace the A/C ampli-

fier.
AC-68
AIR CONDITIONING SYSTEM - SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE DATA
Refrigerant charge volume 700 50 g (24.69 1.76 oz.)
Drive belt tension
New belt 160 25 lbf
Used belt 100 20 lbf
Idle-up speed 1,450 50 RPM
Magnetic clutch clearance 0.5 0.15 mm (0.02 0.0059 in.)
TORQUE SPECIFICATIONS
Part tightened N-m kgf-cm ft-lbf
Compressor x Suction hose 100
Compressor x Discharge hose 100
Compressor x Compressor bracket 250
Receiver x Liquid tube 5.5 48 in.-lbf
Condenser x Liquid tube 5.5 48 in.-lbf
Cooling unit x Liquid tube 140
Cooling unit x Suction tube 330

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AC-1

AIR CONDITIONING SYSTEM

A newly developed refrigerant, R134a (HFC 134a),

PRECAUTIONS FOR SERVICING R134a AIR

2. USE OF PROPER COMPRESSOR OIL

If even a small amount of the wrong oil is changed, it

3. USE OF PROPER O-RINGS AND SEALS

If O-rings and/or seals for R12 air conditioning sys-

4. TIGHTEN CONNECTING PARTS SECURELY

7. WHEN DISCONNECTING THE PLUG, TAKE CARE

SERVICE TOOLS FOR R134a AIR

1. USE MANIFOLD GAUGES FOR R134a AIR CONDI-

2. USE R134a GAS LEAK DETECTOR

3. USE VACUUM PUMP ADAPTER

HANDLING PRECAUTIONS FOR

3. BE CAREFUL THAT LIQUID REFRIGERANT DOES

HANDLING PRECAUTIONS FOR

CHARGING AND LEAK-CHECK METHODS

10 min. Leave for 5 min.

Start Stop Airtight Refrigerant Gas Leak Refrigerant

Check and correct Fill refrigerant in gas state until

SUPPLEMENTAL RESTRAINT SYSTEM

(07117-58060) Refrigerant Drain Service Valve

(07117-58080) Quick Coupler Discharge (diam. 16 mm)

(07117-58090) Quick Coupler Suction (diam. 13 mm)

(07117-78050) Refrigerant Charging Gauge

(07117-88060) Refrigerant Charging Hose Discharge (Red)

(07117-88070) Refrigerant Charging Hose Suction (Blue)

(07117-88080) Refrigerant Charging Hose Utility (Green)

07112-66040 Magnetic Clutch Remover

07112-76060 Magnetic Clutch Stopper

07114-84020 Snap Ring Pliers

07116-38360 Gas Leak Detector Assembly

USE OF MANIFOLD GAUGE SET

5. CONNECT QUICK CONNECTORS TO SERVICE

MANIFOLD GAUGE SET REMOVAL

Inspect cooling system for refrigerant

Blower speed control switch

Condenser fan relay No. 2

Condenser fan relay No. 3

Radiator fan main relay

Condenser fan motor

Inspect outlet air control

Heater main relay

No air temperature control

Compressor operates immediately

No condenser fan operation

No cool air cones out

Cool air comes out immediately

Cool air comes out only at high

No engine idle up when A/C

No warm air comes out

Engine coolant temperature switch

Inspect refrigerant lines

Magnetic clutch AC-34

AIR CONDITIONING SYSTEM

Expansion valve AC-48

Inspect refrigeration control

Dual pressure switch AC-60

A/C amplifier AC-66

Wiring and wiring connections

Vacuum switching valve (VSV) AC-49

REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET