19 air conditioning

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AIR
CONDITIONING
SYSTEM

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GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

HEATER CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 12

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7

AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .

19

COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 4

EVAPORATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 5

CONDENSER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 7

CONDENSER FAN & RELAY . . . . . . . . . . . . . . . . . . . . . . . . .

4 9

BLOWER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 0

ACCUMULATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .

5 2

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GENERAL

SPECIFICATION (H.C.C)

Heater assembly

Type

Heating capacity

Air conditioner

Cooling capacity

Compressor

Model

No. of cylinders and displacement CC/Rev

Maximum allowable continuous rpm

Magnetic clutch

Voltage, power consumption

Control

Idle up device (FBC only)

Protective equipment

Clutch cycling switch

Cut out pressure

Max. cut in pressure

Min. difference pressure

Pressure relief valve

Relief pressure

Exhaust flow

Resealed pressure

Refrigerant and quantity gr. (oz, lb.)

3,800 Kcal/h (15,000 B.T.U/h)

3,300 Kcal/h (13,000 B.T.U/h)

SD-709

7 cylinders, 155

6000

DC12V, 49W

900 ± 25 rpm

167 kPa (1.7 ± 0.1 kg/cm

2

, 24 psi)

324 kPa (3.3 kg/cm

2

, 47 psi)

118 kPa (1.2 kg/cm

2

, 17 psi)

31.6 kg/cm

2

(449 psi) MIN., 42.18 kg/cm

2

(560 psi) MAX.

Min. 113.2

at 42.18 kg/cm

2

(560 psi)

Min. 28.2 kg/cm

2

(401 psi)

R - 1 2 8 5 0 - 9 0 0 ( 3 0 - 3 2 , 1 . 8 7 - 1 . 9 2 )

SERVICE STANDARDS

Amount of deflection of V belt mm (in.)

Engine idle speed

Air gap mm (in.)

8 . 0 - 1 0 . 0 ( 0 . 3 2 - 0 . 4 0 )

700±50 rpm (without MPI)

0.4-0.8 (0.016-0.032)

LUBRICANTS

Recommended lubricant

Quantity

Heater control lever

Compressor oil

Multipurpose grease

Suniso 5GS or equivalant

As required

240 cc (8.1 fl oz)

9 7 - 2

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GENERAL

SPECIAL TOOLS

9 7 - 3

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GENERAL

TROUBLESHOOTING

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM

TEST STEP

RESULT

ACTION TO TAKE

A1

VERIFY THE CONDITION

Check system operation

System cooling

INSTRUCT vehicle owner

properly

on proper use of the

system

System not cooling

GO to A2

Properly

A2 CHECK A/C COMPRESSOR CLUTCH

Does the A/C compressor clutch engage?

Yes

No

GO to A3

REFER to clutch circuit

diagnosis in this section

A3 CHECK OPERATION OF COOLING FAN

Check that the cooling fan runs when the A/C Yes

compressor clutch is engaged

No

GO to A4

Check for cooling fan

electric circuit

A4 COMPONENT CHECK

o Under-hood check of the following:

OK but still not

GO to A6

Loose, missing or damaged compressor drive belt.

cooling

Loose or disconnected A/C clutch or clutch cycling

Not OK

REPAIR AND GO to A5

pressure switch connectors.

Disconnected resistor assembly.

Loose vacuum lines or misadjusted control cables

o Inside vehicle check for:

Blown fuse or improper blower motor operation.

Vacuum motors/temperature door movement-full

travel.

Electrical and vacuum connections.

A5 CHECK SYSTEM

Check system operation

OK

Condition Corrected

GO to A1

Not OK

GO to A6

9 7 - 4

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GENERAL

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM
(Continued)

TEST STEP

RESULT

ACTION TO INTAKE

A6 CHECK COMPRESSOR CLUTCH

Use refrigerant system clutch cycle rate and timing

Compressor cycles

GO to A7

evaluation charts.

very rapidly

Prepare the car as follows

(1 second on)

1. Hook up the manifold gauge set

(1 second off)

2. Set Function lever at max A/C

3. Set blower switch on high

Compressor runs

GO to A8

4. Set temperature lever full cold

continuously (normal

5. Close doors and windows

operation in ambient

6. Use a thermometer to check temperature at center

temperature above

discharge register. Record outside temperature.

27°C. (80°F.)

7. Run engine at approximately 1500 RPM with

depending on

compressor clutch engaged.

humidity conditions)

8. Stabilize with above conditions for 10-15 minutes.

Compressor cycles

GO to A7

Check compressor clutch ON/OFF time. Refer to slow

charts for normal Clutch cycling timing rates.

A7

CHECK CLUTCH CYCLING PRESSURE SWITCH

Bypass the clutch cycling pressure switch with a jumper

Outlet line same

REPLACE clutch cycling

wire.

temperature

pressure switch. Do not

Compressor on continuously.

approximately -2°C. discharge system

Feel evaporator inlet and outlet lines.

4°C. (28°F. - 40°F.)

Switch fitting has

or slightly colder

Schrader valve GO to A8

than inlet line (after

fixed orifice)

Inlet line warmer or GO to A9

(after fixed orifice)

colder than outlet

line

9 7 - 5

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GENERAL

INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM

(Continued)

TEST STEP

RESULT

ACTION TO TAKE

A8 CHECK SYSTEM PRESSURES

Compare readings with normal system pressure ranges. Clutch cycles within

System OK

limits. System pres- GO to A1

sure within limits

Compressor runs

GO to A11

continuously (normal

operation in ambient

temperature above

27°C (80°F.)

depending on

humidity conditions).

Compressor cycles

REPLACE clutch cycling

high or low ON

pressure switch. Do not

above 359 kPa

discharge system

(52 psi) OFF below

Switch timing has

144 kPa (21 psi).

Schrader valve CHECK

system OK.GO to A1

NOT OK.GO to A9

A9 CHECK SYSTEM

Check system for leaks

Leak found

REPAIR, discharge, evac-

uate and charge system.

System OK

GO to A1

No Leak found

Low refrigerant charge

or moisture in system.

Discharge, evacuate and

charge system. System

O K

A10 CHECK CLUTCH CYCLING

Disconnect blower motor wire and check for clutch Clutch cycles OFF

cycling off at 144 kPa (21 psi) (suction pressure)

at 144-179 kPa

(21-26 psi)

Connect blower motor

wire.

System OK

GO to A1

Pressure falls below REPLACE clutch cycling

144 kPa (21 psi)

pressure switch. Do not

discharge system.

Switch fitting has

Schrader valve. System

OK.GO to A1

9 7 - 6

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GENERAL

COMPRESSOR CIRCUIT CLUTCH DIAGNOSIS

TEST STEP

RESULT

ACTION TO TAKE

B1

CHECK SYSTEM OPERATION

o Turn the blower switch ON.

Clutch and fan operate System OK

o Depress the A/C button.

o Turn the ignition switch to the RUN position.

Clutch and fan do not GO to B2

o Compressor clutch should engage and engine

operate

cooling fan should operate.

Only fan operates

GO to B5

B2 CHECK FOR VOLTAGE

o Check for voltage at circuit wire at the clutch Voltage present

cycling pressure switch connector.

No voltage

B3 BY-PASS PRESSURE SWITCH

o Disconnect the connector at the clutch cycling

OK

pressure switch

o Jump connector pins.

Not OK

o Clutch should engage.

GO to B3

GO to A1

GO to B4

GO to B5

B4 CHECK SYSTEM PRESSURE

o Connect the manifold gauge set and check the Pressure above 55 psi REPLACE clutch cycling

system pressure.

pressure switch GO to A1

Pressure below 55 psi CHECK refrigerant

(ambient temperature

system for leaks.

above 50°F)

REPAIR and CHARGE

system as necessary

GO to A1.

B5

CHECK VOLTAGE AT CLUTCH

o Check for voltage at the clutch field coil.

B6

CHECK VOLTAGE AT BATTERY

o Check for voltage at the battery.

B7 CHECK FUSE

Voltage present

No voltage

Voltage Present

No voltage

GO to B7

GO to B6

GO to B7

Check for low battery voltage.

SERVICE as necessary.

GO to A1.

o Check fuse in panel for continuity.

OK

Not OK

GO to B1.

CHECK for short.

SERVICE as necessary.

REPLACE fuse. GO to B1.

9 7 - 7

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GENERAL

SERVICE ADJUSTMENT

ADJUSTMENT OF FAST IDLE CONTROL DEVICE
(without MPI) (F.I.C.D)

The vacuum system is designed to actuate the F.I.C.D. which

raises the idle speed of the engine to ensure better cooling when

the car is stationary.

1. Warm up the engine.

2.

Make sure the engine is at the correct idle speed with the

air conditioner in the “OFF” position.

3. Set the engine speed to the specified rpm with the air

conditioner in the “ON” position.

Specified rpm : 900 ± 25 rpm

4.

Depress and release the accelerator pedal several times, and

make sure that the engine speed returns to the specified

rpm.

9 7 - 8

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GENERAL

CHECKING AND ADJUSTING THE A/C
COMPRESSOR BELT

After installation, check the following points:

1. Check for abnormal vehicle performance.

2.

Check the magnetic clutch for operation (without turning on

the compressor).

3.

Check for any parts left unmounted or any tool left behind

in the vehicle.

4. Check the belt for proper tension.

Belt deflection

Air conditioner compressor belt . . . . . . . . . . . . . . . . . . . . . . .

8.0-10.0 mm (0.34-0.42 in.)

5. Charge the system.

6. Check the idle speed.

7. Test the system for proper operation.

9 7 - 9

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GENERAL

VACUUM SYSTEM SYMPTOM AND PROBABLE CAUSE

9 7 - 1 0

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GENERAL

Symptom

On “FLOOR” position. All air through

defroster or DEF/FLOOR.

Probable cause

o Blue and/or red vacuum hose pinched or disconnected at

vacuum motor.

o Black source hose pinched or disconnected at the connector.

o Engine compartment A/C source hose pinched or discon-

nected at the vacuum manifold.

o Defective vacuum motor.

On “DEF/FLOOR” position. All air through

defroster.

o Blue hose pinched or disconnected at vacuum motor.

o Blue vacuum hoses installed improperly (reversed).

o Black source hose pinched or disconnected at the connector.

o Engine compartment A/C source hose pinched or discon-

nected at the vacuum manifold.

o Defective vacuum motor.

On “PANEL VENTS” position. All air

through defroster.

o Yellow vacuum hose pinched or disconnected at vacuum

motor.

o Black source hose pinched or disconnected at the connector.

o Engine compartment A/C source hose pinched or discon-

nected at the vacuum manifold.

o Defective vacuum motor.

On “PANEL/FLOOR” position. All air

through defroster or panel

o Yellow vacuum hose pinched or disconnected at vacuum

motor.

o Blue hose pinched or disconnected at vacuum motor.

o Black source hose pinched or disconnected at the connector.

o Engine compartment A/C source hose pinched or discon-

nected at the vacuum manifold.

o Defective vacuum motor.

On “DEF” position. (No vacuum)

On “RECIRC” position. All air through

fresh.

o White vacuum hose disconnected at the connector or recirc

duct vacuum motor.

o Black source hose pinched or disconnected at the connector.

o Engine compartment A/C source hose pinched or discon-

nected at the vacuum manifold.

o Defective vacuum motor.

9 7 - 1 1

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HEATER CONTROL ASSEMBLY

HEATER CONTROL ASSEMBLY

COMPONENTS

REMOVAL AND INSTALLATION

1. Pull out the ash tray and remove the bolt.

2. Pull out the heater control panel assembly and then

disconnect the A/C switch, defrostor and cigar lighter

connectors.

3. Remove the heater control assembly mounting bolts.

4.

Pull out the heater control assembly and then disconnect the

blower motor switch connector, vacuum connector and the

temperature control cable.

5. Installation is the reverse of removal.

9 7 - 1 2

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HEATER

COMPONENTS VACUUM TYPE

9 7 - 1 3

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HEATER

COMPONENTS LEVER TYPE

9 7 - 1 4

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VENTILATORS

REMOVAL

1. Disconnect the negative terminal at the battery.

2. Drain the coolant from the radiator.

3. Remove the heater hoses and the evaporator drain hose.

4. Using the special tool (09977-33600 A/B), remove the

suction and the liquid lines.

5. Remove the console assembly (Refer to BODY GROUP).

6. Remove the glove box assembly, main lower crash pad

assembly and lower crash pad center facia panel assembly

(Refer to BODY GROUP).

7. Remove the heater control assembly.

8.

Remove the lower crash pad center skin assembly (Refer to

BODY GROUP).

9. Remove the crash pad center support bracket assembly

(Refer to BODY GROUP).

10. Remove the evaporator unit assembly.

11. Remove the rear heating joint duct assembly.

12. Remove the heater unit assembly.

9 7 - 1 5

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HEATER

INSPECTION

1. Check the linkage mechanism for operation.

2. Check the heater core for restrictions or leakage.

INSTALLATION

1. Installation is the reverse of the removal procedures.

9 7 - 1 6

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VENTILATORS

V E N T I L A T O R S

COMPONENTS

9 7 - 1 7

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HEATER

REMOVAL AND INSTALLATION

1. Remove the main crash pad assembly (Refer to BODY

GROUP)

2. Remove the side air vent louver duct assembly (LH/RH).

3. Remove the side air vent hose assembly (LH/RH).

4. Remove the side air vent louver assembly (LH/RH).

5. Remove the heater connection assembly.

6. Remove the defroster nozzle assembly.

7. Remove the side defroster nozzle assembly (LH/RH).

8. Remove the crash pad upper cover assembly.

9. Remove the rear heating joint duct assembly and rear

heating side duct assembly (LH/RH).

10. Installation is the reverse of removal procedures.

9 7 - 1 8

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AIR CONDITIONER SYSTEM

AIR CONDITIONER

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

9 7 - 1 9

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AIR CONDITIONER SYSTEM

AIR CONDITIONER SYSTEM SERVICE

CAUTIONS

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Never open or loosen a connection before discharging the

system.

When loosening a connection, if any residual pressure is

evident, allow it to bleed off before opening the fitting.

A system which has been opened to replace a component

or one which has discharged must be evacuated before

charging.

Immediately after disconnecting a component from the

system, seal the open fittings with a cap or plug.

Before disconnecting a component from the system, clean

the outside of the fittings thoroughly.

Do not remove the sealing caps from a replacement

component until it is ready to be installed.

Refrigerant oil will absorb moisture from the atmosphere if

left uncapped. Do not open an oil container until ready to

use, and install the cap immediately after using. Store oil

only in a clean, moisture-free container.

Before connecting an open fitting, always install a new

sealing ring. Coat the fitting and seal with refrigerant oil

before making the connection.

When installing a refrigerant line, avoid sharp bends.

Position the line away from the exhaust or any sharp edges

which may chafe the line.

Tighten fittings only to the specified torque. The fittings used

in the refrigerant system should not be over-tightened.

When disconnecting a fitting, use a wrench on both sides

of the fitting to prevent twisting the refrigerant lines.

Do not open a refrigerant system or uncap a replacement

component unless it is as close as possible to room

temperature. This will prevent condensation from forming

inside a component which is cooler than the surrounding air.

Whenever a major component such as an evaporator,

condenser, compressor, or refrigerant line is replaced, it is

mandatory that the accumulator/drier also be replaced.

Keep service tools and the work area clean. Contamination

of a refrigerant system through careless work habits must

be avoided.

9 7 - 2 0

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AIR CONDITIONER SYSTEM

AIR CONDITIONER SYSTEM SERVICE

SAFETY PRECAUTIONS

1.

R-12 liquid refrigerant is highly volatile. A drop on the skin

of your hand could result in localized frostbite. When

handling the refrigerant, be sure to wear gloves.

2. If the refrigerant splashes into your eyes, wash them with

clean water immediately. It is standard practice to wear

goggles or glasses to protect your eyes, and gloves to protect

your hands.

3. The R-12 container is highly pressurized. never leave it in

a hot place, and check that the storage temperature is below

52°C (126°F).

4.

A halide leak detector is often used to check the system for

refrigerant leakage. Bear in mind that R-12, upon coming

into contact with flame (this detector burns propane to

produce a small flame), produces phosgene, a toxic gas.

INSTALLATION OF MANIFOLD GAUGE SET

1. Close both hand valves of the manifold gauge.

2. Install the charging hoses of the gauge set to the fittings.

Connect the low-pressure hose to the low-pressure service

port, and the high-pressure hose to the high-pressure service

port.

Tighten the fittings by hand.

NOTE

Fittings for attaching the manifold gauge set are located

on the compressor discharge hose and the accumulator.

DISCHARGING THE REFRIGERATION

SYSTEM

1. Connect the manifold gauge set to the system.

2. Place the free end of the center hose on a shop towel.

3. Slowly open the high-pressure hand valve to adjust the

refrigerant flow. Open the valve slightly.

NOTE:

If refrigerant is allowed to escape too fast, compressor oil

will be drawn out of the system.

4. Check the shop towel to make sure no oil is being

discharged. If oil is present, partially close the hand valve.

5.

After the manifold gauge reading drops below 434 kPa (3.5

kg/cm

2

, 50 psi), slowly open the low-pressure hand valve.

6.

As the system pressure drops, gradually open both the high

and the low-pressure hand valves until both gauges read 1

kPa (0 kg/cm

2

, 0 psi).

9 7 - 2 1

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AIR CONDITIONER SYSTEM

EVACUATING REFRIGERANT SYSTEM

NOTE:

It is necessary to evacuate the air conditioning system any

time the system has been opened. Evacuation is necessary to

purge the system of all air and moisture that may have been

allowed to enter the unit.

After installation of a component, the system should be

evacuated for approximately 15 minutes. A component in

service that has been opened for repair should be evacuated

for 30 minutes.

1. Engine should be off.

2.

Connect a manifold gauge set to the service ports. Close both

high and low pressure valves.

3. Make sure the refrigerant has been discharged from the

system.

4. Connect the center hose of the gauge set to the vacuum

pump inlet.

5. Start the vacuum pump and then open the high and low

manifold pressure valves.

6.

After about ten minutes, check that the low pressure gauge

reads more than 94.39 kPa (0.96 kg/cm

2

, 13.7 psi) vacuum.

If negative pressure can not be obtained, there is a leak in

the system. In this case, repair the leak as described in the

following.

1) Close both the manifold valves and stop the vacuum

pump.

2) Charge the system with a can of refrigerant [about 0.4

kg (0.9 lb)]. Refer to Charging Refrigerant.

3) Check for refrigerant leakage with a leak detector.

4)

Repair any leakage found. Refer to Checking Refrigerant

Leaks.

5) Discharge the system again, and then evacuate the

system.

7. Start the vacuum pump.

8. Open both manifold pressure valves to obtain 94.39 kPa

(0.96 kg/cm

2

, 13.7 psi) of vacuum.

9.

After the low pressure manifold gauge indicates as close to

94.39 kPa (0.96 kg/cm

2

, 13.7 psi) as possible, continue

evacuating for 15 minutes.

10. After evacuating for 15 minutes, close both manifold

pressure valves and stop the vacuum pump. Disconnect the

hose from the vacuum pump. The system is now ready for

charging.

9 7 - 2 2

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AIR CONDITIONER SYSTEM

HANDLING REFRIGERANT SERVICE TAP

VALVE

1.

Before connecting the valve to the refrigerant container, turn

the handle fully counterclockwise.

2.

Turn the adapter counterclockwise until it reaches its highest

position.

3.

Connect the center hose to the valve fitting. Turn the adapter

fully clockwise by hand.

4.

Turn the handle clockwise to make a hole in the sealed top.

5.

Turn the handle fully counterclockwise to fill the center hose

with air. Do not open the high and low-pressure hand valves.

6.

Loosen the center hose nut connected to the center fitting

of the manifold gauge.

7.

Allow air to escape for a few seconds, and then tighten the

nut.

CHARGING REFRIGERANT SYSTEM
(VAPOR)

NOTE

This step is to charge the system through the low pressure

side with refrigerant in a vapor state. When the refrigerant

container is placed rightside up, refrigerant will enter the

system as a vapor.

1 .

2 .

3.

4.

5.

Install the refrigerant can tap valve as described in Handling

the Refrigerant Service Tap Valve section.

Open the low pressure valve. Adjust the valve so that the

low pressure gauge does not read over 412 kPa (4.2 kg/cm

2

,

60 psi).

Put the refrigerant in a pan of warm water (maximum

temperature 40°C or (104°F) to keep vapor pressure in the

container slightly higher than vapor pressure in the system.

Run the engine at fast idle, and operate the air conditioner.

NOTE:

Be sure to keep the container upright to prevent liquid

refrigerant from being charged into the system through

the suction side, resulting in possible damage to the

compressor.

Charge the system to the specified amount. Then, close the

low pressure valve.

Specified amount: 850-900 g (1.87-1.92 lb)

9 7 - 2 3

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AIR CONDITIONER SYSTEM

When refrigerant charging speed is slow, immerse the

refrigerant can in water, heated to a temperature of about

40°C (104°F).

WARNING

o Under no circumstances should the refrigerant can be

warmed in water heated to a temperature of over 52°C

(126°F).

o A blow torch or stove must never be used to warm up the

can.

CHARGING REFRIGERANT SYSTEM
(LIQUID)

NOTE

This step is to charge an empty system through the high

pressure side with refrigerant in a liquid state. When the

refrigerant container is held upside down, refrigerant will enter

the system as a liquid.

CAUTION:

Never run the engine when charging the system through the

high pressure side.

Do not open the low pressure valve when the system is being

charged with liquid refrigerant.

1.

Close both the high and low pressure valves completely after

the system is evacuated.

2.

Install the refrigerant can tap valve as described in “Handling

Refrigerant Service Tap Valve” section.

3.

Open the high pressure valve fully, and keep the container

upside down.

4.

Charge the system to the specified amount by weighing the

refrigerant with a scale. Overcharging will cause discharge

pressure (high side) to rise. Then, close the high pressure

valve.

Specified amount: 850-900 kg (1.87-1.92 lb)

NOTE:

If the low pressure gauge does not show a reading, the

system is restricted and must be repaired.

5.

After the specified amount of refrigerant has been charged

into the system, close the manifold gauge valve.

6. Check that there are no leaks in the system with a leak

detector. Refer to Checking Refrigerant Leaks.

NOTE:

Conducting a performance test prior to removing the

manifold gauge is a good service operation.

9 7 - 2 4

Immerse in water
heated to about

40°C (104°F) for a

short time.

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AIR CONDITIONER SYSTEM

COMPRESSOR OIL LEVEL CHECK

The oil used to lubricate the compressor circulates in the system

while the compressor is operating. Whenever replacing any

component of the system or when a large amount of gas leakage

occurs, add oil to maintain the original total amount of oil.

Total amount of oil in the system: 240CC (8.1 fl.oz)

Handling of Oil

1.

The oil should be free from moisture, dust, metal fillings, etc.

2. Do not mix oils.

3. The moisture content in the oil increases when exposed to

the air for prolonged periods.

After use, seal the container immediately.

Oil Return Operation

Before checking and adjusting the oil level, operate the

compressor at engine idle speed, with the controls set for

maximum cooling and high blower speed, for 20 to 30 minutes

in order to return the oil to the compressor.

Checking and Adjusting a Used Compressor

The compressor oil should be checked in the following order:

1.

After the oil return operation, stop the engine, discharge the

refrigerant and then remove the compressor from the

vehicle.

2. Drain the oil from the system line connecting ports.

Oil is sometimes hard to drain out when the compressor

i s c o o l . D r a i n o i l w h i l e t h e c o m p r e s s o r i s w a r m

[maintained at 40°-50°C (104-122°F)].

9 7 - 2 5

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AIR CONDITIONER SYSTEM

3. Measure the amount of the oil removed. If the amount is

less than 70cc (2.1 US fl oz, 2.5 Imp fl oz), some oil may

have leaked out. Conduct leak tests at the connections, and

if necessary, repair or replace faulty parts.

4. Check the purity of the oil and then adjust the oil level

following the procedure below.

1) If the oil is clean

Unit: cc (US fl oz, Imp fl oz)

Amount of oil drained

Adjusting procedure

More than 70 (2.3, 2.5)

Oil level is right.

Pour in same amount of oil

as was drained out.

Less than 70 (2.3, 2.5)

Oil level is low.

Pour in 70 (2.3, 2.5) of oil

2) If the oil contains chips or other foreign material flush

with the air conditioner system refrigerant and replace

the accumulator.

Then add the oil.

Adding Oil for Replacement Component Parts

When replacing the system’s component parts, be sure to add

the following amount of oil to the parts being replaced.

Component parts

Amount of oil

to be replaced

cc (US fl oz, Imp fl oz)

Evaporator core

Condenser

Accumulator

90 (3.0, 3.3)

30 (1.0, 1.1)

30 (1.0, 1.1)

9 7 - 2 6

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AIR CONDITIONER SYSTEM

HOSE AND LINE CHECK

Check the heater and air conditioner hoses and lines for damage

due to interference with adjoining parts. If damage is major,

replace the affected parts.

Carefully check the hoses and lines, especially those located

close to moving parts or sharp panel edges.

CHECKING REFRIGERANT LEAKS

Conduct a leak test with an electronic leak detector whenever

leakage of refrigerant is suspected and when conducting service

operations which are accompanied by disassembly or loosening

of connection fittings.

Electronic Leak Detector

The leak detector is a delicate device that detects small amounts

of halogen. In order to use the device properly, read the

manuals supplied by the manufacturer to perform the

specified maintenance and inspections.

If a gas leak is detected, proceed as follows:

1.

2.

3.

4.

Check the torque on the connection fitting and, if necessary,

tighten to the proper torque, Check for leakage with the leak

detector.

If leakage continues even after the fitting has been

retightened, discharge the refrigerant from the system,

disconnect the fitting, and check the seat for damage.

Replace fitting, even if the damage is slight.

Check compressor oil and add oil if required.

Charge the system and recheck for leaks. If no leaks are

found, evacuate and charge the system.

OFF-SEASON MAINTENANCE

In the off-season, turn the compressor on for 10 minutes at least

once a month and run the engine at idle.

Check the compressor belt for proper tension.

Belt deflection

Drive belt.. . . . . . . . . . . . . . . . . 9.0-10.4 mm (0.35-0.40 in.)

A/C compressor belt.. . . . . . . . . . . . . . . . . . . . . . 8.0-10.0 mm

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AIR CONDITIONER SYSTEM

SPRING LOCK COUPLING

DISASSEMBLY

CAUTION

Discharge the system before disconnecting a coupling.

1.

Install the special tool, 09977-33600 (A/B) on the coupling.

2. Push the special tool into the cage opening to release the

female fitting from the garter spring.

3. Pull the male and female fittings apart.

4. Remove the tool from the spring lock coupling.

ASSEMBLY

1. Check for a missing or damaged garter spring.

Remove the damaged spring with a small hooked wire. Install

a new spring if damaged or missing.

2.

After cleaning the fittings, installing new O-rings. Lubricated

with clean refrigerant oil, Assemble the fitting together by

pushing with a slight twisting motion.

3.

To ensure engagement, visually check that the garter spring

is over the flared end of the female fitting.

Male fitting

Cage

Clean fitting

Garter spring

9 7 - 2 8

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AIR CONDITIONER SYSTEM

REFRIGERANT SYSTEM PERFORMANCE
EVALUATION

The best way to diagnose a problem in the refrigerant

system is to note the system pressures (shown by the

manifold gauges) and the clutch cycle rate and times.

Then, compare the findings with the charts (Figures 1

and 2).

o

The system pressures are low (compressor suction)

and high (compressor discharge).

o Clutch cycle times are the lengths of time (in

seconds) that the clutch is ON and OFF.

The following procedure is recommended for achieving

accurate diagnosis results in the least amount of time.

1. Connect a manifold gauge set.

NOTE:

The test conditions, specified at the top of each

chart, must be met to obtain accurate test results.

2.

As soon as the system is stabilized, record the high

and low-pressures as shown by the manifold

gauges.

3. Determine the clutch cycle time.

4. Record clutch off time in seconds.

5. Record clutch on time in seconds.

6. Record center register discharge temperature.

7. Determine and record ambient temperatures.

8. Compare test readings with the applicable chart.

(Figures 2 and 3)

o

Plot a vertical line for recorded ambient temperature

from scale at bottom of each chart to top of each

chart.

o Plot a horizontal line for each of the other test

readings from scale at LH side of appropriate chart.

If the point where the two lines cross or each of the

charts falls within the band of acceptable limits, the

system is operating normally. If the lines cross outside

the band on one or more of the charts, there is a

problem and the specific cause must be determined.

this is easily done by using the Refrigerant System and

Clutch Cycle Timing Evaluation chart (Figure 3).

Refer to the following five system operating conditions

indicated by where the lines cross on the charts.

o System high (discharge) pressure is high, low, or

normal.

o System low (suction) pressure is high, low, or

normal.

o

Clutch cycle rate is fast, slow, or the clutch runs

continuously.

IMPORTANT TEST REQUIREMENTS

The following test conditions must be established to obtain

accurate clutch cycle rate and cycle time readings.
o Run engine at 1500 rpm for 10 minutes.
o Operate A/C system on max A/C (recirculating air)
o Run blower at max speed.
o Stabilize in temperature 70°F to 80°F (21°C to 22°C)

NORMAL CENTER REGISTER
DISCHARGE TEMPERATURES

AMBIENT TEMPERATURES

AMBIENT TEMPERATURES

NORMAL FIXED ORIFICE TUBE CYCLING CLUTCH

REFRIGERANT SYSTEM PRESSURES

Fig.1 Normal Fixed Orifice Tube Refrigerant System Pressure/Temperature Relationships

9 7 - 2 9

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AIR CONDITIONER SYSTEM

IMPORTANT TEST REQUIREMENTS

The following test conditions must be established to

obtain accurate clutch cycle rate and cycle time readings.
o Run engine at 1500 rpm for 10 minutes.
o Operate A/C system on max A/C (recirculating air)
o Run blower at max speed.
o

Stabilize in temperature 70°F to 80°F (21°C to 22°C)

NORMAL CLUTCH

SECONDS

OFF TIME-SECONDS

AMBIENT TEMPERATURES

NORMAL CLUTCH CYCLE RATE MINUTE

CYCLES/MINUTE

NORMAL CLUTCH

SECONDS

ON TIME-SECONDS

AMBIENT TEMPERATURES

Fig. 2 Normal Fixed Orifice Tube Refrigerant System Clutch Cycling Timing Rates

o Clutch on time is long or short.

o

Clutch off time is long or short.

Match these conditions to the conditions shown in the

five columns toward the left in the System Pressure and

Clutch Cycle Timing Evaluation chart (Figure 2). All five

system conditions will be indicated on one line. The

most likely component or components causing the

problem are listed in the column at the RH side of the

chart.

Example:

o High (discharge) pressure is low.

o Low (suction) pressure is normal.

o Clutch cycle rate is very fast.

o Clutch on time is very short.

o Clutch off time is very short.

The component causing the problem is the clutch

cycling pressure switch. The cycling range is too close.

Replace the switch and recheck the system.

Example:

o High (discharge) pressure is normal to low.

o Low (suction) pressure is normal.

o Clutch cycle rate is fast.

o Clutch on time is short.

o Clutch off time is short.

The component causing the problem is the evaporator

core. Airflow is restricted, indicating debris entering

through the cowl air inlet and plugging the core.

The condition can also be detected by checking the

center register discharge temperature. An abnormally

low temperature would mean air is spending more time

in the evaporator and is very cold when discharged,

although the volume is not enough to cool the vehicle

properly.

At the bottom of the chart (Figure 3). additional cause

components are listed for poor compressor operation or

a damaged compressor condition.

9 7 - 3 0

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AIR CONDITIONER SYSTEM

The two diagnosis charts which follow Figure 3 provide

the most direct and sure way to determine the cause

of any problem in a poorly performing refrigerant

system. These charts are titled:

o Insufficient or No A/C Cycling-Fixed Orifice Tube

Cycling Clutch System (Test Steps A1 through A11).

o

Compressor Clutch Circuit Diagnosis (Test Steps B1

through B11)

After servicing and correcting a refrigerant system

problem, take additional pressure readings and observe

the clutch cycle rate while meeting the conditional

requirements (Figure 34) to ensure that the problem has

been corrected.

In ambient temperatures above 38°C (100°F), the

compressor clutch will not normally cycle off and in

many instances, the clutch will not cycle off when

temperatures are above 32°C. (90°F) This will depend

on local conditions and engine/vehicle speed. Also,

clutch cycling will normally not occur when the engine

is operating at curb idle speed. If the system contains

no refrigerant or is extremely low in refrigerant, the

clutch will not engage for compressor operation. A rapid

cycling compressor clutch is usually and indication that

the system is low on refrigerant. Refer to Insufficient

or No A/C Cooling-Fixed Orifice Tube Cycling Clutch

System Diagnosis chart.

9 7 - 3 1

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AIR CONDITIONER SYSTEM

REFRIGERANT SYSTEM PRESSURE AND CLUTCH CYCLE TIMING EVALUATION CHART

NOTE

Normal system conditional requirements must be maintained to properly evaluate retrigerant system pressures.

Refer to charts applicable to system being tested.

High

(Discharge)

pressure

Low

(suction)

pressure

Clutch cycle time

Component-Causes

Rate

ON

OFF

Condenser-Inadequate Airflow

Engine overheating

High

Normal

to high

Normal

High

High

Normal

to High

Continuous run

Air in system

refrigerant overcharge(a)

Humidity or ambient temp very high(b)

Fixed orifice tube-Missing.

O-rings Leaking/Missing

Normal

High

Normal

High

Slow

Long

Long

Clutch cycling switch-High Cut-in

Moisture in refrigerant system.

Excessive refrigerant oil.

Slow or

Long or

no cycle

continuous

Fast

Short

Normal or

no cycle

Normal

Normal

Short

Clutch cycling switch-

Low Cut-in or High Cut-Out

Clutch cycling switch-

Low cut-out

Long

Normal

Normal

to low

Low

High

Normal

to high

Compessor-Low Performance

Continuous run

A/C suction line-Partially Restricted

or Plugged(c)

Normal

to low

Short

Normal

Evaporator-Low Airflow

Condenser, fixed orifice tube, or A/C

liquid line-Partially Restricted or Plugged

Short to

very short

Normal to

long

Normal

to low

Normal

Fast

Low refrigerant charge

Evaporator core-Partially Restricted or Plugged

A/C suction line-Partially Restricted or

Plugged.(d).

Clutch cycling switch-Sticking Closed

Normal

to low

Continuous run

Low

9 7 - 3 2

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AIR CONDITIONER SYSTEM

High

Low

Clutch cycle time

(Discharge) (Suction)

Component-Causes

pressure

pressure

Rate

ON

OFF

Low

Normal

Erratic operation

or compressor not

running

Very

fast

-

Very

short

-

Very

short

-

Clutch cycling switch-Cycling Range Too Close

Clutch cycling switch-Dirty Contacts or Sticking

Open.

Poor connection at A/C clutch connector or

clutch cycling switch connector.

A/C electrical circuit erratic-See A/C Electrical

Circuit Wiring Diagram

Additional possible causes

associated with inadequate compressor operation

o Compressor clutch slipping. o Loose drive belt

o Clutch coil open-Shorted or loose mounting

o Control assembly switch-Dirty contacts or sticking open

o Clutch wiring circuit-High resistance. Open or blown fuse

Additional possible causes

associated with a damaged compressor

o Clutch cycling switch-Sticking closed or compressor clutch seized

o Suction accumulator drier-Refrigerant oil bleed hole plugged

o Refrigerant leaks

1)

Compressor may make noise on initial start-up. This condition can be caused by excessive liquid refrigerant.

2) Compressor clutch may not cycle in ambient temperatures above 80°F depending on humidity.

3)

Low pressure reading will be normal, to high if the pressure readings are taken at the accumulator and if

the restriction is down stream of the service access valve.

4) Low pressure reading will be low if pressure readings are taken near the compessor and the restriction is

upstream of the service access valve.

Fig.3 Refrigerant System Pressure and Clutch Cycle Timing Evaluation-Fixed Orifice Tube Cycling Clutch System.

9 7 - 3 3

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COMPRESSOR ASSEMBLY

C O M P R E S S O R

COMPONENTS

REMOVAL AND INSTALLATION

1. Remove the distributor assembly.

2. Loosen the tension pulley and then remove the belt.

3. Discharge the refrigerant.

4. Disconnect the magnetic clutch connector,

5. Remove the discharge hose and suction hose.

6. Remove the compressor from the compressor bracket

assembly.

7. Installation is the reverse of removal.

9 7 - 3 4

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COMPRESSOR ASSEMBLY

COMPONENTS

TORQUE : Nm (kg.cm, Ib.ft)

9 7 - 3 5

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COMPRESSOR ASSEMBLY

DISASSEMBLY

CLUTCH FRONT PLATE

Removal

1. Removal of U-NUT

1) Temporarily install two M6 bolts, 25 mm (.98 in.) or

longer, in the bolt holes of the clutch front plate.

NOTE:

Make sure the ends of the bolts do not contact the

front housing.

2) Use two box-end wrenches to hold the bolts (so as to

prevent the clutch front plate from turning). Then remove

the nut.

3) Remove the clutch front plate from the shaft.

2. Remove the clutch front plate using the clutch front plate

puller (09977-21110).

1) Align the puller center bolt on the compressor shaft.

2)

Hand tighten the three puller bolts into the thread holes.

3) Turn the center bolt clockwise with the socket until the

clutch front plate is loosened.

3. Remove the clutch shims.

4. Remove the bearing dust cover.

5 . Remove the external front housing snap ring using snap ring

pliers.

9 7 - 3 6

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COMPRESSOR ASSEMBLY

6.

Using the puller, remove the rotor pulley assembly.

7. Loosen the clutch lead wire from the clip on top of the

compressor front housing.

8.

Using snap ring pliers, remove the snap ring and field coil.

INSTALLATION

1.

The coil flange protrusion must match the hole in the front

housing to prevent coil movement and to correctly position

the lead wire.

2. Place the coil snap ring into position using pliers.

NOTE

Make sure the snap ring is firmly in place.

3. Tighten the wire clip

Torque . . . . . . . . . . . . 20-25 Nm (200-250 kg.cm, 14-18)

9 7 - 3 7

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COMPRESSOR ASSEMBLY

4.

5 .

6.

7.

8.

9.

Install the pulley assembly using the special tool. (09977-

21811).

NOTE

1) Press in the rotor bearing outer race.

2) After installation, rotate the pulley assembly and check

for proper installation.

Reinstall the external bearing snap ring with pliers.

NOTE

When installing the snap ring, be careful not to scratch the

surface of the bearing with pliers.

Using the special tool (09977-21800) install the bearing

dust cover,

NOTE

After installation, rotate the clutch pulley. Check that

there is no contact between the cover and front housing.

Reinstall the clutch spacer shims.

NOTE

Check that the original clutch shims are in place on the

compressor shaft.

Align the front plate key-way to the compressor shaft key.

Then install the front plate using a socket.

With the special tool, (09977-21110). tighten the U-Nut to

specifications.

Torque . . . . . . . . . . . . . . 17-19 Nm (170-190, 12-14 Ib.ft)

9 7 - 3 8

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COMPRESSOR ASSEMBLY

10. Check the air gap and clutch engagement.

1) Place a dial gauge onto the clutch front plate.

2)

Apply 8V DC to the coil and check clutch engagment. The

air gap (readings before and after the engagement)

should be as follows.

Air gap between the front plate and clutch rotor: 0.4-0.8

mm (0.016 - 0.032 in.)

3)

If the air gap is out of specifications, remove the U-Nut

and front plate.

4) Replace the shims with ones of different thickness to

adjust the air gap.

SHAFT SEAL ASSEMBLY

Removal

1.

Remove the shaft key by lightly tapping it with a screw driver

and plastic hammer.

2.

Using the snap ring pliers, insert the tool points into the two

holes of the felt ring metal retainer and lift out the felt ring.

3.

Remove the shaft seal seat retaining snap ring with pliers.

9 7 - 3 9

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COMPRESSOR ASSEMBLY

4. Insert the seal seat remover (09977-21400) against the

seal plate and twist the seal seat remover until it engages

the plate and lift out.

5. Insert the shaft seal remover (09977-21500) against the

seal assembly. Press down against the seal spring and twist

the tool until it engages the slots of the seal cage. Lift out

the seal assembly.

INSTALLATION

The shaft seal assembly should never be reused.

Never re-use any parts of the assembly.

Replace the complete assembly.

Make sure all foreign substances are thoroughly removed from

the compressor shaft and front housing.

Do not touch the surface of the seal while handling the seal

assembly.

1. Insert the shaft seal guide (09977-21700) over the

compressor shaft. Apply refrigerant oil onto the outer surface

of the shaft seal guide.

2.

Clean the seal surface and O-ring with an air nozzle. Apply

clean refrigerant oil to the seal surface.

Place the slots of the shaft seal remover (09977-21510)

into the new seal assembly. Firmly press and twist clockwise,

until the seal assembly is engaged. Twist the tool in the

opposite direction to disengage the tool from the seal cage.

Remove the tool.

9 7 - 4 0

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COMPRESSOR ASSEMBLY

3. Coat the seal retainer with clean refrigerant oil.

Use the tool to install. Press lightly against seal.

4. Remove the shaft seal guide.

5. Install the snap ring.

NOTE

The beveled edge faces outward from the compressor and

the flat side faces towards the compressor.

6. Check for refrigerant leakage.

1 ) Install the shaft nut onto the compressor shaft and rotate

the compressor shaft several times using a socket.

2) Charge the compressor and check for leakage at the

shaft seal using a leak detector.

7.

Insert a new felt ring into the front housing and press evenly

with the special tool (09977-21400).

9 7 - 4 1

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COMPRESSOR ASSEMBLY

8. Using pliers, press the key into place. Be careful not to

damage the compressor shaft when installing.

C Y L I N D E R H E A D A N D V A L V E P L A T E

R E M O V A L

1. Remove the six cylinder head cap screws using a 13 mm

socket.

2.

Use a small plastic hammer and a gasket scraper to tap the

outer edge of the cylinder head until it is loose from the valve

plate. (The cylinder head gasket normally sticks to the valve

plate.)

Do not scratch the cylinder head or valve plate when

removing.

3.

Position the gasket scraper between the outside edge of the

valve plate and the cylinder block and tightly tap the valve

plate loose.

9 7 - 4 2

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COMPRESSOR ASSEMBLY

4. Using the gasket scraper, remove the cylinder and head

gaskets.

Do not damage the cylinder block or valve plate surfaces.

INSTALLATION

1. Coat the valve plate with refrigerant oil and install the

cylinder block gasket.

2. Align the valve plate locating pins to the pin holes in the

block and position the valve plate.

3. Coat the valve plate with refrigerant oil and install the

cylinder head gasket.

4. Align the valve plate locating pins to the pin holes in the

cylinder head and position the cylinder head.

Tighten the six bolts in the cylinder head with a torque

wrench.

Torque . . . . . . . . . 34-36Nm (340-360 kg.cm, 25-26 Ib.ft)

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COMPRESSOR ASSEMBLY

Rotor Pulley Bearing

Removal and Installation

1. Remove the bearing snap ring.

2.

Using the special tools, (09977-21811 and 09216-21300)

remove the bearing.

3. Using the special tool, (09977-21811) install the bearing.

9 7 - 4 4

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EVAPORATOR ASSEMBLY

EVAPORATOR

COMPONENTS

REMOVAL AND INSTALLATION

1. Discharge the refrigerant from the lines system.

2. Disconnect the suction and liquid lines.

3. Remove the grommet cover.

4. Remove the console assembly.

5. Remove the glove box assembly.

9 7 - 4 5

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EVAPORATOR ASSEMBLY

6. Remove the main lower crash pad, lower crash pad center

facia panel and lower crash pad center skin.

7. Remove the blower assembly.

8. Remove the evaporator assembly.

9. Installation is the reverse of removal.

INSPECTION

1. Check for damage to the evaporator fins.

2. Check for a damaged or collapsed drain hose.

3. Check for peeling or cracking of the insulation.

9 7 - 4 6

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CONDENSER ASSEMBLY

CONDENSER

COMPONENTS

ON-VEHICLE INSPECTION

1. Check the condenser fins for restriction or damage.

If the fins are restricted, wash them with water and dry with

compressed air. If the fins are bent, straighten with a

screwdriver or fin straightener.

CAUTION

Be careful not to damage the fins.

2. Check the condenser fittings for leakage.

9 7 - 4 7

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CONDENSER ASSEMBLY

REMOVAL

1. Lift the hood.

2. Discharge the refrigerant from the system.

3.

Disconnect the discharge line from the condenser inlet fitting

using the special tool. (09977-33600)

4. Remove the radiator grille.

5. Remove the radiator assembly.

6.

Disconnect the liquid line from the condenser outlet fitting.

INSTALLATION

1. Installation is reverse of removal.

2. If the condenser is replaced, add refrigerant oil to the

compressor (1.8 US fl oz, 1.9 Imp fl oz)

3. Evacuate, charge and test refrigeration system.

9 7 - 4 8

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CONDENSER FAN & RELAY

CONDENSER FAN ASSEMBLY

ON-VEHICLE INSPECTION

1. Check the condenser fan for restrictions or damage.

2. Check the harness connection.

REMOVAL AND INSTALLATION

1. Disconnect the battery ground cable.

2. Disconnect the connector from the A/C harness.

3. Remove the fan assembly.

4. Installation is the reverse of removal.

INSPECTION

1.

Using an ohmmeter, check that there is continuity between

terminals L and B.

RELAY

INSPECTION

1. Using an ohmmeter, check to be sure that there is no

continuity between terminals L and B.

2. Apply 12 volts across Terminals S1 and S2 then check

continuity between terminals L and B.

Replace if necessary.

9 7 - 4 9

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BLOWER ASSEMBLY

B L O W E R A S S E M B L Y

COMPONENTS

REMOVAL AND INSTALLATION

1. Remove the glove box housing cover assembly.

2. Remove the lower crash pad assembly.

3. Disconnect the resistor and blower motor connector.

4.

Pull out the blower unit and then disconnect the fresh/recirc

vacuum connector.

5. Installation is the reverse of removal.

9 7 - 5 0

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BLOWER ASSEMBLY

INSPECTION

1. Check for bending or abnormal deflection of the rotating

shaft of the blower motor assembly.

2. Check for cracking or deterioration of the packing.

3. Check for damage to the fan.

4. Check for damage to the blower case.

5. Check the operation of the inside/outside air selection

damper, and for damage.

6. Connect the blower motor terminals directly to the battery

and check that the blower motor operates smoothly.

7.

Next, reverse the polarity and check that the blower motor

operates smoothly in the reverse direction.

8.

Using an ohmmeter, check that there is continuity between

terminals 1 and 2.

If there is no continuity, replace the resistor.

9 7 - 5 1

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ACCUMULATOR ASSEMBLY

ACCUMULATOR

COMPONENTS

REPLACEMENT

It will be necessary to replace the accumulator for the following

reasons.

1. The accumulator is restricted, plugged or damaged.

2. The system has been left open for more than 24 hours.

(system completely discharged)

3. There is evidence of moisture in the system.

4. A component such as a condenser, evaporator core,

refrigerant line or a seized compressor is replaced.

NOTE:

It is not necessary to replace the accumulator when there

is a partial loss of refrigerant charge or a dent is found

in the outer shell of the accumulator.

9 7 - 5 2

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ACCUMULATOR ASSEMBLY

REMOVAL

1. Discharge the air conditioning system.

2. Disconnect the two suction line from the accumulator.

3. Disconnect the wiring harness.

4. Remove the accumulator from the bracket.

5. Remove the clutch cycling switch.

NOTE

Plug all open fittings immediately to keep moisture out of

the system.

INSTALLATION

1.

Install the accumulator in the bracket.

NOTE

Do not remove the plugs until ready for connection.

2.

3.

4.

5.

6.

7 .

Connect the liquid lines to the accumulator.

If the accumulator is replaced with a new unit, add 30cc of

compressor oil to the accumulator.

Install the clutch cycling switch.

Connect the wiring harness.

Charge the system.

Check for any refrigerant leaks.

9 7 - 5 3


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