AIR CONDITIONING SYSTEM Return To Main Table of Contents GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HEATER CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 12 HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 AIR CONDITIONER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . .
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.
GENERAL SPECIAL TOOLS 97-3
GENERAL TROUBLESHOOTING INSUFFICIENT OR NO A/C COOLING-FIXED ORIFICE TUBE CYCLING CLUTCH SYSTEM TEST STEP A1 RESULT ACTION TO TAKE VERIFY THE CONDITION Check system operation System cooling properly INSTRUCT vehicle owner on proper use of the system System not cooling Properly GO to A2 Yes GO to A3 No REFER to clutch circuit diagnosis in this section Yes GO to A4 No Check for cooling fan electric circuit OK but still not cooling Not OK GO to A6 OK Condition Corrected GO to A1 Not OK GO
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 evaluation charts. Prepare the car as follows 1. Hook up the manifold gauge set 2. Set Function lever at max A/C 3. Set blower switch on high 4. Set temperature lever full cold 5. Close doors and windows 6. Use a thermometer to check temperature at center discharge register. Record outside temperature.
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 limits. System pressure within limits A9 System OK GO to A1 Compressor runs continuously (normal operation in ambient temperature above 27°C (80°F.) depending on humidity conditions). GO to A11 Compressor cycles high or low ON above 359 kPa (52 psi) OFF below 144 kPa (21 psi).
GENERAL COMPRESSOR CIRCUIT CLUTCH DIAGNOSIS TEST STEP B1 ACTION TO TAKE CHECK SYSTEM OPERATION o o o o B2 RESULT Turn the blower switch ON. Depress the A/C button. Turn the ignition switch to the RUN position. Compressor clutch should engage and engine cooling fan should operate. Clutch and fan operate System OK Clutch and fan do not operate GO to B2 Only fan operates GO to B5 CHECK FOR VOLTAGE o Check for voltage at circuit wire at the clutch Voltage present cycling pressure switch connector.
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.
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.
GENERAL VACUUM SYSTEM SYMPTOM AND PROBABLE CAUSE 97-10
GENERAL Symptom Probable cause On “FLOOR” position. All air through defroster or DEF/FLOOR. 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 disconnected at the vacuum manifold. o Defective vacuum motor. On “DEF/FLOOR” position. All air through defroster. o o o o On “PANEL VENTS” position. All air through defroster.
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.
HEATER COMPONENTS VACUUM TYPE 97-13
HEATER COMPONENTS LEVER TYPE 97-14
VENTILATORS REMOVAL 1. 2. 3. 4. Disconnect the negative terminal at the battery. Drain the coolant from the radiator. Remove the heater hoses and the evaporator drain hose. 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.
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.
VENTILATORS VENTILATORS COMPONENTS 97-17
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. 6. 7. 8. Remove Remove Remove Remove the the the the heater connection assembly. defroster nozzle assembly. side defroster nozzle assembly (LH/RH). crash pad upper cover assembly. 9.
AIR CONDITIONER SYSTEM AIR CONDITIONER COMPONENTS TORQUE : Nm (kg.cm, Ib.
AIR CONDITIONER SYSTEM AIR CONDITIONER SYSTEM SERVICE CAUTIONS 0 0 0 0 0 0 0 0 0 0 0 0 0 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.
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.
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.
AIR CONDITIONER SYSTEM HANDLING REFRIGERANT SERVICE TAP VALVE 1. 2. 3. 4. 5. 6. 7. Before connecting the valve to the refrigerant container, turn the handle fully counterclockwise. Turn the adapter counterclockwise until it reaches its highest position. Connect the center hose to the valve fitting. Turn the adapter fully clockwise by hand. Turn the handle clockwise to make a hole in the sealed top. Turn the handle fully counterclockwise to fill the center hose with air.
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.
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.
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.
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.
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. Male fitting 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.
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. 6.
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.
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).
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.
AIR CONDITIONER SYSTEM High Low (Discharge) (Suction) pressure pressure Low Clutch cycle time Component-Causes Normal Erratic operation or compressor not running Rate ON OFF 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.
COMPRESSOR ASSEMBLY COMPRESSOR COMPONENTS REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. 6. Remove the distributor assembly. Loosen the tension pulley and then remove the belt. Discharge the refrigerant. Disconnect the magnetic clutch connector, Remove the discharge hose and suction hose. Remove the compressor from the compressor bracket assembly. 7. Installation is the reverse of removal.
COMPRESSOR ASSEMBLY COMPONENTS TORQUE : Nm (kg.cm, Ib.
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.
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.
COMPRESSOR ASSEMBLY 4. Install the pulley assembly using the special tool. (0997721811). NOTE 1) Press in the rotor bearing outer race. 2) After installation, rotate the pulley assembly and check for proper installation. 5 . 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. 6. Using the special tool (09977-21800) install the bearing dust cover, NOTE After installation, rotate the clutch pulley.
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.
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.
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.
COMPRESSOR ASSEMBLY 8. Using pliers, press the key into place. Be careful not to damage the compressor shaft when installing. CYLINDER HEAD AND VALVE PLATE REMOVAL 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.
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.
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.
EVAPORATOR ASSEMBLY EVAPORATOR COMPONENTS REMOVAL AND INSTALLATION 1. 2. 3. 4. 5. Discharge the refrigerant from the lines system. Disconnect the suction and liquid lines. Remove the grommet cover. Remove the console assembly. Remove the glove box assembly.
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.
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.
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.
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. 2. 3. 4. Disconnect the battery ground cable. Disconnect the connector from the A/C harness. Remove the fan assembly. Installation is the reverse of removal. INSPECTION 1. Using an ohmmeter, check that there is continuity between terminals L and B. RELAY INSPECTION 1.
BLOWER ASSEMBLY BLOWER ASSEMBLY 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.
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.
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.
ACCUMULATOR ASSEMBLY REMOVAL 1. 2. 3. 4. 5. Discharge the air conditioning system. Disconnect the two suction line from the accumulator. Disconnect the wiring harness. Remove the accumulator from the bracket. 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. Connect the liquid lines to the accumulator.
