24-1

HEATERS AND AIR CONDITIONING

CONTENTS AIR CONDITIONING ............................. 17
44 55 45 48 45 52 53 31 32 43 44 42 32 36 37 32 36 18 17 17 17 17 18

N.?4AA2

HEATERS *.....*.....,..........................,.*....

AIR CONDlTlONER SWITCH ........................ COMPRESSOR ............................................. FRONT EVAPORATOR ................................. REAR EVAPORATOR .................................... ...................................... REAR FAN SWITCH REAR VENTILATORS ................................... RECEIVER DRIER, CONDENSER, COMPRESSOR CLUTCH ASSEMBLY ......... SAFETY PRECAUTIONS ............................... SERVICE ADJUSTMENT PROCEDURES ..... Compressor Drive Belt Adjustment ........... Compressor Noise ..................................... Handling Tubing and Fittings ..................... Manifold Gauge Set Installation ................ Performance Test ...................................... Refrigerant Leak Repair Procedure ........... ........................................ Test Procedures Testing System for Leaks .......................... SPECIAL TOOLS ........................................... SPECIFICATIONS ......................................... ............................... General Specifications Service Specifications ............................... ................................ Torque Specifications TROUBLESHOOTlNG ................................... Air is Emitted but is Not Cool Cool Air Flow is Intermittent Insufficient Air Flow Insufficient Cooling

BLOWER ASSEMBLY .. .. . . . . .. . . . . . . . .. .. .. . . . . ..a..... 13 HEATER CONTROL . . . . . . . .. . . . . . . .. . . . . . ..a............. 8 HEATER UNIT . . . . . . . . . . . . .. . .. . . . .. .. . . . . . . . . . .. .. . . . . . . . . . . 11 SERVICE ADJUSTMENT PROCEDURES ..... 5 Temperature Control System Adjustment . . . . . . . . . . . . . .._._...............-....-......... 5 Water Valve Replacement . .. .. . . . . . . . . .. . . . ..~.~.. 7 SPECIFICARONS . . . .. .. .. .. .. . .. . .. . . . . . . . . . .. . . . . . . . . . .. 2 General Specifications _._..._.._.._ _______ _._........ 2 TROUBLESHOOTING . . . . . . . ..*.......*..........*...... 2 Improper Heat No Ventilation Even When Mode Selection Lever is Operated VENTILATORS . . . . . . . . . .. .. . . .. . . .. . . . . . . . . . . . . . .. . . . . . . . . . . 14

24-2

HEATERS

- Specifications

/ Troubleshooting

HEATERS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Items Type Performance kJ/h (kcal/h. B.T.U./h) Specifications Selective recirculating, warm water type (air-miytype) 17,372(4,150, 16,468)

N24cA.A

TROUBLESHOOTING
Symptom Improper heat Probable cause Obstructed floor outlets Remedy Correct Correct Replace Adjust -

Pd24SUl

Changeover dampers improperly adjusted or binding Obstructed heaters hoses control cables

Improperly &usted

Plugged or partially plugged heater core mz Clearn or replace No ventilation even when mode selection lever is operated Incorrect adjustment dampers of changeover : Adjust ---~ Repair or replace Adjust

Incorrect installation mode selection control wire Ducts are incorrectly incompletely connected, crushed, bent or clogged.

HEATERS HEATER
CIRCUIT

- Troubleshooting

24-3

CIRCWT
DIAGRAM c2.6L Engine>

Ignition switch

Remark For information concernin the ground points (example: En,). refer to GROUP E&ectncal System Parts Loch wiring color code B: Black Br: Brown U: Light blue 0: Orange G: Green P: Pink

OPERATION l When the ignition switch is at ON, current flows through fuse No. 3, heater relay (coil), and ground, causing the heater relay contacts to close. l Then when the blower switch is set at any of L, M,, I, MY, or H, current flows through fuse No. 6, heater relay (contacts), blower switch, resistor, blower motor, and ground, causing the blower motor to rotate.
1 TSB Revision

TROUBLESHOOTING Blower motor turns l Check resistor.

HINTS only at high speed.

24-4
HEATER CIRCUIT

HEATERS

- Troubleshootinn

CIRCUIT DIAGRAM <3.OL Engine>

SK Brawn
il: L&M blue 0: OEdlQe

OPERATION l When the ignition switch is at ON, current flows through fuse No. 3, heater relay (coil). and ground, causing the heater relay contacts to close. l Then when the blower switch is set at any of #y-m, M, .,, I, MY, or H, current flows through fuse No. 6, heater relay (contacts), blower switch, resistor, blower motor, and ground, causing the blower motor to rotate. 1 TSB Revision

TROUBLESHOOTING Blower motor turns 8 Check resistor.

HINTS
only at high speed.

~c

HEATERS

Service

Adjustment

Procedures

24-5 PROCEDURES
SYSTEM ADJUSTN24Fc99

SERVICE ADJUSTMENT
gEi-EMl;ERATURE

CONTROL

MODE SELECTION LEVER 1. Move the mode selection lever to each position and check the air flow with the blower operating. 2. If the air flow is not correct for any position of the mode selection lever, adjust the mode selection control wire. If this adjustment does not help, adjust the damper. Adjustment of the Mode Selection Control Wire 1. Disconnect the defroster duct and the lap heater duct (B) at the drivers seat side from the heater unit. 2. Disconnect the mode selection control wire from the mode selection damper lever and the heater units clip.

3. Set the mode selection lever of temperature control q position. 4. Turn the mode selection damoer lever all the way direction of the arrow. 5. Connect the mode selection control wire to the selection damper lever. and to the clip part of the unit. Caution Be careful 6. that the lever does not move when

to the in the mode heater

clipping.

Check to be sure that the mode selection lever moves smoothly to each position and that the air flow is correct for each position. 7. If the air flow is not correct for any position of the mode selection lever even after the mode selection control wire has been adjusted, adjust the VENT damper and the FOOT/DEF damoer. 8. Connect the drivers side defroster duct and lap heater duct (B) to the heater unit.

Adjustment of the Damper 1. Disconnect the. mode selection control wire from the mode selection damoer lever and the heater units clip. 2. Adjust the VENT damper as described below: (1) Unfasten the clip of the mode selection damper lever, and disconnect the link for the VENT damper from the mode selection damper lever.

levision

m-.*.-

24-6

HEATERS - Service Adjustment

Procedures

(2) Turn the mode selection

damper lever all the way in the direction of the arrow. (3) Pull the VENT damper lever completely downward and move the VENT damper to the position (not visible) shown in the figure. (4) Attach the end of the link for the VENT damper to the mode selection damper lever.

3. Adjust the FOOT/DEF damper as described below. (1) Unfasten the clip of the mode selection damper lever, and disconnect the link for the FOOT/DEF damper from the mode selection damper lever. (2) Turn the mode selection damper lever all the way in the direction of the arrow.

(3) Pull the FOOT/DEF damper lever completely upward and move the FOOT/DEF damper to the position shown in the figure. (The packing should contact the case.) NOTE Confirmation can be made that the FOOTKIEF damper is raised upward through the defroster blower outlet of the heater unit (with defroster duct disconnected).

(4) Attach the end of the link for the FOOT/DEF to the mode selection damper lever.

damper

NOTE When attaching it, pull the lever end (A in the figure) in the direction of the arrow. 4. Referring to the section which explains the adjustment of the mode selection control wire, connect the control wire to the mode selection damper lever.

TEMPERATURE CONTROL LEVER

1. Move the temperature control lever from its extreme left position to its extreme right position and check to be sure that it moves correctly and smoothly to each position. 2. Then move the temperature control lever to the extreme left position, and check to be sure that warm air does not come out when the blower is operated. 3. If the air flow is not correct in the above step, adjust the temperature control wire.
:f

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HEATERS

- Service Adjustment

Procedures

24-7

Adjustment of the Blend Air Damper 1. Move the warm water flow control lever to the extreme left position. 2. Disconnect the water valve control wire from the blend air damper lever and the heater units clip. 3. Remove the water valve cover.

4.

Unfasten the clip of the blend air damper lever, and disconnect the link for water valve lever from the blend air damper lever.

5. Push the water valve lever all the way inward so that the water valve is at the closed position. 6. Turn the blend air damper lever all the way in the direction of the arrow so that the blend air damper is completely closed at the lower most position. 7. Attach the end of the link for the water valve lever to the blend air damper lever. 8. Install the water valve cover. 9. After connecting the water valve control wire to the blend air damper lever, connect to the clip part of the heater unit. Caution Be careful that the lever does not move when clipping.

IO. Check to be sure that operates smoothly at each that the blend air damper temperature control lever position and the extreme

the temperature control lever position. Also check to be sure is completely closed when the is moved to the extreme left right position.

WATER

VALVE

REPLACEMENT

W4FBAF

1. Set the temperature control lever to the extreme right position. 2. Remove the radiator drain plug, and then drain the engine coolant. 3. Remove the air cleaner <2.6L Engine> 4. Remove the air intake plenum <3.OL Engine> (Refer to GROUP II-Air Intake Plenum) 5. Remove the heater hose clamp to disconnect the heater hose. 1 TSB Revision I

,.

_,.,.

=_

HEATERS

- Service Adjustment
6.

Procedures

/ Heater Control
_ --1 B&z. =i

Disconnect the water valve control wire from the blend air damper lever and the heater units clip. 7. Remove the water valve_cover.

8. 9. 10. 11. 12. 13. 14. 15. 16.

Remove the piping clamp. Unfasten the clip of blend air damper lever, and disconnect the link for the water valve lever from the blend air damoer lever. Remove the joint hose clamp. Cut the joint hose. Remove the water valve from the heater core. Apply a coating of soapywater to the inside surface of the new joint hoses, and then connect them to the pipe part of the water valve and the heater core. Connect the link, and then install the heater cover. Close the radiator drain plug and refill the engine cooling system with coolant. Check operation. 8 9

HEATER CONTROL
REMOVAL I AND INSTALLATION

N24GA?

Removal
*+

steps
1. Glove box stoppers 2. Air selection control wire ++ e)+ *c+~** ++

l +

3. Knobs
4. Pluas

8. 9. 10. 11. 12.

Defroster duct Mode selection conlrol wire Water valve control wire Heater control assembly Blower switch to reinstall. of Removal. of Installation.

5. Center panel
6. Connection of center ness to front wiring 7. Lap heater duct (B) panel wiring harharness connector

NOTE (1) Reverse the removal procedures (2) *I, : Refer to Service Points 13) +41 : Refer tu Service Points

( TSB Revision

HEATERS
2.

- Heater Control POINTS OF REMOVAL

24-9
N24GBu

SERVICE

REMOVAL OF AIR SELECTION CONTROL WIRE (1) Use a screwdriver to pry and remove the clip that holds the outer cable of the air selection control wire. (2) Disconnect the inner cable of the air selection control wire from the end of the recirculation/fresh-air changeover damper lever.

9.

REMOVAL OF MODE SELECTION (1) While using a screwdriver to pry outer cable of the mode selection outer cable to remove it from (2) Disconnect the inner cable of control wire from the end of damper lever.

CONTROL WIRE the clip that holds the control wire, pull the the clip. the mode selection the mode selection

10. REMOVAL OF WATER VALVE CONTROL WIRE (1) Use a screwdriver to pry and remove the clip that holds the outer cable of the water valve control wire. (2) Disconnect the inner cable of the water valve control wire from the end of the water valve control lever.

INSPECTION
BLOWER SWITCH Operate the switch, minals. lW4GCACI and check the continuity between the ter-

NOTE 0-O indicates that there is continuity between the terminals.

2OW7Oi

svision

HEATERS - Heater Control

Top view Bottom view

SERVICE POINTS OF INSTALLATION

I

AS-

11. APPLICATION SEMBLY

OF GREASE

TO HEATER CONTROL

Apply the multipurpose grease to all the moving the heater control assembly.

parts of

2OW553

2OWS.34

10. INSTALLATION OF WATER VALVE CONTROL WIRE Connect the water valve control wire to the water valve control lever by following the steps below. (1) Move the temperature control lever to the extreme left position. (2) With the water-valve control lever pressed inward in the direction indicated by the arrow, connect the inner cable of the water-valve control wire to the end of the water-valve control lever, and then secure the outer cable by using a clip.
\
2OW75C

9.

INSTALLATION OF MODE SELECTlON CONTROL WIRE Connect the mode selection control wire to the mode selection damper lever by following the steps below. (1) Move the mode selection lever to the-Z position. (2) With the mode selection damper lever pressed inward in the direction indicatecl by the arrow, connect the inner cable of the mode selection control wire to the end of the mode selection lever, and then secure the outer cable by using a clip.

2.

INSTALLATION OF AIR SELECTION CONTROL WIRE Connect the air selection control wire to the air selection damper lever by following the steps below. (1) Move the air selection control lever to the &3 position. (2) With the air selection damper lever pressed inward in the direction indicated by the arrow, connect the inner cable of the air selection control wire to the end of the air selection lever, and then secure the outer cable by using a clip.

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HEATERS - Heater

Unit

24-11
NZ4lA..

HEATER UNIT
REMOVAL AND INSTALLATION
l

Pre-removal Draining ($&reo

Operation of Coolant GROUP 0 - Maintenance

l l

Removal of the Air Cleaner <2.6L Engine> Removal of the Air Intake Plenum <3.OL Engine> (Refer to GROUP 11 - Air Intake Plenum)

Post-installation Operation l Installation of the Air Cleaner <2.6 iL Engine> . I<+2 llation of the Air Intake Plenum <3.OL Engine> (Refer to .-.---- -Intake Plenum) GROUP 11 -Air 0 Supplying of Coolant (Refer to GROUP 0 - Maintenance Service)
,, ..-

2OW823

Removal
+* **

steps
1. Heater hose connection 2. instrument panel

3. Duct
4. Center 5. Heater ventilator unit duct

N.OTE (1) Reverse the removal procedures (2) +* : Refer to Service Points (3) I)* : Refer to Service Points

to reinstall. of Removal of installation.

SERVICE POINTS OF REMOVAL

2. REMOVAL
Refer

NUIBAN

OF INSTRUMENT PANEL to GROUP 23 - Instrument Panel.

INSPECTION
l

tu41cAA

a
l

Check the damper and link mechanism for operation. Check the heater core for clogging or water leakage. Check the water valve for operation and clogging.

j TSB Revision

24-12

HEATERS - Heater
1. Remove

Unit

HEATER CORE REPLACEMENT

the water valve cover.

2.

Remove the fcllowing (1) Piping clamp (2) Water valve link (3) Joint hose clamp (4) Joint hose (5) Screw

parts to remove

the water

valve.

Remove the FOOT/DEF-damper link from the mode selection damper lever. 4. Move the damper lever to the position at which the mode selection damper lever does not protrude very much to the heater core side. 5.. Remove the heater core. If at this time the damper lever and heater core are in contact, making removal difficult, remove the damper lever. Caution To prevent interference between the heater core and case, use care not to peel the heater core felt away when the heater core is removed. 6. After installing the heatercore and water valve, install the link for each damper after referring to the Service adjustment procedures section.

3.

SERVICE POINTS OF INSTALLATION

2. INSTALLATION OF INSTRUMENT Refer to GROUP 23 - Instrument PANEL Panel.

1 TSB Revision

HEATERS - Blower Assembly

24-13

BLOWER

ASSEMBLY

REMOVAL AND INSTALLATION

Removal steps 1. Lap heater duct (C)
2. Glove box

++ I)+
*I)

3. Air selection
4. Duct

control wire

5. Blower assembly 6. Resistor 7. Hose 8. Blower motor 9. Packing IO. Fan

TE Reverse the removal procedures ** : Refer to Service Points ** : Refer to Service Points

to reinstall. of Removal. of Installation

-6
2OW606

SERVICE POINTS OF REMOVAL

3.

N24K6A

REMOVAL OF AIR SELECTION CONTROL WIRE (1) Use a screwdriver to pry and remove the clip that holds the outer cable of the air selection control wire. (2) Disconnect the inner cable of the air selection control wire from the end of the air selection damper lever.

5. REMOVAL OF BLOWER ASSEMBLY (I) Disconnect the connector of the front wiring harness (connected to the resistor). (2) Remove the ground installation bolt. (Tightened together with the blower assembly.) (3) Remove the blower assembly installation bolt.

INSPECTION
RESISTOR Connect an ohmmeter to each terminal measure the resistance. Terminal connections
I-2(M,) 1-3(Mz)

NZMCAD
of the resistor Resistance
Approx. Approx. I Approx. Approx. 1.22n 0.41R 2.250 OQ I

and

I
rTSB Revision
. a

I-4(Low) 1 -5(High)

24-14

HEATERS - Blower Assembly / Ventilators

BLOWER MOTOR (1) Connect the blower motor terminals directly to the battery and check that the blower motor operates smoothly. (2) Next, reverse the polarity and check that the blower motor operates smoothly in the reverse direction.

SERVICE POINTS OF INSTALLATION

3. INSTALLATION Refer OF AIR SELECTION CONTROL to P. 24-10.

NSKOAG

WIRE

VENTILATORS
REMOVAL AND INSTALLATON (Ventilators of instrument panel)

Removal *+

steps

++

++ c+ *+ *+ *+

Demister grille Lap heater garnish Lap heater duct (B) Lap heater duct (C) Defroster duct (L.H.) Lap heater duct (A) Defroster duct (R.H.) Air duct [R.H.) (Only vehicles with air conditioner) 9. Lap heater duct (A) 10. Air duct (L.H.) (Only vehicles with air conditioner)

1. 2. 3. 4. 5. 6. 7. 9.

++

Il. 12. 13. 14. 15. 16. 17.

Instrument panel Defroster duct Center ventilator duct Center air outlet Knob Air duct Side air outlet

cyTEeverse the removal procedures to reinstall. (2) ++ : Refer to Service Points of Removal. .-

HEATERS - Ventilators SERVICE POINTS OF REMOVAL

I.

24-15
W?4MBAG#

REMOVAL OF DEMISTER GRILL While using a screwdriver to pry the lock of the demister grill, use another screwdriver to pry the end of the clemister grill to remove it.

2.

REMOVAL OF LAP HEATER GARNISH While using a screwdriver to pry the lock of the lap heater garnish, use another screwdriver to pry the end of the lap heater garnish to remove it.

6.

REMOVAL OF LAP HEATER DUCT (A) Remove the screw at the side of the instrument then remove the lap heater duct (A).

panel, and

7.

REMOVAL OF DEFROSTER DUCT (R.H.)/8. (R.H.) (1) Open the glove box lid. (2) Remove the glove box stopper. (3) Pull the glove box outward. (4) Remove the defroster duct (R.H.) (5) Remove the air duct (R.H.)

AIR DUCT

9.

REMOVAL OF LAP HEATER DUCT (A) (1) Remove the center panel. (Refer to GROUP 23 - Floor Console) (2) Remove the heater control assembly. (Refer to P.24-3.) (3) Insert a hand through the heater control assembly installation hole in the instrument panel, and remove the installation screw of the lap heater duct (A).

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24-16

HEATERS

- Ventilators
AIR DUCT (L.H.) combination meter. Gauges) air duct (L.H.). (Refer to GROUP 8 -

10. REMOVAL OF (1) Remove the Meters and (2) Remove the

I 1. REMOVAL OF INSTRUMENT PANEL Refer to GROUP 23 - Instrument Panel.

REMOVAL

AND

INSTALLATION

(Rear heater

ducts)

W4MA.B

Removal

steps 1. Floor console 2. Front seat 3. Rail cover

4. Carpet 5. Rear heater duct (B) 6. Rear heater duct (A)

NOTE Reverse the removal prczedures to reinstall.

\ TSB Revision