Heating, Ventilation & Air Conditioning GENERAL [AIR CONDITIONING SYSTEM MANUAL A/C COMPRESSOR CONTROLS... VACUUM SYSTEM HEATER. BLOWER CONTROLS BLOWER AND AIC CONTROLSHAD HEATING, VENTILATION & AIR CONDITIONING GENERAL SPECIFICATIONS (R-134A) coco Tem ‘Spectction ‘Font fester assombiy “Tipe Solectron, var water ype (ani 9p) Heating capecty 400 +490 Kean Far hoatorsssorbiy ee ‘Selective recelating, warm water pe (a-mxpe) ating capacity 4300 = 490 Real Font evaporator ‘ore be Serpentine Soong cacy 4300 teath ‘Rear evaporator ‘Cor pe Serpentine Coating eapacty 2500 teath ‘Gwwmoad wraporior ‘Core 0 Serpentine Cootng eaoacty 1800 Keath ‘Compressor Mose HSIs Dipcemont 186 cokew Model HsI8 Displacement 180 cokev ‘Gondoneer an mar war oage : Dc 120 Gurent 11.314 sw otage : DC 12V Gurren: 75 217A ont up dove 4,000 + 50 1pm rrgeranr quantay 1.20 = 259 owagoR) 7 50 = 259 fan) SERVICE STANDARDS cove tom _ ‘Speciication ‘Anouris of caecton ot V bol 10mm (081-089 in) Eng ile speed 750 fnGENERAL Has LUBRICANTS sss Tem econmended lubricant uantty esr cond aver Mspurpose grease As required ‘Compressor HSS Fotsxc (eka) s00st080 Hsia, FONEXG (PAG) 210st000 SPECIAL TOOLS usm Tool mbar nd na) iosraen rr ess-000 Femoral fl cot Scag anor paler carr aro o pa Be Frese pte bl renavar 4 68, cs arr enol andaaton oa Sa eel enor andar 5 | ‘arr a3a00 Removal of enap emg ‘Snap ring remover —<_—Hast HEATING, VENTILATION & AIR CONDITIONING TROUBLESHOOTING exc eaTER Spon Probable cause Remeay ‘Cannot control temperature by | Thermostat maifunetion — [Replace seaming angus cel | Copgedr danaged coi Fae Covet or ace Claged or diraged hese ore Covet or epace ‘Ars eamper ancion Cones or repace Wong lonperar cont eal connection Corea Tr out cange oer [Ar out changeover danper mafuncon Const pce operated burner fow fn at changeover centro abe Wrengy comected dt ‘lower moter ems abnormal | Foreign substance inside ‘ower a Unbalanced bower motor Damaged fan ‘lower motor wil nat funeten | Fuse town ‘Blower motor Swen malfunction Blower motor maltunetion Fear heater main sich maluinstion Fear heater ay mattuntion ‘lower wil nat change speed Blowor moor ressor masuncton ‘Blower motor ew mauneton [Remarauionias ar [Raced a nove" arbor maancon ehangoover ost Ree”) Wrens eereuaionteshr abla connacton ‘ar changeover coated {IR CONDMONING Symptom Probable cau Femeay ‘Campresor does notin, | Nalinatoning AIG rey ‘Gheck oparaton| crane poorly Natnctening dis pressure swton (Greck operation Maturctoning tormosiet, Check operation atnctoning AIC saeh {Ghack operation | Maunconing blower swch heck operation Blown AG" fuse andor "BLOWER" hse Foplace Locao compressor are bok Feadust Baty votage to ow Feenarge batery Irteral maturetin 6! comoressor patra place compressor ‘Short eet the magnet eal Foplace (on ele taco lost or repice tc {Gap bewaon dive pat and putay too age | Agus gan (Open exe inthe magnet ea Feplace (Open cloose canton slot cou pal ope-ceeuted pontGENERAL HAS [Symptom Probable couse Remedy Fetiorant pressure | Normal prossure are is abeoral igh prossure: 1470-1760 KPa (213298 pd, 15-18 kt) Low pressure: 180290 KPa (2642 pal, 1828 kalo) “wmon, arbienttomperature : 25°C (65) | Engine speed : 1500 rm _ {low pressure 60 Figh | ternal mafncion of compressor ‘Repo replace compressor Fay contac at ansing bu oto expansion avs | Repar Fauty Insult at sensing bub of ha Fepair ‘oparsionvaios Expansion vals, opening i 10 ae eair Tow pressure Boo Tow | inset rthigorant ‘Charge atigoaa FecalverDrver Sogged Replace Expansion vas elonpee piace Fauty bermostt (heck operation Frosted ping. Clean oF ela ppos igh pressures to igh | Instone cooing ofthe condenser ‘Check an clean condenser “To mich coigoan | Dscetga rlegorant | | Aen sjstem vacua and charge stom | | Manotoni condense fan motors ‘heck operation” igh pressure foo ow | Instone retegerant ‘Charge reriera | ntrat matuncon of compressor Rept or piace compressor ‘Netibwer operation | Bown “BLOWER use Foplace Malineton boner motor Repiace Fauly eater Peplaoe Matinton Blower contol seh Fopiaco (Open ease conection malate cout epar open-ceouted point Inoue a ‘Obsruston inthe int ofthe lower unt Remove obstton (Cegged evaporator ean ear win Frosted evsporator (Check armostt Leaking a (Check for leakage on both isos ff oot unt ae ar cts | Bown COMP tse FeplsoeHAS. HEATING, VENTILATION & AIR CONDITIONING DIAGNOSTIC CHART SYSTEN cee —-» [Baise ‘enet coo! oe ‘Gheckhe arcondionerewieh Sp] Check or piace Check the dual pressure switch ‘yo | Raplace i | Checkine magnencclutch ‘wo| Replace ———— ime SS See eee = a ee eee “in ee Foreign matorals in evaporator | Clean the condenser autace | Replace =GENERAL HAT Insufficient blow | Airleskage ductjointioose | Check the duct ‘Check or readjust the] Teanga Evaporator Fst (heck he torment place Fein metas napa | Cock ta Hermosa place Bad Bower mater ‘Ghoakne Bower nator Fepiace Tnaufelert RPM | Aewalor nat aning (Chock he actuator Replace one Solenoid valve notraning | Cheek he slenoidvaive epace (Check he wing Replace Vane ang ‘Check tho vacuum ose Feacjus or olacoHAS AIR CONDITIONING SYSTEM INSPECTION AND ADJUSTMENT OF AIR. CON DITIONER COMPRESSOR BELT TENSION esis 1. Pres bet at ndated pont shown inthe agra at about 1001 (10g. 22 bs) and chock xy is ‘ation mm) | Tension Ko Used 10 031-058) - ‘New set | 555 (020021) ses 2 Adjust oxy not win the standardvalue. 8 Looton cane bot ort of anion pully. 3 Aqust wh aqusing bot or eat otal Next ‘Sin ho sandr vale, © Tin cor bot oF rtf tnsion pully. INSPECTION AND ADJUSTMENT OF AIR CONDITIONER IOLE Up (FAST 1OLE CONTROL, Bevice) 1. Run engine ti coolant temperature 1s 20-90% (76-108) 2, Tuff alight and acossoris. 8. Conf engine ing rpm is at he standard val. 4 Loosen nuts A and. HEATING, VENTILATION & AIR CONDITIONING ‘Adjust rodlongth wah aster so that gap between fuel njoctin pup ovr and rod as the measure rant ah in th agra. “Toon nus A ana, Poston ber motor sich othe a ight (anc tum ar eordone teh ON Cont ar ontonor up rms wii th sta ard value not, remove over, loosen cing nt nd ast tho up aster som Bantad ae 0002 SOR “um arcratoner altos ON andOFFseveraltnes. Conte tote opener i operating creat. Conte fue injecton pup over doesnot ouch oa ‘fen a eenionr ath 6 OFF, (Oo J seinemHA-10 THE FOLLOWING PRECAUTIONS MUST BE OB- SERVED. 4 Wn tis neoaeesrytoapen the retgoration ayo, have evry you wi noe ta servos the stom ready cote systom wl not be lat open any fnger 1d tings 28 soon 8 they re ‘opened prevent ne enanes of it ara moisture, 8. Allies and components In pars stock shoud be ‘appod sacle unl thoy ar ready 1 be usa. 4 Newer attempt fo eben mad ings ft. Uso he ‘orc te rte iatalaton you are seco. 5. Altai. incucng he refrgerant dpensing mano, ‘ho gauge sel manioidandtesthoess, soudbo kop ‘oan and cy. SAFETY PRECAUTIONS cass 1. Tho R-194s gud clegerantishighy volte. A ckop {ntheakn of yourhand could eau ncalzod rst bie. When nanaing te rotor bo suo fo weer ‘vs. 2. eigen epashe ino your ees, when ham twthclasn stor medial. It's sancard pracioo {o moar gogo or laces fo rotoc our ees, end (owes to prota your ands. 8. ThoR-124a contra a highly pressurized vase Neverisaveitin atte, and check obo suo ho ‘storage tomperatze below 52°C (125) 4. Aide lak detocor i olen used 0 check ho y+ {mor rorigerant leakage. Bear med tat P1948, Upon coming into contac wah fame (his cotctor burns ike propane to preduce 2 small ae), pro ‘hoe poagena, atone gos HEATING, VENTILATION & AIR CONDITIONING INSTALLATION OF MANIFOLD GAUGE SET seo & caution ‘When conntcting the manifold gauge sot, be sure to observe stay precautions. 1. Close bots hand vanes ofthe mantlé gauge tings. 2. Installhectarging hoes of to gauge sotto th Fe tings. Coneat nel pressure rose the 0s re sarvign port and he high poser hse tothe high preeeu sevice pat. Tigh te hose mus By rane Grore Whenchargng the refigeran do tateromoving he ngs cov and he a ate hose REFRIGERANT DISCHARGING PROCEDURE sown Connor the ranfol gauge sto te ost 2. Puta tome! under he apon end of to corer nos. 3 Open ta gn possi vale slowly to charg tho ralsgrent. 8 caumion lechargig the erigeranttoo fast, compressor ‘ll may drain rom the system, 44. Chockitthtowalia tina whl eo gen the vee 5. thomas gauge racing crop blow 9. 5len, ‘pen ha ow pressure va Soh tocrop he system pressure ur ho kgAIR CONDITIONING SYSTEM INSTRUCTIONS. WHEN HANOLING REFRIGERANT 1 7 -194a tigi eigen ie ighly volta co on ‘he sino! your hand oud resutmacalzod fost, When handling bereligerantbesueto wear gaves. Its stands pracioe fo wear goggles or glass o prolet yur eyes, and govs to protec! your hands In etosrant splashes ino your ees, wash ham wh loan walor mado ‘To FetS4a container is highly pressurized. Never Toate iin @ fot plac, and chace atthe storego temperatura is below 82°C (1257) 2 electronic lak decor shouldbe usa to check tha sya for otigorant leakage. Bear mind tat |no Tata, upon coming ino contact wth Nama, pe- ‘hos pogo, aight oe a Use ony econmendod the bbsicat or R134a sys- tom ubrcars oer han the recommended ene so syste fare may occu PAG uber bor molt rom the alrasphere at a raped rte, terafre th folowing prcaions + When removing regent components from s ‘hil, cap nmeditly he component 1 pr Vert rom he entry of mele. + When isting retigrant components oa vo hel, de not remove the cap ul st bore oan ectng th conporans Complnta he connec oa rlegerant bee snd hoses wineut oly to prove tho AIC sy {om fem tkrg on mate Use the eormensod lian from a sled contain on an actental charge Inthe sytem coeur, we tata the work are blo resuing saree Hao WHEN REPLACING PARTS ON AIC SYSTEM 1. Neveropenorisosen a connection bale dcharging the stom 2. Seal tho opn tags of components wth exp or lug inmate Yo prevent usin of mote oF ust S. Do notromove the saing caps rom a replacement component uri tis ead tobe stated 4 Below conoctng an open fing, as instal anew ‘seaing rng. Coat the ftng and se! wih rlegorant ‘bere aking the connection. ie a) Sma WHEN INSTALLING CONNECTING PARTS FLANGE WITH GUIDE PIN Chock no now Ong to damage (use ony the spetod) fd unrest ing comprossor 3 Tighten the nto spoctod ous fe eo" we in “6 03 / oe HANDLING TUBING AND FITTINGS ‘The ena parts one reigoraton syst wleman in Salo of chemial stably as org as puro oistretroe Fetegerantand"igrant lr used. Abnormal amounts Of rt moister scan upset he chara ably ard aise prolome otorous damageAIR CONDITIONING SYSTEM EVACUATING REFRIGERANT sxsso Daore tis ocossary to evacuate the ar condoning 595- {am any tn he system has been eponed. Evacua- toni nocossary 10 te syst of ala and mas turethat may have boon alowed ts enter the unit At fer istataton oa compenan the system shots be ‘s1acuated for approximately 15 mites. A compo. anti senice ha hasbeen opened rea shoud be evacuate fo 30 mints. 1. Engino outs be ot 2 Connect a mans gauge set to the compressor {gauge tinge. Close bot Nigh and low pressure Sates 3. Make su tne system, he etigeranthas boon discharged fom 4 Gonnget he canter hose ofthe gauge sotto he vae- ‘aan pur re. 5. Start ho vacuum pup and then open the high an low maniold pressure vate, 5. Aur sbou ton mits, chock hatte low presse (gauge reads mare than 9439 kPa (96 glam, 13.7 Blof vacuum. nopatve pressure can not bo ob- famed, eres a lak nthe systom. In is C356, repair ho lak as ows: {Chose bth mantld valves and tp he vacuum pu. HAs Charge tho systom with a can of rofigaant (bout (08.), Feer6 Carona Aero ©. Chocidrretigorantlonkage wih alnk tector Fopal ary lekage found Rel to Checking Fetrgwant Loa. ‘4. Discharge rtigerant agen, end then evacuate tho stom, In leaks are ound, contin eae. ating the stom. ‘Start the veeuum pump, ot ‘Open bath nano pasture vals to aban 94.90 Pa (0.98 jem, 137 pl of vou. ‘Ate holou pressure mano gauge indeates cose 9.94.38 KPa (0.98 kior, 13,7 ps), cot ovace- tng for 1S minut. ‘Aor evacuaing fr 15 minutes, close bon manos prossur vas and stop the vacuum pump, Disa hoc the hos For tho vacuum pur. The sytem ow reed br charging.HANDLING THE REFRIGERANT SERVICE TAP VALVE coor Beto connwsing te vee the rotigrant con ‘aay, um the handle uly counorocewse. “Turnthe dc couterctocknsuuntlitroachs ts high- st postion. CConnac th estar howe tothe va tng Tan he (es hly Soci by hans ‘Tumthehand cackvisetomake sola inthe seals wp “Turn thehandle uly counterscoio filth cantor owe thar Oo not open he high and oa reasze and ves Loosen the centr note nut connected to he cantar titg of manok gauge. ‘Mow ato oscape or tw secon, and hen ightsn HEATING, VENTILATION & AIR CONDITIONING (CHARGING REFRIGERANT SYSTEM (VAPOR) ese Grore This sep bf charge the sysom trough the low poss a win vei avapr state, When tne retrgoant coraner pace inset hg. fran wl entre systom as a apa 1. insta te wligarant can tap valve as ceebed in anaing the Retnigorart Sari Tap Vee scion. 2 Open th ow prossure vale, Adjust he val shat the ow presure gauge docs not ead over 412 KPa (2 egeme0 ps). 8. Putt etigorantin a pan of warm water (maxirum temperature 80°C o (S047) Yo koe vapor pressure inthe contane sight higher han vo: pressure n the syst.AIR CONDITIONING SYSTEM 4. Fun tho engine at taste, and operate toa cond BS cauion Be sure to keep th container upright to prevent Iiguldreigerant rom being charge Int the sys: tem through the suction side. resulting In poss. ble damage to the compressor '5. Charge the systom tothe speciad amount. Then, ‘ose ie low pres va ‘Specified amount: ‘WAGON : 1200 + 259 (R-194a) VAN 650 255 (FS) Wen roigerent charging speed is slow, mmerse rotigoran ean war, heal o 8 trperatire of about a0 (104. @ warning + Under any etcumstances the refrgerant can ‘must not te warmed inatr bested to om. perature of over 52°C (128°) + Ablow torch or stove mist never be used to ‘warm up the ean. CHARGING REFRIGERANT SYSTEM (LIQUID) san ‘Tn stops to charg and empty system trough the ‘gn pressure sce win etgorant na kid state ino he roigerant contr isl wpa down, retigerant i eter the systom a 990. Ay eaurion Nevo rm the engine when charging te aye tough the igh pessre sia Bo nt open thew pressure vv en he syst sng ‘hrged wth ud rerige at 4. Close bth high and ow pasture valves completely ator he sytem is evacuated 2. instal the tigerant can tap valve as described in “Hanging Petigorant Sarvie Ta” secon. 3. Opn thehigh prosswe va uly, and agp th con: taior woo cow, 4. Charge th system the pected amount by weg 1ng tho flegorant wah see. Ovorcharging wil cause clecrarge pressure (hah le) to ee. Ten, ‘ou th hips prone are, “Specified meant WAGON: 1200» 259 YVAN 650 259 Grore ‘A tay charged system i indeated bythe recohor Sgn pls tog ho o ry buble Ine tow prassuregaupe does no show a reading, Ine systom 3 rates and must be raped 5. After the spiced emoun of tigerant has been ‘hargedins system, close manlld gauge abe. 5. Confimthatthere ae no lak in system checking vith a Teak sotecor.Refor to Checng Religorant oak14 Gnore Conc perma ts pri to removing ho Imai gauge good sence eration. COMPRESSOR OIL LEVEL CHECK comm ‘Theo used to ible ho compressor cuss i the system whl the compressors operating. Whenever placing any component ofthe system or whon age ‘Bmourtat gs leakage oc, ad ola manta tea. ‘alo amount oF ‘Total amount of ailin To pageHA-2 HANDLING OF OM 1. Theo shouts bo roo om moist, dst, tl Ings. ote 2. Thempleturcontentshoulbe na marethan 20 pom. 8. Do rot mio 4 The moisre content in heal neeases when exe oso th aor longed period. ‘torso, sal ba contaner madly (OL RETUAN OPERATION ‘Thera actos aint boweon theo arathoratigoant, sothat dung normal peraton pa fhe of ocrovatos wen therlegerant bo systom, “Tartan check ne amount fol the systom or replacing any component of to esto, the compressor ‘must run nacange ot retum operat, ‘his procoduro a tolows 1. the amount of raigeratin the estom decasses, topit up oe prescred quan 2 Run the evaporate blower at HIGH" poston. 3. Run tne comprosso for st last 20 minutes between 800 and 1200 rp in erdor'6 operat he system, OIL CHECK INTERVAL [AS with tho ongine ol tis not necessary to Hequently ‘heck er change te compressor However ts necessary a chck andrapleih or replace ‘ho compressor ono folowing casos 1. Whanovar tne compressor, colng unt condenser or ‘oud tank rained 2. Whenover gases laoked rom hoses or lps tn ‘he cooing oe 8. Whenovar as or oihas leaked rom tho compressor. HEATING, VENTILATION & AIR CONDITIONING 4. Wanover sigeant le suddenly cleat Krom the cooing eee, 5. Whanevr zy ol-atod problems cecuria he 00 Ing vee (CHECKING PROCEDURE ‘Te compressor shoud be checkedin ho faowing o- dar wen beng toascid io. Uted sytem 1 erty oar operation. Rater eparagraph "Ol Fetum Option: 2, Remove the compressor fom the vehicle, 3. Dian hoof rom te system ine connecting pots. 4. Moceue te extract ot win maasueng ender 5. Chack tne lor contamination, Refer to paragraph "Manaing © of. 6. Filwih ot ough the dscharge por. (CHARGING ANOUNT 1S AS FOLLOWS : Collected emount (25 tampon 25 amps oz) Charging amount 7020 (2.5 imp Hon) hon itis mpossitlet pro lt operation, the ‘compressor ol s10U Be check in ho loning ocrAIR CONDITIONING SYSTEM. 7. Remove the compressor or the yh 8. Mesure the extracted ol wit a messing eyinder, 19, Chock hoot fr contamination. Retr to Paragraph landing of of. 10, Hore nan 70:25 fox) fi waracearm ‘he eampresser, supply the samo amount of oo tho comproseo: to be nse Iie amount of of axrected i os han Toes (2.5 lanpfiea) chock compressor olin the folowing a" Sippy S00 (1. Blam 2) fo tothe compres- {ora atal ton te oh 'b. erform a return operation, ter to paragragh “Ol aun Opera Remo the compressor and chek tho aunt 6 Swpay now oo tho comprossor. ‘CHARGING AMOUNT IS AS FOLLOWS Collected amount |__ Charging amount more than 70ce tee ee 7oae (25 mp ta») laps than 7020 (25 lamp fo) poe eee MAGNETIC CLUTCH TEST ros 1. _Disconnoethe conto (1P tothe magnetic cite. 2. Connect bar (4) votag coat tthe connacor for be magnet. 3. themagnati ch sora, hore wi be ele Ihe pulley and. armatu do not make contact (clk), thre a matuncton. RECEIVER DRIER TEST sovm 1. Operate hunt and check he piping temperate by touching he rocover cr out ana lt 2, thro iss teronca i the temperatures he r= Coheed REFRIGERANT LEVEL CHECK. scine 1. Start he erpine and nod to engine speod at 1,800 om 2. Set the ACen oe “ON poston, 8. Settho temperature conoleverte he maxinamcold pater. 4. Sot the bower atu epood. 5. Chock ho sight glass after ve minds. Evaluate sccordng se allowing aeHEATING, VENTILATION & AIR CONDITIONING “Amount of refrigerant | very ite retigerant | Insutfcent | Suitable | Too much efrgerant chock tam [Temperature of | Almost no diference | High pressure side | High pressure side i | High presoure side la | nigh essure and_|bemean high Is warm and iow | hot andiew pressure | abnormal hot Tow pressure tines | pressure ard low | pressure sige is | so ts cold pressure side fay cols emer ‘enaion in sight | Bunbies tow con | The bubioe are | Aoat enaparen | No bubbles can | sess ‘envousy, Buttes | seen at tervals of | Bubbles my epscar_| be scr will sappeae and | 1:2 seconds when erga speeds Somenng tke Falsodand ower ‘ist wl fo when No Gear doarce on bobwean ‘etigerantsnesry % as ae breve Wo cons ‘Pressure o system | High prossure sides | Bath pressure on | Both pressure on | Bain pressure on normaly bn | high ad ow pressure | high arto poesure | high and low presure S608 ae sity ow | sidos zerommal | see ae abnormally, . ° high opal ‘Sop compressor | Gheok Tor ges Discharge retigrant fand conduct an | lodge, repair from servcevave of ‘ral heck ‘ule, pene ‘ow prose sie, and charge syst |& The bublos soon through the sight glass 10 io need by tha bent omperatue. Since the bud 1s are hart eyo pomp Ia tn Poraiues, tolow 20-0 (08°). Nghe tempore ‘he babi se coarse Wham ne secon nt recover de flogged the bubbies wil appear even ho amount a eigerant | oral. ints caso, tho cute side ppe of he ‘ceiver der booms Conall clAIR CONDITIONING SYSTEM HOSE AND PIPE CHECK cn ‘Chacko nestor and ar contionr hoses and nes for ‘omage duo fo mterrence ih adoinng pas. dem ago maj, repiaco the afletes pat Caretuty chock the hoses and nes, expec hose f= ‘tod &o90 fo moving pars or sharp panel edges. CHECKING REFRIGERANT LEAKS. sows Conduct lask'ost wth an electron let detector when- fr loekage of refigrat ls suspected and hon con. {tuctng service operations tha are aocompanie by ax fsssembiy or losening of connection ftngs Grore ‘note use the device rope. adh mana ‘ploy emanate peta Spc ‘aiaree an recto. Tra gas lak i detect, pocood as Sotons 1 Check te trque onthe connection ing and 100 loose, gron fo the proper forge. Check for gas leskapo witha oak stoner 2. ‘eakage coninuss even ater he fting has been taghened discharge the ralegerant rom na system, dsconnet te fings, and chock ts seat face ft damage. Adnays replace oven Ita damage sgh 3. Chock compressor of and a6 ol #requred, 4 Charge te systom and veaock orga lake. no leks ara ound, evacust and charge the astmHA-18 HEATING, VENTILATION & AIR CONDITIONING REFRIGERATION CYCLE DIAGRAM sass a 3 == zs ‘om prowur tas ‘omeoa feign ret seatiee Ste | Scien Spun Ge a =e | See Sigs ssihegene. Clggaons fa reer CZ ensAIR CONDITIONING SYSTEM HAA REFRIGERANT LINE FRONT REFRIGERANT LINE cass ‘comPONENTS Removal steps | 1. Ug pe 8 2 Unis ppe 2 Pcie irae 1 Suton pe 6 Ugatppe c 8.Decharge nese 10, Dich po A 1. Oetane peHA 20 HEATING, VENTILATION & AIR CONDITIONING REAR REFRIGERANT LINE (BUILTAN TYPE) x20 COMPONENTS sussonpbe Hoses and pipes disconnection 1. asta hs 2 arse 4 Ud pp E 5. Suctonppe ©. UqudipeAIR CONDITIONING SYSTEM Ha21 REAR REFRIGERANT LINE (OVERHEAD TYPE). saione ‘COMPONENTS Removal stepsHa 22 HEATING, VENTILATION & AIR CONDITIONING MANUAL As COMPRESSOR CONTROLS COMPRESSOR COMPONENTS eam SF fbass oesaso,r17-108) Menlsaney agate uch conection ©. 4s goes, 24-1.9) TORQUE : Nm (karem,Ib-t)MANUAL A/C COMPRESSOR CONTROLS, HA-23 COMPRESSOR CIRCUIT DIAGRAM (1)HA24 HEATING, VENTILATION & AIR CONDITIONINGMANUAL A/C COMPRESSOR CONTROLS: ‘COMPRESSOR CIRCUIT DIAGRAM (3)HA-26 CONDENSER FRONT CONDENSER AND CONDENSER, FAN MOTOR some COMPONENTS removal steps + chargng wscharged treat 1 Dring rsp cote 1: Osage bes esque A orneton 2, Sonne fn er ‘When replacing the rot condenser tt ‘wha spected amount of compressor a HEATING, VENTILATION & AIR CONDITIONINGMANUAL A/C COMPRESSOR CONTROLS. HA27 ‘CONDENSER CIRCUIT DIAGRAM (1)HEATING, VENTILATION & AIR CONDITIONINGMANUAL A/C COMPRESSOR CONTROLS HA.29 ‘CONDENSER CIRCUIT DIAGRAM (3)HA-30 HEATING, VENTILATION & AIR CONDITIONING CLUTCH HUB AND PULLEY DISASSEMBLY cams 1 emove the uch hub retain bl wit the aldo spanner wren, re ps tokreroer (cer Se 2. Pulte cktch hub and shims trom he compressor shat. Ithehubesnretbepuled tame compressor ‘hat, scrw an Grim bo io tho sat hole of ho ‘uch uo free hu Wom the sat 44 Pulte pull a bearing assembiy rm tho orm pressor, REASSEMBLY couse 1. Caan the guloybostng sue of the comerssor oad rove any er corosion. 2. Install ne ply proseor Th aed an, propery algne, chal sip. he com prossor hee, Instat pile tang snap ing whe bes side ofthe snap rg ou, 4. Ploo one rominl thickness epacer shim isi the hub spin opening an sige te hub cn he ed ot ‘he compressor shaMANUAL A/C COMPRESSOR CONTROLS. 5, Tvead a new hub retaning bot ito th end ofthe Compressor that. Tighan te hub etaning bat “Tightening tore : 302-159 Nn (102-155 kgem, 75-113 to (nore Do nat use ai toot 8. Chock th ch a gap betnoon the cc nub nd the pulley mating surges wih footer gauge. The Ar ap shou be aston, “Standard 0:05 me (00157-00288 mn) (Check a three lcstions equally spaced around he pues. Hast 7. thectutohal gaps nt witin th mension spac: Mea above.opeat saps hough 8 wah De vous ticknoss sims unt ho ar gap isbetwoon he spec:Ha 32 CLUTCH FIELD COIL DISASSEMBLY xm 1. Remove teeth hub and pully folowing the pro: codure gen. 2. Intl sat petztor elon the nose opering of bo 3. Intl he pul: onthe comprossor as shown nthe iugeaton Place hp fhe pur tering aca on ‘he cer dnp of he shat protocor and to [awe of ho laud he back 88 the el 4. Thon tho fring sera win a wrench pulecot Toose rom he compressor ort head Guore Do note arto REASSEMBLY casos 1 ean the ol pres amet of he front head re- ‘move any dt er oreo, 2. Wh the compressor in a verte poston (nose up), paca te con postin on he ert head ofthe com pressor. Assure athe ele cal lotic! conc tors postonod corey. {3 Pace the col pressing tol n poston over he com- restornaee ana the ner ras ofthe ld col HEATING /ENTILATION & AIR CONDITIONING Poston an sigh (8) rch wo ja ule oto com pressor andprossing toa as shown th ilataton, ‘The aws of ne pul spout! be tly engaged wah {he ear sie the compressor ont mounts and he forcing seen shouldbe poled on the center of he rssing to ‘Tighten tnatreng soow wth a wrench by han unt 32 cols Fossod completely onto Te comprossor ‘ron hood Shock to asere ta oft eal btm ‘gamete font Read at al pots aud the col ‘outer camer Instathe ich pulley andhub onthe compressor as outinesvacuum system 000 sg VACUUM SYSTEM VENTILATORS VENTILATORS (FRONT) som ‘coMPONENTS Disassembly steps 2 Sis ctor ne 2 tot nore 5. Si arose sont vers) 6. Ceneraotetasetly (versie) 7, Sle aout eset pmzoners ie) Ste tester gleVACUUM SYSTEM. HA 35 ROOF DUCT acme ‘COMPONENTS Standard wheolbase> ee Dicassombiy steps 1, Sia |Ha-26 HEATER EVAPORATOR UNIT EVAPORATOR (FRONT) scx ‘COMPONENTS vaportorant Bloor nt 2 Plug al ofthe open tings immediatly ater removal In oder to keep moisture cut of he ar contonng Sytem 6 1. Disconnect atlory negate trina 2 Discharge rtigoan rom he a conionng sye- HEATING, VENTILATION & AIR CONDITIONING ‘oa Diaassombly spe op rotor ae pe barbara sere chat Thema ange Ge Epa ve 1 Brpontor Remove love crash pad pana glove box, cst a- cla panel, and man crash pad ascmbly (eer o Be Bb.Grow) Remove ine evaporator upper and lower mounting ote Remove the eaporter unt INSTALLATION. sxcim Instatation i he rovers ode of rmoval 3. Disconneet tings conecte tothe eaporator unt.HEATER HA-37 INSPECTION earsco ‘THERMOSTAT INSPECTION 1. Apply batryvotage between he thermostat orm ‘ale shown the thataton, and commas amp {o'eminal 2. 2. ow ooo i onto hea therm sensor and obec {hal th et lamp swaches of whan he coo a om retro bocomes aproxnatly 6° or los ole \ AIR THERMO SENSOR INSPECTION nen to esistanoe value between the sensor terminals |G rnasuzed andr wo or move lonperature condor, ‘he estan valu should be coe othe aes shown Inte gash ase Fearne)HA-38 HEATING, VENTILATION & AIR CONDITIONING EVAPORATOR (REAR) sora COMPONENTS: Removal sap = ~ 1. Rear wate’ hos tion A ex reesei eae / Pana sonen See ee eaten LL Cons 4 {Rew tit soy 8 Rowront at earn kat nore Bete remevat achargeretigerant ‘nd rain clot ving haness| rnc owe) Use tnt othe packing baton RRanoroe cows tcp, and then remove tw upper cae,HEATER, HA 39 INSPECTION cae: [AIR THERMO SENSOR nen the resistance value between th sensor termine 's measured undo ho o¢ mae toperature conor, tho esslance value shouldbe coset he values show ini graph asomen()HA-40 HEATING, VENTILATION & AIR CONDITIONING HEATER CONTROL ASSEMBLY HEATER CONTROL ASSEMBLY (FRONT) sacun COMPONENTS: REMOVAL ene 1. Remove tower erash pad panel & glovebox (Retro BD Grow), 2. isconnac the connectors 3. Disconnect the a mng damper cable rom he bot ‘om ofthe heater st. 4 Remove the he en contol panel mounting Serus INSTALLATION. ssisn 5. Remove the heater cool parelassonly rom tho cluster Tals pane, rstalatan ihe rovers od ofthe rerova.HEATER HA INSPECTION socom BLOWER MOTOR SWITCH Operate lower contol ion ancceck conus betwen ‘motor stn frminls blower ritor ey wh uk tester biome ‘AR CONOMONING swiTcH 1. Chacko cortinuty between terminals a shown be- ‘eontnuty i net specie, rplace th swich jenna 7 [2] 3 [4] 518 Swi naka] fre fos Tz poston ne Po ESEAEA oN, Pannet urination = ©Ha 42 HEATING, VENTILATION & AIR CONDITIONING [AR MIXING DAMPER CABLE ADJUSTHENT Set the tomperature conto! kneb on he tont pane ‘sssomby tothe MAX HOT pestion. Set th sie mix camper lover atthe botom ofthe 2st" unt tothe MAK. HOT postion, and instal the ce to the ovr, ulna oar ablintre deco ofthe arrows tat ‘hors no eosenes,andthan lampHEATER HEATER CONTROL ASSEMBLY (REAR) ee COMPONENTS HA-43HA-44 HEATING, VENTILATION & AIR CONDITIONING INSPECTION acon BLOWER MoTOR swiTcH 1. Chock for cont between amine shown below. contnuty snot as spactod replace te sch ‘AR CONDITIONING SWITCH 1. Check or cont betneon terminals a8 shown be- emmanel 7 [2] 3] 4] 38 se] potion OFF aad veer Panel uminaon cont not spect, rplace the sthAg OUTLET CHANGEOVER DAMPER CABLE INSIALUARON 1. Sotthe airoutet ver on th eer pane! assem to the lace pesto, 2 Sel th ai ovtet changeover damper lover ofthe hasta nit 0 face postion, and ial he eae to the lover pe 3. Pulthocutercaboi he eteton ofthe arom oat tar is no oosoess, an hen clamp Gnore The air ming demo cable has yolow lentes: (en mark on te en. AIR MIXING DAMPER CABLE INSTALLATION 1 Set he temperature conto lever on tne te panel asso the MAX, COOL postion 2. Sot te ar mi damper ovr atthe botom of he haar untto tne MAX. COOL positon, sndinal ie cable foe oer pnHA-46 HEATING, VENTILATION & AIR CONDITIONING HEATER UNIT FRONT HEATER AND BLOWER SYSTEM toxom HEATER UNIT (FRONT) ‘COMPONENTS: aportocunt wernt REMOVAL cnn 1 Deconnset he nogaivo terminal om the battery. 2 Dsconpect th engine coolat inet andthe out oto the hear unt, nore ‘Pug th onde of it and ot hoses inmelaaly ater asconnocion 3. Ramove th lower rash pad panel, love box, user fac panol, conor supper bac, nd mah crash pad essary “4 Remove ta xaperator un tat. 5, Remove the heat unit mounting bok a the heater oneHEATER INSTALLATION. sxsoo 2 Insta ithe rover rd of rmova ‘Aor stalin, eacust, charge and fst the ar {onatonng system. CChack that the tempertire contol cable sides oath the fl stroke ht ook Hot oy, eadust te ampere conta cable HA-47HA-40 HEATING, VENTILATION & AIR CONDITIONING HEATER UNIT (REAR) toro CcomPoNenrsHEATER Haat INSPECTION caw HEATER CORE 1. Using spi! o, raat he hasta ore on ie ‘ndthe cored le cogged, 2, Pace the eto core a wate, then apply 2004Pa (ips) pressure Holding foro mints, while eheckng fr akage tom te ester eo. Irtnor i lakgo, ep oreplace he heater coro,HA-50 HEATING, VENTILATION & AIR CONDITIONING BLOWER CONTROLS BLOWER UNIT BLOWER UNIT (FRONT) sara COMPONENT LOCATIONS Dicassombiy stops {1 Motor ooing be 5, Blowercasedoner Hestrint ——Evgpordar unt Stover nit estrada) trresten 3. Glover roster 7. Bier whee! 2 Motor aoe REMOVAL soso 1. Disconeethe negative terminal tom the bat. 2. Disconnect the evaporator nt For dtalod removal pgs, rhe Rona ote ets 3. Diconneet he blowar motor connector and the 4, Remove he mounting bots ofthe lower unt. 15, Remove he bower unit INSTALLATION xs Inetatation i the rovers oda of rmova Dore ‘Aer instalition, evacuate, charge and est ine air onan stom.BLOWER CONTROLS INSPECTION saan BLOWER MOTOR 1. Check or bending oc abnormal dteston fh oat ‘ng shaft of th onor moor assonbly ‘Check or eracng or detereraton ofthe packing. ‘Ghack or damage oto fa, ‘Ohack or damage othe blower caso. (Chackh opration of ho rldetoutside ar eotecton ampor, ana for damage. Const tne blower motr terminals det tothe batory and chock tat the Bower malar peratas nosiny, 7. Nox, reverse the polary and check that he lower motor operates smooth inthe reverse rect, BLOWER RESISTOR osaurtominaito tena resistance of he tower fe- tise, F measured resistance lena win specteaton, tho Bier resistor mus bo rplacd. HASt Oman + [2 [2 [+ Treasures fnsetan wea | contained od NOTE: (C—O indeates tht there continuity betweon pon =BLOWER CONTROLS HA-53 INSPECTION cos BLOWER FAN AND MOTOR ASSEMBLY When batery volage is apofed between the terminals ‘check ob eve hat he motor operates, ‘io, check be suo ha there nostra roe, Baty imine TactHAs8 HEATING, VENTILATION & AIR CONDITIONING BLOWER AND A/C CONTROLS LOWER CONTROL CIRCUIT DIAGRAM (1)HA56 HEATING, VENTILATION & AIR CONDITIONING [NC CONTROL CIRCUIT DIAGRAM (1)HAST BLOWER AND A/C CONTROLS. [IC CONTROL CIRCUIT DIAGRAM (2)HA 58 [AG CONTROL CIRCUIT OIAGRAM (3) HEATING, VENTILATION & AIR CONDITIONINGBLOWER AND AIC CONTROLS. HA-59 [NC CONTROL. CIRCUMT DIAGRAM (#)HA-60 HEATING, VENTILATION & AIR CONDITIONING [NC CONTROL CIRCUTT DIAGRAM (5)BLOWER AND A/C CONTROLS Hast ‘AIC CONTROL CIRCUIT DIAGRAM (6)Has2 HEATING, VENTILATION & AIR CONDITIONING ‘NC CONTROL CIRCUIT DIAGRAM (7)BLOWER AND AIC CONTROLS: Ha s3 OVERHEAD BLOWER CONTROL CIRCUIT DIAGRAM (1)HA-64 REAR BLOWER CONTROL CIRCUIT DIAGRAM (1)