Page 2 of 149

Heating,Ventilation, Air Conditioning > General Information > Troubleshooting

Troubleshooting
Problem Symptoms Table
Before replacing or repairing air conditioning components, first determine if the malfunction is due to the refrigerant
charge, air flow or compressor.
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause
of the problem. Check each part in order. If necessary, replace these parts.
After correcting the malfunction, check the complete system to ensure that performance is satisfactory.
Standard:
Symptom Suspect Area
1. Blower fuse
2. Blower relay
3. Blower motor
No blower operation
4. Power transistor
5. Blower speed control switch
6. Wire harness
No air temperature 1. Engine coolant capacity
control 2. Heater control assembly
1. Refrigerant capacity
2. A/C Fuse
3. Magnetic clutch
No compressor 4. Compressor
operation 5. A/C pressure transducer
6. A/C switch
7. Evaporator temperature sensor
8. Wire harness
1. Refrigerant capacity
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
No cool comes out
6. A/C pressure transducer
7. Evaporator temperature sensor
8. A/C switch
9. Heater control assembly
10. Wire harness
1. Refrigerant capacity
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
Insufficient cooling
6. Expansion valve
7. Evaporator
8. Refrigerant lines
9. A/C pressure transducer
10. Heater control assembly
 Page 3 of 149
No engine idle-up
1. Engine ECM
when A/C switch
2. Wire harness
ON
No air inlet control 1. Heater control assembly
1. Heater control assembly
No mode control
2. Mode actuator
1. Cooling fan fuse
No cooling fan 2. Fan motor
operation 3. Engine ECM
4. Wire harness

Heating,Ventilation, Air Conditioning > General Information > Special Service Tools
Special Service Tools
Tool
Illustration Use
(Number and name)
09977-29000 Removal and installation of the disc & hub
Disc & hub assembly bolt assembly bolt
remover

Heating,Ventilation, Air Conditioning > Air conditioning System > General Information
Instructions
When Handling Refrigerant
1. R-134a 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. It is standard practice to wear goggles or glasses to protect your eyes, and gloves to protect your hands. If the
refrigerant splashes into your eyes, wash them with clean water immediately.
3. The R-134a container is highly pressurized. Never leave it in a hot place, and check that the storage temperature
is below 52°C (126°F)
4. An electronic leak detector should be used to check the system for refrigerant leakage. Bear in mind that the R-
134a, upon coming into contact with flame, produces phosgene, a highly toxic gas.
5. Use only recommended the lubricant for R-134a systems. If lubricants other than the recommended one used,
system failure may occur.
6. PAG lubricant absorbs moisture from the atmosphere at a rapid rate, therefore the following precautions must be
observed:
A. When removing refrigerant components from a vehicle, cap immediately the components to prevent from the
entry of moisture.
B. When installing refrigerant components to a vehicle, do not remove the cap until just before connecting the
components.
C. Complete the connection of all refrigerant tubes and hoses without delay to prevent the A/C system from
taking on moisture.
D. Use the recommended lubricant from a sealed container only.
 Page 4 of 149
7. If an accidental discharge in the system occurs, ventilate the work area before resuming service.

When Replacing Parts On A/c System

1. Never open or loosen a connection before discharging the system.
2. Seal the open fittings of components with a cap or plug immediately to prevent intrusion of moisture or dust.
3. Do not remove the sealing caps from a replacement component until it is ready to be installed.
4. 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 Connecting Parts

Flange With Guide Pin
Check the new O-ring for damage and lubricate it using the specified compressor oil. Tighten the nut to specified
torque.
 Page 5 of 149
Tightening torque [ N.m (kg.m, lbf.ft) ]
Size General bolt, nut
4T 7T
M6 5-6(0.5 - 0.6, 3.6 - 4.3) 9-11(0.9 - 1.1, 6.5 - 7.9)a
M8 12-14(1.2 - 1.4, 8.7 - 10) 20 - 26 (2.0 - 2.6, 14 - 18)
M10 25 - 28 (2.5 - 2.8, 18 - 20) 45 - 55 (4.5 - 5.5, 32 - 39)
Flange bolt, nut
Size
4T 7T
M6 5-7(0.5 - 0.7, 3.6 - 5.0) 8-12(0.8 - 1.2, 5.8 - 8.6)
M8 10-15(1.0 - 1.5, 7 - 10) 19 - 28 (1.9 - 2.8, 14 - 20)
M10 21 - 31 (2.1 - 3.1, 15 - 22) 39 - 60 (3.9 - 6.0, 28 - 43)

Handling Tubing And Fittings

The internal parts of the refrigeration system will remain in a state of chemical stability as long as pure moisture-free
refrigerant and refrigerant oil are used. Abnormal amounts of dirt, moisture or air can upset the chemical stability and
cause problems or serious damage.
The Following Precautions Must Be Observed
1. When it is necessary to open the refrigeration system, have everything you will need to service the system ready
so the system will not be left open any longer than necessary.
2. Cap or plug all lines and fittings as soon as they are opened to prevent the entrance of dirt and moisture.
3. All lines and components in parts stock should be capped or sealed until they are ready to be used.
4. Never attempt to rebind formed lines to fit. Use the correct line for the installation you are servicing.
5. All tools, including the refrigerant dispensing manifold, the gauge set manifold and test hoses, should be kept clean
and dry.

Heating,Ventilation, Air Conditioning > Air conditioning System > Description and Operation
Refrigeration Cycle
 Page 6 of 149

IBlOWER
Fi.eds air in !tie va:hic!o undar
prsssure 10 the 9\'aporator and
kleds cooled a1r lfllo Ille ve:hicfo.

All:OWs U1e ref,t~era.nt

lo rnpldLy El)(pa~ l'ltO
lo v temperal(.lre and
COMIPAl:SSOR low p:res:sufe llquld
Tlhis i:s drivirn by !l V-belt (atomized)
from Ille engtne ,to c tlange
lt1e evapo ral1,--<l 1tJhigimmt
into hig'h pressure
t
(high ternptmtlure) gas arcl
supply it lo lhe concfemrer.
The mag:emilrc clU11c1 is
installed lo enablf! cycling
ol the c ompre-ssor.

CONDENS,ER RECEIVER DRIER

This is inste1IIBd i111 front \'.~._-t_tt~tt~~~t~"!,7,,~~-:.?, Ttis i.6 a single body lw,a wiltr
of 1110 r.ad iaior. It coos h1g ·1 ctimlenser ruid illleta1rec al 1he
pressure and hi:gtl temp01- aide o1IXlllden~r.
!llllrn mfriger:an1 to ils II stores ·~ne relnigerarril arld
00111:ifmsat:on potrlt and remove5, U11e wa•er a.11d! IOreign
101urns ii 10 ll[gt prnssure mate-, 1 a,m,on.g of re'f11 ig~t\t.
liq11id.

t t t t

""li.gh 1Pressu re and

hi,gh tsmi::eratulf'EI gas D ILow pressure and
lc>w t,emperatura liquid

,Ugh pmssure a:oo Low pressure and

mediat~ tempsrature liquid ~ tow temperature gas

Heating,Ventilation, Air Conditioning > Air conditioning System > Repair procedures
Refrigerant System Service Basics
Refrigerant Recovery
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove
HFC-134a(R-134a) from the air conditioning system.
 Page 7 of 149
U\ui®II
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
- Be careful when connecting service equipment.
- Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R-134a refrigerant
Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port
(C) as shown, following the equipment manufacturer's instructions.

2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be
sure to install the same amount of new refrigerant oil back into the A/C system before charging.
System Evacuation
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove
HFC-134a(R-134a) from the air conditioning system.
U\ui®II
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
- Be careful when connecting service equipment.
- Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. When an A/C System has been opened to the atmosphere, such as during installation or repair, it must be
evacuated using an R-134a refrigerant Recovery/Recycling/Charging System. (If the system has been open for
several days, the receiver/dryer should be replaced, and the system should be evacuated for several hours.)
 Page 8 of 149
2. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B)
and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.

3. If the low-pressure does not reach more than 93.3 kPa (700 mmHg, 27.6 in.Hg) in 10 minutes, there is probably
a leak in the system. Partially charge the system, and check for leaks (see Leak Test.).
4. Remove the low pressure valve from the low-pressure service port.
System Charging
Use only service equipment that is U.L-listed and is certified to meet the requirements of SAE J2210 to remove
HFC-134a(R-134a) from the air conditioning system.
l&ii®II
- Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
- Be careful when connecting service equipment.
- Do not breathe refrigerant or vapor.
If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
1. Connect an R-134a refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) as
shown, following the equipment manufacturer's instructions.

2. Add the same amount of new refrigerant oil to system that was removed during recovery. Use only specified
refrigerant oil. Charge the system with 29.98 ± 0.88 oz. (850 ± 25g) of R-134a refrigerant. Do not overcharge
the system the compressor will be damaged.
Refrigerant Leak Test
Always conduct a leak test with an electronic leak detector whenever leakage or refrigerant is suspected and when
conducting service operations which are accompanied by disassembly or loosening or connection fittings.

In order to use the leak detector properly, read the manual supplied by the manufacturer.
If a gas leak is detected, proceed as follows:
1. Check the torque on the connection fittings and, if too loose, tighten to the proper torque. Check for gas leakage
with a leak detector (A).
 Page 9 of 149
2. If leakage continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect
the fittings, and check their seating faces for damage. Always replace, even if the damage is slight.
3. Check the compressor oil and add oil if required.
4. Charge the system and recheck for gas leaks. If no leaks are found, evacuate and charge the system again.
>

Heating,Ventilation, Air Conditioning > Air conditioning System > Components and Components
Location
Component Location Index
Engine Room
 Page 10 of 149

NC pressure transducer
Condenser

/,'
I
/I
I r
'I
(_______ __,.
\ ...........
\ ~
/
/

\
It
' l... j
r
I /
i (j l Compressor
"-.,

\(
'\

.........

Interior
 Page 11 of 149

~----------
.- -----~-~
.,..----

I,

tJ

/
\ \

----.----

Blower and A/C controler

Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor oil > Repair procedures
INSPECTION
Oil Specification
1. The HFC-134a system requires synthetic (PAG) compressor oil whereas the R-12 system requires mineral
compressor oil. The two oils must never be mixed.
2. Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of
compressor.
Handling of Oil
1. The oil should be free from moisture, dust, metal powder, etc.
2. Do not mix with other oil.
3. The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-
134a Compressor Oil absorbs moisture very easily.)
4. The compressor oil must be stored in steel containers, not in plastic containers.
Compressor oil check
The oil used to lubricate the compressor is circulating with the refrigerant.
 Page 12 of 149
Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the
original amount of oil.

Oil total volume in system:

FRONT ONLY : 150 ± 10cc (5.07 ± 0.338 fl.oz)
FRONT & REAR : 210 ± 10cc (7.1 ± 0.33 fl.oz)

Oil Return Operation

There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of
oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return
operation. The procedure is as follows:
1. Open all the doors and the engine hood.
2. Start the engine and air conditioning switch to "ON" and set the blower motor control knob at its highest position.
3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system.
4. Stop the engine.

Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Components and
Components Location
Component Location
 Page 13 of 149

Components
 Page 14 of 149

8 J~
®I·

,s

1
11

t 7
10

3. 4

1. Bolt 6. Retainer ring (Field

2. Disc & hub assembly Oil)
3. Shim (Gap washer) 7. Field coil
4. Retainer ring (Pulley) 8. Screw
5. Pulley 9. Connector bracket
10. Compressor
assembly
11. Compressor bracket

Heating,Ventilation, Air Conditioning > Air conditioning System > Compressor > Repair procedures
Removal
1. If the compressor is marginally operable, run the engine at idle speed, and let the air conditioning work for a few
minutes, then shut the engine off.
2. Disconnect the negative cable from the battery.
3. Recover the refrigerant with a recovery/charging station.
4. Loosen the drive belt.
 Page 15 of 149
5. Remove the bolts, then disconnect the suction line (A) and discharge line (B) from the compressor. Plug (C) or
cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

6. Disconnect the compressor clutch connector (A), and then remove 4 mounting bolts and the compressor.

Installation
1. Make sure of the length of compressor mounting bolts.

2. Install in the reverse order of removal, and note these items.

A. If you're installing a new compressor, drain all the refrigerant oil from the removed compressor, and measure
its volume, Subtract the volume of drained oil from 120cc(4.20 oz.) the result is the amount of oil you should
drain from the new compressor (through the suction fitting).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them.
Be sure to use the right O-rings for R-134a to avoid leakage.
C. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other
refrigerant oils.
D. Immediately after using the oil, replace the cap on the container and seal it to avoid moisture absorption.
E. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint,
wash it off immediately.
F. Adjust the drive belt.
G. Charge the system and test its performance.
 Page 16 of 149

Inspection
1. Check the plated parts of the disc & hub assembly (A) for color changes, peeling or other damage. If there is
damage, replace the clutch set.
2. Check the pulley (B) bearing play and drag by rotating the pulley by hand. Replace the clutch set with a new one
if it is noisy or has excessive play/drag.

3. Measure the clearance between the pulley (B) and the disc & hub assembly (A) all the way around. If the
clearance is not within specified limits, remove the disc & hub assembly and add or remove shim (gap washer) as
needed to increase or decrease clearance.

Clearance: 0.45 ± 0.1mm (0.018 ± 0.004 in.)

The shims (gap washers) are available in seven thicknesses: 0.7mm, 0.8mm, 0.9mm, 1.0mm, 1.1mm,
1.2mm and 1.3mm.

4. Check operation of the magnetic clutch.Connect the compressor side terminals to the battery (+) terminal and the
ground battery (-) terminal to the compressor body.
Check the magnetic clutch operating noise to determine the condition.
 Page 17 of 149

Disassembly
1. Remove the center bolt (A) while holding the disc & hub assembly with a commercially available disc & hub
assembly bolt remover; Special tool number 09977-29000.

TORQUE: 10~15N.m (1.02~1.53kgf.m, 7.37~11lbf.ft)

,2 - I~ H.m
099TI-290QO 2: ~ 1.!1 l!{Jl'..m,
U IMt}

...

2. Remove the disc & hub assembly (A) and shim (gap washer) (B), taking care not to lose the shims. If the clutch
needs adjustment, increase or decrease the number and thickness of shims as necessary, then reinstall the disc &
hub assembly, and recheck its clearance.

3. If you removal the field coil, remove retainer ring (A) with retainer ring pliers.

- Be careful not to damage the pulley (B) and compressor during

removal/installation.
- Once retainer ring (A) is removed, replace it with a new one.
 Page 18 of 149
4. Remove the screw (A) from the field coil ground terminal. Remove the retainer ring (B) and then remove the field
coil (C) from the shaft with a puller. Be careful not to damage the coil and compressor.

5. Reassemble the compressor clutch in the reverse order of disassembly, and note these items :
A. Clean the pulley and compressor sliding surfaces with non-petroleum solvent.
B. Install new retainer rings, and make sure they are fully seated in the groove.
C. Make sure that the pulley turns smoothly after its reassembled.

Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Components and
Components Location
Component Location
 Page 19 of 149

!\
·,.,i I,II
·,(

condenser

Heating,Ventilation, Air Conditioning > Air conditioning System > Condenser > Repair procedures
Inspection
1. Check the condenser fins for clogging and damage. If clogged, clean them with water, and blow them with
compressed air. If bent, gently bend them using a screwdriver or pliers.
2. Check the condenser connections for leakage, and repair or replace it, if required.

Replacement
Condenser Assembly
1. Recover the refrigerant with a recovery/ recycling/ charging station.
2. Disconnect the negative (-) battery terminal.
3. Remove the radiator. (Refer to EM- Radiator)
 Page 20 of 149
4. Remove 2 bolts, and then remove the condenser (A) by lifting it up. Be careful not to damage the radiator and
condenser fins when removing the condenser.

5. Install in the reverse order of removal, and note these items :

A. If you're installing a new condenser, add refrigerant oil ND-OIL8.
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them.
Be sure to use the right O-rings for R-134a to avoid leakage.
C. Be careful not to damage the radiator and condenser fins when installing the condenser.
D. Be sure to install the lower mount cushions of condenser securely into the holes.
E. Charge the system, and test its performance.
Desiccant
1. Remove the condenser, and then remove the bottom cap (B) with L wrench (A) from the condenser.

TORQUE: 20~25N.m (2.0~2.5kgf-m, 14.5~18.2lb-ft)

2. Remove the desiccant (A) from condenser using a long nose plier. Check for crumbled desiccant and clogged
bottom cap filter.

-A

3. Apply air conditioning compressor oil along the O-rings and threads of the new bottom cap.
4. Insert the new desiccant into the receiver drier tank. The desiccant must be sealed in vacuum before it is exposed
to air for use.
 Page 21 of 149
5. Install the new bottom cap to the condenser.

- Always replace the desiccant and bottom cap at the same time.
- Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before
installing them. Be sure to use the right O-rings for R-134a to avoid leakage.
- Be careful not to damage the radiator and condenser fins when installing the condenser.
- Be sure to install the lower mount cushions of condenser securely into the holes.
- Charge the system, and test its performance.

Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Components and
Components Location
Component Location

-...._____

--- ,..--------·. -~-==-------~

Refrigerant line --•......._\

"

Heating,Ventilation, Air Conditioning > Air conditioning System > Refrigerant line > Repair procedures
Replacement
1. Discharge refrigerant from refrigeration system.
 Page 22 of 149
2. Replace faulty tube or hose.

Cap the open fittings immediately to keep moisture or dirt out of the
system.
3. Tighten joint of bolt or nut to specified torque.

I I
Connections should not be tighter than the specified
torpue.

Part tightened N.m Kgf.m lbf.ft

Condenser -
Discharge
hose
Condenser -
Liquid tube
Compressor -
Discharge 8 ~ 12 0.8~1.2 5.8 ~ 8.7
hose
Compressor -
Suction hose
Expansion
valve -
Evaporator

4. Evacuate air in refrigeration system and charge system with refrigerant.

FRONT ONLY : 600 ± 25(g) (21.164 ± 0.88 [oz])

FRONT & REAR : 850 ± 25(g) (29.98 ± 0.88 [oz])

5. Inspect for leakage of refrigerant.

Using a gas leak detector, check for leakage of refrigerant.
6. Inspect A/C operation.

Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer >
Components and Components Location
Component Location
 Page 23 of 149

A/C Prressure Transducer

/
/
I,
( -~---
X

I
-\
~-----
---- ~ .....

'
~--;............._
,; -----'

Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer >
Description and Operation
Description
The A/C presssur transducer converts the pressur value of the high pressur line into a voltage value after
measurement. The ECM controls the coolings fan speed based of the converted voltage valu. The ECM also stops
the operation of the compressor when the temperature of the refrigerant line it too high or low to for optimal
operation.

Heating,Ventilation, Air Conditioning > Air conditioning System > A/C pressure transducer > Repair
procedures
Inspection
 Page 24 of 149
1. Measure the pressure of high pressure line by measuring voltage output between NO.1 and NO.2 terminals.

2. Verify that the voltage value is within specification.

Voltage = 0.025 * Pressure + 0.1 [kgf/cm²]

Voltage = 0.001758 * Pressure + 0.074162 [PSIA]

3. If the measured voltage value is not specification, replace the A/C pressure transducer.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Verify that the voltage value is within specification.
3. Disconnect A/C pressure transducer connector (3P) (A).
, 1

l]
\
\
\
I
I
\
I I
\\ \
\ \
'
I \ ',
', t
•, \ \
\ \ \

\\
\

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\ '

Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
Components and Components Location
Component Location
 Page 25 of 149

-----------------
-----~ .....
.--------- -------- -----·--.....'

-====-~--~==----...
,...,...,..--~ _

___.,.

......,....

Evaporator temperature sensor

Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
Description and Operation
Description
The evaporator temperature sensor will detect the evaporator core temperature and interrupt compressor relay
power in order to prevent evaporator freezing by excessive cooling.

Heating,Ventilation, Air Conditioning > Air conditioning System > Evaporator temperature sensor >
Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect evaporator temperature sensor.
 Page 26 of 149
3. Using the multi-tester, Measure resistance between terminal "1" and "2" of evaporator temperature sensor.

Specification
Evaporator core temperature
Resistance [KΩ]
[°C(°F)]
-10(14) 43.35
-5(23) 34.48
0(32) 27.62
5(41) 22.27
10(50) 18.07
15(59) 14.75
20(68) 12.11
25(77) 10.00
30(86) 8.30
35(95) 6.93
40(104) 5.81
45(113) 4.90
50(122) 4.15

4. If the measured resistance is within specification, substitute with a known-good evaporator temperature sensor
and check for proper operation.
5. If the problem is corrected, replace the evaporator temperature sensor.

Replacement
1. Disconnect the negative (-) battery terminal.
 Page 27 of 149
2. Remove the center lower side cover.

\\

3. Disconnect the evaporator sensor connector (A).

4. Remove the evaporator temperature sensor(B), by pulling it after rorating 90° in a counterclockwise direction.

1 --•®1■
Take care that evaporator core pins are not bent.
5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Components and
Components Location
Component Location
 Page 28 of 149

- -.=!

(i/::;--,..,
; ,
' ✓- ::'j. ~
: . . .:: •!'t
--~- ;-

In oor sensor

Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Description and
Operation
Description
1. In-car air temperature sensor is located inside of the cresh pad panel.
2. The sensor contains a thermistor which measures the temperature of the inside. The signal, decided by the
resistance value which changes in accordance with perceived inside temperature, is delivered to heater control
unit and according to this signal the control unit regulates incar temperature to intended value.

Heating,Ventilation, Air Conditioning > Air conditioning System > In-car sensor > Repair procedures
INSPECTION
1. Ignition "ON"
 Page 29 of 149
2. Blow air with changing temperature to the in car sensor air inlet. Measure sensor resistance between 2 and 4
terminals.

□ =i □ □□ □
1 2 ~ 4 S 6

1, MaLOf(-) 4, ln aca r E8neor LBm□ , :;ignai

2. SOOror gmund M 5. Sensarpa,,'!!1f+)
3, • 6, \il □ Lo r (+)

Specification
Temperature [°C(°F)] Resistance between terminals 2and 4 (kΩ)
60(140) 7.463 ± 2.6%
50(122) 10.810 ± 2.2%
35(95) 19.59 ± 1.6%
25(77) 30.00 ± 1.2%
15(59) 47.130 ± 1.7%
0(32) 97.710 ± 2.4%
-15(5) 216.1 ± 3.2%
-30(-22) 509.36 ± 4.1%

In car sensor is negative type thermistor that resistance will rise with lower temperature, and reduce with
higher temperature.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the A/C control pannel. (Refer to BD group).
3. Disconnect the connector of in-car sensor (A).Loosen the mounting 1 screws and then remove the in-car sensor
(B).

4. Installation is the reverse order of removal.

 Page 30 of 149
Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Components and
Components Location
Component Location

Photo oonsor

__ ..,....---~ - -

- _..,..,--- ~---- --
--~---
'"'-..,..._

__..,..----
--~---------------~

Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Description and
Operation
Description
1. The photo sensor (A) is located at the right side of defrost nozzle.
2. The photo sensor contains a photovoltaic (sensitive to sunlight) diode. The solar radiation received by its light
receiving portion, generates an electromotive force in proportion to the amount of radiation received which is
transferred to the automatic temperature control module so that the solar radiation compensation will be
performed.

Heating,Ventilation, Air Conditioning > Air conditioning System > Photo sensor > Repair procedures
Inspection
1. Ignition "ON"
2. Using the scan tool.
 Page 31 of 149
3. Emit intensive light toward photo sensor using a lamp, and check the output voltage change.
4. The voltage will rise with higher intensive light and reduce with lower intensive light.

I . r1lato( ) 5.. Dr f-ll olD(-}

2. - 6. Siglal
3- Pa Phci!:I{-) ;_ Ve,:: {+5V)
4, - 8- GND

Replacement
1. Disconnect the negative (-) battery terminal.
2. With the (-) driver, remove the photo sensor (B) from the center of defrost nozzle (A).

3. Install in the reverse order of removal.

Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
Components and Components Location
Component Location
 Page 32 of 149

C (

' t, I
\
)')j~t-_..>.....
Haateroore

.... ·--. Water temprawre sensor

Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor >
Description and Operation
Description
1. Water temperature sensor is located at the heater unit.
2. It detects coolant temperature. Its signal is used for cold engine lockout control. When the driver operates the
heater before the engine is warmed up, the signal from sensor causes the heater control unit to reduce blower
motor speed until coolant temperature reaches the threshold value.

Heating,Ventilation, Air Conditioning > Air conditioning System > Water temperature sensor > Repair
procedures
Inspection
1. Ignition "ON"
 Page 33 of 149
2. Using the multi-tester, Measure resistance between terminal "1" and "2" of water temperature sensor.

1. Walar l.emperaiure sensor[+)

2. Ground M

Specification
Coolant temperature [°C(°F)] Resistance (kΩ) Voltage (V)
-10(14) 55.85 ± 3% 4.24 ± 3%
0(32) 32.91 ± 3% 3.83 ± 3%
10(50) 19.99 ± 3% 3.33 ± 3%
20(68) 12.51 ± 3% 2.78 ± 3%
30(86) 8.047 ± 3% 2.23 ± 3%
40(104) 5.311 ± 3% 1.73 ± 3%
50(122) 3.588 ± 3% 1.32 ± 3%
60(140) 2.476 ± 3% 0.99 ± 3%
70(158) 1.742 ±3% 0.74 ± 3%
80(176) 1.246 ± 3% 0.55 ± 3%

3. If the measured resistance is not specification, substitute with a known-good water temperature sensor and check
for proper operation.
4. If the problem is corrected, replace the water temperature sensor.

Negative type thermistor that resistance will rise with lower temperature, and reduce with higher
temperature.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the console side cover. (Refer to BD group)
 Page 34 of 149
3. Disconnect the connector (A) of water temperature sensor and then remove the water temperature sensor (B) by
pulling out.
A

4. Installation is the reverse order of removal.

Take care that wire of water temperature sensor is not to be

damaged

Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Components and
Components Location
Component Location
 Page 35 of 149

{ l)

---- .....

.,.-----.... ......
_.,.__
//
,'

Amblnt temperatura sensor

Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Description and
Operation
Description
1. The ambient temperature sensor is located at the front of the condenser and detects ambient air temperature. It is
a negative type thermistor; resistance will increase with lower temperature, and decrease with higher
temperatures.
 Page 36 of 149
2. The sensor output will be used for discharge temperature control, temperature regulation door control, blower
motor level control, mix mode control and in-car humidity control.

During AUTO mode the A/C compressor will be stopped when the ambient temperature is below
2.0°C(35.6F).
The compressor can still be turned on with manual control.

Heating,Ventilation, Air Conditioning > Air conditioning System > Ambient sensor > Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect ambient temperature sensor.
3. Check the resistance of ambient temperature sensor between terminals 1 and 2 whether it is changed by changing
of the ambient temperature.
Specification
Ambient temperature [°C(°F)] Resistance between terminals 1and 2 (kΩ)
-30(-22) 480.41
-20(-4) 278.85
-10(14) 162.38
0(32) 95.10
10(50) 58.80
20(68) 36.50
30(86) 24.26
40(104) 16.13
50(122) 10.95
60(140) 7.58

4. If the measured resistance is not specification, substitute with a known-good ambient temperature sensor and
check for proper operation.
5. If the problem is corrected, replace the ambient temperature sensor.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper.
 Page 37 of 149
3. Remove the ambient temperature sensor (A).

...
~~~
::-

=
'1. r,{'
,1/),-
·1 '

4. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Components and Components Location
Component Location

Heatar unit

Components
 Page 38 of 149

, 2
-----
~-:-::.
- .- --~
-::.
-- 5
____....,.... ','
-~. ,....

ITTl
UJJJ

n ~
- _ .Q

- -{Q]

..- ~@
8

1. Mode control actuator 7. Temp control door (Dual type)

2. Mode cam 8. Lower case
3. Heater & Evaporator case (L) 9. Water temperature sensor
4. Defrost door 10. Heater core
5. Vent door 11. Heater core cover
6. Temp control door (Single 12. Temp control actuator
type)
 Page 39 of 149

1 3

[jJ

1. Evaporator case seal 5. Plenum duct

2. Evaporator core 6. Temp control actuator
3. Evaporator temprature sensor 7. Heater & Evaporator case
4. Plenum duct seal (R)
8. Separator (Dual type only)

Heating,Ventilation, Air Conditioning > Heater > Heater Unit > Repair procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Recover the refrigerant with a recovery/ recycling/ charging station.
3. When the engine is cool, drain the engine coolant from the radiator.
 Page 40 of 149
4. Remove the bolts (A) and the expansion valve (B) from the evaporator core.
Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination.

___ _,. -- .
~

5. Disconnect the inlet (C) and outlet (D) heater hoses from the heater unit.

_,- /_

\~j-:~

~·~~
- ·~ - -
½::---;;= ~=-==-
Engine coolant will run out when the hoses are disconnected; drain it into a clean drip pan. Be sure not to
let coolant spill on electrical parts or painted surfaces. If any coolant spills, rinse it off immediately.

6. Remove the crash pad.

7. Remove the cowl cross bar assembly.
8. Disconnect the connectors from the temperature control actuator, the mode control actuator and the evaporator
temperature sensor and blower motor.
9. Remove the heater & blower unit after loosening 3 mounting bolts.
 Page 41 of 149
10. Remove the blower unit (B) from heater unit after loosening 3 screws.

11. Remove the water temperature sensor. (Refer to HA - Water temp sensor)
12. Remove the heater core (B) after remove the cover (A).

13. Loosen a screw and then remove the heater unit cover(A).

-~ .
...
' .,·.
; ~ ~,.,,_
~ '1,-{, ......--=:.

-~~---<
--
l
·.,,_
::..:..:_ -' .....

1,.,
.-I.~
/'1
A/
{

l
@1 I ,'-if .
I ;,!,./
--(_~,'r .~ '
I ,t,

14. Remove the evaporator core(A).

15. Be careful that the inlet and outlet pipe are not bent during heater core removal, and pull out the heater core.
16. Install the heater core in the reverse order of removal.
 Page 42 of 149
17. Installation is the reverse order of removal, and note these items :
A. If you're installing a new evaporator, add refrigerant oil (ND-OIL8).
B. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing
them. Be sure to use the right O-rings for R-134a to avoid leakage.
C. Immediately after using the oil, replace the cap on the container, and seal it to avoid moisture absorption.
D. Do not spill the refrigerant oil on the vehicle ; it may damage the paint ; if the refrigerant oil contacts the paint,
wash it off immediately
E. Apply sealant to the grommets.
F. Make sure that there is no air leakage.
G. Charge the system and test its performance.
H. Do not interchange the inlet and outlet heater hoses and install the hose clamps securely.
I. Refill the cooling system with engine coolant.

Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Components and
Components Location
Component Location
 Page 43 of 149

Temp oontroli actuator

Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Description and
Operation
Description
1. Heater unit includes mode control actuator and temperature control actuator.
2. Temperature control actuator is located at the heater unit. It regulates the temperature by the procedure as
follows. Signal from control unit adjusts position of temperature door by operating temperature switch and then
temperature will be regulated by the hot/cold air ratio decided by position of temperature door

Heating,Ventilation, Air Conditioning > Heater > Temperature Control Actuator > Repair procedures
Inspection
 Page 44 of 149
1. Ignition "OFF"
2. Disconnect the connector of temperature control actuator.
3. Verify that the temperature control actuator operates to the hot position when connecting 12V to the terminal 3
and grounding terminal 4.
Verify that the temperature control actuator operates to the cool position when connecting in the reverse.
[Driver]

3 4 6 2

1. - ~.!:iV(VCC)
2. . 6. Feedti,a,ct signal
3, Co,;,1 ll'Q!;i"~ij 7, &irl!iur gn;,1.lnd
4. Hot pcaltian

Specification
Door position Voltage (6-7) Error detecting
Low voltage :
Max. cooling 0.3 ± 0.15V
0.1V or less
High voltage :
Max. heating 4.7 ± 0.15V
4.9V or more

[Passenger]

31 4 5 :2

1. - 5. S g,ound
2.' 6. Feedboot -.inaJ
3. H'ot 'PO'<!ilion, 1 sv (VCQ)
4. COOi posttion

Specification
Door position Voltage (5-6) Error detecting
Low voltage :
Max. cooling 0.3 ± 0.15V
0.1V or less
High voltage :
Max. heating 4.7 ± 0.15V
4.9V or more

It will feedback current position of actuator to controls.

4. If the measured voltage is not specification, substitute with a known-good temperature control actuator and
check for proper operation.
5. If the problem is corrected, replace the temperature control actuator.

Replacement
1. Disconnect the negative (-) battery terminal.
 Page 45 of 149
2. Remove the driver’s crush pad lower panel (Refer to BD- Crash pad)
3. Disconnect the temperature control actuator connector (A) after removing the air duct.
4. Loosen the mounting screw and then remove the temperature control actuator (B).
[Passenger's]

~~
~:~i~~
--f"'-~ ~~""" 'l -
==--=,-~:.-==- •j
-~~.J.·~
I
'
/

.❖\

[Driver's]

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Components and
Components Location
Component Location
 Page 46 of 149

.,,-- ------ --=-~--

------ __,...,...-
-- -------
=---- ---------
_(r--:.:-:------==-----
--......
...___

__)

:Mode control acwator

Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Description and Operation
Description
The mode control actuator is located at the heater unit.
It adjusts position of mode door by operating mode control actuator based on signal of A/C control unit. Pressing
mode select switch makes the mode control actuator shift in order of vent→ B/L → floor → mix → def.

Heating,Ventilation, Air Conditioning > Heater > Mode Control Actuator > Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect the connector of mode control actuator.
3. Verify that the mode control actuator operates to the defrost mode when connecting 12V to the terminal 3 and
grounding terminal 4.
 Page 47 of 149
4. Verify that the mode control actuator operates to the vent mode when connecting in the reverse.

1.• 5, 6El'llii0r QltiUOO

2. • l! . SVNCC)
3. Defrost mode 7. Feedback gnal
4. Vent mode

5. Check the voltage between terminals 5 and 7.

Door position Voltage (5-7) Error detecting
Low voltage :
Vent 0.3 ± 0.15V
0.1V or less
High voltage :
Defrost 4.7 ± 0.15V
4.9V or more

It will feedback current position of actuator to controls.

6. If the measured voltage is not specification, substitute with a known-good mode control actuator and check for
proper operation.
7. If the problem is corrected, replace the mode control actuator.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the driver’s crush pad lower panel (Refer to BD group).
3. Disconnect the temperature control actuator connector (A) after removing the air duct.
4. Loosen the mounting screw and then remove the temperature control actuator (B).

a --~:~~
~-\

\\
\ )
I

• 11 I

'·-
5. Installation is the reverse order of removal.
 Page 48 of 149
Heating,Ventilation, Air Conditioning > Rear Heater > Rear Heater Unit > Components and
Components Location
Component Location

,,
-::.:---==-
-;:....._
•{ --·-
4/' / -
llr \,__ ,,,.
11 I
\ \
\

Components
 Page 49 of 149

.,.

t, 7

r, ,,
2
3

t~~
a

1. Rear blower motor 6. Lower case seal

2. Rear blower 7. Lower case
resistor 8. Drain hose
3. Rear A/C case (L) 9. Rear A/C case (R)
4. Rear refrigerant
5. Rear evaporator
core

Heating,Ventilation, Air Conditioning > Rear Heater > Rear Heater Unit > Repair procedures
Replacement
1. Disconnect the negative(-) battery terminal.
2. Recover the refrigerant with a recover/ recycling/ charging station.
3. Remove luggage side trim.
4. Remove the rear wheel guard.
 Page 50 of 149
5. Loosen the refrigerant line mounting nuts.

6. Loosen the refrigerant line mounting bolts, and then remove the rear refrigerant line(A).

7. Loosen the mounting bolts and a nut and then remove the rear heater unit(A).

8. Disconnect the rear evaporator core cover(A) and then remove the evaporator core(B).

9. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Rear Heater > Rear Blower Unit > Repair procedures
 Page 51 of 149
Inspection
1. Connect the battery voltage and check the blower motor rotation.

2. If the blower motor voltage is not operated well, substitute with a known-good blower motor and check for
proper operation.
3. If the problem is corrected, replace the blower motor.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove luggage side trim. (Refer to BD- Interior trim)
3. Disconnect the connector (A) of the blower motor.
4. Remove the blower motor (B) after loosening the mounting screws.

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Rear Heater > Rear Blower Resister > Repair procedures
Inspection
1. Measure terminal-to-terminal resistance of the blower resistor.
 Page 52 of 149
2. If measured resistance is not within specification, the blower resistor must be replaced. (After removing the
resistor)

3 4

1. . a. L-O
2. MH 4_ HI

2 3 4

MeaE1JIBrnetnl
Of ~5'.:'1-
bet,iee{l
11ai:h Iormina!

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the luggage side trim. (Refer to BD- Interior trim)
3. Disconnect the rear blower resister connector (A).
4. Remove rear blower resister (B) after loosening the mounting screws.

\
---.·\
---- I,
----1
'11

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Rear Heater > Rear Control Panel > Components and
Components Location
Components
 Page 53 of 149

ldl
0

LO
00

1 2 3 4
11 □ □ c=J

5 6 7 8 910 1i1
C=:J □□ DD □ c==J

[CONNECTOR]
 Page 54 of 149
PIN
1 LOW
2 ILL(+)
3 ILL(-)
4 MIDDLE
5 HIGH
6 -
7 -
8 -
9 -
10 COMMON
11 GND

Heating,Ventilation, Air Conditioning > Rear Heater > Rear Control Panel > Repair procedures
Replacement
1. Remove the rear side trim. (Refer to BD- Interior Trim)
2. Loosen the mounting screw and then remove the rear blower controler(A) from the rear side trim.
 Page 55 of 149
3. Loosen the mounting screw and then remove the rear blower cintrol unit (A) from the air vant(B).

4. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Components and Components Location
Component Location

-----~------ ...... -
------------ --.

-....,

Blower unit
....__

Components
 Page 56 of 149

I ,
I ~. •.»,.""
@~0.~
i----- 5
J,11t
·

'' ' 1',y1

9
8

JI,
ll

1. Intake duck seal 7. Blower upper case

2. Air inlet case 8. Blower lower case
3. Intake door 9. Blower seal
assembly 10. Blower motor
4. Intake actuator 11. Mos-Fet
5. Air filter
6. Air filter housing

Heating,Ventilation, Air Conditioning > Blower > Blower Unit > Repair procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crush pad.(Refer to BD-crashpad)
 Page 57 of 149
3. Disconnect the connectors from the intake actuator, the blower motor and blower resister.
4. Remove the blower unit (A) from the heater unit after loosening a mounting bolt and 3 screws.

Make sure that there is no air leaking out of the blower and duct joints.
5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Components and Components
Location
Component Location
 Page 58 of 149

· • r motor
Blowe

Heating,Ventilation, Air Conditioning > Blower > Blower Motor > Repair procedures
Inspection
 Page 59 of 149
1. Connect the battery voltage and check the blower motor rotation.

2. If the blower motor voltage is not operated well, substitute with a known-good blower motor and check for
proper operation.
[ ] MANUAL AUTO
1 3.8V AUTO LO(4.5V)
2 4.9V 4.6~5.5V
3 6.1V 5.6~6.7V
4 7.2V 6.8~7.7V
5 8.3V 7.8~8.9V
6 9.5V 9.0~10.1V
7 10.6V 10.2~AUTO HI(10.6V)
8 B+

3. If the problem is corrected, replace the blower motor.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the blower under cover after loosening 2 screws.
3. Disconnect the connector (A) of the blower motor.

A
 Page 60 of 149
4. Remove the blower motor (A) after loosening the mounting screws.

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Components and Components
Location
Component Location

.......__ _

I.,.____ __.,.,....,.--

Power mosfe1

Heating,Ventilation, Air Conditioning > Blower > Power Mosfet > Repair procedures
Inspection
1. Ignition "ON"
2. Manually operate the control switch and measure the voltage of blower motor between pin 1 and 2.
 Page 61 of 149
3. Select the control switch to raise voltage until high speed.

AJC oontrol

[Specification]
Motor Voltage
Fan
Manual
First speed 3.8 ±0.5V
Second speed 4.9 ±0.5V
Third speed 6.1 ±0.5V
Fourth speed 7.2 ±0.5V
Fifth speed 8.3 ±0.5V
Sixth speed 9.5 ±0.5V
Seventh speed 10.6 ±0.5V
eighth speed BAT(+)

*AUTO COOLING: Auto speed (4.5V~B+)

*AUTO HEATING: Auto speed (4.5V~10.5V)
4. If the measured voltage is not specification, substitute with a known-good power mosfet and check for proper
operation.
5. If the problem is corrected, replace the power mosfet.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Disconnect the power mosfet connector (A) at the connecting part between heater and blower unit.
3. Remove the power mosfet(B) after loosening the mounting screws.
 Page 62 of 149
4. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Description and Operation
Description
This has particle filter which eliminates foreign materials and odor. The particle filter includes odor filter as well as
conventional dust filter to ensure comfortable interior environment.

Heating,Ventilation, Air Conditioning > Blower > Climate control air filtar > Repair procedures
Replacement
1. Open the glove box (B).
Lower the glove box down completely by removing the glove box stopper (A) to the glove box.

2. Remove the glove box(B) from the left(A).

\ \ I, \
I,\__ \

3. Remove the filter cover (A) with pushing the knob.

 Page 63 of 149
4. Replace the air filter (B).

--□~J\~,~rn~n
f'Cl~ r
~-r
-~- }

In case of driving in an air-polluted area or rugged terrain, check and replace the air filter as frequently as
possible.

Replacement period: Approximately 15,000 km or 10,000 miles

Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Components and Components
Location
Component Location
 Page 64 of 149

Intake actuator

Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Description and Operation
Description
1. The intake actuator is located at the blower unit.
2. It regulates the intake door by signal from control unit.
3. Pressing the intake selection switch will shift between recirculation and fresh air modes.

Heating,Ventilation, Air Conditioning > Blower > Intake Actuator > Repair procedures
Inspection
1. Ignition "OFF"
2. Disconnect the intake actuator connector.
3. Verify that the actuator operates to the recirculation position when connecting 12V to the terminal 3 and
grounding terminal 4.
 Page 65 of 149
4. Verify that the intake actuator operates to the fresh position when connecting in the reverse.

m
1 •
2 -
e s
S, 5V{VCC)
76, Foo,1 bac .,.,,
~e~nal
S F · Stlf\s,:1rgroln'.l
4 Ro::

5. If the intake actuator is not operated well, substitute with a known-good intake actuator and check for proper
operation.
6. If the problem is corrected, replace the intake actuator.

Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the glove box (Refer to BD- Crach pad).
3. Disconnect the intake actuator connector.
4. Loosen the mounting screw and then remove the intake actuator (A) from the blower unit.

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) >
Components and Components Location
Component
 Page 66 of 149

DD DD ::J □ DD DD □□□
- ~~
B1 B2 83 B4 85 BB B7 Ba 8D 8-0 Bl B12 Bl
0000:J □ uDD □□□□
814 Bl5 131/l B17 818 Br.. EHl BZ1 ~ Em ffil 135

[Connector Pin Function]

 Page 67 of 149
Connector PIN NO. Function Connector PIN NO. Function
1 TAIL LAMP 14 RHEOSTAT (ILL-)
2 BATTERY 15 FET (G)
3 A/C OUT PUT 16 FET (D)
MODE ACT'R
4 17 TEMP ACT'R F/B
(VENT)
MODE ACT'R
5 18 MODE ACT'R F/B
(DEF)
TEMP ACT'R INTAKE ACT'R
6 19
(COOL) F/B
TEMP ACT'R EVAP SENSOR
7 20
Connector (B) (WARM) Connector (B) (+)
INTAKE ACT'R BLOWER MOTOR
8 21
(FRE) (+)
INTAKE ACT'R A/C SELECT
9 22
(REC) SIGNAL
DEF SELECT DEF INDICATOR
10 23
SIGNAL OUTPUT
SENSOR
11 24 SENSOR GND
REF(+5V)
12 - 25 -
13 IGN2 26 GND

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Manual) > Repair
procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad center lower garnish(A).
 Page 68 of 149
3. Remove the heater & A/C controller (A) after loosening 4 screws.

4. Dissconnect the connector(A).

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic) >
Components and Components Location
Component
 Page 69 of 149

,y
I
I

~
11
====
=i===c:::c::::.2

A El

[Connector Pin Function]

Connector PIN NO. Function Connector PIN NO. Function
1 TAIL LAMP 1 SENSOR REF(+5V)
2 BATTERY 2 AQS SIGNAL
3 A/C OUTPUT 3 AMB SENSOR(+)
A/C SELECT
4 4 -
SIGNAL
 Page 70 of 149
INCAR
5 - 5
SENSOR(+)
6 K-LINE 6 EVAP. SENSOR(+)
WATER TEMP
7 - 7
SENSOR(+)
DEF SELECT
8 8 SENSOR REF(+5V)
SIGNAL
DEF INDCATOR
9 9 FET (G)
OUTPUT
10 - 10 FET (D)
BLOWER MOTOR
11 - 11
(+)
12 IGN2 12 SENSOR GND
TEMP ACT’R DR
13 IGN2 13
(COOL)

Connector(A) Connector(B) TEMP ACT’R DR

14 RHEOSTAT 14
(WARM)
15 - 15 DR PHOTO (-)
TEMP ACT’R
16 16 PS PHOTO (-)
PS(COOL)
TEMP ACT’R
17 17 INCAR MOTOR (-)
PS(WARM)
TEMP ACT’R PS TEMP ACT’R DR
18 18
F/B F/B
MODE BLOWER ON
19 19
ACT’R(VENT) SIGNAL
MODE
20 20 -
ACT’R(DEF)
21 MODE ACT’R F/B 21 -
INTAKE ACT’R
22 22 -
(FRE)
INTAKE ACT’R
23
(REC)
INTAKE ACT’R
24
F/B
25 GND
26 GND

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic) >
Troubleshooting
 Page 71 of 149
Selfdiagnosis
1. Self-diagnosis process

IG KEY SNJON

l
Press the Mode switch more then 4 times within
2 saoonds whi le pressing the OFF switcti.

1
Perlorm se.l f diagnosis after displating
"DCC(HCC)" and then all of the LCD display
graphicsfliickering twice of the each text at
0.5 sec intervals.

1
Diagnos,1s s!art (Conti nuance operation),

Press A/C swi,tch

1 Select AUTO switdh
'I SBlect OFF switch
Diag no'sis (Step operation)
1

to do next steip
J., Select OFF switch
If the set 'temperature before self dia.gTiosis is
AUTO/OUAL slal:e, Return, AUTO/OUAL state

2. How to read self-diagnostic code

After the display panel flickers three times every 0.5 second, the corresponding fault code flickers on the setup
temperature display panel every 0.5 second and will show two figures. Codes are displayed in numerical format
Fault code
Fault code
Fail description
Control unit DTC
00 - Normal
11 B1234 In-car temperature sensor open
12 B1233 In-car temperature sensor short
13 B1238 Ambient temperature sensor open
14 B1237 Ambient temperature sensor short
15 B1202 Water temperature sensor open
16 B1203 Water temperature sensor short
17 B1242 Evaporator temperature sensor open
18 B1241 Evaporator temperature sensor short
19 B1245 Temperature control actuator feed back open (Drive's)
19 B1246 Temperature control actuator feed back short (Drive's)
20 B2406 Temperature control actuator failure
21 B1249 Mode control actuator open
21 B1250 Mode control actuator short
 Page 72 of 149
22 B2409 Mode control actuator failure
25 B1208 Intake potentiometer open
25 B1209 Intake potentiometer short
26 B2408 Intake potentiometer failure
27 B1257 AQS sensor open
28 B1258 AQS sensor short
31 B1259 AQS sensor failure
32 B1204 Temperature control actuator open (Passenger's)
32 B1205 Temperature control actuator short (Passenger's)
33 B2415 Temperature control actuator failure

3. Fault code display

(1) Continuance operation : DTC code is one.

ON ON

Df:splay OFF OFF

o.ssec - ·- 0.5sec

(2) Continuance operation : DTC code is more two.

Code 1 Code 11 Code.2 Code2

IDtsplay

(3) STEP operation

A. Nomal or one fault code is same as a continuance operation.
B. DTC code os more two.

Code1 Code1 Code2 Code2

Display

AJCSW
Select

4. Diagnostic procedure refer to DTC code.

 Page 73 of 149
5. Fail safe
(1) In-car temperature sensor: Control with the value of 25°C(77°F)
(2) Ambient temperature sensor: Control with the value of 20°C(67°F)
(3) Evaporator temperature sensor: Control with the value of -2°C(28.4°F)
(4) Temperature sensor : Control with the value of -2°C (28.4°F)
(5) Temperature control actuator (Air mix potentiometer):
If temperature setting 17°C-24.5°C, fix at maximum cooling position.
If temperature setting 25°C-32°C, fix at maximum heating position.
(6) Mode control actuator (Direction potentiometer):
Fix vent position, while selecting vent mode.
Fix defrost position, while selecting all except vent mode.
(7) Intake control actuator :
Fix fresh position, while selecting fresh mode.
Fix recirculation position, while selecting recirculation mode.
(8) AQS sensor : AQS operation OFF.
Intake position : The position before selecting AQS switch.

Heating,Ventilation, Air Conditioning > Controller > Heater & A/C Control Unit(Full Automatic) >
Repair procedures
Replacement
1. Disconnect the negative (-) battery terminal.
2. Remove the crash pad center lower garnish(A).

3. Remove the heater & A/C controller (A) after loosening 4 screws.
 Page 74 of 149
4. Dissconnect the connector(A).

5. Installation is the reverse order of removal.

Heating,Ventilation, Air Conditioning > Controller > B1202 Heater Water Temperature Sensor
Open(High)
Component Location

General Description
A water temp sensor located at heater unit detects coolant temperature. It contains negative type themistor whoses
resistance value is in inverse proportion to temperature. Resistance of watersensor that varies with temperature
makes signal voltage of A/C ECU change. In this way A/C ECU detects temperature. Signal of water sensor is used
for cold engine lockout control - When the driver operates the heater before the engine is warmed up enough, to
prevent driver from unpleasantness of cold air. the heater control unit reduces blower motor speed until coolant
temperature reaches the threshold value -

DTC Description
The ECM sets DTC B1202 if there is an open circuit in water temp sensor signal harness or the measured voltage
value of the sensor is more than the threshold value(4.9V)

DTC Detecting Condition

 Page 75 of 149
Item Detecting Condition Possible Cause

DTC Strategy • Voltage check • Open Circuit in signal

harness
• Open Circuit in
Threshold value • > 4.9V
ground harness
• Faulty water temp.
Detecting time • 0.3sec
Sensor
• Faulty A/C Control
Fail safe • Control with the value of 28.4°F Unit

Signal Waveform
Resistance value of water temp sensor as a function of temperature.
Temperature(°C) Resistance(kΩ) Temperature(°C) Resistance(kΩ)
14 55.85 104 5.31
32 32.91 140 2.48
68 12.51 176 1.25

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "WATER TEMP SENSOR" Parameter on the Scantool.

Fig1) The current data in abnormal state

Fig2) DTC B1202
4. Are the DTC B1202 present and is parameter of "WATER TEMP SENSOR" fixed?

Parameter of "WATER TEMP SENSOR" will be fixed at 28.4°F, if there is any fault in WATER TEMP
SENSOR

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
 Page 76 of 149
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness.
1. Ignition "OFF".
2. Disconnect water temp. sensor.
3. Measure resistance between terminal "1" of water temp. sensor and terminal "7" of A/C Control Unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection" procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF"
2. Disconnect water temp. sensor.
3. Measure resistance between terminal "2" of water temp sensor and terminal "12" of A/C Control Unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check WATER TEMP Sensor
1. Ignition "OFF".
2. Disconnect water temp. sensor.
 Page 77 of 149
3. Measure resistance between terminal "1" and "2" of water temp. sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of water temp sensor as a function of temperature.
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)
Go to "Check A/C Control Unit" procedure.

Ell Substitute with a known-good water temp. sensor and check for proper operation. If the
problem is corrected, replace water temp. sensor and then go to "Verification of Vehicle
Repair" procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Disconnect water temp. sensor.
3. Measure Voltage between terminal "7" of A/C Control Unit and chassis ground

Specification : Approx. 5V

[ill]
4. Is the measured voltage within specifications?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.

Ell System is performing to specification at this

time.

Heating,Ventilation, Air Conditioning > Controller > B1203 Heater Water Temperature Sensor
Short(Low)
Component Location
 Page 78 of 149

General Description
A water temp sensor located at heater unit detects coolant temperature. It contains negative type themistor whoses
resistance value is in inverse proportion to temperature. Resistance of watersensor that varies with temperature
makes signal voltage of A/C ECU change. In this way A/C ECU detects temperature. Signal of water sensor is used
for cold engine lockout control - When the driver operates the heater before the engine is warmed up enough, to
prevent driver from unpleasantness of cold air. the heater control unit reduces blower motor speed until coolant
temperature reaches the threshold value -

DTC Description
The ECM sets DTC B1203 if there is a short circuit in water temp sensor signal harness or the measured voltage
value of the sensor is less than the threshold value(0.1V)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Open Circuit in signal
harness
Threshold value • <0.1V
• Faulty water temp.
Detecting time • 0.3sec Sensor
• Faulty A/C Control
Fail safe • Control with the value of 28.4°F Unit

Signal Waveform
Resistance value of water temp sensor as a function of temperature.
Temperature(°C) Resistance(kΩ) Temperature(°C) Resistance(kΩ)
14 55.85 104 5.31
32 32.91 140 2.48
68 12.51 176 1.25

Monitor Scantool Data

 Page 79 of 149
1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "WATER TEMP SENSOR" Parameter on the Scantool.

Fig1) The current data in abnormal state

Fig2) DTC B1203
4. Are the DTC B1203 present and is parameter of "WATER TEMP.SENSOR" fixed ?

Parameter of "WATER TEMP SENSOR" will be fixed at 28.4°F, if there is any fault in WATER TEMP
SENSOR

1111 Go to "Inspection & Repair" procedure.

Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short to ground in harness
1. Ignition "OFF".
2. Disconnect water temp. sensor.
3. Measure resistance between terminal "1" of water temp sensor and chassis ground.

Specification : Approx. ∞ Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Component Inspection" procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.
 Page 80 of 149
Component Inspection
■ Check WATER TEMP Sensor
1. Ignition "OFF".
2. Disconnect water temp. sensor.
3. Measure resistance between terminal "1" and "2" of water temp. sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of water temp sensor as a function of temperature.
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)

Im Go to "Check A/C Control Unit" procedure.

Ell Substitute with a known-good water temp. sensor and check for proper operation. If the
problem is corrected, replace water temp. sensor and then go to "Verification of Vehicle
Repair" procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Disconnect water temp. sensor.
3. Measure Voltage between terminal "7" of A/C Control Unit and chassis ground

Specification : Approx. 5V

4. Is the measured voltage within specifications?

I Im Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?

Im Go to the applicable troubleshooting

procedure.

Ell System is performing to specification at this

time.
 Page 81 of 149
Heating,Ventilation, Air Conditioning > Controller > B1204 Air Mix Potentiometer Open
(Low)–Passenger
Component Location

Te~pera:ture Gontro1 Actuator

General Description
Temperature control actuator located at heater unit. It contains temp motor that changes temp door position and
potentiometer that monitors position of temp door. Temperature control actuator regulates the temperature by the
procedure as follows. Signal from control unit adjusts position of temp door by operating temp motor and then
temperature will be regulated by the hot/cold air ratio decided by position of temp door. In operation, potentiometer
delivers temp door position transformed into voltage value to A/C ECU .

DTC Description
The ECM sets DTC B1204 if there is an open circuit or poor connection in the passenger air mix actuator signal
harness.

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
Threshold value • <0.1V • Poor connection of
connected part
Detecting time • 0.3sec • Open circuit in harness
• Setting temperature : 63°F-76.1°F • Short circuit in harness.
fix at max. cooling position • Faulty passenger air mix
Fail safe actuator
• Setting temperature : 77°F-89.6°F
fix at max. heating position

Signal Waveform
Voltage value of Air Mix potentiometer as a function of temp door position.
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more
 Page 82 of 149

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "PASSENGER AIR MIX D" Parameter on the Scantool. While operating passenger temp switch.

Fig1) The current data in abnormal state

Fig2) DTC B1204
4. Are the DTC B1204 present and is parameter of "PASSENGER AIR MIX D" fixed?

Parameter of "PASSENGER AIR MIX D" will be fixed at d at 100%(or any value above 90%), or 0%
(or any value below 10%), if there is any fault in passenger air mix actuator.

Go to "Inspection & Repair" procedure.

Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness.
1. Ignition "OFF".
2. Disconnect passenger air mix actuator.
3. Measure resistance between terminal "6" of passenger air mix actuator and terminal "18" of A/C control unit.

Specification : Approx. 0 Ω
 Page 83 of 149
4. Is the measured resistance within specifications?
Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness.

1. Ignition "OFF".
2. Disconnect passenger air mix actuator.
3. Measure resistance between terminal "6" of passenger air mix actuator and chassis ground.

Specification Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Power circuit Inspection" procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Power Supply Circuit Inspection

■ Check for open in harness
1. Ignition "ON".
2. Connect passenger air mix actuator.
3. Measure resistance between terminal "7" of passenger air mix actuator and terminal "1" of A/C Control Unit

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Check for short in harness " procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

■ Check for short in harness

1. Ignition "ON".
2. Connect passenger air mix actuator.
3. Measure resistance between terminal "7"of passenger air mix actuator and chassis ground.

Specification : Approx. ∞ Ω

[ill]
 Page 84 of 149
4. Is the measured resistance within specifications?
Go to "Component Inspection" procedure.
Check for short in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Component Inspection
■ Check A/C Control Unit
1. Engine "ON".
2. Disconnect passenger air mix actuator.
3. Measure voltage value between terminal "1" of A/C control unit and chassis ground.

Specification : 5V

4. Is the measured voltage within specifications?

Go to "Check passenger air mix actuator" procedure.

Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

■ Check passenger air mix actuator.

1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect passenger air mix actuator.
(3) Connect (+) terminal of battery to terminal 3 of passenger air mix actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the hot position
(5) Verify that the temperature actuator operates to the cool position with reverse connecting.( (+) to 4 and (-) to
3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.
 Page 85 of 149
2. Check actuator potentiometer
(1) Ignition "ON".
(2) Connect passenger air mix actuator.
(3) Measure voltage between terminal "5" and "6"of passenger air mix actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of Air Mix potentiometer as a function of temp door position.
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
Bill Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
Bill System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1205 Air Mix Potentiometer Short
(High)–Passenger
Component Location
 Page 86 of 149

~
Tem,pe:ratu:re Gonrn1 Acwator

General Description
Temperature control actuator located at heater unit. It contains temp motor that changes temp door position and
potentiometer that monitors position of temp door.Temperature control actuator regulates the temperature by the
procedure as follows. Signal from control unit adjusts position of temp door by operating temp motor and then
temperature will be regulated by the hot/cold air ratio decided by position of temp door. In operation, potentiometer
delivers temp door position transformed into voltage value to A/C ECU .

DTC Description
The ECM sets DTC B1205 if there is a short to power in the passenger air mix actuator signal harness.

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
Threshold value • >4.9V
• Open circuit in harness
Detecting time • 0.3sec • Short circuit in harness.
• Setting temperature : 63°F-76.1°F • Faulty passenger air
fix at max. cooling position mix actuator
Fail safe
• Setting temperature : 77°F-89.6°F
fix at max. heating position

Signal Waveform
Voltage value of Air Mix potentiometer as a function of temp door position.
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
 Page 87 of 149
3. Monitor the "PASSENGER AIR MIX D" Parameter on the Scantool. While operating passenger temp switch.

Fig1) The current data in abnormal state

Fig2) DTC B1205
4. Are the DTC B1205 present and is parameter of "PASSENGER AIR MIX D" fixed ?

Parameter of "PASSENGER AIR MIX D" will be fixed at d at 100%(or any value above 90%), or 0%
(or any value below 10%), if there is any fault in passenger air mix actuator.

Im Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short in harness
1. Ignition "OFF".
2. Disconnect passenger air mix actuator.
3. Measure resistance between terminal "6" and "7"of passenger air mix actuator.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection" procedure.
Check for short to power harness in signal harness. Repair as necessary and go to
"Verification of Vehicle Repair" procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF"
 Page 88 of 149
2. Disconnect passenger air mix actuator.
3. Measure resistance between terminal "5" of passenger air mix actuator and chassis ground.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check passenger air mix actuator.
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect passenger air mix actuator.
(3) Connect (+) terminal of battery to terminal 3 of passenger air mix actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the hot position
(5) Verify that the temperature actuator operates to the cool position with reverse connecting.( (+) to 4 and (-) to
3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect passenger air mix actuator.
(3) Measure voltage between terminal "5" and "6"of passenger air mix actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of Air Mix potentiometer as a function of temp door position.
 Page 89 of 149
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1208 Intake Potentiometer Open (Low)
Component Location

~ ~
.~-

l'ntake D·oor
•. A01uator
-}f"Jr -
rT][
, J}r - '1~-

General Description
Intake door located at heater unit controls the inlet of car. It contains intake motor that changes intake door position
and potentiometer that monitors position of intake door. When driver operates the intake switch, ECU receives
mode signal from intake switch and operates intake door motot to turn intake door to intended position. (with FRE
mode signal, intake door is closed and with REC mode signal, intake door is opened)
In operation, potentiometer delivers intake door position transformed into voltage value to A/C ECU .

DTC Description
The ECM sets DTC B1208 if there is an open circuit or poor connection in the Intake actuator signal harness.
 Page 90 of 149
DTC Detecting Condition
Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Poor connection of
Threshold value • < 0.1V connected part
• Open circuit in
Detecting time • 0.3sec signal/power harness
• Setting mode : REC • Short circuit in
Fix at REC position signal/power harness
Fail safe
• Setting mode : Except REC • Faulty Intake
Fix at FRE position potentiometer

Signal Waveform
Voltage value of Intake potentiometer as a function of position of Intake door.
Door position Voltage Error Detecting Condition
FRE 0.3±0.15V Undervoltage : 0.08V or less
REC 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the " Intake potentiometer" Parameter on the Scantool. While operating Intake switch.

Fig1) The current data in abnormal state

Fig2) DTC B1208
4. Are the DTC B1208 present and is parameter of "Intake potentiometer" fixed?

Parameter of "Intake potentiometer" will be fixed at 100%(or any value above 90%), or 0% (or any
value below 10%), if there is any fault in Intake actuator.

Go to "Inspection & Repair" procedure.

Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared. Thoroughly check
connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage. Repair or replace as necessary and then go to "Verification of Vehicle Repair"
procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
 Page 91 of 149
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect Intake actuator.
3. Measure resistance between terminal "6" of Intake actuator and terminal "24" of A/C control unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF".
2. Disconnect Intake actuator
3. Measure resistance between terminal "6" of Intake actuator and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Power circuit Inspection" procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Power Supply Circuit Inspection

■ Check for open in harness
1. Ignition "ON".
2. Connect Intake actuator.
3. Measure resistance between terminal "5" of intake actuator and terminal "1" of A/C Control Unit.

Specification :Approx. 0 Ω

[ill]
 Page 92 of 149
4. Is the measured resistance within specifications?
Go to "Check for short in harness " procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

■ Check for short in harness

1. Ignition "ON".
2. Connect Intake actuator.
3. Measure resistance between terminal "5" of intake actuator and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection" procedure.
Check for short in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Component Inspection
■ Check A/C Control Unit
1. Engine "ON".
2. Disconnect intake actuator.
3. Measure voltage value between terminal "1" of A/C control unit and chassis ground.

Specification : 5V

[@
4. Is the measured voltage within specifications?

1111 Go to "Check intake actuator" procedure.

!Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

■ Check intake actuator.

 Page 93 of 149
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect intake actuator.
(3) Connect (+) terminal of battery to terminal 3 of intake actuator and (-) terminal to terminal 4
(4) Verify that the actuator operates to the FRE position
(5) Verify that the temperature actuator operates to the REC position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.

!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect intake actuator.
(3) Measure voltage between terminal "6" and "7" of passenger air mix actuator while operating the intake switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
FRE 0.3±0.15V Undervoltage : 0.08V or less
REC 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of intake potentiometer as a function of intake door position.
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
 Page 94 of 149
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1209 Intake Potentiometer Short (High)
Component Location

Intake Ooor
. Aciuator
•

General Description
Intake door located at heater unit controls the inlet of car. It contains intake motor that changes intake door position
and potentiometer that monitors position of intake door. When driver operates the intake switch, ECU receives
mode signal from intake switch and operates intake door motot to turn intake door to intended position. (with FRE
mode signal, intake door is closed and with REC mode signal, intake door is opened)
In operation, potentiometer delivers intake door position transformed into voltage value to A/C ECU .

DTC Description
The ECM sets DTC B1209 if there is a short to power in the Intake actuator signal harness.

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
Threshold value • < 4.9V • Open circuit in
ground harness
Detecting time • 0.3sec • Short to power in
• Setting mode : REC signal harness
Fix at REC position • Faulty Intake
Fail safe potentiometer
• Setting mode : Except REC
Fix at FRE position
 Page 95 of 149
Signal Waveform
Voltage value of Intake potentiometer as a function of position of Intake door.
Door position Voltage Error Detecting Condition
FRE 0.3±0.15V Undervoltage : 0.08V or less
REC 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the " Intake potentiometer" Parameter on the Scantool. While operating Intake switch.

Fig1) The current data in abnormal state

Fig2) DTC B1208
4. Are the DTC B1208 present and is parameter of "Intake potentiometer" fixed?

Parameter of "Intake potentiometer" will be fixed at 100%(or any value above 90%), or 0% (or any
value below 10%), if there is any fault in Intake actuator.

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short in harness
1. Ignition "OFF".
2. Disconnect Intake actuator.
 Page 96 of 149
3. Measure resistance between terminal "5" and "6"of intake actuator.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection" procedure.
Check for short to power harness in signal harness. Repair as necessary and go to
"Verification of Vehicle Repair" procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF".
2. Disconnect Intake actuaor.
3. Measure resistance between terminal "7"of Intake actuator and chassis ground.

Specification : Approx. 0 Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check intake actuator.
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect intake actuator.
(3) Connect (+) terminal of battery to terminal 3 of intake actuator and (-) terminal to terminal 4
(4) Verify that the actuator operates to the FRE position
(5) Verify that the temperature actuator operates to the REC position with reverse connecting.( (+) to 4 and (-)
to 3)
[ill]
(6) Dose the actuator work properly?
Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.
 Page 97 of 149
2. Check actuator potentiometer
(1) Ignition "ON".
(2) Connect intake actuator.
(3) Measure voltage between terminal "6" and "7" of passenger air mix actuator while operating the intake switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
FRE 0.3±0.15V Undervoltage : 0.08V or less
REC 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of intake potentiometer as a function of intake door position.
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
Bill Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
Bill System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1233 In-Car Temperature Sensor Short (Low)
Component Location
 Page 98 of 149

General Description
The incar temperature sensor joined to Humidity sensor as one body is located at heater control unit. It contains a
thermistor which measures the temperature of the inside. The signal,decided by the resistance value which changes in
accordance with perceived inside temperature, is delivered to heater control unit.
According to this signal, the control unit regulates incar temperature to intended value.

DTC Description
The ECM sets DTC B1233 if there is a short circuit in incar temp sensor signal harness or the measured voltage
value of the sensor is less than the threshold value(0.1V)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Short circuit in
Threshold harness
• < 0.1V • Faulty incar
value
temp.sensor
Detecting time • 0.3sec
• Faulty A/C Control
Fail safe • Control with the value of 77°F Unit

Signal Waveform
Resistance value of incar temp sensor as a function of temperature.
Resistance(kΩ)
Temperature(°C)
Min Mid Max
5 209.2 216.1 223.0
32 95.4 97.7 100.1
59 46.3 47.1 47.9
77 29.3 30.0 30.4
95 19.3 19.6 19.9
122 10.6 10.8 11.0
 Page 99 of 149

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "INCAR TEMP.SENSOR" Parameter on the Scantool.

Fig1) The current data in abnormal state

Fig2) DTC B1233
4. Are the DTC B1233 present and is parameter of "INCAR TEMP.SENSOR" fixed ?

Parameter of "INCAR TEMP.SENSOR" will be fixed at 77°F, if there is any fault in INCAR SENSOR.

Go to "Inspection & Repair" procedure.

El Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short to ground in harness
1. Ignition "OFF".
2. Disconnect incar sensor.
3. Measure resistance between terminal "4" of incar sensor and chassis ground.

Specification : Approx. ∞ Ω
 Page 100 of 149
4. Is the measured resistance within specifications?
Go to "Component Inspection" procedure.
Check for short to ground in harness. Repair as necessary and go to "Verification of Vehicle
I'------
= _______l_____l_ _ ___JI
Repair" procedure.

Component Inspection
■ Check Incar Temp. sensor
1. Ignition "OFF".
2. Disconnect incar sensor.
3. Measure resistance between terminal "4" and "2" of incar sensor.

Specification : Refer the specifications in fig3)

Fig3) Specifications : Resistance value of incar sensor as a function of temperature

-
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)
Go to "Check A/C Control Unit" procedure.

El Substitute with a known-good incar sensor and check for proper operation.
If the problem is corrected, replace incar sensor and then go to "Verification of Vehicle Repair"
procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Disconnect incar sensor.
3. Measure Voltage between terminal "5" of A/C Control Unit and chassis ground.

Specification : Approx. 5V

[ill]
4. Is the measured voltage within specifications?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

El Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
 Page 101 of 149
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
El System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1234 In-Car Temperature Sensor Open (High)
Component Location

lncar Temperature Sensor

General Description
The incar temperature sensor joined to Humidity sensor as one body is located at heater control unit. It contains a
thermistor which measures the temperature of the inside. The signal,decided by the resistance value which changes in
accordance with perceived inside temperature, is delivered to heater control unit.
According to this signal, the control unit regulates incar temperature to intended value.

DTC Description
The ECM sets DTC B1234 if there is an open circuit in incar temp sensor signal harness or the measured voltage
value of the sensor is more than the threshold value(4.9V)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Open Circuit in
Threshold harness
• < 4.9V • Faulty incar
value
temp.sensor
Detecting time • 0.3sec
• Faulty A/C Control
Fail safe • Control with the value of 77°F Unit

Signal Waveform
Resistance value of incar temp sensor as a function of temperature.
 Page 102 of 149
Resistance(kΩ)
Temperature(°C)
Min Mid Max
5 209.2 216.1 223.0
32 95.4 97.7 100.1
59 46.3 47.1 47.9
77 29.6 30.0 30.4
95 19.3 19.6 19.9
122 10.6 10.8 11.0

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "INCAR TEMP.SENSOR" Parameter on the Scantool.

4. Are the DTC B1234 present and is parameter of "INCAR TEMP.SENSOR" fixed ?

Parameter of "INCAR TEMP.SENSOR" will be fixed at 77°F, if there is any fault in INCAR
SENSOR.

ml Go to "Inspection & Repair" procedure.

Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect incar temp.sensor.
 Page 103 of 149
3. Measure resistance between terminal "4" of incar temp.sensor and terminal "5" of A/C Control Unit

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

ml Go to "Ground circuit Inspection " procedure.

Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF".
2. Disconnect incar temp.sensor.
3. Measure resistance between terminal "2" of incar temp.sensor and terminal "12" of A/C Control Unit.

Specification : Approx. 0 Ω

[ill]
4. Is the measured resistance within specifications?

ml Go to "Component Inspection " procedure.

Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check Incar Temp. sensor
1. Ignition "OFF".
2. Disconnect incar sensor.
3. Measure resistance between terminal "4" and "2" of incar sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of incar sensor as a function of temperature
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)

ml Check connectors for looseness, poor connection, bending, corrosion, contamination,

deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

!Ell Substitute with a known-good incar sensor and check for proper operation.
If the problem is corrected, replace incar sensor and then go to "Verification of Vehicle Repair"
procedure.
 Page 104 of 149

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?

1111 Go to the applicable troubleshooting

procedure.
!Ell System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1237 Ambient Temperature Sensor Short (Low)
Component Location

--------,....__,__

---=---
~~it~;~~~;~:c -~#t#ilJ-.-tilr ·7 ,,..,"z___
===
_ '==~====',='"',~--
.. - Ambient Temp. Sensot

;':;a:··r:~l\Li /~O -- _; . :::::;;;,,~

General Description
The ambient temperature sensor located at the center stay of the condensor detects ambient air temperature. It is
joined to AQS sensor as one boby. It is a negative type thermistor whose resistance is inversely proportional to
temperature. Its output is used for sensor fail-safe, temperature regulation door lock, blower motor level control, mix
mode control and in-car humidity control.

DTC Description
The ECM sets DTC B1237 if there is a short circuit in ambient temp sensor signal harness or the measured voltage
value of the sensor is less than the threshold value(0.1V)

DTC Detecting Condition

 Page 105 of 149
Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Short circuit in
harness
Threshold value • < 0.1V
• Faulty ambient
Detecting time • 0.3sec temp.sensor
• Faulty A/C Control
Fail safe • Control with the value of 68°F Unit

Signal Waveform
Resistance value of ambient temp.sensor as a function of temperature.
Temperature(°C) Resistance(kΩ) Temperature(°C) Resistance(kΩ)
-4 271.1 122 10.9
32 95.1 176 3.83
77 30.0

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "AMBIENT TEMP.SENSOR" Parameter on the Scantool.

Fig1) The current data in abnormal state

Fig2) DTC B1237
4. Are the DTC B1237 present and is parameter of "AMBIENT TEMP.SENSOR" fixed ?

Parameter of "AMBIENT TEMP.SENSOR" will be fixed at 68°F, if there is any fault in AMBIENT
TEMP.SENSOR.

ml Go to "Inspection & Repair" procedure.

Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
 Page 106 of 149
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short to ground in harness
1. Ignition "OFF".
2. Disconnect ambient sensor.
3. Measure resistance between terminal "1" of ambient sensor and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection" procedure.
Check for short to ground in harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check Ambient sensor
1. Ignition "OFF".
2. Disconnect ambient sensor.
3. Measure resistance between terminal "1" and "2" of ambient sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of ambient sensor as a function of temperature
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)

1111 Go to "Check A/C Control Unit" procedure.

Ell Substitute with a known-good ambient sensor and check for proper operation.
If the problem is corrected, replace ambient sensor and then go to "Verification of Vehicle
Repair" procedure.

■ Check A/C Control Unit

1. Engine : "ON".
2. Disconnect ambient sensor.
 Page 107 of 149
3. Measure voltage between terminal "3" of A/C Control Unit and chassis ground.

Specification : Approx. 5V

4. Is the measured voltage within specifications?

ml Check connectors for looseness, poor connection, bending, corrosion, contamination,

deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?

ml Go to the applicable troubleshooting

procedure.

!Ell System is performing to specification at this

time.

Heating,Ventilation, Air Conditioning > Controller > B1238 Ambient Temperature Sensor Open (High)
Component Location

------
----==----
:: :: :: ::".,-=~"."':~~~~~~:';--~-~-;,;,.;,-
--------- •.....,..,,_
..~.~~~-~--c!'··"'~'-' =?
__""_;~~-""'
-..
AmbientTemp. Sensor
~~-: , : ?:,;~~{ [,- ;~~:, - - r-
□-~/i.~.'_:;\;.~:/;;
' • ·= •:,:_'.'. \ •,, { '~ -= -~.=i!m ;_,\'_'_'_'_-."~

\\ ¢} ---(J/''

General Description
The ambient temperature sensor located at the center stay of the condensor detects ambient air temperature. It is
joined to AQS sensor as one boby. It is a negative type thermistor whose resistance is inversely proportional to
temperature. Its output is used for sensor fail-safe, temperature regulation door lock, blower motor level control, mix
 Page 108 of 149
mode control and in-car humidity control.

DTC Description
The ECM sets DTC B1238 if there is an open circuit in ambient temp sensor signal harness or the measured voltage
value of the sensor is more than the threshold value(4.9V)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Open circuit in
harness
Threshold value • < 4.9V • Faulty ambient
Detecting time • 0.3sec temp.sensor
• Faulty A/C Control
Fail safe • Control with the value of 68°F Unit

Signal Waveform
Resistance value of ambient temp.sensor as a function of temperature.
Temperature(°C) Resistance(kΩ) Temperature(°C) Resistance(kΩ)
-4 271.1 122 10.9
32 95.1 176 3.83
77 30.0

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "AMBIENT TEMP.SENSOR" Parameter on the Scantool.

Fig1) The current data in abnormal state

Fig2) DTC B1238
4. Are the DTC B1238 present and is parameter of "AMBIENT TEMP.SENSOR" fixed ?

Parameter of "AMBIENT TEMP.SENSOR" will be fixed at 68°F, if there is any fault in AMBIENT
TEMP.SENSOR.

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.
 Page 109 of 149
Terminal and Connector Inspection
1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect ambient temp.sensor.
3. Measure resistance between terminal "1" of ambient temp.sensor and terminal "3" of A/C Control Unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection " procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF"
2. Disconnect ambient temp.sensor.
3. Measure resistance between terminal "2" of ambient temp.sensor and terminal "12" of A/C Control Unit

Specification : Approx. 0 Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check Ambient sensor
1. Ignition "OFF".
2. Disconnect ambient sensor.
 Page 110 of 149
3. Measure resistance between terminal "1" and "2" of ambient sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of ambient sensor as a function of temperature.
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)

Im Check connectors for looseness, poor connection, bending, corrosion, contamination,

deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good ambient sensor and check for proper operation.
If the problem is corrected, replace ambient sensor and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.

!Ell System is performing to specification at this

time.

Heating,Ventilation, Air Conditioning > Controller > B1241 Evaporator Sensor Short (Low)
Component Location

Evaporator Temp . Sensor

General Description
The Evaporator sensor located on heater unit detects the core temperature. It is a negative type thermistor whose
 Page 111 of 149
resistance is inversely proportional to temperature. Evaporator sensor transforms measured temperature into voltage
value and delivers it to A/C ECU. when core temperature is blow threshold value, A/C ECU interrupts compressor
relay power, in order to prevent evaporator freezing by excessive cooling.

DTC Description
The ECM sets DTC B1241 if there is a short circuit in evaporator sensor signal harness or the measured voltage
value of the sensor is less than the threshold value(0.1V)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Short circuit in
harness
Threshold value • < 0.1V
• Faulty ambient
Detecting time • 0.3sec temp.sensor
• Faulty A/C Control
Fail safe • Control with the value of 28.4°F Unit

Signal Waveform
Resistance value of evaporator sensor as a function of temperature.
Temperature(°C) Resistance(kΩ) Temperature(°C) Resistance(kΩ)
14 13.56 68 3.06
32 8 86 1.97
50 4.87 104 1.31

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "EVAPORATIVE SENSOR" Parameter on the Scantool.

1. Are the DTC B1241 present and is parameter of "EVAPORATIVE SENSOR" fixed ?

Parameter of "EVAPORATIVE SENSOR" will be fixed at 28.4°F, if there is any fault in

EVAPORATIVE SENSOR.

Go to "Inspection & Repair" procedure.

El Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.
 Page 112 of 149

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short to ground in harness
1. Ignition "OFF".
2. Disconnect evaporator sensor.
3. Measure resistance between terminal "2" of evaporator sensor and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Im Go to "Component Inspection" procedure.

Ell Check for short to ground in harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check evaporator sensor
1. Ignition "OFF".
2. Disconnect evaporator sensor.
3. Measure resistance between terminal "1" and "2" of evaporator sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of evaporator sensor as a function of temperature
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)

Im Go to "Check A/C Control Unit" procedure.

Ell Substitute with a known-good evaporator sensor and check for proper operation.
If the problem is corrected, replace evaporator sensor and then go to "Verification of Vehicle
Repair" procedure.

■ Check A/C Control Unit

 Page 113 of 149
1. Engine : "ON"
2. Disconnect evaporator sensor.
3. Measure voltage between terminal "6" of A/C Control Unit and chassis ground.

Specification : Approx. 5V

[ill]
4. Is the measured voltage within specifications?

I m1 Check connectors for looseness, poor connection, bending, corrosion, contamination,

deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
-,
procedure.
System is performing to specification at this
time.
______l_____ _ _ _ _ _j

Heating,Ventilation, Air Conditioning > Controller > B1242 Evaporator Sensor Open (High)
Component Location

Evaporator Te mp. Sensor

General Description
The Evaporator sensor located on heater unit detects the core temperature. It is a negative type thermistor whose
 Page 114 of 149
resistance is inversely proportional to temperature. Evaporator sensor transforms measured temperature into voltage
value and delivers it to A/C ECU. when core temperature is blow threshold value, A/C ECU interrupts compressor
relay power, in order to prevent evaporator freezing by excessive cooling.

DTC Description
The ECM sets DTC B1242 if there is an open circuit in evaporator sensor signal harness or the measured voltage
value of the sensor is more than the threshold value(4.9V)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Open circuit in
harness
Threshold value • < 4.9V
• Faulty Evaporator
Detecting time • 0.3sec sensor
• Faulty A/C Control
Fail safe • Control with the value of 28.4°F Unit

Signal Waveform
Resistance value of evaporator sensor as a function of temperature.
Temperature(°C) Resistance(kΩ) Temperature(°C) Resistance(kΩ)
14 13.56 68 3.06
32 8 86 1.97
50 4.87 104 1.31

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "EVAPORATIVE SENSOR" Parameter on the Scantool.

Fig1) The current data in abnormal state

Fig2) DTC B1242
 Page 115 of 149
4. Are the DTC B1242 present and is parameter of "EVAPORATIVE SENSOR" fixed ?

Parameter of "EVAPORATIVE SENSOR" will be fixed at 28.4°F, if there is any fault in

EVAPORATIVE SENSOR.

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect evaporator sensor.
3. Measure resistance between terminal "2" of evaporator sensor and terminal "6" of A/C Control Unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection " procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF".
2. Disconnect evaporator sensor.
 Page 116 of 149
3. Measure resistance between terminal "1" of evaporator sensor and terminal "12" of A/C Control Unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

ml Go to "Component Inspection " procedure.

!Ell Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check evaporator sensor
1. Ignition "OFF"
2. Disconnect evaporator sensor.
3. Measure resistance between terminal "1" and "2" of evaporator sensor.

Specification : Refer the specifications in fig3)

[ill]
[ill]
Fig3) Specifications : Resistance value of evaporator sensor as a function of temperature
4. Is the measured resistance within specifications in fig3)? (tolerance limits ±3%)

ml Go to "Check A/C Control Unit" procedure.

!Ell Substitute with a known-good evaporator sensor and check for proper operation.
If the problem is corrected, replace evaporator sensor and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?

ml Go to the applicable troubleshooting

procedure.

!Ell System is performing to specification at this

time.

Heating,Ventilation, Air Conditioning > Controller > B1245 Air Mix Potentiometer Open (Low)-Driver
Component Location
 Page 117 of 149

T empe:rature Control: Actuator

General Description
Temperature control actuator located at heater unit. It contains temp motor that changes temp door position and
potentiometer that monitors position of temp door. Temperature control actuator regulates the temperature by the
procedure as follows. Signal from control unit adjusts position of temp door by operating temp motor and then
temperature will be regulated by the hot/cold air ratio decided by position of temp door. In operation, potentiometer
delivers temp door position transformed into voltage value to A/C ECU .

DTC Description
The ECM sets DTC B1245 if there is an open circuit or poor connection in the driver air mix actuator signal
harness.

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
Threshold value • <0.1V • Poor connection of
connected part
Detecting time • 0.3sec • Open circuit in harness
• Setting temperature : 63°F-76.1°F • Short circuit in harness.
fix at max. cooling position • Faulty DR Air Mix
Fail safe
• Setting temperature : 77°F-89.6°F actuator
fix at max. heating position

Signal Waveform
Voltage value of Air Mix potentiometer as a function of temp door position.
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
 Page 118 of 149
2. Engine "ON".
3. Monitor the "DR AIR MIX potentiometer" Parameter on the Scantool. While operating temp switch.

Fig1) The current data in abnormal state

Fig2) DTC B1245
4. Are the DTC B1245 present and is parameter of "DR AIR MIX potentiometer" fixed?

Parameter of "DR AIR MIX potentiometer" will be fixed at d at 100%(or any value above 90%), or
0% (or any value below 10%), if there is any fault in DR AIR MIX actuator.

Go to "Inspection & Repair" procedure.

Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect DR Air Mix actuator.
3. Measure resistance between terminal "6" of DR Air Mix actuator and terminal "18" of A/C control unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF".
2. Disconnect DR Air Mix actuator.
 Page 119 of 149
3. Measure resistance between terminal "6" of DR Air Mix actuator and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Power circuit Inspection" procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Power Supply Circuit Inspection

■ Check for open in harness
1. Ignition "ON".
2. Connect DR Air Mix actuator.
3. Measure resistance between terminal "5" of DR Air Mix actuator and terminal "1" of A/C Control Unit.

Specification : Approx. 0 Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Check for short in harness " procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

■ Check for short in harness

1. Ignition "ON".
2. Connect DR Air Mix actuator.
3. Measure resistance between terminal "5"of DR Air Mix actuator and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection" procedure.
Check for short in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Component Inspection
■ Check A/C Control Unit
1. Engine "ON".
2. Disconnect DR Air Mix actuator.
 Page 120 of 149
3. Measure voltage value between terminal "1" of A/C control unit and chassis ground.

Specification : 5V

4. Is the measured voltage within specifications?

ml Go to "Check DR Air Mix actuator" procedure.

Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

■ Check DR Air Mix actuator.

1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect DR Air Mix actuator.
(3) Connect (+) terminal of battery to terminal 3 of DR Air Mix actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the cool position
(5) Verify that the temperature actuator operates to the warm position with reverse connecting.( (+) to 4 and (-)
to 3)
[ill]
(6) Dose the actuator work properly?

ml Go to "Check potentiometer" procedure.

Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect DR Air Mix actuator.
(3) Measure voltage between terminal "6" and "7"(LHD) of DR Air Mix actuator while operating the temp
switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of Air Mix potentiometer as a function of temp door position.
 Page 121 of 149
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
!Ell System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1246 Air Mix Potentiometer Short (High)-Driver
Component Location

,.~2:~

- ===
J
-~-:?
~-::::=.==~-~.

~..i,\ \\
[ .ls, \ I

-~ '

Tempe:rature Control: Actuator

General Description
Temperature control actuator located at heater unit. It contains temp motor that changes temp door position and
potentiometer that monitors position of temp door. Temperature control actuator regulates the temperature by the
procedure as follows. Signal from control unit adjusts position of temp door by operating temp motor and then
temperature will be regulated by the hot/cold air ratio decided by position of temp door. In operation, potentiometer
delivers temp door position transformed into voltage value to A/C ECU.

DTC Description
The ECM sets DTC B1246 if there is a short to power in the driver air mix actuator signal harness.
 Page 122 of 149
DTC Detecting Condition
Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
Threshold value • >4.9V • Open circuit in
harness
Detecting time • 0.3sec • Short circuit in
• Setting temperature : 63°F-76.1°F harness.
fix at max. cooling position • Faulty DR Air Mix
Fail safe actuator
• Setting temperature : 77°F-89.6°F
fix at max. heating position

Signal Waveform
Voltage value of Air Mix potentiometer as a function of temp door position.
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "DR AIR MIX potentiometer" Parameter on the Scantool. While operating temp switch.

Fig1) The current data in abnormal state

Fig2) DTC B1246
4. Are the DTC B1246 present and is parameter of "DR AIR MIX potentiometer" fixed ?

Parameter of "DR AIR MIX potentiometer" will be fixed at d at 100%(or any value above 90%), or
0% (or any value below 10%), if there is any fault in DR AIR MIX actuator.

Go to "Inspection & Repair" procedure.

Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
 Page 123 of 149
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short in harness
1. Ignition "OFF".
2. Disconnect DR Air Mix actuator.
3. Measure resistance between terminal "5" and "6" of DR Air Mix actuator.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection" procedure.
Check for short to power harness in signal harness. Repair as necessary and go to
"Verification of Vehicle Repair" procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF".
2. Disconnect DR Air Mix actuator.
3. Measure resistance between terminal "7" of DR Air Mix actuator and chassis ground.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check DR Air Mix actuator.
 Page 124 of 149
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect DR Air Mix actuator.
(3) Connect (+) terminal of battery to terminal 3 of DR Air Mix actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the cool position
(5) Verify that the temperature actuator operates to the warm position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.

!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect DR Air Mix actuator.
(3) Measure voltage between terminal "6" and "7" of DR Air Mix actuator while operating the temp switc.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of Air Mix potentiometer as a function of temp door position.
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
 Page 125 of 149
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
El System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1249 Direction Potentiometer Open (Low)-
Driver
Component Location

-~
-~~,;J

Mode Con1rol Actuator

General Description
The mode control actuator mounted on heater unit adjusts position of mode door by operating Direction Motor
based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of
vent→ B/L → floor → mix.

DTC Description
The ECM sets DTC B1249 if there is an open circuit or poor connection in the DR Direction actuator signal
harness.

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
• Poor connection of
Threshold value • <0.1V connected part
Detecting time • 0.3sec • Open circuit in harness
• Short circuit in
• Setting mode : VENT harness.
Fix at VENT position
Fail safe • Faulty DR Direction
• Setting mode : Except VENT actuator
Fix at DEF position
 Page 126 of 149
Signal Waveform
Voltage value of Direction potentiometer as a function of position of mode switch.
Door position Voltage Error Detecting Condition
VENT 0.3±0.15V Undervoltage : 0.10V or less
DEF 4.7±0.15V Overvoltage : 4.92V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "DR DIRECTION POTENTIO" parameter on the scantool. While operating mode switch.

Fig1) The current data in abnormal state

Fig2) DTC B1249
4. Are the DTC B1249 present and is parameter of "DR DIRECTION POTENTIO" fixed ?

Parameter of "DR DIRECTION POTENTIO" will be fixed at 100%(or any value above 90%), or 0%
(or any value below 10%), if there is any fault in DR Direction actuator.

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect DR Direction Actuator.
 Page 127 of 149
3. Measure resistance between terminal "6" of DR Direction actuator and terminal "21" of A/C control unit.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF".
2. Disconnect DR Direction Actuator.
3. Measure resistance between terminal "6" of DR Direction actuator and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Power circuit Inspection" procedure
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Power Supply Circuit Inspection

■ Check for open in harness
1. Ignition "ON".
2. Connect DR Direction Actuator.
3. Measure resistance between terminal "7" of DR Direction Actuator and terminal "1" of A/C Control Unit

Specification : Approx. 0 Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Check for short in harness " procedure.
Check for open in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

■ Check for short in harness

1. Ignition "ON".
2. Connect DR Direction Actuator.
 Page 128 of 149
3. Measure resistance between terminal "7" of DR Direction Actuator and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection" procedure.
Check for short in harness. Repair as necessary and go to "Verification of Vehicle Repair"
procedure.

Component Inspection
■ Check A/C Control Unit
1. Engine "ON".
2. Disconnect DR Direction Actuator.
3. Measure voltage value between terminal "1" of A/C control unit and chassis ground.

Specification : 5V

[ill]
4. Is the measured voltage within specifications?
Go to "Check DR Direction Actuator" procedure.

Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

■ Check DR Direction Actuator.

1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect DR Direction Actuator.
(3) Connect (+) terminal of battery to terminal 3 of DR Direction Actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the DEF position
(5) Verify that the temperature actuator operates to the VENT position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.
 Page 129 of 149
2. Check actuator potentiometer
(1) Ignition "ON".
(2) Connect DR Direction Actuator.
(3) Measure voltage between terminal "5" and "6" of DR Direction Actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
VENT 0.3±0.15V Undervoltage : 0.10V or less
DEF 4.7±0.15V Overvoltage : 4.92V or more

Fig3) Specifications : Voltage value of Direction potentiometer as a function of temp door position.
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
Bill Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
Bill System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B1250 Direction Potentiometer Short (High)-
Driver
Component Location
 Page 130 of 149

=--
~~'¥~
~J,
-~,,_r;i

.I .,, ,·
,,-:_,,·)'
. y* (
,)
j,~,11 ' ';?/,. Mode Control Actuator
~

General Description
The mode control actuator mounted on heater unit adjusts position of mode door by operating Direction Motor
based on signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in order of
vent→ B/L → floor → mix.

DTC Description
The ECM sets DTC B1250 if there is a short to power in the DR Direction actuator signal harness.

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
Threshold value • >4.9V • Open circuit in
harness
Detecting time • 0.3sec • Short circuit in
• Setting mode : VENT harness.
Fix at VENT position • Faulty DR Direction
Fail safe actuator
• Setting mode : Except VENT
Fix at DEF position

Signal Waveform
Voltage value of Direction potentiometer as a function of position of mode switch.
Door position Voltage Error Detecting Condition
VENT 0.3±0.15V Undervoltage : 0.10V or less
DEF 4.7±0.15V Overvoltage : 4.92V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
 Page 131 of 149
3. Monitor the "DR DIRECTION POTENTIO" parameter on the scantool. While operating mode switch.

Fig1) The current data in abnormal state

Fig2) DTC B1250
4. Are the DTC B1250 present and is parameter of "DR DIRECTION POTENTIO" fixed ?

Parameter of "DR DIRECTION POTENTIO" will be fixed at 100%(or any value above 90%), or 0%
(or any value below 10%), if there is any fault in DR Direction actuator.

Im Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for short in harness
1. Ignition "OFF".
2. Disconnect DR Direction potentiometer.
3. Measure resistance between terminal or "6" and "7"of DR Direction potentiometer

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Ground circuit Inspection " procedure.
Check for short to power harness in signal harness. Repair as necessary and go to
"Verification of Vehicle Repair" procedure.

Ground Circuit inspection

■ Check for open in ground harness
1. Ignition "OFF".
 Page 132 of 149
2. Disconnect DR Direction Actuator.
3. Measure resistance between terminal "5" of DR Direction Actuator and chassis ground.

Specification : Approx. 0 Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection " procedure.
Check for open in ground harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

Component Inspection
■ Check DR Direction Actuator.
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect DR Direction Actuator.
(3) Connect (+) terminal of battery to terminal 3 of DR Direction Actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the DEF position
(5) Verify that the temperature actuator operates to the VENT position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect DR Direction Actuator.
(3) Measure voltage between terminal "5" and "6" of DR Direction Actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
VENT 0.3±0.15V Undervoltage : 0.10V or less
DEF 4.7±0.15V Overvoltage : 4.92V or more

Fig3) Specifications : Voltage value of Direction potentiometer as a function of temp door position.
 Page 133 of 149
(4) Is the measured voltage within specifications in fig3)?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
!Ell System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B2406 Air Mix Motor-Driver
Component Location

Temperature Control Actuator

General Description
Temperature control actuator located at heater unit. It contains temp motor that changes temp door position and
potentiometer that monitors position of temp door. Temperature control actuator regulates the temperature by the
procedure as follows. Signal from control unit adjusts position of temp door by operating temp motor and then
temperature will be regulated by the hot/cold air ratio decided by position of temp door. In operation, potentiometer
delivers temp door position transformed into voltage value to A/C ECU.

DTC Description
The ECM sets DTC B2406 if the driver air mix actuator dosen’t move to intended position within 40sec (The ECM
attempts to move the temp door for a 2 second duration at a frequency of 3 times every 20 seconds before storing a
DTC.)
 Page 134 of 149

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
• Poor connection of
Threshold value • 0.5V<Potentiometer voltage < 4.5V connected part
Detecting time • 40sec • Open circuit in harness
• Short circuit in harness.
• Setting temperature : 63°F-76.1°F • Faulty DR Air Mix
fix at max. cooling position actuator
Fail safe
• Setting temperature : 77°F-89.6°F
• Fault A/C Control Unit
fix at max. heating position

Signal Waveform
Voltage value of Air Mix potentiometer as a function of temp door position.
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "DR AIR MIX potentiometer" Parameter on the Scantool. While operating temp switch.

Fig1) The current data in abnormal state

Fig2) DTC B2406
4. Are the DTC B2406 present and is parameter of "DR AIR MIX potentiometer" fixed?

There is any fault in DR AIR MIX Motor. If the parameter of "DRIVER AIR MIX DOOR" is 30% or
less when the actuator operates to the hot position, or If the parameter is 60% and more when the actuator
operates to the cold position.

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
 Page 135 of 149
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect DR Air Mix Actuator.
3. Measure resistance between terminal "3" of DR Air Mix Actuator and terminal "13" of A/C control unit.
4. Measure resistance between terminal "4" of DR Air Mix Actuator and terminal "14"of A/C control unit.

Specification : Approx. 0 Ω

5. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF".
2. Disconnect DR Air Mix Actuator.
3. Measure resistance between terminal "3,4" of DR Air Mix Actuator and chassis ground.

Specification : Approx. ∞ Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Component Inspection " procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Component Inspection
■ Check DR Air Mix actuator.
 Page 136 of 149
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect DR Air Mix actuator.
(3) Connect (+) terminal of battery to terminal 3 of DR Air Mix actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the cool position
(5) Verify that the temperature actuator operates to the warm position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect DR Air Mix actuator.
(3) Measure voltage between terminal "6" and "7" of DR Air Mix actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Fig3) Specifications : Voltage value of Air Mix potentiometer as a function of temp door position.
(4) Is the measured voltage within specifications in fig3)?
Go to "Check A/C Control Unit" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Connect A/C Control Unit.
3. Measure voltage between terminal "13" and "14" of A/C Control Unit while operating the temp switch.

Specification : Approx. 12V

[ill]
 Page 137 of 149
4. Is the measured voltage within specifications?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B2408 Intake Motor

Component Location

General Description
Intake door located at heater unit controls the inlet of car. It contains intake motor that changes intake door position
and potentiometer that monitors position of intake door. When driver operates the intake switch, ECU receives
mode signal from intake switch and operates intake door motot to turn intake door to intended position. (with FRE
mode signal, intake door is closed and with REC mode signal, intake door is opened)
In operation, potentiometer delivers intake door position transformed into voltage value to A/C ECU.

DTC Description
The ECM sets DTC B2408 if the intake motor dosen’t move to intended position within 40sec(The ECM attempts
to move the intake door for a 2 second duration at a frequency of 3 times every 20 seconds before storing a DTC.)
 Page 138 of 149

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Poor connection of
Threshold value • < 0.1V connected part
• Open circuit in
Detecting time • 0.3sec harness
• Setting mode : REC • Short circuit in
Fix at REC position harness.
Fail safe
• Setting mode : Except REC • Faulty Intake
Fix at FRE position actuator.

Signal Waveform
Voltage value of Intake potentiometer as a function of position of Intake door.
Door position Voltage Threshold value
FRE 0.3±0.15V voltage value > 0.08V
REC 4.7±0.15V voltage value > 4.9V

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the " Intake potentiometer" Parameter on the Scantool. While operating Intake switch.

Fig1) The current data in abnormal state

Fig2) DTC B2408
4. Are the DTC B2408 present and is parameter of "Intake potentiometer" fixed?

There is any fault in Intake actuator. If the parameter of "Intake potentiometer" is 30% or less when the
actuator operates to the FRE position, or If the parameter is 60% and more when the actuator operates to
the REC position

ml Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
 Page 139 of 149
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect Intake actuator.
3. Measure resistance between terminal "3" of Intake actuator and terminal "22"of A/C control unit.
4. Measure resistance between terminal "4" of Intake actuator and terminal "23" of A/C control unit.

Specification : Approx. 0 Ω

5. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF".
2. Disconnect Intake actuator.
3. Measure resistance between terminal "3,4" of Intake actuator and chassis ground.

Specification : Approx. ∞ Ω

[ill]
4. Is the measured resistance within specifications?
Go to "Component Inspection " procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Component Inspection
■ Check intake actuator.
 Page 140 of 149
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect intake actuator.
(3) Connect (+) terminal of battery to terminal 3 of intake actuator and (-) terminal to terminal 4
(4) Verify that the actuator operates to the FRE position
(5) Verify that the temperature actuator operates to the REC position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer.

(1) Ignition "ON".
(2) Connect intake actuator.
(3) Measure voltage between terminal "6" and "7"of passenger air mix actuator while operating the intake switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Threshold value
FRE 0.3±0.15V voltage value > 0.08V
REC 4.7±0.15V voltage value > 4.9V

Fig3) Specifications : Voltage value of intake potentiometer as a function of intake door position.
(4) Is the measured voltage within specifications in fig3)?
Go to "Check A/C Control Unit" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Connect A/C Control Unit.
3. Measure voltage between terminal "22" and "23" of A/C Control Unit while operating the Intake switch.

Specification : Approx. 12V

[ill]
 Page 141 of 149
4. Is the measured voltage within specifications?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B2409 Direction Control Motor-Driver
Component Location

Fr---~~~-~ --.

~~T,·y
-·;i
== \;_

M'oda Co nt rol
· Actuat,or

General Description
The mode control actuator mounted on heater unit adjusts position of mode door by operating Direction Motor in
accordance with signal of A/C control unit. Pressing mode select switch makes the mode control actuator shift in
order of vent→ B/L → floor → mix.

DTC Description
The ECM sets DTC B2409 if the direction motor dosen’t move to intended position within 40sec(The ECM
attempts to move the temp door for a 2 second duration at a frequency of 3 times every 20 seconds before storing a
DTC.)
 Page 142 of 149
DTC Detecting Condition
Item Detecting Condition Possible Cause
DTC Strategy • Voltage check • Poor connection of
connected part
Threshold value • < 0.1V • Open circuit in harness
Detecting time • 0.3sec • Short circuit in
harness.
• Setting mode : VENT • Faulty DR Direction
Fix at VENT position actuator
Fail safe
• Setting mode : Except VENT • Fault A/C Control
Fix at DEF position Unit

Signal Waveform
Voltage value of Direction potentiometer as a function of position of mode switch
Door position Voltage Error Detecting Condition
VENT 0.3±0.15V Undervoltage : 0.10V or less
DEF 4.7±0.15V Overvoltage : 4.92V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "DR DIRECTION POTENTIO" parameter on the scantool. While operating mode switch.

Fig1) The current data in abnormal state

Fig2) DTC B2409
4. Are the DTC B2409 present and is parameter of "DR DIRECTION POTENTIO" fixed?

There is any fault in DR Direction Motor. If the parameter of "DR DIRECTION POTENTIO" is 10%
or less on "VENT" mode, or If the parameter is 90% or more on "DEF" mode.

Ell Go to "Inspection & Repair" procedure.

Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.
 Page 143 of 149
3. Has a problem been found?
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Signal Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect DR Direction Actuator.
3. Measure resistance between terminal "3" of DR Direction actuator and terminal "20"of A/C control unit.
4. Measure resistance between terminal "4" of DR Direction actuator and terminal "19" of A/C control unit.

Specification : Approx. 0 Ω

5. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF"
2. Disconnect DR Direction Actuator.
3. Measure resistance between terminal "3,4" of DR Direction Motor and chassis ground.

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection " procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Component Inspection
■ Check DR Direction Actuator.
 Page 144 of 149
1. Check actuator motor
(1) Ignition "OFF"
(2) Disconnect DR Direction Actuator.
(3) Connect (+) terminal of battery to terminal 3 of DR Direction Actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the DEF position
(5) Verify that the temperature actuator operates to the VENT position with reverse connecting.( (+) to 4 and (-)
to 3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect DR Direction Actuator.
(3) Measure voltage between terminal "5" and "6"of DR Direction Actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

Fig3)
Door position Voltage Error Detecting Condition
VENT 0.3±0.15V Undervoltage : 0.10V or less
DEF 4.7±0.15V Overvoltage : 4.92V or more

Fig3) Specifications : Voltage value of Direction potentiometer as a function of temp door position.
(4) Is the measured voltage within specifications in fig3)?
Go to "Check A/C Control Unit" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Connect A/C Control Unit.
3. Measure voltage between terminal "19" and "20" of A/C Control Unit while operating the temp switch.

Specification : Approx. 12V

[ill]
 Page 145 of 149
4. Is the measured voltage within specifications?
Check connectors for looseness, poor connection, bending, corrosion, contamination,
deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.
!Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?
Go to the applicable troubleshooting
procedure.
!Ell System is performing to specification at this
time.

Heating,Ventilation, Air Conditioning > Controller > B2415 Air Mix Door Motor-Passenger
Component Location

~-=-~~--
~~=-=----
~;-~~~~/]
(ii,=." =-- -~ =----:::..
~ --¾._"'

Tem,perature Contro1 AcWator

J

General Description
Temperature control actuator located at heater unit. It contains temp motor that changes temp door position and
potentiometer that monitors position of temp door. Temperature control actuator regulates the temperature by the
procedure as follows. Signal from control unit adjusts position of temp door by operating temp motor and then
temperature will be regulated by the hot/cold air ratio decided by position of temp door. In operation, potentiometer
delivers temp door position transformed into voltage value to A/C ECU .

DTC Description
The ECM sets DTC B2415 if the passenger air mix actuator dosen’t move to intended position within 40sec (The
ECM attempts to move the temp door for a 2 second duration at a frequency of 3 times every 20 seconds before
 Page 146 of 149
storing a DTC.)

DTC Detecting Condition

Item Detecting Condition Possible Cause
DTC Strategy • Voltage check
• Poor connection of
Threshold value • < 0.1V connected part
Detecting time • 0.3sec • Open circuit in harness
• Short circuit in harness.
• Setting temperature : 63°F-76.1°F
• Faulty passenger Air
fix at max. cooling position Mix actuator
Fail safe
• Setting temperature : 77°F-89.6°F
• Fault A/C Control Unit
fix at max. heating position

Signal Waveform
Voltage value of Air Mix potentiometer as a function of temp door position.
Door position Voltage Error Detecting Condition
Max. cool 0.3±0.15V Undervoltage : 0.08V or less
Max.warm 4.7±0.15V Overvoltage : 4.9V or more

Monitor Scantool Data

1. Connect scantool to Data Link Connector(DLC).
2. Engine "ON".
3. Monitor the "PA AIR MIX potentiometer" Parameter on the Scantool. While operating temp switch

Fig1) The current data in abnormal state

Fig2) DTC B2415
4. Are the DTC B2415 present and is parameter of "PA AIR MIX potentiometer" fixed?

There is any fault in Passenger AIR MIX Motor. If the parameter of "PA AIR MIX DOOR" is 30% or
less when the actuator operates to the hot position, or If the parameter is 60% and more when the actuator
operates to the cold position.

Go to "Inspection & Repair" procedure.

!Ell Fault is intermittent caused by poor contact in the sensor’s and/or A/C control unit’s
connector or was repaired and A/C control unit memory was not cleared.
Thoroughly check connectors for looseness, poor connection, bending, corrosion,
contamination, deterioration, or damage. Repair or replace as necessary and then go to
"Verification of Vehicle Repair" procedure.

Terminal and Connector Inspection

 Page 147 of 149
1. Many malfunctions in the electrical system are caused by poor harness and terminals.
Faults can also be caused by interference from other electrical systems, and mechanical or chemical damage.
2. Thoroughly check connectors for looseness, poor connection, bending, corrosion, contamination, deterioration,
or damage.

,---------,------1
3. Has a problem been found?

I: I
Repair as necessary and go to "Verification Vehicle Repair"
procedure.
Go to "W/Harness Inspection" procedure.

Power Supply Circuit Inspection

■ Check for open in harness
1. Ignition "OFF".
2. Disconnect passenger Air Mix Actuator.
3. Measure resistance between terminal "3" of passenger Air Mix Actuator and terminal "17"of A/C control unit.
4. Measure resistance between terminal "4" of passenger Air Mix Actuator and terminal "16"of A/C control unit.

Specification : Approx. 0 Ω

5. Is the measured resistance within specifications?

Go to "Check for short to ground in harness" procedure.
Check for open in signal harness. Repair as necessary and go to "Verification of Vehicle
Repair" procedure.

■ Check for short to ground in harness

1. Ignition "OFF".
2. Disconnect passenger Air Mix Actuator.
3. Measure resistance between terminal "3,4" of passenger Air Mix Actuator and chassis ground

Specification : Approx. ∞ Ω

4. Is the measured resistance within specifications?

Go to "Component Inspection " procedure.
Check for short to ground in signal harness. Repair as necessary and go to "Verification of
Vehicle Repair" procedure.

Component Inspection
■ Check passenger air mix actuator.
 Page 148 of 149
1. Check actuator motor
(1) Ignition "OFF".
(2) Disconnect passenger air mix actuator.
(3) Connect (+) terminal of battery to terminal 3 of passenger air mix actuator and (-) terminal to terminal 4
(4) Verify that the temperature actuator operates to the hot position
(5) Verify that the temperature actuator operates to the cool position with reverse connecting.( (+) to 4 and (-) to
3)

(6) Dose the actuator work properly?

Go to "Check potentiometer" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

2. Check actuator potentiometer

(1) Ignition "ON".
(2) Connect passenger air mix actuator.
(3) Measure voltage between terminal "5" and "6"of passenger air mix actuator while operating the temp switch.

Specification : Refer the specifications in fig3)

(4) Is the measured voltage within specifications in fig3)?

Go to "Check A/C Control Unit" procedure.
Substitute with a known-good actuator and check for proper operation. If the problem is
corrected, replace actuator and then go to "Verification of Vehicle Repair" procedure.

■ Check A/C Control Unit

1. Engine "ON".
2. Connect A/C Control Unit.
3. Measure voltage between terminal "16" and "17" of A/C Control Unit while operating the Intake switch.

Specification : Approx. 12V

[ill]
4. Is the measured voltage within specifications?

ml Check connectors for looseness, poor connection, bending, corrosion, contamination,

deterioration, or damage. Repair or replace as necessary and then go to "Verification of
Vehicle Repair" procedure.

Ell Substitute with a known-good A/C Control Unit and check for proper operation.
If the problem is corrected, replace A/C Control Unit and then go to "Verification of Vehicle
Repair" procedure.
 Page 149 of 149

Verification of Vehicle Repair

After a repair, it is essential to verify that the fault has been corrected.
1. Connect scantool and selet "Diagnostic Trouble Codes(DTCs)" mode and then clear DTC.
2. Operate the vehicle and monitor the DTC on the scantool.
3. Are any DTCs present?

1111 Go to the applicable troubleshooting

procedure.
!Ell System is performing to specification at this
time.
 Page 1 of 16
SANTAFE(CM) > 2009 > G 2.7 DOHC > Manual Transaxle System

Manual Transaxle System > General Information > Specifications (M5GF2)

Specifications
Engine type μ 2.7
Manual transaxle type M5GF2
Gear ratio 1st 3.615
2nd 1.931
3rd 1.696
4th 1.276
5th 1.027
Reverse 3.588
Final gear ratio 5.071 (for 1,2,R)/3.737 (3,4,5)
1.9 liter (2.0077US qt,
T/M oil capacity(ℓ)
1.6718mp qt)
Recommended transaxle oil SAE75W/85 or API GL-4

The quantity in the chart above is for the reference. The actual filling quantity of the automatic transaxle fluid must
be set according to 'INSPECTION' or 'REPLACEMENT' procedure of the automatic transaxle fluid.
Tightening Torques
Item Nm kgf.m lb-ft
Oil drain plug 30~35 3.0~3.5 21.7~25.3
Oil filler plug 30~35 3.0~3.5 21.7~25.3
Back up lamp switch 30~35 3.0~3.5 21.7~25.3
Control shaft complete 10~12 1.0~1.2 7.2~8.7
Select lever 43~55 4.3~5.5 31.1~39.8
Shift link assembly 43~55 4.3~5.5 31.1~39.8
Transaxle mounting
65~85 6.5~8.5 47.0~61.5
bracket assembly
Transaxle and enging
65~85 6.5~8.5 47.0~61.5
mounting bolt

Service Standard