AC–1

AIR CONDTIONING –

AIR CONDITIONING SYSTEM

AC–2
AIR CONDTIONING – General Information

GENERAL INFORMATION
1. WHEN HANDLING REFRIGERANT (R–12), FOLLOWING
PRECAUTIONS MUST BE OBSERVED
(a) Do not handle refrigerant in an enclosed area or near
an open flame.
(b) Always wear eye protection.
(c) Be careful that liquid refrigerant does not get in your
eyes or on your skin.
If liquid refrigerant gets in your eyes or on your skin;
• Do not rub.
• Wash the area with a lot of cool water.
• Apply clean petroleum jelly to the skin.
• Go immediately to a physician or hospital for profes-
sional treatment.
• Do not attempt to treat yourself.

2. WHEN REPLACING PARTS ON REFRIGERANT LINE;

(a) Discharge refrigerant slowly before replacement.
(b) Insert a plug immediately in disconnected parts to
prevent entry of moisture and dust.
(c) Do not leave a new condenser or receiver, etc., lying
around with the plug removed.

(d) Discharge refrigerant from the charging valve before

installing the new compressor.
If the refrigerant is not discharged first, compressor oil
will spray out with the refrigerant gas when the plug is
removed.
(e) Do not use a burner for bending or lengthening op-
erations on tubes.
If tubes are heated with a burner, a layer of oxidation
forms inside the tube, causing the same kind of
trouble as an accumulation of dust.

3. WHEN TIGHTENING CONNECTING PARTS;

(a) Apply a few drops of compressor oil to O–ring fittings
for easy tightening and to prevent leaking of refrig-
erant gas.
(b) Tighten the nut using two wrenches to avoid twisting
the tube.
 AC–3
AIR CONDTIONING – General Information

(c) Tighten the 0–ring fittings or the bolted type fittings to the
specified torque
4. WHEN CONNECTING MANIFOLD GAUGE;
(a) Be sure to connect the charging hose end with a pin to the
compressor charging valve.
(b) The letter ”D” engraved near the compressor service valve
indicates the high pressure side, and ”S”
indicates the low pressure side. Pay careful attention
when connecting the hose.
(c) Tighten hose by hand.
(d) To prevent loosening of connected hose, do not ap–
ply drops of compressor oil to the seat of connection.
HINT: After connecting the manifold gauge and the refriger-
ant container (service can), discharge any air in the hoses.
5. WHEN EVACUATING;
Approx. 15 minutes after removal, check the system for
leaks, then take at least another 15 minutes to make sure
the air is fully removed.

6. WHEN HANDLING REFRIGERANT CONTAINER (SERVICE

CAN);
(a) Must never be heated.
(b) Must be kept below 40°C (104°F).
(c) If warming service can with hot water, be careful that the
valve on top of the service can is never immersed in the
water, as the water may permeate into the refrigerant
cycle.
(d) Empty service cans must never be re–used.
7. WHEN A/C IS ON AND REFRIGERANT GAS IS BEING
REPLENISHED;
(a) If there is not enough refrigerant gas in the refrigerant
cycle, oil lubrication becomes insufficient and compres-
sor burnout may occur, so take care to avoid this.
(b) If the valve on the high pressure side is opened, refriger-
ant flows in reverse and causes the service can to rup-
ture, so only open and close the valve on the low pres-
sure side.
(c) If the service can is inverted and refrigerant is inserted in
a liquid state, the liquid is compressed and the compres-
sor breaks down, so the refrigerant must be inserted in
a gaseous state.
(d) Be careful not to insert too much refrigerant gas, as this
causes trouble such as inadequate cooling, poor fuel
economy, engine overheat, etc.
8. WHEN USING GAS–CYLINDER TYPE LEAK DETECTION
INSTRUMENT;
(a) As a naked flame is used, first make sure that there are
no flammable substances nearby before using it.
(b) Be careful, as poisonous gas is produced when refrigerant
gas comes in contact with heat parts.
AC–4
AIR CONDTIONING – Air Conditioning System Circuit

AIR CONDITIONING SYSTEM CIRCUIT

 AC–5
AIR CONDTIONING – Air Conditioning System Circuit

AIR CONDITIONING SYSTEM CIRCUIT (Cont’d)

AC–6
AIR CONDTIONING – System Components

SYSTEM COMPONENTS
 AC–7
AIR CONDTIONING – General Description

GENERAL DESCRIPTION
REFRIGERATION CYCLE
1. The compressor discharges high temperature and high pres-
sure refrigerant containing the heat absorbed from the evapo-
rator plus the heat created by the compressor in a discharge
stroke.
2. This gaseous refrigerant flows into the condenser. In the con-
denser, the gaseous refrigerant condenses into liquid refrig-
erant.
3. This liquid refrigerant flows into the receiver which stores and fil-
ters the liquid refrigerant till the evaporator requires the refrig-
erant.
4. The liquid refrigerant is changed by the expansion valve into a low temperature, low pressure liquid and gas-
eous mixture.
5. This cold and foggy refrigerant flows to the evaporator. Vaporizing the liquid in the evaporator, the heat from
the warm air stream passing through the evaporator core is transferred to the refrigerant. All
the liquid is changed into gaseous refrigerant in the evaporator and only heat–laden gaseous refriger-
ant is drawn into the compressor. Then the process is repeated again.
AC–8
AIR CONDTIONING – General Description

1. PRINCIPLE OF A/C ELECTRICAL CIRCUIT

2. HOW IS MAGNETIC CLUTCH ENERGIZED?

The general process until the magnetic clutch is energized is shown below.

Ignition Switch ”ON”

Blower Switch ”ON” → Heater Relay ”ON” (Blower Motor ”RUN”)

A/C Switch ”ON” → A/C Amplifier ”ON” (A/C Amp. Main Power Supply)

Dual Pressure Switch ”ON”:

Refrigerant Condition (2.1 kg/cm2 (30 psi, 206 kPa) less than 27 kg/cm2 (384 psi, 2,648 kPa))
Thermistor supplies temperature signal of evaporator to A/C amplifier.

VSV ”ON” E/G Idle–Up

Magnetic Clutch Relay ”ON”’

Temperature Sensor ”ON”:

Temperature of Temperature Sensor is less than 180°C (356°F).

Magnetic Clutch ”ON”

Revolution Detecting Sensor supplies RPM signal of compressor to A/C amplifier.

If compressor is not locked, magnetic clutch is continuously energized.

 AC–9
AIR CONDTIONING – Troubleshooting

SPECIAL TOOLS AND EQUIPMENT

Tool SST No. Use
Ohmmeter To perform electrical diagnosis
Voltmeter To perform electrical diagnosis
Ammeter To perform electrical diagnosis
Air conditioner Service Tool Set To evacuate and charge system
Magnetic clutch remover To remove pressure plate
Magnetic clutch stopper To remove and install pressure plate
Snap ring pliers (External type) To remove and install rotor and stator

SSM (SPECIAL SERVICE MATERIALS)

Part Name Part No. Use etc.
DENSOOIL 7 Compressor for 4A–GE E/G
or equivalent
DENSOOIL 6, Compressor for 4A–FE E/G
SUNISO No.5GS or equivalent

TROUBLESHOOTING
Problem Possible cause Remedy Page
No cooling
Blower does not operate
(a) GAUGE fuse blown Replace fuse and check for short AC–4 to 5
(b) FL blown Replace FL and check for short AC–4 to 5
(c) Circuit breaker faulty Check circuit breaker AC–4 to 5
(d) HEATER relay faulty Check relay BE–56
(e) HEATER fuse blown Replace fuse and check for short AC–4 to 5
(f) Blower motor faulty Check blower motor BE–56
(g) Blower resistor faulty Check blower resistor BE–56
(h) Blower switch faulty Check blower switch BE–56
(i) Wiring or ground faulty Repair as necessary AC–4 to 5
Magnetic clutch does not engage
(a) FL (30A CDS) blown Replace FL and check for short AC–4 to 5
(b) Magnet clutch relay faulty Check relay AC–4 to 5
(c) Magnetic clutch faulty Check magnetic clutch AC–16
(d) A/C fuse faulty Replace fuse and check for short AC–4 to 5
(e) ECU–IG fuse faulty Replace fuse and check for short AC–4 to 5
(f) A/C switch faulty Check switch AC–36
(g) Thermistor faulty Check thermistor AC–35
(h) A/C amplifier faulty Check amplifier AC–37 to 38
(i) Temperature switch on the com- Check switch AC–16
pressor faulty (4A–GE E/G )
(j) Pressure switch faulty Check switch AC–30
(k) Wiring or ground faulty Repair as necessary AC–4 to 5
(I) Refrigerant empty Check refrigerant pressure AC–11, 15

FL: Fusible Link

AC–10
AIR CONDTIONING – Troubleshooting

TROUBLESHOOTING (Cont’d)
Problem Possible cause Remedy Page
No cooling (cont’d) Compressor does not rotate properly
(a) Drive belt loose or broken Adjust or replace drive belt AC–14
(b) Compressor faulty Replace compressor AC–17
Expansion valve faulty Check expansion valve AC–31
Leak in system Test system for leaks AC–34
Fusible plug on receiver blown or Check receiver AC–26
clogged screen

Insufficient cooling Condenser clogged Check condenser AC–27

Drive belt slipping Check or replace drive belt AC–14
Magnetic clutch faulty Check magnetic clutch AC–16
Compressor faulty Check compressor AC–16
Expansion valve faulty Check expansion valve AC–31
Thermistor faulty Check thermistor AC–35
A/C amplifier faulty Check amplifier AC–37 to 38
Insufficient or too much refrigerant Check refrigerant volume AC–11, 15
Air or excessive compressor oil in system Evacuate and charge system
Receiver clogged Check receiver AC–26
Water valve cable set faulty Reset water valve cable BE–55

Insufficient velocity of Evaporator clogged or frosted Clean evaporator fins or filters AC–33
cool air Air leakage from cooling unit or air duct Repair as necessary
Air inlet blocked Repair as necessary
Blower motor faulty Replace blower motor
A/C amplifier faulty Check amplifier AC–38 to 39

A/C switch indicator Drive belt slipping Check or replace drive belt AC–14
flashing A/C amplifier faulty Check amplifier AC–37 to
38

Cool air comes out Magnetic clutch slipping Check magnetic clutch AC–16
intermittently Expansion valve faulty Check expansion valve AC–31
Excessive moisture in the system Evacuate and charge system
A/C amplifier faulty Check amplifier AC–37 to 38
Wiring connection faulty Repair as necessary AC–4 to 5

Cool air comes out only Condenser clogged Check condenser AC–27
at high speed Drive belt slipping Check or replace drive belt AC–14
Compressor faulty Check compressor AC–16
Insufficient or too much refrigerant Check refrigerant volume AC–11, 15
Air in system Evacuate and charge system

Discharging of Refrigeration System

Evacuating and Charging of
Refrigeration System
(See Air Conditioning Fundamentals and Repairs Pub.
No. 36950E)
 AC–11
AIR CONDTIONING – Troubleshooting

Checking of Refrigeration System with Manifold Gauge

This is a method in which the trouble is located by using a manifold gauge. Read the manifold
gauge pressure when the following conditions are established:
(a) Temperature at the air inlet is 30 – 35°C (86 – 95°F)
(b) Engine running at 1,500 rpm
(c) Blower fan speed switch set at high speed
(d) Temperature control lever set at cool side
HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature
conditions.

NORMALLY FUNCTIONING
REFRIGERATION SYSTEM:
Gauge reading
Low pressure side
1.5 – 2.0 kg/cm2
(21 – 28 psi, 147 – 196 kPa)
High pressure side
14.5 – 15.0 kg/cm2
(206 – 213 psi,
1,422 – 1,471 kPa)
Each pointer of manifold gauge point to
position A.

Position of
No. Trouble Condition Pointers

Moisture present in refrigeration system Periodically cools and then fails to cool

Insufficient refrigerant Insufficient cooling

Poor circulation of refrigerant Insufficient cooling
Refrigerant overcharge or insufficient
cooling of condenser Does not cool sufficiently

Expansion valve improperly mounted, heat

sensing tube defective (opens too wide) Insufficient cooling

Air present in refrigeration system Does not cool sufficiently

Refrigerant does not circulate Does not cool (Cools from time to time in some
cases)
Insufficient compression Does not cool
AC–12
AIR CONDTIONING – Troubleshooting

Checking of Refrigeration System with Manifold Gauge (Cont’d)

Symptom seen in
No. refrigeration system Probable cause Diagnosis Remedy

During operation, pressure Moisture entered in (1) Replace receiver

at low pressure side refrigeration system freezes Drier in oversaturated
and drier
sometimes becomes a at expansion valve orifice and state
(2) Remove moisture
vacuum and sometimes temporarily stops cycle, but ↓
in cycle through
normal normal state is restored after Moisture in refrigeration
repeated vacuum
a time when the ice melts system freezes at
purging
expansion valve orifice
(3) Charge refrigerant
and blocks circulation of
to proper amount
refrigerant

Pressure low at both low and Gas leakage at some Insufficient refrigerant in
high pressure sides place in refrigeration (1) Check with gas
system
leak tester and repair
Bubbles seen in sight glass system ↓
Insufficient cooling Refrigerant leaking
performance
(2) Charge refrigerant
to proper amount

Pressure low at both low Refrigerant flow Receiver clogged Replace receiver
and high pressure sides obstructed by dirt in
Frost on tubes from receiver
receiver to unit

Pressure too high at both Unable to develop sufficient Excess refrigerant in (1) Clean
low and high pressure performance due to cycle→ refrigerant condenser
sides excessive refrigerant in overcharged (2) Check fan motor
system operation
Condenser cooling (3) If (1) and (2) are
insufficient normal, check
Condenser cooling
insufficient → condenser refrigerant amount
fins clogged or fan motor HINT: Vent out
faulty refrigerant through
gauge manifold low
pressure side by
gradually opening
valve.

Pressure too high at both Trouble in expansion (1) Check heat

Excessive refrigerant in low
low and high pressure valve or heat sensing tube sensing tube
sides pressure piping
not installed installed condition
correctly
Refrigerant flow out
(2) If (1) is normal,
Frost or large amount of Expansion valve opened test expansion valve
dew on piping at low too wide in unit
pressure side
(3) Replace if
defective

Pressure too high at Air entered refrigeration (1) Replace

both low and high system Air present in refrigeration receiver and drier
pressure sides system (2) Check
↓ compressor oil to
Insufficient vacuum purging see if dirty or
insufficient
(3) Vacuum purge
and charge new
refrigerant
* Note at No. 6
These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without
vacuum purging.
 AC–13
AIR CONDTIONING – Troubleshooting

Checking of Refrigeration System with Manifold Gauge (Cont’d)

Symptom seen in
No. refrigeration system Probable cause Diagnosis Remedy

Vacuum indicated at low Refrigerant flow obstructed Expansion valve orifice Allow to stand for some time
pressure side, very low by moisture or dirt in clogged and then restart operation to
pressure indicated at high refrigerant freezing or ↓ determine if trouble is
pressure side adhering to expansion valve Refrigerant does not flow caused by moisture or dirt.
Frost or dew seen on piping orifice If caused by moisture refer
before and after receiver Refrigerant flow obstructed to procedures Step
and drier or expansion valve by gas leakage from 2 on page AC–12.
expansion valve If caused by dirt, remove
expansion valve and clean
off dirt by blowing with air. If
unable to remove dirt,
replace valve.
Vacuum purge and charge
new refrigerant to proper
amount.
For gas leakage from heat
sensing tube, replace
expansion valve.

Pressure too high at low Internal leak in compressor Compression defective Repair or replace
pressure side ↓ compressor
Pressure too low at high Valve leaking or broken
pressure side sliding parts
(Piston, cylinder, gasket,
etc. ) broken
AC–14
AIR CONDTIONING – On–Vehicle Inspection

ON–VEHICLE INSPECTION
1. CHECK CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, clean them with pressurized
water.
NOTICE: Be careful not to damage the fins.
2. MAKE SURE THAT DRIVE BELT IS INSTALLED COR–
RECTLY
Check that the drive belt fins properly in the ribbed
grooves.
3. CHECK DRIVE BELT TENSION
Using a belt tension gauge, check the drive belt ten-
sion.
Belt tension gauge:
Nippondenso BTG–20 (95506–00020 and
09216–00030) or
Borroughs No. BT–33–73F
Engine New belt Used belt

HINT:
• ”New belt” refers to a belt which has been used less
than 5 minutes on a running engine.
• ”Used belt” refers to a belt which has been used on
a running engine for 5 minutes or more.
• After installing the drive belt, check that if fits proper-
ly in the ribbed grooves.
4. START ENGINE
5. TURN ON A/C SWITCH
Check that the A/C operates at each position of the
blower switch.
If blower does not operate, check circuit breaker.
6. CHECK MAGNETIC CLUTCH OPERATION
If magnetic clutch does not engage, check the A/C
fuse.
7. CHECK THAT IDLE INCREASES
When the magnetic clutch engages, engine revolution
should increase.
Standard idle–up rpm: 900 – 1,000 rpm
8. CHECK CONDENSER FAN MOTOR ROTATES
9. CHECK AMOUNT OF REFRIGERANT
If you can see bubbles in the sight glass, additional
refrigerant is needed. (See page AC–15)
10. IF NO COOLING OR IT IS INSUFFICIENT, INSPECT
FOR LEAKAGE
Using a gas leak tester, inspect each component of the
refrigeration system.
 AC–15
AIR CONDTIONING – Refrigeration System

REFRIGERATION SYSTEM
Checking of Refrigerant Volume
1. RUN ENGINE AT APPROX. 1,500 RPM
2. OPERATE AIR CONDITIONER AT MAXIMUM COOLING
FOR A FEW MINUTES
3. CHECK AMOUNT OF REFRIGERANT
Observe the sight glass on the receiver.

Item Symptom Amount of refrigerant Remedy

Bubbles present in sight glass Insufficient Check for leak with gas leak tester

No bubbles present in sight glass Empty, proper or too much Refer to items 3 and 4
No temperature difference between Empty or nearly empty Evacuate and charge system.
compressor inlet and outlet Then check for leak with gas leak
detector.

Temperature between compressor Proper or too much Refer to items 5 and 6

inlet and outlet is noticeably different

Immediately after air conditioner is Too much Discharge excess refrigerant to

turned off, refrigerant in sight glass specified amount
stays clean

When air conditioner is turned off, Empty, proper or too much Refer to items 3 and 4
refrigerant foams and then stays
clear

Installation of Manifold Gauge Set

1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
2. INSTALL CHARGING HOSES OF GAUGE SET TO
CHARGING VALVES
Connect the low pressure hose to the low pressure
charging valve and the high pressure hose to the high
pressure charging valve. Tighten the hose nuts by
hand.
HINT: Do not apply compressor oil to the seat of the
connection.
AC–16
AIR CONDTIONING – Compressor

COMPRESSOR
ON–VEHICLE INSPECTION
1. INSTALL MANIFOLD GAUGE SET
(See page AC–15)
2. RUN ENGINE AT APPROX. 1,500 RPM
3. CHECK COMPRESSOR FOR FOLLOWING:
(a) High pressure gauge reading is not lower and low
pressure gauge reading is not higher than normal.
(b) Metallic sound
(c) Leakage from shaft seal
If defects are found, repair the compressor.
4. CHECK MAGNETIC CLUTCH
(a) Inspect the pressure plate and the rotor for signs of
oil.
(b) Check the clutch bearings for noise and grease leak-
age.
(e) Using an ohmmeter, measure the resistance of the
stator coil between the clutch lead wire and ground.
Standard resistance: 3.4 – 3.8  at 20°C (68°F)
If resistance value is not as specified, replace the coil.
(d) Connect the positive (+) lead from the battery to termi-
nal 1, check that the magnetic clutch is energized.
If magnetic clutch is not energized, replace the coil.
NOTICE: Do not short the positive (+) lead wire on the
vehicle by applying battery voltage.

5. CHECK TEMPERATURE SWITCH

(4A–GE engine model only)
Check that the continuity between terminals C and D.
If continuity is not as specified, replace the switch.
 AC–17
AIR CONDTIONING – Compressor

REMOVAL OF COMPRESSOR
1. RUN ENGINE AT IDLE SPEED FOR 10 MINUTES WITH
AIR CONDITIONING ON
2. STOP ENGINE
3. DISCONNECT NEGATIVE CABLE FROM BATTERY
4. DISCONNECT CONNECTOR FOR MAGNETIC CLUTCH,
TEMPERATURE SWITCH
5. DISCHARGE REFRIGERANT FROM REFRIGERATION
SYSTEM
6. DISCONNECT TWO HOSES FROM COMPRESSOR
SERVICE VALVES
Cap the open fitting immediately to keep moisture out of
the system.
7. REMOVE COMPRESSOR
(a) Loosen the drive belt.
(b) Remove the compressor mounting bolts and the com-
pressor.
AC–18
AIR CONDTIONING – Compressor

DISASSEMBLY OF MAGNETIC
CLUTCH
(4A–GE EIG MODEL)
1. REMOVE PRESSURE PLATE
(a) Using a socket and SST, remove the shaft nut.
SST 07112–76060

(b) Install SST to the pressure plate.

SST 07112–66040

(c) Using SST and the socket, remove the pres-

sure plate.
SST 07112–76060 and 07112–66040
 AC–19
AIR CONDTIONING – Compressor

(d) Remove the shims from the shaft.

2. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114–84020

(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE: Be careful not to damage the pulley when
tapping on the rotor.

3. REMOVE STATOR
(a) Disconnect the stator lead wires from the compressor
housing.

(b) Using SST, remove the snap ring.

SST 07114–84020
AC–20
AIR CONDTIONING – Compressor

(c) Remove the stator.

ASSEMBLY OF MAGNETIC CLUTCH

1. INSTALL STATOR
(a) Install the stator on the compressor.
(b) Using SST, install the new snap ring.
SST 07114–84020

(c) Connect the stator lead wires to the compressor

housing.

2. INSTALL ROTOR
(a) Install the rotor on the compressor shaft.
(b) Using SST, install the new snap ring.
SST 07114–84020

3. INSTALL PRESSURE PLATE

(a) Adjust the clearance between the pressure plate and
rotor by putting shims on the compressor shaft.
Standard clearance: 0.5 + 0.15 mm
(0.020 ± 0.0059in.)
If the clearance is not within tolerance, change the
number of shims to obtain the standard clearance.
 AC–21
AIR CONDTIONING – Compressor

(b) Using SST and torque wrench, install the shaft

nut.
SST 07112–76060
Torque: 140 kg–cm (10 ft–Ib, 14 N–m)

CHECK CLEARANCE OF MAGNETIC CLUTCH

(4A GE E/G MODEL)
(a) Set the dial–gauge to the pressure plate of the mag-
netic clutch.
(b) Connect the magnetic clutch lead wire to the positive
(+) terminal of the battery.
(c) Check the clearance between the pressure plate and
rotor, when connect the negative (–) terminal of the
battery.
Standard clearance: 0.5 ± 0.15 mm
(0.020 ± 0.0059 in. )
If the clearance is not within standard clearance adjust
the clearance using shims to obtain the standard clear-
ance.

DISASSEMBLY OF MAGNETIC CLUTCH

(4A–FE E/G MODEL)
1. REMOVE PRESSURE PLATE
(a) Using SST and socket, remove the shaft bolt.
SST 07112–76060
AC–22
AIR CONDTIONING – Compressor

(b) Install SST to the pressure plate.

SST 07112–66040

(c) Using SST and the socket, remove the pressure

plate.
SST 07112–76060

(d) Remove the shims from the pressure plate.

2. REMOVE ROTOR
(a) Using SST, remove the snap ring.
SST 07114–84020

(b) Using a plastic hammer, tap the rotor off the shaft.
NOTICE: Be careful not to damage the pulley when
tapping on the rotor.
 AC–23
AIR CONDTIONING – Compressor

3. REMOVE STATOR
(a) Disconnect the stator lead wire from the compressor
housing.

(b) Using SST, remove the snap ring.

SST 07114–84020

(c) Remove the stator.

ASSEMBLY OF MAGNETIC CLUTCH

1. INSTALL STATOR
(a) Install the stator on the compressor.

(b) Using SST, install the new snap ring.

SST 07114–84020
AC–24
AIR CONDTIONING – Compressor

(c) Connect the stator lead wires to the compressor

housing.

2. INSTALL ROTOR
(a) Install the rotor on the compressor shaft.
(b) Using SST, install the new snap ring.
SST 07114–84020

3. INSTALL PRESSURE PLATE

(a) Install the shims to the pressure plate.

(b) Using SST and torque wrench, install the shaft

bolt.
SST 07112–76060
Torque: 140 kg–cm (10 ft–Ib, 14 N–m )

4. CHECK CLEARANCE OF MAGNETIC CLUTCH

Check the clearance between the pressure plate and
rotor using thickness gauge.
Standard clearance: 0.5 ± 0.15 mm
(0.020 ± 0.0059 in. )
If the clearance is not within tolerance, change the
number of shims to obtain the standard clearance.
 AC–25
AIR CONDTIONING – Compressor

INSTALLATION OF COMPRESSOR
(See page AC–17)
1. INSTALL COMPRESSOR WITH FOUR MOUNTING
BOLTS
Torque: 250 kg–cm (18 ft–Ib, 25 N–m)
2. INSTALL DRIVE BELT
(a) Install the drive belt to the pulley.
(b) Tighten the belt with the adjusting bolts.
(c) Adjust drive belt tension
(See step 2 and 3 on page AC–14)
3. CONNECT TWO HOSES TO COMPRESSOR SERVICE
VALVES
Torque:
Discharge line 250 kg–cm (18 ft–Ib, 25 N–m)
Suction line 250 kg–cm (18 ft–Ib, 25 N–m)
4. CONNECT EACH LEAD WIRE TO WIRING HARNESS
5. CONNECT NEGATIVE CABLE TO BATTERY
6. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
7. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 650 – 750 g (1.4 – 1.7 Ib)
AC–26
AIR CONDTIONING – Receiver

RECEIVER
ON–VEHICLE INSPECTION
CHECK SIGHT GLASS, FUSIBLE PLUG AND FITTINGS
FOR LEAKAGE
Use a gas leak tester. Repair as necessary.
REMOVAL OF RECEIVER
(See page AC–6)
1. DISCHARGE REFRIGERATION SYSTEM
2. DISCONNECT TWO LIQUID TUBES FROM RECEIVER
HINT: Cap the open fittings immediately to keep mois-
ture out of the system.
3. REMOVE RECEIVER FROM RECEIVER HOLDER
INSTALLATION OF RECEIVER
(See page AC–6)
1. INSTALL RECEIVER IN RECEIVER HOLDER
HINT: Do not remove the blind plugs until ready for
connection.
2. CONNECT TWO LIQUID TUBES TO RECEIVER
Torque: 55 kg–cm (48 in.–Ib, 5.4 N–m)
3. IF RECEIVER WAS REPLACED, ADD COMPRESSOR
OIL TO COMPRESSOR
Add 20cc (0.7 fl.oz. )
Compressor oil:

DENSOOIL 7 or
4A–GE E/G equivalent
DENSOOIL 6,
4A–FE EIG SUNISO No. 5GS or
equivalent

4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM

5. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 650 – 750 g (1.4 – 1.7 Ib)
 AC–27
AIR CONDTIONING – Condenser

CONDENSER
ON–VEHICLE INSPECTION
1. CHECK CONDENSER FINS FOR BLOCKAGE OR
DAMAGE
If the fins are clogged, wash them with water and dry
with compressed air.
NOTICE: Be careful not to damage the fins.
If the fins are bent, straighten them with a screwdriver
or pliers.
2. CHECK CONDENSER FITTINGS FOR LEAKAGE
Repair as necessary.
REMOVAL OF CONDENSER
(See page AC–6)
1. DISCHARGE REFRIGERATION SYSTEM

2. REMOVE FOLLOWING PARTS:

(a) Front grille
(b) Hood lock and center brace
(c) Condenser fan motor
(d) Horn
(e) Bumper
(f) Oil cooler (4A–GE engine only)
HINT: Oil cooler hoses are not removed.
3. DISCONNECT LIQUID TUBE AND DISCHARGE HOSE
FROM CONDENSER OUTLET FITTING
HINT: Cap the open fittings immediately to keep mois-
ture out of the system.
4. REMOVE CONDENSER
Remove the two bolts.
INSTALLATION OF CONDENSER
(See page AC–6)
1. INSTALL CONDENSER
2. CONNECT LIQUID TUBE, DISCHARGE HOSE TO
CONDENSER
Torque:
Discharge hose 250 kg–cm (18 ft–Ib, 25 N–m)
Liquid tube 135 kg–cm (10 ft–Ib, 13 N–m)
AC–28
AIR CONDTIONING – Condenser

3. INSTALL FOLLOWING PARTS:

(a) Front grille
(b) Hood lock and center brace
(c) Condenser fan motor
(d) Horn
(e) Bumper
(f) Oil cooler (4A–GE. engine only)
4. IF CONDENSER WAS REPLACED, ADD COMPRESSOR
OIL TO COMPRESSOR
Add 40 – 50cc (1.4 – 1.7 fl.oz. )
Compressor oil:
DENSOOIL 7 or
4A–GE E/G equivalent
DENSOOIL 6,
4A–FE EIG SUNISO No. 5SG or
equivalent

5. EVACUATE AIR FROM AIR CONDITIONING SYSTEM

6. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 650 – 750 g (1.4 – 1.7 Ib)
CONDENSER FAN MOTOR
(See page AC–6)
1. INSPECT FAN MOTOR
(a) Disconnect 2–P connector of the fan motor.
(b) Using wire harness, apply battery voltage to the connector.
(c) Confirm smooth rotation of the motor within the specified
current flow.
Standard current: 6.7 ± 0.7A
If defective, replace the motor.
INSPECTION OF CONDENSER FAN
MOTOR
CHECK OPERATION OF FAN MOTOR
HINT: The fan motor operates at two speeds depending on
the water temperature and the A/C switch.

A/C Magnetic Fan motor

switch clutch Water temperature
speed
 AC–29
AIR CONDTIONING – Relays

RELAYS
INSPECT RELAY CONTINUITY
CHECK MAGNETIC CLUTCH RELAY AND A/C FAN RELAY
NO.3 CONTINUITY

Terminal
Condition
Constant
Apply battery voltage to
terminals 1 and 3

If continuity is not as specified, replace the relay.

AC–30
AIR CONDTIONING – Relays

A/C RELAY N0.2

Terminal
Condition

Constant

Apply battery voltage to

terminals 6(+) and 2(–)

If continuity is not as specified, replace the relay.

PRESSURE SWITCH
(See page AC–7)
ON–VEHICLE INSPECTION
1. DISCONNECT CONNECTOR OF PRESSURE SWITCH
2. INSPECT PRESSURE SWITCH
(a) Install the manifold gauge set.
(b) Observe the gauge reading.
(c) Check the continuity between the two terminals of the
pressure switch shown in the below.

If defective, replace the pressure switch.

3. CONNECT CONNECTOR OF PRESSURE SWITCH
WATER TEMPERATURE SWITCH
INSPECT SWITCH CONTINUITY
Inspect the switch continuity between each terminal at
each the water temperature.

Specified value
Continuity No continuity
Switch

Connector color (Wire Harness Side);

A: WHITE – For condenser fan
B: BLUE – For A/C cut (4A–FE Engine: with A/T)
 AC–31
AIR CONDTIONING – Cooling Unit

COOLING UNIT
(See page AC–6)
ON–VEHICLE INSPECTION OF
EXPANSION VALVE
1. CHECK QUANTITY OF REFRIGERANT GAS DURING
REFRIGERATION CYCLE
2. INSTALL MANIFOLD GAUGE SET
(See page AC–15)
3. RUN ENGINE
Run the engine at 2,000 rpm for at least 5 minutes.
4. CHECK EXPANSION VALVE
If the expansion valve is clogged, the low pressure read-
ing will drop to 0 kg/cm2 (0 psi, 0 kPa), otherwise it is
OK.
REMOVAL OF COOLING UNIT
1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. DISCHARGE REFRIGERATION SYSTEM
3. DISCONNECT SUCTION TUBE FROM COOLING UNIT
OUTLET FITTING
4. DISCONNECT LIQUID TUBE FROM COOLING UNIT
INLET FITTING
HINT: Cap the open fittings immediately to keep mois-
ture out of the system.

5. REMOVE GROMMETS FROM INLET AND OUTLET FIT–

TINGS

6. REMOVE GLOVE BOX COMPARTMENT

7. DISCONNECT CONNECTORS
8. REMOVE COOLING UNIT
Remove four nuts and four screws.
AC–32
AIR CONDTIONING – Cooling Unit

DISASSEMBLY OF COOLING UNIT

1. REMOVE LOWER AND UPPER UNIT CASE

(a) Disconnect connectors.
(b) Remove the wire harness.
(c) Remove four clips.
(d) Remove four screws.
(e) Remove upper unit case.
(f) Remove lower unit case.

2. REMOVE EXPANSION VALVE

(a) Disconnect the liquid tube from the inlet fitting of the
expansion valve.
(b) Remove the packing and heat sensing tube from suc-
tion tube of evaporator.
 AC–33
AIR CONDTIONING – Cooling Unit

(c) Remove expansion valve.

Evaporator
INSPECTION OF EVAPORATOR
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
NOTICE: Never use water to clean the evaporator.
2. CHECK FITTINGS FOR CRACKS OR SCRATCHES
Repair as necessary.
ASSEMBLY OF COOLING UNIT
INSTALL COMPONENTS OF EVAPORATOR
(a) Connect the expansion valve to the inlet fitting of the
evaporator. Torque the nut.
Torque: 230 kg–cm (17 ft–Ib, 23 N–m)
HINT: Be sure that the 0–rings are positioned on the
tube fitting.
(b) Install the holder to the suction tube with heat sensitiz-
ing tube.
(c) Connect the liquid tube to the inlet fitting of the expan-
sion valve. Torque the nut.
Torque: 140 kg–cm (10 ft–Ib, 14 N–m)
(d) Install lower unit case to the evaporator.
(e) Install thermistor to the evaporator.
(f) Install upper unit case
(g) Install four screws.
(h) Install four clips.
(i) Install wire harness.
(j) Connect connectors.
INSTALLATION OF COOLING UNIT
1. INSTALL COOLING UNIT
Install the cooling unit with three nuts and four bolts.
2. CONNECT CONNECTORS
3. INSTALL GLOVE BOX COMPARTMENT
AC–34
AIR CONDTIONING – Refrigerant Lines

4. INSTALL GROMMETS ON INLET AND OUTLET FITTINGS

5. CONNECT LIQUID TUBE TO COOLING UNIT INLET
FITTING
Torque the nut.
Torque: 130 kg–cm (10 ft–Ib, 13 N–m)
6. CONNECT SUCTION TUBE TO COOLING UNIT OUTLET
FITTING
Torque the nut.
Torque: 330 kg–cm (24 ft–Ib, 32 N–m)
7. IF EVAPORATOR WAS REPLACED, ADD COMPRESSOR
OIL TO COMPRESSOR
ADD 40 – 50 cc (1.4 – 1.7 fl.oz. )

4A–GE EIG DENSOOIL 7 or equivalent

DENSOOIL 6, SUNISO No.5GS or
4A–FE E/G equivalent

8. EVACUATE AIR FROM AIR CONDITIONING SYSTEM

9. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 600 – 750 g (1.3 – 1.7 Ib)
REFRIGERANT LINES
(See page AC–6)
ON–VEHICLE INSPECTION
1. INSPECT HOSES AND TUBES FOR LEAKAGE
Use a gas leak tester. Replace, if necessary.
2. CHECK THAT HOSE AND TUBE CLAMPS ARE NO1
LOOSE
Tighten or replace, as necessary.
REPLACEMENT OF REFRIGERANT
LINES
1. DISCHARGE REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
HINT: Cap the open fittings immediately to keep mois–
ture out of the system.
3. TIGHTENING TORQUE FOR O–RING FITTINGS AND
BOLTED TYPE FITTINGS (See page AC–7)
4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM
5. CHARGE AIR CONDITIONING SYSTEM WITH
REFRIGERANT AND CHECK FOR GAS LEAKAGE
Specified amount: 650 – 750 g (1.4 – 1.7 Ib)
 AC–35
AIR CONDTIONING – Thermistor

THERMISTOR
ON–VEHICLE INSPECTION
(See page AC–6)
1. DISCONNECT NEGATIVE CABLE FROM BATTERY
2. REMOVE GLOVE BOX COMPARTMENT

3. CHECK RESISTANCE OF THERMISTOR

Measure the resistance between terminals.
Resistance: 1,500 Ω at 25°C (75°F)
If resistance value is not as specified, replace the
thermistor.
REMOVAL AND INSPECTION OF
THERMISTOR
1. REMOVE AND DISASSEMBLE COOLING UNIT
(See page AC–31)
2. REMOVE THERMISTOR FROM EVAPORATOR
3. CHECK THERMISTOR OPERATION
(a) Place the thermistor in cold water. While varying the
temperature of the water, measure the resistance at
the connector and, at the same time, measure the
temperature of the water with a thermometer.
(b) Compare the two readings on the chart.
If the intersection is not between the two lines, replace
the thermistor.

INSTALLATION OF THERMISTOR
1. INSTALL THERMISTOR TO EVAPORATOR
2. ASSEMBLE AND INSTALL COOLING UNIT
AC–36
AIR CONDTIONING – AC Switch

AC SWITCH
1. REMOVE A/C SWITCH
(a) Disconnect negative battery cable.
(b) Remove center panel.
(c) Remove A/C switch.
2. CHECK A/C SWITCH
Inspect the switch continuity between terminals.

Terminal Illumination
Switch position

OFF
A/C

If continuity is not as specified, replace the switch.

3. INSTALL A/C SWITCH
(a) Install A/C switch.
(b) Install center finish panel.
(c) Connect negative battery cable.
 AC–37
AIR CONDTIONING – Air Conditioner Amplifier

AIR CONDITIONER AMPLIFIER

(See page AC–6)
INSPECTION OF AMPLIFIER
INSPECT AMPLIFIER CIRCUIT
Disconnect the amplifier and inspect the connector o
the wire harness side as shown in the chart below.
Test conditions:
(1) Ignition switch: ON
(2) Temperature control lever: MAX COOL
(3) Blower switch: HI

14A–GE engine w/PS)

Check for Tester connection Condition Specified value
Constant
Constant
Constant
Turn A/C switch on
Turn A/C switch off
Turn blower switch on
Turn blower switch off
Turn blower switch on
Turn blower switch off
Turn blower switch on
Turn blower switch off
Start engine
Stop engine
Turn blower switch on
Turn blower switch off
Turn A/C switch on
Turn A/C switch off
Constant
Constant
Constant

If circuit is correct, replace the amplifier.

AC–38
AIR CONDTIONING – Air Conditioner Amplifier

AIR CONDITIONER AMPLIFIER

(Cont’d)

(4A–FE engine)
Check for Tester connection Condition Specified value
Constant
Constant
Turn blower switch on
Turn blower switch off
Turn blower switch on
Turn blower switch off
Turn blower switch on
Turn blower switch off
Turn A/C switch on
Turn A/C switch off
Turn blower switch on
Turn blower switch off
Start engine
Stop engine
Constant
Constant

If circuit is correct, replace the amplifier.

 AC–39
AIR CONDTIONING – Vacuum Switching Valve (VSV)

VACUUM HOSE CIRCUIT

VACUUM SWITCHING VALVE (VSV)

(See page AC–6)
INSPECTION OF VSV
1. REMOVE VSV

2. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY

BLOWING AIR INTO PIPES
(a) Connect the VSV terminals to the battery terminals as
illustrated.
(b) Blow into pipe ”A” and check that air comes out of pipe
”B” but does not come out of filter ”C”.
(c) Disconnect the battery
(d) Blow into pipe ”A” and check that air– comes out of
pipe ”C” but does not come out of pipe ”B”.
If a problem is found, replace the VSV.
AC–40
AIR CONDTIONING – Vacuum Switching Valve (VSV )

3. CHECK FOR SHORT CIRCUIT

Using an ohmmeter, check that there is no continuity
between each terminal and the VSV body.
If a short circuit is found, repair or replace the VSV.

4. CHECK FOR OPEN CIRCUIT

Using an ohmmeter, measure the resistance between
the two terminals.
Resistance: 37 – 44 Ω at 20°C (685°F)
If resistance value is not as specified, replace the VSV.