Service Manual2005 MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SECTION 7B

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

A/C System Charging Capacity

Application	Description
R-134a System	.
- Left Hand Drive	730 ± 20g
Refrigerant Oil in A/C System	Synthetic PAG 265 ml

Fastener Tightening Specifications

Application	N•m	Lb-Ft	Lb-In
Air Cleaner Housing Assembly Retaining Bolts	12	-	106
Band Clamp Bolt	5	-	44
Clamp Bolts	4	-	35
Clutch Plate and Hub Assembly Retaining Nut	17	13	-
Discharge Hose Connecting Block-to-Compressor Retaining Nut	33	24	-
Discharge Hose Connecting Block-to-Condenser Retaining Nut	16	12	-
Expansion Valve Bolts	10	-	89
Front Compressor-to-Bracket Mounting Bolts	35	26	-
High-Pressure Pipe-to-Evaporator Flange Connecting Block Nut	10	-	89
High-Pressure Pipe-to-Receiver-Dryer Connecting Block Nut	10	-	89
Liquid Evaporator Pipe Clamp Bolt	5	-	44
Pressure Relief Valve	16	12	-
Pressure Transducer	7	-	62
Rear Compressor-to-Bracket Mounting Bolts	20	15	-
Receiver-Dryer to Condenser Pipe Nut	14	10	-
Suction Hose Clamp Bolt	10	-	89
Suction Hose Connecting Block Retaining Nuts	10	-	89
Suction Hose Support Clamp Retaining Bolt	5	-	44
Suction Hose Support Clamp Retaining Nut	5	-	44
Through-Bolts	10	-	89
Upper Condenser Mount Nuts	4	-	35
Vacuum Tank-to-Fire Wall Nuts	4	-	35

SPECIAL TOOLS

Special Tools Table

	J-5403 Snap Ring Pliers
	J-6083 Snap Ring Pliers
	J-8092 Driver Handle
	J-8433-1 Puller Crossbar
	J-8433-3 Forcing Screw
	J-9398-A Bearing Remover
	J-9481 Bearing Installer
	J-9553-1 O-Ring Remover
	J-9625-A Pressure Testing Connector
	J-23128-A Seal Seat Remover and Installer
	J-35372 Support Block
	J-33011 O-Ring Installer
	J-33013-B Hub and Drive Plate Remover and Installer
	J-34993 Cylinder Alignment Rods
	J-33017 Pulley Rotor and Bearing Installer
	J-33019 Bearing Staking Tool Set Includes: J-33019-1 Bearing Staking Guide J-33019-2 Bearing Staking Pin
	J-33020 Pulley Puller
	J-34614 Shaft Seal Protector
	J-33022 Shaft Nut Socket
	J-33023-A Puller Pilot
	J-33024 Clutch Coil Installer Adapter
	J-33025 Clutch Coil Puller Legs
	J-34992 Compressor Holding Fixture
	J-33027 Clutch Hub Holding Tool

SCHEMATIC AND ROUTING DIAGRAMS

A/C System - Typical

Compressor
Pressure Relief Valve
Condenser
Receiver-Dryer
Evaporator
Expansion Valve

Manual Control A/C Diagram

DIAGNOSIS

GENERAL DIAGNOSIS

Testing the Refrigerant System

If you suspect a problem in the refrigerant system, check for the following conditions:

Check the outer surfaces of the radiator and the condenser cores to be sure that the airflow is not blocked by dirt, leaves, or other foreign material. Check between the condenser and the radiator, as well as all outer surfaces.
Check for restrictions or kinks in the condenser core, the hoses, and the tubes.
Check the operation of the blower fan.
Check all the air ducts for leaks or restrictions. Low airflow rate may indicate a restricted evaporator core.
Check for slippage of the compressor clutch.
Check the drive belt tension.

Insufficient Cooling "Quick Check" Procedure

Perform the following "hand-feel" procedure to get a quick idea of whether the A/C system has the proper charge of Refrigerant-134a. The air temperature must be above 21°C (70°F) for most models.

Warm up engine. Run the engine at idle.
Open the hood and all the doors.
Turn the A/C switch ON.
Set the temperature control to the full cold position.
Set the blower speed switch on the maximum speed setting.
"Hand-feel" the temperature of the evaporator outlet pipe. The pipe should be cold.
Check for other problems. Refer to "Testing the Refrigerant System" in this section.
Leak check the system. Refer to "Leak Testing the Refrigerant System" in this section. If you find a leak, discharge the system and repair the leak as required. After completing the repair, evacuate the system and charge it.
If there is no leak, refer to "Insufficient Cooling Diagnosis" in this section.

Pressure-Temperature Relationship of R-134A

Temperature °C (°F)*	Pressure kPa (psig)*	Temperature °C (°F)*	Pressure kPa (psig)*
-8 (17.6)	113.1 (16.4)	9 (48.2)	296.2 (43.0)
-7 (19.4)	121.5 (17.6)	10 (50.0)	309.6 (44.9)
-6 (21.2)	130.2 (18.9)	15 (59.0)	383.7 (55.7)
-5 (23.0)	139.1 (20.2)	20 (68.0)	467.7 (67.8)
-4 (24.8)	148.4 (21.5)	25 (77.0)	567.5 (82.3)
-3 (26.6)	157.9 (22.9)	30 (86.0)	667.8 (96.9)
-2 (28.4)	167.6 (24.3)	35 (95.0)	785.6 (113.9)
-1 (30.2)	177.8 (25.8)	40 (104.0)	916.4 (133.0)
0 (32.0)	188.2 (27.3)	45 (113.0)	1 062.2 (154.0)
1 (33.8)	198.8 (28.8)	50 (122.0)	1 222.1 (177.2)
2 (35.6)	209.9 (30.4)	55 (131.0)	1 398.2 (202.8)
3 (37.4)	221.2 (32.1)	60 (140.0)	1 589.6 (230.5)
4 (39.2)	232.9 (33.8)	65 (149.0)	1 799.0 (260.9)
5 (41.0)	245.0 (35.5)	70 (158.0)	2 026.6 (293.9)
6 (42.8)	257.4 (37.3)	75 (167.0)	2 272.2 (329.5)
7 (44.6)	269.8 (39.1)	80 (176.0)	2 544.0 (369.0)
8 (46.4)	282.9 (41.0)	-	-

* All calculated values are rounded to one decimal place.

Evaporator Range: From -7 to 7°C (19.4 to 44.6°F), the temperatures represent the gas temperatures inside the coil and not on the coil surfaces. Add 2 to 6°C (4 to 11°F) to the coil and air-off temperatures.

Condenser Range: From 45 to 70°C (113°to 158°F), the temperatures are not ambient. Add 19 to 22°C (34 to 40°C) to the ambient temperatures for proper heat transfer. Then refer to the pressure chart.

Example:

32°C (90°F) Ambient temperature + 22°C (40°F) = 54°C (130°F)

Condenser temperature, which yields 1 379 kPa (200 psig), based on 50 km/h (31 mph) airflow.

Leak Testing Refrigerant System

Test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the lines or the connections. Leaks are commonly found at the refrigerant fittings or at the connections. Leaks are commonly caused by the following problems:

Improper torque.
Damaged O-ring seals.
Dirt or lint on the O-ring seals.

Liquid Leak Detectors

Use a liquid leak detector solution on locations such as fittings. Apply the solution to the area in question with the swab that is supplied with the solution. Look for bubbles to appear. This will indicate the existence and the location of any leak.

For areas where this is not practical, such as sections of the evaporator and the condenser, an electronic leak detector is more useful.

Electronic Leak Detectors

Follow the manufacturer's instructions for calibration, operation, and maintenance of an electronic leak detector. Battery condition is especially important to the accuracy of a portable model. Set the detector to R-134a before beginning the test.

Notice : Electronic leak detectors are sensitive to windshield washing solutions, solvents and cleaners, and certain vehicle adhesives. Surfaces must be clean to prevent false readings. Make sure that all surfaces are dry to prevent damage to the detector.

General Testing Instructions

Follow the entire path of the refrigerant system.
Completely circle each joint at 25 to 50 mm (1 to 2 inches) per second.
Hold the probe tip within 6 mm (1/4 inch) of the surface.
Do not block the air intake.
The audible tone changes from 1 to 2 clicks per second into a solid alarm if there is a leak. Adjust the balance control to maintain 1 to 2 clicks per second.
Test all of the following areas, even after one leak has been confirmed:

Evaporator inlet and outlet.
Receiver-drier inlet and outlet.
Condenser inlet and outlet.
Brazed and welded areas.
Damaged areas.
Hose couplings.
Compressor rear head.
All fittings and joints.

Testing Service Ports/Access Valves

The sealing caps provide protection for the service ports. Make sure that these caps are not missing or loose. Always use the correct cap for each port.

Testing the Evaporator Core

Leaks in the evaporator core are difficult to find. Test the evaporator core using the following procedure:

Run the blower fan at the maximum speed setting for at least 15 minutes.
Turn the blower OFF.
Wait for 10 minutes.
Remove the blower motor resistor. Refer to Section 7A, Heating and Ventilation System.
Insert the leak detector probe as closely as possible to the evaporator core. The detector will indicate a leak with a solid alarm.
Use a flashlight to search for refrigerant oil on the core surface.

Testing the Compressor Shaft Seal

Blow shop air behind and in front of the compressor clutch/pulley for at least 15 seconds.
Wait 1 to 2 minutes.
Probe the area in front of the pulley. If the detector emits a solid alarm, there is a leak.

V5 SYSTEM AIR CONDITIONING DIAGNOSIS

Insufficient Cooling Diagnosis

Test Description

The numbers below refer to steps on the diagnostic table.

See the Important below.

Important : Perform this test under garage conditions with the air temperature at 21-32°C (70-90°F), and no sun load. Follow this test carefully for accurate results.

See the Important below.

Important : Perform this test exactly as described to obtain accurate results.

Insufficient Cooling Diagnosis

Step	Action	Value(s)	Yes	No
1	Record the customer's complaint. Can you verify the customer's complaint?	-	Go to Step 2	System OK
2	Check the A/C fuse. Check the blower fan operation. Check the engine cooling fan operation. Check the A/C compressor belt. Check the A/C condenser for restricted airflow. Check the clutch coil connection. Repair or replace any components as needed. Check the discharge air temperature with the A/C turned ON. Is the discharge air temperature normal?	At least 7°C (12°F) below ambient air temperature	System OK	Go to Step 3
3	Turn the ignition switch to LOCK. Connect the high- and the low-pressure gauges. Are both pressures within the value specified?	69-345 kPa (10-50 psi)	Go to Step 4	Go to Step 5
4	Check the A/C system for leaks. Repair any refrigerant leaks as needed. Recover, evacuate, and recharge the A/C system. Observe the two pressure gauges. Are both pressures above the value specified?	345 kPa (50 psi)	Go to Step 7	-
5	Observe the two pressure gauges. Are both pressures below the value specified?	69 kPa (10 psi)	Go to Step 6	Go to Step 7
6	Add 0.45 kg (1 pound) of refrigerant R-134a. Check the A/C system for leaks. Repair any refrigerant leaks, as needed. Recover, evacuate, and recharge the A/C system. Observe the two pressure gauges. Are both pressures above the value specified?	345 kPa (50 psi)	Go to Step 7	-
7	Start the engine and allow it to run at idle. Set the A/C controls to the following positions: The A/C switch to the ON. The fresh air control switch to fresh air (indicator lamp OFF). The blower motor to 4. The temperature to full cold. Does the A/C compressor clutch engage?	-	Go to Step 8	Go to Step 10
8	Check for a knocking noise from the A/C compressor. Cycle the A/C compressor ON and OFF in order to verify the source of the noise. Do you hear a loud knocking noise?	-	Go to Step 9	Go to Step 13
9	Recover the A/C system refrigerant. Replace the A/C compressor. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the compressor running normally?	-	Go to Step 13	-
10	Turn the ignition switch to LOCK. Disconnect the A/C compressor clutch coil connector. Connect a jumper wire from ground to one A/C compressor clutch coil terminal. Connect a fused jumper wire from the positive battery terminal to the other A/C compressor clutch coil terminal. Does the A/C clutch engage?	-	Go to Step 11	Go to Step 12
11	Repair the electrical circuit to the A/C compressor clutch coil. Does the A/C clutch engage?	-	Go to Step 8	-
12	Replace the A/C compressor clutch coil. Does the A/C clutch engage?	-	Go to Step 8	-
13	Close all of the vehicle's windows and doors. Close all of the vehicle's windows and doors. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Start the engine and allow it to run at idle for 5 minutes. Feel the evaporator inlet and outlet pipes. Is there a noticeable difference in the temperature of the evaporator inlet and outlet pipes?	-	Go to Step 15	Go to Step 14
14	Turn the ignition switch to LOCK. Recover the A/C system refrigerant. Examine the high-pressure pipe for an obstruction. Examine the expansion valve for an obstruction or a malfunction. Repair the obstruction or replace the expansion valve as needed. Evacuate and recharge the A/C system. Check the A/C system for leaks. Note the discharge air temperature with the A/C ON. Is the discharge temperature normal?	At least 7°C (12°F) below ambient air temperature	Go to Step 15	Go to Step 13
15	Record the low- and the high-side pressures after the A/C system has been operating for 5 minutes or more with the engine cooling fan ON. Locate the intersection of the low- and the high side pressures. Refer to "Low- and High-Side Pressure Relationship Chart" in this section. Do the low- and the high-side pressures intersect in the white area of the chart?	-	System OK	Go to Step 16
16	Check the high- and the low-side pressures. Do the low- and the high-side pressures intersect in the gray area of the chart?	-	Go to Step 17	Go to Step 20
17	Feel the liquid pipe between the condenser and the expansion valve. Is the pipe cold?	-	Go to Step 18	Go to Step 19
18	Examine the condenser for any restriction of the airflow. Check the cooling fans for proper operation. Remove the restriction or repair the fans, as required. Is the pipe temperature normal now?	At least 7°C (12°F) below ambient air temperature	Go to Step 13	-
19	Recover, evacuate, and recharge the A/C system. Check the A/C system for leaks. Is the system free from leaks?	-	Go to Step 13	-
20	Observe the readings on the pressure gauges. Are the A/C compressor high- and the low-side pressures within the specified value of each other?	207 kPa (30 psi)	Go to Step 21	Go to Step 26
21	Run the engine at 3,000 rpm. Set the A/C controls to the following positions: The A/C switch to the ON. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Close all of the vehicle's windows and doors. Turn the A/C switch ON and OFF every 20 seconds for 3 minutes. Are the A/C compressor high- and the low-side pressures within the specified value of each other?	207 kPa (30 psi)	Go to Step 22	Go to Step 13
22	Observe the pressure rise on both gauges and the temperatures of both the compressor suction pipe and the discharge pipe. Is the pressure rise on both gauges slow and the suction pipe warm with the discharge pipe very hot?	-	Go to Step 25	Go to Step 23
23	Turn the ignition switch to LOCK. Make sure the compressor clutch is disengaged. Attempt to turn the clutch driver (not the pulley). Can you turn the clutch driver freely by hand?	-	Go to Step 25	Go to Step 24
24	Start the engine. Observe the low-side pressure gauge while running the engine between 3,000 and 3,800 rpm. Does the low-side pressure rise rapidly?	-	Go to Step 32	Go to Step 25
25	Recover the A/C system refrigerant. Replace the A/C compressor. Evacuate and recharge the A/C system. Is the compressor functioning normally?	-	Go to Step 13	-
26	Check the low-side pressure. Is the low-side pressure within the specified value?	172-241 kPa (27-38 psi)	Go to Step 27	Go to Step 32
27	Feel the high-side pipe leading up to the expansion valve connecting block. Is the pipe cold before the connecting block?	-	Go to Step 28	Go to Step 29
28	Check for a restriction in the high-side pipe before the expansion valve. Repair or replace the high-side pipe. Is the pipe performing normally?	-	Go to Step 13	-
29	Add the specified amount of refrigerant to the A/C system. Does the cooling performance improve?	0.40 kg (14 ounces)	Go to Step 30	Go to Step 31
30	Check the A/C system for leaks. Repair any refrigerant leaks, as needed. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the system free from leaks?	-	Go to Step 13	-
31	Recover the refrigerant. Check the expansion valve for obstructions. Repair or replace the expansion valve, as required. Evacuate and recharge the system. Check the A/C system for leaks. Is the system free from leaks?	-	Go to Step 13	-
32	Run the engine for 5 minutes at 2,000 rpm. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to recirculate (indicator lamp ON). The blower motor to 1. The temperature to full cold. Close all of the vehicle's windows and doors. Open the vehicle hood. Is the low-side pressure within the specified value?	172-241 kPa (25-35 psi)	Go to Step 13	Go to Step 33
33	Recover the A/C system refrigerant. Replace the A/C compressor control valve. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the system free from leaks?	-	Go to Step 13	-

SYMPTOM DIAGNOSIS

Pressure Test Chart (R-134A System)

Test Results	Related Symptom	Probable Cause	Remedy
Discharge(high) pressure abnormally high	After stopping the compressor, the pressure drops about 299kPa (28psi) quickly, then falls gradually	There is air in the system.	Recover, evacuate and recharge the system with the specified amount of refrigerant.
	The condenser is excessively hot.	There is excessive refrigerant in the system.	Recover, evacuate and recharge the system with the specified amount of refrigerant.
	Reduced or no airflow through the condenser.	The condenser or the radiator fins are clogged.	Clean the condenser or the radiator fins.
	.	The condenser or the radiator fan is not working properly.	Check the voltage and the fan rpm. Check the fan direction.
	Line to the condenser is excessively hot.	Restricted flow of refrigerant in the system.	Locate and repair the restriction.
Discharge pressure abnormally low	The condenser is not hot.	Insufficient refrigerant in the system.	Check the system for a leak. Charge the system.
	High and low pressures are balanced soon after stopping the compressor.	Faulty compressor pressure relief valve.	Repair or replace the compressor.
	Low-side pressure is higher than normal.	Faulty compressor seal.	.
	The outlet of the expansion valve is not frosted, low pressure gauge indicates vacuum.	Faulty expansion valve.	Replace the expansion valve.
	.	Moisture in the system.	Recover, evacuate, and recharge the system.
Suction (low) pressure abnormally low	Condenser is not hot.	Insufficient refrigerant in the system.	Repair the leaks. Recover, evacuate, and recharge the system.
	The expansion valve is not frosted and the low pressure line is not cold.	Frozen expansion valve.	Replace the expansion valve.
	Low Pressure gauge indicates a vacuum.	Faulty expansion valve.	.
	Discharge temperature is low and the air flow from the vents is restricted.	The evaporator is frozen.	Clear the restricted evaporator case drain.
	The expansion valve is frosted.	The expansion valve is clogged.	Clean or replace the expansion valve.
	The receiver/drier outlet is cool and the inlet is warm.	The receiver/drier is clogged.	Replace the receiver/drier.
Suction pressure abnormally high	Low pressure hose and check joint are cooler than the temperature around the evaporator.	The expansion valve is opened for too long.	Replace the expansion valve.
Suction pressure abnormally high	.	A capillary tube is loose.	.
Suction pressure abnormally high	Suction pressure is lowered when the condenser is cooled by water.	There is excessive refrigerant in the system.	Recover, evacuate, and recharge the system.
	High and low pressure are equalized as soon as the compressor is stopped and both gauges fluctuate while the compressor is running.	A gasket is faulty.	Repair or replace the compressor.
	.	The high pressure valve is faulty.	.
	.	Foreign particles are stuck in the high pressure valve.	.
Suction and discharge pressure abnormally high	Reduced airflow through the condenser.	The condenser or the radiator fins are clogged.	Clean the condenser and the radiator.
	.	The radiator cooling fans are not working properly.	Check the voltage and the radiator cooling fan rpm. Check the fan direction.
	Condenser is excessively hot.	There is excessive refrigerant in the system.	Recover, evacuate, and recharge the system.
Suction and discharge pressure abnormally low	Low pressure hose and metal end areas are cooler than the evaporator.	Clogged or kinked low pressure hose.	Repair or replace the low pressure hose.
Suction and discharge pressure abnormally low	Temperature around the expansion valve is low compared to that around the receiver/dryer.	The high pressure line is clogged.	Repair or replace the high pressure line.
Refrigerant leaks	The compressor clutch is dirty.	The compressor shaft seal is leaking.	Repair or replace the compressor.
	The compressor bolts are dirty.	Leaking around a compressor housing bolt.	Tighten the bolt(s) or replace the compressor.
	The compressor gasket is wet with oil.	The compressor gasket is leaking.	Repair or replace the compressor.

Low and High Side Pressure Relationship Chart