Service Manual2004 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.

DESCRIPTION AND OPERATION

AIR CONDITIONING

Vehicle air conditioning is the cooling (refrigeration), heating, and ventilation of the air in the passenger compartment. Refrigeration is accomplished by making practical use of the three laws of nature. These laws of nature and their practical application are as follows:

Heat transfer
Latent heat of vaporization
Effect of pressure on boiling or condensation

Heat Transfer

The principle of heat transfer are that the heat always flow from hot to cold, the rate of heat transfer will increase as the difference in temperature between two objects increases, and the mass of an object remains the same regardless of its heat contents.

Latent Heat of Vaporization

Everything in the world is composed of matter, and the matter exists in one of following states;

Solid
Liquid
Vapor

When a liquid boils, it changes to vapor and absorbs heat without raising the temperature of the resulting vapor.

When the vapor condenses, it changes back to a liquid and gives off heat without lowing the temperature of the resulting liquid.

Effect of Pressure on Boiling or Condensing

When the pressure on the liquid or vapor changes, the boiling point changes. Increasing the pressure increases the boiling point, while the boiling point decreased by decreasing the pressure on the liquid or vapor.

Another effect of the compression is an increase in temperature even though heat has not been added. For example, if you compress the refrigerant R-134a from 206 kPa (30 psi) to 1206 kPa (175 psi) the temperature of vapor will increase from 0°C (32°F) to 54°C (130°F) and boiling point increase. Condensing point also will increase.

THE V5 A/C SYSTEM

The V5 variable displacement compressor, along with the thermal expansion valve on the evaporator, constitutes a largely self regulating system. There is no pressure cycling switch, no high and low pressure cutoff switch. The compressor clutch is controlled by the electronic control module (ECM), which receives data from various engine systems and the pressure transducer located in the high-pressure refrigerant pipe. In normal operation, the clutch is engaged continuously. Should one of the monitored conditions become abnormal, the ECM will disengage the compressor clutch until normal operation is restored. The abnormal conditions under which the ECM will disengage the compressor clutch are the following:

Wide open throttle
High engine coolant temperature.
High engine rpm
Refrigerant low pressure.
Refrigerant high pressure.

SYSTEM COMPONENTS-FUNCTIONAL

Compressor

All compressors are belt-driven from the engine crankshaft through the compressor clutch pulley. The compressor pulley rotates without driving the compressor shaft until an electromagnetic clutch coil is energized. When voltage is applied to energize the clutch coil, the clutch plate and hub assembly is drawn rearward toward the pulley. The magnetic force locks the clutch plate and pulley together as one unit to drive the compressor shaft.

As the compressor shaft driven, it compresses the low-pressure refrigerant vapor from evaporator into high-pressure, high temperature vapor. The refrigerant oil that is used to lubricate the compressor is carried with the refrigerant.

Pressure Relief Valve

The compressor is equipped with a pressure relies valve which is placed in the system as a safety factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure at approximately at 3171 to 4137 kPa (460 to 600 psi) in an R-134a system. Conditions that might cause this valve to open, such as a defective pressure transducer, an inoperative cooling fan, etc., should be corrected. The refrigerant oil and the refrigerant should be replaced as necessary.

Condenser Core

The condenser assembly in front of the radiator consists of coils, which carry the refrigerant and cooling fins that provide the rapid transfer of heat. The air passing through the condenser cools the high-pressure refrigerant vapor and causes it to condense into a liquid.

Expansion Valve

The expansion valve is attached to the evaporator core, inside the heater/air distributor case under the instrument panel.

The expansion valve can fail in three different positions: open, closed, or restricted.

An expansion valve that fails in open position will result in a noisy A/C compressor or no cooling. The cause can be a broken spring, a broken ball, or excessive moisture in the A/C system. If the spring or the ball are found to be defective, replace the expansion valve. If excessive moisture is found in the A/C system recycle the refrigerant.

An expansion valve that fails in the closed position will result low suction pressure and no cooling. This may be caused by a failed power dome or excessive moisture in the A/C system. If the power dome on the expansion valve is founded to be defective, replace the expansion valve. If excessive moisture is found in the A/C system recycle the refrigerant.

A restricted expansion valve will result in low suction pressure and no cooling. This may be caused by debris in the refrigerant system. If debris is believed to be the cause, recycle the refrigerant, replace the expansion valve, and replace the receiver-drier.

Evaporator Core

The evaporator is a device which cools and dehumidifies the air before it enters the vehicle. High pressure liquid refrigerant flows through the expansion tube (orifice) and becomes a low pressure gas in the evaporator. The heat in the air passing through the evaporator core is transferred to the cooler surface or the core, which cools the air.

As the process of heat transfer from the air to the evaporator core surface is taking place, any moisture (humidity) in the air condenses on the outside surface of the evaporator core and is drained off as water.

Receiver-Drier

The sealed receiver-drier assembly is connected between the condenser and evaporator. It acts as a refrigerant storing container, receiving liquid and some vapor and refrigerant oil from the condenser.

At the bottom of the receiver-drier is the desiccant, which acts as drying agent for the moisture that may have entered the system. An oil bleed hole is located near the bottom of the receiver-drier outlet pipe to provide an oil return path to the compressor. The receiver dryer is serviceable as an assembly.

Heater Core

The heater core heats the air before it enters the vehicle. Engine coolant is circulated through the core to heat the outside air passing over the pin of the core. The core is functional at all times and may be used to temper conditioned air in the A/C mode as well as in heat or the vent mode.

SYSTEM COMPONENTS-CONTROL

Controller

The operation of the A/C system is controlled by the switches and knob on the control head. This console-mounted controller contains following control knobs.

Rotary Temperature Control Knob

Actuates by cable.
Raise the temperature of the air entering the vehicle by sliding to the right, or the red portion of the knob.
Varies the mix of the fresh air from outside the vehicle with the heated air from inside the vehicle to suit individual performance.

Rotary Mode Control Knob

Actuates by cable.
Regulates the air distribution between the windshield, the instrument panel, and the floor vents.

Rotary Blower Control Knob

Turns on to operate the blower motor at four speeds.
Turns OFF to stop the blower.
Operates completely independently from both the mode control knob and temperature control knob.
Changes the fan speed in any mode and at any speed.

Push Inlet Air Control Knob

Operates by electricity.
Switches between recirculating the passenger compartment air and bringing outside air into the passenger compartment.
Is normally in fresh air mode.
Illuminates the indicator lamp when in the recalculating mode.

Push A/C Knob

Controls the A/C
Turns the A/C ON when the knob is pressed and the indicator lamp is illuminated. (The rotary blower control knob must be in one of the its four positions for the A/C to function).

Pressure Transducer

Pressure transducer switching incorporates the functions of the high-pressure and the low-pressure cutout switches along with the fan cycling switch. The pressure transducer is located in high side liquid refrigerant line between the right strut tower and the air cleaner assembly. The output from this pressure transducer goes to the ECM which controls the compressor function based on the pressure signal.

Wide-Open Throttle (WOT) Compressor Cutoff

During full throttle acceleration, the throttle position (TP) sensor sends a signal to the ECM, which then controls the compressor clutch.

V5 COMPRESSOR-GENERAL DESCRIPTION

Vehicles using the V5 compressor may have differences between installations in the mounting brackets, the drive system, the pulleys, the connections, and the system capacities. Basic overhaul procedures are similar between the compressors used on different vehicles.

When servicing the compressor, keep dirt and foreign material from getting on or into the compressor parts and the system. Clean tools and a clean work area are important for proper service. The compressor connections and outside of the compressor should be cleaned before performance of any on-vehicle repairs and before removal of the compressor. The parts must be kept clean at all times and any parts that are to be reassembled should be cleaned with trichloroethane, naphtha, stoddard solvent, kerosene or equivalent solvents and dried with dry air. Use only lint-free cloths to wipe the parts.

The operations described are based on bench overhaul with the compressor removed from the vehicle, except as noted. They have been prepared in the order of accessibility of the components. When a compressor is removed from the vehicle for servicing, the amount of oil remaining the compressor should be drained, measured and recorded. This should then be discarded and new polyalkaline glycol (PAG) refrigerant oil added to the compressor.

Important : the oil drain plug must be removed and the oil drained through the plug opening to insure complete draining of oil from the compressor.

V5 COMPRESSOR-OPERATION

The V5 is a variable displacement compressor that can match the automotive air conditioning demand under all conditions without cycling. The basic compressor mechanism is a variable angle wobble-plate with seven axially oriented cylinders. The center of the control of the compressor displacement is a billows-actuated control valve located in the rear head of the compressor that senses compressor suction pressure.

The wobble-plate angle and the compressor displacement are controlled by the crankcase suction pressure differential. When the A/C capacity demand is high, the suction pressure will be above the control point. The valve will maintain a bleed from crankcase to suction. With no crankcase suction pressure differential, the compressor will have maximum displacement.

When the A/C capacity demand is lower and the suction pressure reaches the control point, the valve will bleed discharge gas in the crankcase and close off a passage from the crankcase to suction plenum. The angle of the wobble-plate is controlled by a force balance of seven pistons. A slight elevation of the crankcase suction pressure differential creates total force on the piston resulting in a movement about the wobble-plate pivot pin that reduces the plate angle.

The compressor has a unique lubrication system. The crankcase suction bleed is routed through the rotating wobble-plate for lubrication of wobble-plate bearing. The rotation acts as an oil separator that removes some of the oil from the crankcase suction bleed, rerouting it to the crankcase where it can lubricate the compressor mechanism.

COMPONENT LOCATOR

A/C SYSTEM COMPONENTS

High Pressure Pipe
Suction Hose
Evaporator
Discharge Hose
Condenser
Receiver-Drier
Compressor
A/C Pressure Sensor

DIAGNOSTIC INFORMATION AND PROCEDURES

GENERAL DIAGNOSIS

For general diagnosis of heating and ventilation including blower motor and controller, refer to Section 7A, Heating and Ventilation System.

TESTING THE REFRIGERANT SYSTEM

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

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 pipes.
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-R134a. the air temperature must be above 21°C (70°F) for most models.

Warm up the engine. Run the engine at idle.
Open the hood and all the doors.
Set the A/C switch to the ON position.
Set the temperature control to the full cold position.
Set the blower speed switch on setting 4.
"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.
Check leaks 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 and charge the system.
If there is no leak, refer to "Insufficient Cooling Diagnosis" in this section.

A/C PERFORMANCE TEST

RELATIVE HUMIDITY (%)	AMBIENT AIR TEMPERATURE °C °F	LOW SIDE PRESSURE kPa psig	ENGINE SPEED (RPM)	CENTER DUCT AIR TEMPERATURE °C °F	HIGH SIDE PRESSURE kPa psig
20	21 (70) 27 (81) 32 (90) 38 (100)	200 (29) 200 (29) 207 (30) 214 (31)	2000	4 (39) 7 (45) 9 (48) 14 (57)	1034 (150) 1310 (190) 1689 (245) 2103 (305)
30	21 (70) 27 (81) 32 (90) 38 (100)	200 (29) 207 (30) 214 (31) 221 (32)	2000	6 (43) 8 (46) 11 (52) 16 (61)	1034 (150) 1413 (205) 1827 (265) 2241 (325)
40	21 (70) 27 (81) 32 (90) 38 (100)	200 (29) 207 (30) 221 (32) 269 (39)	2000	7 (45) 9 (48) 13 (55) 18 (64)	1138 (165) 1482 (215) 1931 (280) 2379 (345)
50	21 (70) 27 (81) 32 (90) 38 (100)	207 (30) 221 (32) 234 (34) 276 (40)	2000	8 (46) 12 (54) 15 (59) 21 (70)	1241 (180) 1620 (235) 2034 (295) 2413 (350)
60	21 (70) 27 (81) 32 (90) 38 (100)	207 (30) 228 (33) 248 (36) 296 (43)	2000	9 (48) 13 (55) 17 (63) 23 (73)	1241 (180) 1655 (240) 2068 (300) 2482 (360)
70	21 (70) 27 (81) 32 (90) 38 (100)	207 (30) 234 (34) 262 (38) 303 (44)	2000	10 (50) 14 (57) 18 (64) 24 (75)	1276 (185) 1689 (245) 2103 (305) 2517 (365)
80	21 (70) 27 (81) 32 (90)	207 (30) 234 (34) 269 (39)	2000	10 (50) 15 (59) 19 (66)	1310 (190) 1724 (250) 2137 (310)
90	21 (70) 27 (81) 32 (90)	207 (30) 248 (36) 290 (42)	2000	10 (50) 17 (63) 22 (72)	1379 (200) 1827 (265) 2275 (330)

PRESSURE-TEMPERATURE RELATIONSHIP OF R-134A

TEMPERATURE °C (°F)*	PRESSURE kPa (psig)*	TEMPERATURE °C (°F)*	PRESSURE kPa (psig)*
-8.89 (16)	105.70 (15.33)	37.78 (100)	856.84 (124.27)
-7.78 (18)	114.87 (16.66)	38.89 (102)	886.56 (128.58)
-6.67 (20)	124.32 (18.03)	40.00 (104)	916.35 (132.98)
-5.56 (22)	134.11 (19.45)	41.11 (106)	947.92 (137.48)
-4.44 (24)	144.24 (20.92)	42.22 (108)	979.64 (142.08)
-3.33 (26)	154.65 (22.43)	43.33 (110)	1012.11 (146.79)
-2.22 (28)	165.48 (24.00)	44.44 (112)	1045.21 (151.59)
-1.11 (30)	176.65 (25.62)	45.56 (114)	1079.14 (156.51)
0.00 (32)	188.16 (27.29)	46.67 (116)	1113.75 (161.53)
1.11 (34)	200.02 (29.01)	47.78 (118)	1149.12 (166.66)
2.22 (36)	212.30 (30.79)	48.89 (120)	1185.18 (171.89)
3.33 (38)	224.98 (32.63)	50.00 (122)	1222.07 (177.24)
4.44 (40)	238.08 (34.53)	51.11 (124)	1259.72 (182.70)
7.22 (45)	272.49 (39.52)	52.22 (126)	1298.12 (188.27)
10.00 (50)	309.58 (44.90)	53.33 (128)	1337.35 (193.96)
12.77 (55)	349.51 (50.69)	54.44 (130)	1377.35 (199.76)
15.56 (60)	392.33 (56.90)	57.22 (135)	1480.91 (214.78)
18.33 (65)	438.18 (63.55)	60.00 (140)	1589.57 (230.54)
21.11 (70)	487.27 (70.67)	62.78 (145)	1703.62 (247.08)

* All values rounded to two decimal places.

EVAPORATOR RANGE: From -6.67 to 7.22°C (20 to 45°F), the temperatures represent the gas temperatures inside the coil and not on the coil surfaces. Add 1.67 to 5.56°C (3 to 10°F) the temperature for coil and air-off temperatures.

CONDENSER RANGE: From 110 to 160°F, temperatures are not ambient. Add 19.4 to 22.2°C (35 to 40°F) 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 = 1379 kPa (200 psig)

Based on 48.3 km/h (30 mph) air flow.

LEAKING TESTING THE 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 location of any leak.

For areas where that are not practical, such as sections of the evaporator and the condenser, an electrical 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.

Important : 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 Refrigerant Charge Ports/Access Valves

The sealing caps provide protection for the refrigerant charge 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 speed setting 4 for at least 15 minutes.
Turn the blower to OFF.
Wait for 10 minutes.
Remove the blower motor resistor. Refer to "Blower Motor Resistor" in this section.
Insert the leak detector probe as close as possible to the evaporator core. The detector will indicate a leak with a solid alarm.
Use a flashlight to search for refrigerant oil in 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 number(s) below refer to step(s) on the diagnostic table.

13. See the first Important below.

32. See the second 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.

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 EF24. Check the blower fan operation. Check the engine cooling fan operation. Check the A/C compressor belt. Check the A/C condenser for restricted air flow. Check the 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 to LOCK. Connect the high- and low-pressure gauges. Are both pressures within the specified value?	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 specified value?	345 kPa (50 psi)	Go to Step 7	-
5	Observe the two pressure gauges. Are both pressures below the specified value?	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 specified value?	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 to ON. The intake air control switch to fresh air (indicator lamp OFF). The blower motor to 4. The temperature control knob 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 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	Important : perform this test under garage conditions; 21 - 32°C (70 - 90°F) and no sun load. Follow this test carefully for accurate results. Close all of the vehicle's windows and doors. Set the A/C controls to the following positions: The A/C switch to ON position. The intake air control switch to fresh air. The blower motor to 4. The temperature control knob to full cold. Start the engine and allow it to run at idle for 5 minutes. Check the discharge air temperature. 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 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 16
15	Record the high- and low-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 high- and low-side pressures. Refer to "Low-and High-Side Pressure Relationship Chart" in this section. Do the high- and low-side pressures intersect in the white area of the chart?	-	System OK	Go to Step 16
16	Check the high- and low-side. Do the high- and low-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 fan(s) as required. Is the pipe temperature normal now?	-	Go to Step 13	-
19	Recover, evacuate, and recharge the A/C system. Check the A/C system for leaks. Is the system leak tight?	-	Go to Step 13	-
20	Observe the readings on the pressure gauges. Are the A/C compressor high and low side pressure 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 ON position. The intake air control switch to fresh. (indicator lamp OFF). The blower motor to 4. The temperature control knob 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 low side pressure 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 gages 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 hot?	-	Go to Step 25	Go to Step 23
23	Turn the ignition switch to LOCK. Check that 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 3000 and 3800 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 the 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 again the A/C system for leaks. Is the system leak free?	-	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 A/C system. Check again the A/C system for leaks. Is the system leak free?	-	Go to Step 13	-
32	Important : perform this test exactly as described to obtain accurate results. 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 intake air control switch to recirculation (indicator lamp ON). The blower motor to 1. The temperature control knob 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	-

COMPRESSOR MAGNETIC CLUTCH DOES NOT ENGAGE

Refer to "Manual Control A/C Diagram" for the electrical schematic diagram of the circuits described in the procedure.

Step	Action	Value(s)	Yes	No
1	Disconnect the A/C compressor magnetic clutch connector. Turn the ignition switch to ON. Turn the A/C on. Measure the voltage between terminal 1 of A/C compressor magnetic clutch connector and ground. Is the voltage within the specified value?	11.14 V	Go to Step 2	Go to Step 5
2	Measure the resistance between terminal 2 and ground. Is the resistance equal to the specified value?	~0Ώ	Go to Step 4	Go to Step 3
3	Repair open circuit between terminal 2 of A/C compressor magnetic clutch and ground. Is the repair complete?	-	System OK	-
4	Repair A/C compressor magnetic clutch or replace the compressor assembly. Is the repair complete?	-	System OK	-
5	Check the fuse EF24. Is the fuse blown?	-	Go to Step 6	-
6	Repair short circuit between fuse EF24 and terminal 1 of A/C compressor magnetic clutch connector. Is the repair complete?	-	System OK	-
7	Turn the ignition switch to ON. Turn the A/C ON. Using the test lamp, check terminal 86 and terminal 85 of the A/C compressor clutch. Dose the test lamp illuminate?	-	Go to Step 9	Go to Step 8
8	Repair open circuit in power supply circuit including fuse F17 and A/C compressor relay. Is the repair complete?	-	System OK	-
9	Disconnect the ECM connector. Measure resistance between terminal K29 (MR-140) /A15 (ITMS-6F) /41(SIRIUS D4) of ECM and terminal 85 of A/C compressor relay. Is the resistance equal to the specified value?	~0Ώ	Go to Step 11	Go to Step 10
10	Repair open circuit between terminal 85 of A/C compressor relay and specific terminal of the ECM. Is the repair complete?	-	System OK	-
11	Replace the ECM. Is the repair complete?	-	System OK	-

SYMPTOM DIAGNOSIS

PRESSURE TEST CHART (R-134A SYSTEM)

TEST RESULTS	RELATED SYMPTOMS	PROBABLE CAUSE	REMEDY
Discharge (high) pressure abnormally high	After stopping the compressor, the pressure drops about 299 kPa (28 psi) 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 air flow through the condenser.	The condenser or the radiator fins are clogged.	Clean the condenser or the radiator fins.
	Reduced or no air flow through the condenser.	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 (high) 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.
		Faulty compressor seal.	Repair or replace the compressor.
	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 pressure abnormally low	The 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. Low pressure gauge indicates a vacuum.	Frozen expansion valve.	Replace the expansion valve.
		Faulty expansion valve.	Replace the 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	The 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.
		A capillary tube is loose.	Replace the expansion valve.
	The suction pressure is lowered when the condenser is cooled by water.	There is excessive refrigerant in the system.	Recover, evacuate, and recharge the system.
	The 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	There is reduced airflow through the condenser.	The condenser or the radiator fins are clogged.	Clean the condenser and the radiator.
	There is reduced airflow through the condenser.	The radiator cooling fans are not working properly.	Check the voltage and the radiator cooling fan rpm. Check the fan direction.
	The condenser is excessively hot.	There is excessive refrigerant in the system.	Recover, evacuate, and recharge the system.
Suction and discharge pressure abnormally low	The low pressure hose and metal end areas are cooler than the evaporator.	There is clogged or kinked low pressure hose.	Repair or replace the low pressure hose.
Suction and discharge pressure abnormally low	The temperature around the expansion valve is low compared to that around the receiver/drier.	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

REPAIR INSTRUCTIONS

GENERAL A/C SYSTEM SERVICE PROCEDURES

O-RING REPLACEMENT

Important : Even though O-rings may look identical, it is extremely important that only recommended service replacement air conditioning O-rings be used, or excessive leakage of the refrigerant may occur.

Important : Always slip the O-ring onto the flange tube to ensure proper locating and sealing.

Install new DAEWOO approved service replacement air conditioning O-rings whenever a joint or a fitting is disassembled, except when the O-rings are provided on new components.

When replacing O-rings on an air conditioning component or a joint connection, the fitting design should be identified to ensure installation of the correct air conditioning service replacement O-ring. Some joint connections and components will implement a "captured" O-ring design fitting that uses a groove to retain the Oring. Others do not have a groove and use a "non-captured" or "standard" O-ring. Assembly and tightening procedures are the same for both designs, but the Orings are different.

Before installation, verify that both O-rings and fittings have not been nicked or deformed. Deformed or nicked parts must be replaced. Failure to use the proper service replacement parts and procedures may result in excessive refrigerant leakage.

HANDLING REFRIGERANT

Caution : Always work in a well-ventilated area and avoid breathing any refrigerant fumes. If you have difficulty breathing, seek medical attention immediately. If refrigerant comes in contact with any part of your body, flush the exposed area with water. If a rash or pain develops, seek medical attention.

Air conditioning systems contain refrigerant. This is a chemical mixture which requires special handling procedures to avoid personal injury.

Always wear goggles and wrap a clean cloth around the fittings, the valves, and the connections when performing work that involves opening the refrigerant system. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components.

All refrigerant drums are shipped with a heavy metal screw cap. The purpose of the cap is to protect the valve and the safety plug from damage. It is good practice to replace the cap after each use of the drum.

If it is necessary to transport or carry any container of refrigerant in a vehicle, do not carry it in the passenger compartment.

HANDLING OF REFRIGERANT LINES AND FITTINGS

Notice : Using too low or too high a torque when tightening a fitting can result in loose joints or deformed joint parts.

Both conditions can result in refrigerant leakage.

Keep all metal tubing lines free of dents or kinks. Any line restrictions will cause the loss of system capacity.
Never bend a flexible hose line to a radius of less than four times the diameter of the hose.
Never allow a flexible hose line to come within 63.5 mm (2-1/2 inches) of the exhaust manifold.
Inspect flexible hose lines regularly for leaks or brittleness.
Replace flexible hose lines with new lines if there are signs of deterioration or leaking.
Discharge the refrigeration system of all refrigerants before disconnecting any fitting in the refrigeration system.
Proceed very cautiously regardless of the gauge readings.
Open the fittings very slowly.
Keep your face and your hands away from the fitting so that you will not be injured if there happens to be liquid refrigerant in the line.
If pressure is noticed when loosening a fitting, allow the pressure to bleed off as described in "Discharging, Adding Oil, Evacuating and Charging Procedures for A/C System" in this section.
Cap or tape any refrigerant line immediately after it is opened. This will prevent the entrance of moisture and dirt, which can cause internal compressor wear or plugged lines in the condenser, the evaporator core, the expansion valve or the compressor inlet screens.

Important : Use two proper wrenches to connect the Oring fittings.

Back up the opposing fitting to prevent the distortion of the connecting lines or the components.
Back up both the swaged fitting on the flexible hose connections and the coupling to which it is attached with two wrenches to prevent turning the fitting and damaging the ground seat.
Keep the O-rings and the seats in perfect condition. A burr or a piece of dirt may cause a refrigerant leak.
Dip new O-rings in clean polyalkalene glycol (PAG) refrigerant oil before installation.

MAINTAINING CHEMICAL STABILITY IN THE REFRIGERATION SYSTEM

The efficient operation and life of the air conditioning system is dependent upon the chemical stability of the refrigeration system. When foreign materials, such as dirt, air, or moisture, contaminate the refrigeration system, they will change the stability of the refrigerant and the polyalkalene glycol (PAG) compressor oil. They will also affect the pressure-temperature relationship, reduce efficient operation, and can possibly cause interior corrosion and abnormal wear of moving parts.

Observe the following practices to ensure chemical stability in the system:
Wipe away dirt or oil at and near any connection before opening that connection. This will reduce the chance of dirt entering the system.
Cap, plug, or tape both sides of a connection as soon as possible after opening the connection. This will prevent the entry of dirt, foreign material, and moisture.
Keep all tools clean and dry, including the manifold gauge set and all replacement parts.
Use a clean and dry transfer device and container to add PAG refrigerant oil. This will ensure that the oil remains as moisture-free as possible. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedures for A/C System" in this section.
When opening an A/C system, have everything needed to perform all operations ready. Do not leave the A/C system open any longer than necessary.
Evacuate and recharge any A/C system that has been opened. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedures for A/C System" in this section for the instructions to perform this procedure properly.

All service parts are dehydrated and sealed before shipping. They should remain sealed until just before making connections. All the parts should be at room temperature before uncapping. This prevents condensation of moisture from the air from entering the system. Reseal all parts as soon as possible if the caps have been removed but the connections cannot be made promptly.

DISCHARGING, ADDING OIL, EVACUATING, AND CHARGING PROCEDURES FOR A/C SYSTEM

Caution : Use only refillable refrigerant tanks that are authorized for the charging station being used. The use of other tanks may cause personal injury or void the warranty. Refer to the manufacturer's instructions for the charging station.

Caution : To avoid personal injury, always wear goggles and gloves when performing work that involves opening the refrigeration system.

A charging station discharges, evacuates, and recharges an air conditioning (A/C) system with one hookup.

Filtering the refrigerant during the recovery cycle together with filtering during the evacuation cycle ensures a supply of clean, dry refrigerant for A/C system charging.

Notice :

Never use the R-134a charging station on a system charged with R-12. The refrigerants and the oils from each system are not compatible and must never be mixed, in even the smallest amount. Mixing refrigerant residue will damage the equipment.

Never use adapters which convert from one size fitting to another. Such use allows contamination, which may cause system failure.

Charging Station Setup and Maintenance

There are many charging stations available. All perform the various tasks required to discharge the system and recover refrigerant, evacuate the system, add a measured amount of oil, and recharge an air conditioning system with a measured amount of refrigerant. Refer to the manufacturer's instructions for all initial setup procedures and all maintenance procedures.

Control Panel Functions

A charging station will have controls and indicators to allow the operator to control and monitor the operation in progress. Refer to the manufacturer's instructions for details. These can be expected to include the following:

Main Power Switch

Supplies electrical power to the control panel.

Display

Shows the time programmed for vacuum.
Shows the weight of the refrigerant programmed for recharging.
Refer to the manufacturer's instructions for detailed programming information.

Low-Side Manifold Gauge

Shows the system's low-side pressure.

High-Side Manifold Gauge

Shows the system's high-side pressure.

Control Panel

Controls the various operating functions.

Low-Side Valve

Connects the low side of the A/C system to the unit.

Moisture Indicator

Shows whether the refrigerant is wet or dry.

High-Side Valve

Connects the high side of the A/C system to the unit.

Refrigerant Recovery

Important : Use only a refrigerant tank that is designed for the charging station in use. The unit's overfill limitation mechanism is calibrated specifically for use with this tank. The tank's valves are also manufactured specifically for this unit.

Attach the high-side hose with the quick disconnect coupler to the high-side fitting of the vehicle's A/C system.
Open the coupler valve.
Attach the low-side hose with the quick disconnect coupler to the low-side fitting of the vehicle's A/C system.
Open the coupler valve.
Check the high-side and the low-side gauges on the unit's control panel to ensure that the A/C system has pressure. If there is no pressure, there is no refrigerant in the system to recover.

Important : If there is no refrigerant in the system, do not continue with the recovery operation. Under this condition, this would draw air into the recovery tank.

Open both the high-side and the low-side valves.
Open the gas and the liquid valves on the tank.
Drain any oil that may be in the oil separator.
Close the oil drain valve.
Plug the unit into the proper voltage outlet. 11. Turn on the main power switch.

Notice : Never reuse refrigerant oil. Damage to the A/C system may result. Dispose of the refrigerant oil properly.

Begin the recovery process. Refer to the manufacturer's instructions for the charging station in use.

Important : Some A/C system polyalkalene glycol (PAG) lubricating oil may be removed with the refrigerant during recovery. The amount of oil removed varies. A charging station separates the oil from the refrigerant and provides a means of determining how much oil was removed. Replace the same amount of oil when recharging the system.

Refer to the manufacturer's instructions for the charging station in use.

Wait 5 minutes, then check the control panel low-side gauge. If the A/C has maintained vacuum, the recovery is complete.
If the low-side gauge pressure rises above zero, there is more refrigerant in the system. Recover the additional refrigerant. Repeat this step until the system maintains vacuum for 2 minutes.

Important : If the control indicator shows that the refrigerant tank is full during the recovery process and the unit shuts off, install an empty unit tank to store the refrigerant needed for steps later in the procedure. Do not use any other type of tank.

Evacuation

The unit tank must contain a sufficient amount of R-134a refrigerant for charging. Check the amount of refrigerant in the tank. If there is less than 3.6 kg (8 pounds) of refrigerant, add new refrigerant to the tank. Refer to the manufacturer's instructions for adding refrigerant.

Verify that the high-side and the low-side hoses are connected to the A/C system. Open both the high-side and the low-side valves on the unit's control panel.
Open both the gas and the liquid valves on the tank.

Important : Refer to the manufacturer's instructions for the charging station in use. It is necessary to evacuate the system before recharging it with new or recycled refrigerant.

Start the vacuum pump and begin the evacuation process. Non-condensable gases (mostly air) are vented from the tank automatically during the recycling process. The pressure being released may be heard.
Check for leaks in the system. Refer to the manufacturer's instructions for the charging station in use.

Important : Change the vacuum pump oil frequently. Refer to the manufacturer's instructions for the charging station in use.

A/C System Oil Charge Replenishing

Any oil removed from the A/C system during the recovery process must be replenished at this time.

Use the correct graduated bottle of polyalkalene glycol (PAG) oil for the R-134a system.

Important : Refer to the manufacturer's instructions for the charging station in use. Add the proper amount of PAG oil to the system.

Close the valve when the required oil charge has been pulled into the system.

Charging

Important : Evacuate the A/C system before charging.

Close the low-side valve on the control panel.
Open the high-side valve on the control panel.
Refer to the manufacturer's instructions for the charging station in use.
Enter the amount of refrigerant needed to charge the A/C, making sure to use the correct system of measurement, i.e. kilogram (kg) or pound (lb).
Begin the charging process.

Successful Transfer Complete

Close the high-side valve on the unit's control panel. Both valves should be closed.
Start the vehicle and the A/C system.
Let the engine run until the readings on the high-side and low-side gauges stabilize.
Compare the readings to the system specifications.
Check the evaporator outlet temperature to ensure that the A/C system is operating within the system specifications.
Keep the A/C running.
Close the high-side coupler valve.
Disconnect the high-side hose from the vehicle.
Open the high-side and low-side valves on the control panel.
The system will quickly draw in refrigerant from both hoses through the low-side hose.
Close the low-side coupler valve.
Disconnect the low-side hose from the vehicle.

Unsuccessful Transfer

Sometimes the total charge does not transfer into the A/C system. There are two reasons why this may occur:

The pressure in the unit's tank and the pressure in the A/C system are roughly equal.

This will cause the transfer to proceed too slowly.
Refer to the manufacturer's instructions for the charging station in use.

There was not enough refrigerant in the unit's tank to transfer the full charge.

It is necessary to recover the partial charge of refrigerant from the vehicle and then evacuate and charge the A/C system again.
Refer to the manufacturer's instructions for the charging station in use.

ON VEHICLE SERVICE

CONTROL ASSEMBLY AND CONTROL CABLE

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning)

BLOWER MOTOR

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning).

BLOWER RESISTOR

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning).

INTAKE AIR DOOR ACTUATOR

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning).

HEATER HOSES

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning).

HEATER CORE

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning)

HEATER/AIR DISTRIBUTOR CASE ASSEMBLY

Refer to Section 7A, Heating and Ventilation System(Without Air Conditioning)

A/C PRESSURE SENSOR

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove air cleaner hose clamp.
Remove three bolt that securing air cleaner housing and remove air cleaner housing.

Disconnect the pressure sensor connector.
Remove the pressure sensor.

Installation Notice

Tightening Torque

7 N•m (62 lb-in)

Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

HIGH PRESSURE PIPE

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove air cleaner housing assembly. Refer to Section 1B, Engine Mechanical.
Remove the nut on the flange of receiver-drier.

Installation Notice

Tightening Torque

14 N•m (10 lb-ft)

Remove O-ring and discard it.
Remove A/C pressure sensor. Refer to "A/C Pressure Sensor" in this section.
Remove two nuts on the flange of evaporator.

Installation Notice

Tightening Torque

14 N•m (10 lb-ft)

Remove O-ring and discard it.

Remove one bolt and nut that securing the high pressure pipe.
Remove the high pressure pipe(receiver-drier-to-evaporator).
Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

SUCTION HOSE

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove the snorkel and air cleaner housing. Refer to Section 1B, Engine Mechanical.
Remove one nut on the flange of the compressor.

Installation Notice

Tightening Torque

33 N•m (24 lb-ft)

Remove the sealing washer and discard it.
Remove two nuts on the flange of evaporator.

Installation Notice

Tightening Torque

14 N•m (10 lb-ft)

Remove O-ring and discard it.

Remove one bolt and one nut that securing discharge hose.

Installation Notice

Tightening Torque

4 N•m (35 lb-in)

Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

DISCHARGE HOSE

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove two bolts and the air inlet duct. Refer to Section 1B, Engine Mechanical.

Installation Notice

Tightening Torque

8 N•m (71 lb-in)

Remove the nut on the flange of compressor and sealing washer.

Installation Notice

Tightening Torque

33 N•m (24 lb-ft)

Remove the nut on the flange of condenser.

Installation Notice

Tightening Torque

16 N•m (12 lb-ft)

Remove O-ring and discard it.

Remove the high pressure pipe.
Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

CONDENSER

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.
Remove the radiator. Refer to Section 1D, Engine Cooling.
Remove two nuts on the flange of the A/C pipe line, on both side of the condenser.

Installation Notice

Tightening Torque	to Discharge Hose	16 N•m (12 lb-ft)
Tightening Torque	to Receiver-Drier	14 N•m (10 lb-ft)

Remove O-rings and discard them.

Remove two condenser-retaining nuts.

Installation Notice

Tightening Torque

4 N•m (35 lb-in)

Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

COMPRESSOR

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove serpentine accessory drive belt.
Remove the nut and suction/discharge hose from compressor.

Installation Notice

Tightening Torque

33 N•m (24 lb-ft)

Remove two sealing washer and discard it.

Lift the vehicle and support safely.
Remove engine under cover. Refer to Section 9N, Frame and Underbody.
Disconnect the compressor clutch connector
Remove the three front compressor mounting bolts.

Installation Notice

Tightening Torque

38 N•m (28 lb-ft)

Remove the three rear compressor mounting bolts.

Installation Notice

Tightening Torque

22 N•m (16 lb-ft)

Remove the compressor.

Drain the oil from the compressor into a container.

Remove the drain plug and drain the oil the opening.
Drain the oil from the suction port and the discharge port of the compressor.
Measure the amount of oil drained. Discard the used oil.

Notice : Add oil to the compressor. Use the exact amount of oil that was drained from the compressor.

Installation Notice

Tightening Torque

20 N•m (15 lb-ft)

Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

RECEIVER-DRIER

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove two bolts and one nut of right side head lamp.
Remove head lamp.

Remove two nuts on the flange of high pressure pipes from the top of the receiver-drier

Installation Notice

Tightening Torque

14 N•m (10 lb-ft)

Remove O-ring and discard it
Loosen the bolt securing the receiver-dryer band clamp.
Remove the receiver-drier.
Cap the open connections to prevent contamination.
Drain the oil from the receiver-dryer into a container. Measure the amount of oil drained from the receiver/dryer. Discard this used oil.

Notice : Add oil to the compressor. Use the exact amount of oil that was drained from the receiver-drier.

Installation should follow the removal procedure in the reverse order.

Important : Do not uncap the new unit until just prior to installation.

Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

EVAPORATOR CORE

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove the heater/air distributor case assembly. Refer to Section 7A, Heating and Ventilation System.
Remove wiring on the heater module.
Disconnect connectors for blower motor, blower resister or power transistor, air mix door motor, and mode control motor.
Remove five screws and two clips and separate heater module from evaporator/blower module.
Remove A/C filter.

Remove 11 screws and two clips that fastening upper and lower case.
Separate upper and lower case and remove evaporator with expansion valve.
Remove expansion valve.

Notice : Be careful not to damage the sealing material. If damaged change with new equivalent material.

Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

A/C EXPANSION VALVE

Removal and Installation Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedure for A/C System" in this section.
Remove two nuts on the evaporator flange.

Installation Notice

Tightening Torque

14 N•m (10 lb-ft)

Remove two stud bolts and expansion valve.
Remove O-rings and discard them.

Installation Notice

Tightening Torque

14 N•m (10 lb-ft)

Installation should follow the removal procedure in the reverse order.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuation, and Charging Procedures for A/C System" in this section.

UNIT REPAIR

V5 AIR CONDITIONING COMPRESSOR OVERHAUL

CLUTCH PLATE AND HUB ASSEMBLY

Tools Required

J-33013-B Hub and Drive Plate Remover and Installer

J-33027 Clutch Hub Holding Tool

J-34992 Compressor Holding Fixture

Disassembly and Assembly Procedure

Remove the compressor. Refer to "Compressor" in this section.
Install the compressor holding fixture J-34992 to the compressor and hold the compressor holding fixture using a bench vise.
Use the clutch hub holding tool J-33027 to keep the clutch drive plate and the hub assembly from turning.
Remove the shaft nut.

Remove snap ring.
Thread the hub and drive plate remover and installer J-33013-B into the hub. Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch drive plate and the hub assembly.

Remove the clutch hub key. Retain the key for assembly.

Assembly Procedure

Install the clutch hub key into the hub keyway. Allow the key to project approximately 3.2 mm (1/8 inch) out of the keyway. The hub key is curved slightly to provide an interference fit in the hub key groove.
Be sure the frictional surface of the clutch plate and the pulley rotor are clean before installing the clutch drive plate and the hub assembly.

Notice : Do not drive or pound on the clutch hub or the shaft. Internal damage to the compressor may result.

Align the clutch hub key with the shaft keyway. Place the clutch drive plate and the hub assembly onto the compressor shaft.

Remove the hub and drive plate remover and installer J-33013-B center bolt and reverse the body direction on the center bolt. The body of the hub and drive plate remove and installer J-33013-B should be backed off sufficiently to allow the center bolt to be threaded onto the end of the compressor shaft.

Important : If the center bolt is threaded fully onto the end of the compressor shaft, or if the body of the hub and drive plate remover and installer J-33013-B is held and the center bolt is rotated, the key will wedge and could break the clutch drive plate and the hub assembly.

Install the hub and drive plate remover and installer J-33013-B and the bearing onto the clutch drive plate. Thread the center bolt onto the compressor shaft.
Hold the center bolt with a wrench. Tighten the hex portion of the hub and drive plate remover and installer J-33013-B body to press the hub onto the shaft. Tighten the body several turns.
Remove the hub and drive plate remover and installer J-33013-B and check to see that the clutch hub key is still in place in the key way before installing the clutch drive plate and the hub assembly to its final position. The air gap between frictional surfaces of the clutch drive plate and the clutch pulley rotor should be 0.38 to 0.64 mm (0.015 to 0.025 inch).

Remove the hub and drive plate remover and installer J-33013-B. Check for proper positioning of the clutch hub key. It should be even or slightly above the clutch hub.
Install the shaft nut.

Tightening Torque

17 N•m (13 lb-ft)

Spin the pulley rotor by hand to verify that the pulley is not rubbing the clutch drive plate.
Remove the compressor from the bench vise and remove the J-34992 compressor holding fixture on the compressor.
Install the compressor. Refer to "Compressor" in this section.

CLUTCH ROTOR AND BEARING

Tools Required

J-9398-A Bearing Remover

J-9481 Bearing Installer

J-33020 Pulley Puller

J-33023-A Puller Pilot

J-33019 Bearing Staking Tool Set

Includes: J-33019-1 Bearing Staking Guide

Includes: J-33019-2 Bearing Staking Pin

J-33017 Pulley Rotor and Bearing Assembly Installer

J-8433-1 Puller Crossbar

J-34992 Compressor Holding Fixture

J-8092 Driver Handle

J-8433-3 Forcing Screw

Disassembly Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging for A/C System" in this section.
Remove the compressor. Refer to "Compressor" in this section.
Remove the clutch drive plate and the hub assembly. Refer to "Clutch Plate and Hub Assembly" in this section.
Remove the pulley rotor and the bearing assembly retaining ring using the snap ring pliers.

Install the pulley puller J-33020 into the inner circle of slots in the pulley rotor. Turn the pulley puller J-33020 clockwise in the slots to engage the puller tangs with the segments between the slots in the rotor.
Hold the pulley puller J-33020 in place and tighten the puller bolt against the compressor shaft to remove the pulley rotor and the bearing assembly.

Notice : The rotor hub must be properly supported to prevent damage to the pulley rotor during bearing removal.

Remove the puller bolt from the pulley puller J-33020. With the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks.

Notice : It is not necessary to remove the staking in front of the bearing to remove the bearing. It will be necessary to file away the old stake metal for proper clearance for the new bearing to be installed into the rotor bore or the bearing may be damaged.

Drive the bearing out of the rotor hub with the bearing remover J-9398-A and the driver handle J-8092.

Assembly Procedure

Notice : Do not support the rotor by resting the pulley rim on a flat surface during the bearing installation or the rotor face could be damaged.

Invert the pulley rotor and place it on a support block to fully support the rotor hub during bearing installation.
Align the new bearing squarely in the pulley bore. Use the bearing installer J-9481 and the driver handle J-8092, drive the bearing fully into the pulley bore.

Place the bearing staking guide J-33019-1 and the bearing staking pin J-33019-2 in the rotor hub core. Shift the rotor and bearing assembly on the block to give full support to the hub under the staking pin location. A heavy-duty rubber band may be used to hold the staking tool pin in the guide. The pin should be properly positioned in the guide after each impact on the pin.

Caution : When striking the pin with a hammer, take care to avoid personal injury.

Strike the pin with a hammer until a metal stake, similar to the original, is formed down to, but not touching, the bearing. The metal stake should not contact the outer race of the bearing to avoid the possibility of distorting the outer race. Stake in three places, each 120 degrees apart.

With the compressor mounted to the holding fixture J-34992, position the rotor and the bearing assembly on the compressor housing.
Position the pulley rotor and bearing assembly installer J-33017 and the puller pilot J-33023-A directly over the inner race of the bearing.
Position the puller crossbar J-8433-1 center forcing bolt on the puller pilot J-33023-A and assemble the two through-bolts and the washers through the puller crossbar J-8433-1 slots. Thread them into the holding fixture. The thread of the through-bolts should engage the full thickness of the fixture.
Tighten the center forcing screw J-8433-3 in the puller crossbar J-8433-1 to force the pulley rotor and the bearing assembly onto the compressor housing.
Install the rotor and the bearing assembly retainer ring using the snap ring pliers.
Reinstall the clutch drive plate and hub assembly. Refer to "Clutch Drive Plate and Hub Assembly" in this section.
Install the compressor. Refer to "Compressor" in this section.
Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

CLUTCH COIL

Tools Required

J-8433-1 Puller Crossbar

J-8433-3 Forcing Screw

J-33023-A Puller Pilot

J-33024 Clutch Coil Installer Adapter

J-33025 Clutch Coil Puller Legs

J-34992 Compressor Holding Fixture

Disassembly Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the compressor. Refer to "Compressor" in this section.
Remove the clutch plate and hub assembly. Refer to "Clutch Plate and Hub Assembly" in this section.
Remove the clutch rotor and bearing. Refer to "Clutch Rotor and Bearing" in this section.
Mark the clutch coil terminal location on the compressor housing.
Install the puller pilot J-33023-A on the compressor housing. Also install the puller crossbar J-8433-1 with the clutch coil puller legs J-33025.
Tighten the forcing screw J-8433-3 against the puller pilot J-33023-A to remove the clutch coil.

Assembly Procedure

Place the clutch coil assembly on the compressor housing with the terminals positioned at the "marked" location.
Place the clutch coil installer adapter J-33024 over the internal opening of the clutch coil housing and align the clutch coil installer adapter J-33024 with the compressor housing.

Center the puller crossbar J-8433-1 in the countersunk center hole of the clutch coil installer adapter J-33024. Install the compressor holding fixture J-34992, the through-bolts, and the washers through the crossbar slots. Thread the through-bolts into the holding fixture to the full thickness of the holding fixture.

Important : Be sure the clutch coil and the installer stay ''in-line'' during installation.

Turn the forcing screw J-8433-3, or use a suitable vise, to force the clutch coil onto the compressor housing.

When the clutch coil is fully seated on the compressor housing, use a 3 mm (1/8 inch) diameter drift punch and stake the housing at three places, each 120 degrees apart, to ensure that the clutch coil will remain in position. Stake point size should be only one-half the area of the punch tip and approximately 0.28 to 0.35 mm (0.010 to 0.015 inch) deep.
Install the clutch rotor and bearing assembly. Refer to "Clutch Rotor and Bearing" in this section.
Install the clutch plate and hub assembly. Refer to "Clutch Plate and Hub Assembly" in this section.
Install the compressor. Refer to "Compressor" in this section.
Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

SHAFT SEAL REPLACEMENT

Tools Required

J-9553-1 O-Ring Remover

J-23128-A Seal Seat Remover and Installer

J-33011 O-Ring Installer

J-34614 Shaft Seal Protector

Important : A shaft seal should not be replaced because a small amount of oil is found on the adjacent surface. The seal is designed to leak some oil for lubrication purposes. A shaft seal should only be changed when a large amount of sprayed oil is found. Then, only after actual refrigerant leakage is found by using an approved leak detection procedure. Refer to "Leak Testing the Refrigerant System" in this section. Should a compressor shaft seal ever have to be replaced, the receiver-dryer in this system must also be removed from the vehicle. The oil in the receiver-dryer must then be drained, measured and replaced. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

Disassembly Procedure

Disconnect the negative battery cable.
Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Loosen and reposition the compressor in the mounting brackets.
Remove the clutch drive plate and hub assembly from the compressor. Refer to "Clutch Plate and Hub Assembly" in this section.
Use the snap ring pliers J-5403 to remove the shaft seal retaining ring.

Notice : Any dirt or foreign material that enters the compressor may cause damage.

Thoroughly clean the inside of the compressor housing area surrounding the shaft, the exposed portion of the seal, the shaft itself and the O-ring groove.
Fully engage the knurled tangs of the seal seat remover and installer J-23128-A into the recessed portion of the seal by turning the handle clockwise. Remove and discard the seal from the compressor with a rotating-pulling motion. The handle should be hand-tightened securely. Do not use a wrench or pliers to tighten the handle.

Remove and discard the O-ring from the compressor neck using the O-ring remover J-9553-1.
Thoroughly clean the seal O-ring groove in the compressor housing.
Inspect the shaft and the inside of the compressor housing neck for dirt or foreign material. These parts must be perfectly clean before installing any new parts.

Assembly Procedure

Important : Seals must not be reused. Always use a new specification service seal kit. Be sure that the seal to be installed is not scratched or damaged in any way. The seal must be free of lint and dirt that may damage the seal surface or prevent proper sealing.

Dip the new seal O-ring in clean polyalkalene glycol (PAG) refrigerant oil and assemble the O-ring onto the O-ring installer J-33011.
Insert the O-ring installer J-33011 into the compressor neck until the installer "bottoms." Lower the moveable slide of the O-ring installer J-33011 to release the O-ring into the seal O-ring lower groove.

(The top groove of the compressor neck is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring and then remove the installer.

Attach the shaft lip seal to the seal seat remover and installer J-23128-A. Dip the seal in clean PAG oil.
Install the shaft seal protector J-34614 in the seal. Place it over the shaft and push the seal into place with a rotary motion.

Use the snap ring pliers J-5403 to install the shaft seal retaining ring with its flat side against the seal.
Remove any excess oil around the shaft and the inside of the compressor housing neck.
Install the clutch plate and hub assembly. Refer to "Clutch Plate and Hub Assembly" in this section.
Reposition the compressor in its mounting.
Adjust the tension on the drive belt.
Connect the negative battery cable.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating and Charging Procedures for A/C System" in this section.
Perform a leak test of the system. Refer to "Leak Testing the Refrigerant System" in this section.

PRESSURE RELIEF VALVE

Disassembly Procedure

Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Raise the vehicle.
Remove the pressure relief valve.
Clean the valve seat area.

Assembly Procedure

Lubricate the O-ring of the new pressure relief valve with new polyalkalene glycol (PAG) oil.
Install the new valve.

Installation Notice

Tightening Torque

17 N•m (12 lb-ft)

Lower the vehicle.
Evacuate and recharge the system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

CONTROL VALVE ASSEMBLY

Tools Required

Disassembly Procedure

Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.
Remove the control valve retaining ring using the snap ring pliers.
Remove the control valve assembly.

Assembly Procedure

Coat all the O-rings with clean polyalkalene glycol (PAG) oil.
Push the control valve in place using thumb pressure.
Use the snap ring pliers J-5403 to install the valve retaining ring. The high point of the curved sides must be against the valve housing. Be sure the retaining ring is properly seated in the ring groove.
Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

SPECIFICATIONS

COOLING CAPACITY

Application	Description
Type	Air mix type
Max. Capacity	4,500 kcal/h (17857 Btu/h)
Max. Blowing Capacity	7.0m2/min
Refrigerant	R-134a
Refrigerant capacity	700 +/- 20 g (RHD: 770 +/- 20 g)

COMPRESSOR

Application	Description
Model	V5
Type	Wobble Plate Variable Displacement
Displacement	9.8 - 151 cc (0.6 - 9.21 cu in)/rev
Capacity (at 2000 R.P.M)	7415 W(25300 BTU/hr)
Oil	220ml (Synthetic Oil)
High Pressure Relief Valve	3171 - 4137 kPa (460 - 600 psi)
Control Valve	290 +/- 7 kPa (42 +/- 1 psi)

CONDENSER

Application	Description
Type	Parallel type(Multi Flow Condenser)
Capacity	11400 kcal/h (45239 Btu/h)
Size	607.6 x 369.2 x 20

RECEIVER-DRIER

Application	Description
Desiccant	XH-9 or equivalent (30g)
Type	Aluminum type
Capacity	250 cc (15.3 cu in)

A/C PRESSURE SENSOR

Application	Description
High(Gauge Pressure)	ON: 2115 kPa (307 psi) OFF: 2936 kPa (426 psi)
Low(Gauge Pressure)	ON: 230 kPa (33 psi) OFF: 192 kPa (28 psi)

EVAPORATOR

Application	Description
Type	Tank laminated
Size	263.0 x 197.6 x 88.9
Capacity	6300 kcal/h (25000Btu/h)

HEATER UNIT

Application	Description
Heating Capacity	8250 kcal/h (32739 Btu/h)
Heater Core Size	200.4 x 168.2 x 25.0

FASTENER TIGHTENING SPECIFICATIONS

Application	N•m	Lb-Ft	Lb-In
A/C Pressure Sensor	7	-	62
Receiver-Drier Flange Nut	16	12	-
Expansion Valve-to-High Pressure Pipe Nut	14	10	-
Suction/Discharge Hose-to-Compressor Nut	33	24	-
Suction Hose-to-Expansin Valve Nut	14	10	-
Suction Hose retaining Clamp Nut	4	-	35
Air Cleaner Snorkel Bolt	8	-	71
Discharge Hose-to-Condenser Nut	16	12	-
Condenser-to-Receiver-Drier Nut	14	10	-
Condenser Retaining Nut	4	-	35
Compressor Front Mounting Bolt	38	28	-
Compressor Rear Mounting Bolt	22	16	-
Compressor Drain Plug	20	15	-
Expansion Valve Stud Bolts	14	10	-

SCHEMATIC AND ROUTING DIAGRAMS

A/C SYSTEM - TYPICAL

Condenser
Expansion Valve
Evaporator
Receiver-Dryer
Compressor

AIRFLOW - TYPICAL

Mode Door
Heater Core
Fresh Air/Recalculation Air Door
Inside Air Inlet
Outside Air Inlet
Blower
Evaporator (A/C Only)
Heater (Air Mix) Door
Foot Outlets
Vent Outlets
Defroster Outlets

Manual Control A/C Diagram (1/4)

SPECIAL TOOLS

SPECIAL TOOLS TABLE

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