AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–1 AIR CONDITIONING SYSTEM PRECAUTION 1. NOTICE FOR INITIALIZATION When disconnecting the cable from the negative (-) battery terminal, initialize the following system(s) after the cable is reconnected. System name See procedure Power Window Control System See page WS-1 2. 3. 4. 5. NOTICES FOR HYBRID SYSTEM ACTIVATION • When the warning light is illuminated or the battery has been disconnected and reconnected, pressing the power switch may not start the system on the first try. If so, press the power switch again. • With the power switch's power mode changed to ON (IG), disconnect the battery. If the key is not in the key slot during reconnection, DTC B2799 may be output. BECAUSE COMPRESSOR HAS HIGH-VOLTAGE CIRCUIT, WEAR INSULATED GLOVES AND PULL OUT SERVICE PLUG TO CUT HIGH-VOLTAGE CIRCUIT BEFORE INSPECTION DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION AC02810E06 6. AC02811E01 7. 8. BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: (a) Wash the area with lots of cold water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a hospital or see a physician for professional treatment. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME BE CAREFUL NOT TO DROP CONTAINER OR APPLY PHYSICAL SHOCKS TO IT AC AC–2 AIR CONDITIONING – AIR CONDITIONING SYSTEM Wrong Okay LO LO HI 9. HI N011084E02 AC DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system, oil lubrication will be insufficient and compressor burnout may occur. Necessary care should be taken to avoid this. 10. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING Open and close only the low pressure valve. If the high pressure valves are opened, refrigerant flows in the reverse direction causing the charging cylinder to rupture. 11. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating, etc. 12. PRECAUTIONS TO BE OBSERVED WHILE SERVICING NOTICE: • For the electric inverter compressor, use the NDOIL 11. • Electrical insulation performance may decrease significantly if even a small amount of oil other than ND-OIL 11 is used or enters the refrigeration cycle, causing a DTC to be output. • Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than ND-OIL 11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing a DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug clip before inspection, as some of the procedures require disconnecting the high-voltage connectors. AC–3 AIR CONDITIONING – AIR CONDITIONING SYSTEM PARTS LOCATION ENGINE ROOM NO. 2 RELAY BLOCK - PS HTR RELAY* INTEGRATION - PTC HTR1 RELAY* RELAY (UNIT C) - PTC HTR2 RELAY* PRESSURE SWITCH FUSIBLE LINK BLOCK ASSEMBLY (UNIT A) - HTR H-FUSE HEATER WATER PUMP ASSEMBLY AMBIENT TEMPERATURE SENSOR ENGINE ROOM JUNCTION BLOCK - INTEGRATION RELAY - FUSIBLE LINK BLOCK ASSEMBLY (HTR H-FUSE) - PS HTR H-FUSE* - PTC HTR1 FUSE* - PTC HTR2 FUSE* ELECTRIC INVERTER COMPRESSOR (w/ MOTOR COMPRESSOR ASSEMBLY) AIR CONDITIONING INVERTER (INVERTER WITH CONVERTER ASSEMBLY) *: Cold Area Models E118676E01 AC AC–4 AIR CONDITIONING – AIR CONDITIONING SYSTEM STEERING PAD SWITCH LH SPIRAL CABLE STEERING PAD SWITCH RH COMBINATION METER MULTI-DISPLAY GATEWAY ECU SOLAR SENSOR HYBRID CONTROL ECU ECM DLC3 DRIVER SIDE JUNCTION BLOCK - MAIN BODY ECU - HTR RELAY - A/C (HTR) FUSE - GAUGE FUSE - ECU-B FUSE AIR CONDITIONING AMPLIFIER (AIR CONDITIONING CONTROL ASSEMBLY) ROOM TEMPERATURE SENSOR (Built in ROOM HUMIDITY SENSOR) E118677E01 AC AC–5 AIR CONDITIONING – AIR CONDITIONING SYSTEM NO. 1 COOLER EVAPORATOR COOLER EXPANSION VALVE AIR INLET CONTROL SERVO MOTOR BLOWER ASSEMBLY EVAPORATOR TEMPERATURE SENSOR AIR OUTLET CONTROL SERVO MOTOR PTC HEATER* AIR MIX CONTROL SERVO MOTOR BLOWER WITH FAN MOTOR SUB-ASSEMBLY AIR CONDITIONING RADIATOR ASSEMBLY HEATER RADIATOR UNIT ASSEMBLY *: Cold Area Models E118678E02 AC AC–6 AIR CONDITIONING – AIR CONDITIONING SYSTEM SYSTEM DIAGRAM Air Conditioning Amplifier Gateway ECU Combination Meter ECU Main Body ECU Multi-display Hybrid Control ECU ECM : BEAN : AVC-LAN : CAN E125227E02 AC AC–7 AIR CONDITIONING – AIR CONDITIONING SYSTEM Transmitter Receiver Line Signal Air Conditioning Amplifier Combination Meter ECU BEAN Ambient temperature A/C AUTO indicator display signal Room temperature indicator display signal Fr. DEF indicator display signal Rr. DEF indicator display signal Multi-display AVC-LAN Ambient temperature AUTO, FRS, REC, Fr.DEF, Rr.DEF, A/C, FACE, B/L, FOOT, F/D display signal Buzzer sounding signal A/C indicator screen display signal A/C diagnosis status signal Blower airflow volume display signal A/C function information signal (rear A/C, A/C type (single, right/ left independent), Rec/Frs control, temperature display, air purifier presence, blower step, destination) Inside multi-display D/P seats temperature display signal Hybrid Control ECU CAN Compressor operation signal A/C status signal Water pump ON / OFF demand signal E/G ON demand signal ECM CAN Water temperature signal E/G speed signal Ambient temperature signal Thermal storage 3-port valve heater side closed signal AC AC–8 AIR CONDITIONING – AIR CONDITIONING SYSTEM Transmitter Receiver Line Signal Combination Meter ECU Air Conditioning Amplifier BEAN Vehicle speed signal BEAN DTC clear signal Body ECU Diagnosis tool demand signal Vehicle specs signal Multi-display AVC-LAN Hybrid Control ECU CAN A/C operation signal A/C control signal Use permissible power signal A/C water pump operation signal Standby condition signal Shift position signal Drive ready indication signal SOC level data signal EV mode state signal A/C motor speed signal A/C input power signal A/C motor current flow order signal A/C inverter temperature signal A/C inverter voltage signal A/C ECU diagnosis signal AC AC–9 AIR CONDITIONING – AIR CONDITIONING SYSTEM Air Mix Servo Motor Fan Relays Air Mix Damper Position Sensor Heater Relay Air Outlet Servo Motor Air Outlet Damper Position Sensor Blower Motor Controller Blower Motor Rear Defogger Relay Rear Defogger Mirror Heater Relay Mirror Heater Air Conditioning Amplifier Air Inlet Servo Motor PTC Relay* PTC Heater* (in Heater Core) PTC Relay* PTC Heater* (in Air Duct) Air Inlet Damper Position Sensor Room Temperature Sensor Room Humidity Sensor *: Cold Area Models E125228E02 AC AC–10 AIR CONDITIONING – AIR CONDITIONING SYSTEM Evaporator Temperature Sensor Combination Meter ECU A/C Indicator Light Gateway ECU Multi-display Solar Sensor Wiper Switch Converter Air Conditioning Amplifier ECM - Engine Coolant Temperature - Ambient Temperature - Engine Speed Battery ECU - Room Temperature and Ambient Temperature Sensor Signal Reception - Blower Motor Mode Reception - Hybrid Battery Cooling System Reception Steering Pad Switch Pressure Switch : BEAN Hybrid Control ECU - Compressor Control Signal Reception - Blower Motor Mode Reception - Water Pump Control Signal Reception A/C Inverter Water Pump Relay Electric Inverter Compressor A/C Water Pump : AVC-LAN : CAN E125229E03 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–11 SYSTEM DESCRIPTION 1. 2. 3. GENERAL The air conditioning system has the following features: • An ES18 type Electric Inverter Compressor is used. This compressor is driven by an alternating current provided by the A/C inverter, which is built into the inverter of the hybrid system. As a result, the air conditioning system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption. • A blower motor controller, which regulates the speed of the blower motor by controlling the output voltage in accordance with the duty cycle signal provided by the air conditioning amplifier, is used. As a result, the power loss associated with the heat generation of the conventional blower linear controller is reduced, thus realizing low fuel consumption. • A humidity sensor function is added to the room temperature sensor in order to optimize the amount of dehumidification effort during the operation of the air conditioning system. • A compact, lightweight and highly efficient RS (Revolutionary Slim) evaporator is used. • A compact, lightweight and highly efficient MF-IV (Multi Flow-IV) condenser is used. • A compact, lightweight, and highly efficient electrical water pump is used in order to ensure the proper heater performance while the engine is stopped. • Fuzzy control is used for calculating the required outlet air temperature (TAO: Temperature Air Outlet) and the blower volume in the automatic air conditioning control system. Accordingly, the air conditioning ECU is able to calculate the outlet air temperature, blower volume, air outlet, and compressor speed that is suited to the operating environment. As a result, the comfort level of the occupants is improved. AIR CONDITIONING OPERATION • The air conditioning is controlled by using the switches that appear on the air conditioning screen display of the multi-display and the switches provided on the steering pad. • In addition to the air conditioning screen display, the operating conditions of the AUTO, RECIRCULATION, front DEF, and rear DEF switches are indicated by the indicator lights in the combination meter. HEATER CORE AND PTC HEATER • A compact, lightweight, and highly efficient straight flow (full-path flow) aluminum heater core is used. A PTC (Positive Temperature Coefficient) heater is built into the heater core tube. AC AC–12 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4. AC • The PTC heater contains electrodes that are interposed with a PTC element, to which current is applied in order to warm the air that passes through the fins. • The PTC heater is provided in the air duct at the footwell outlet in front of the air conditioning unit. This PTC heater, which is a honeycomb-shaped PTC thermistor, directly warms the air that flows in the duct. COMPRESSOR • ES18 Electric Inverter Compressor is actuated by a built-in electric motor. • The electric motor is actuated by the alternating current power (201.6 V) supplied by the A/C inverter, which is integrated in the hybrid system inverter. As a result, the air conditioning control system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption. • The electric inverter compressor controls the compressor speed at the required speed calculated by the air conditioning amplifier. Thus, cooling, dehumidification performance and power consumption are optimized. • The suction and discharge hoses at the compressor are low-moisture permeation hoses. This minimizes the entry of moisture into the refrigeration cycle. • The compressor uses high-voltage alternating current. If a short or open circuit occurs in the compressor wiring harness, the hybrid control ECU will cut off the A/C inverter circuit in order to stop the power supply to the compressor. • The Electric Inverter Compressor consists of a spirally wound fixed scroll and variable scroll that form a pair, a brushless motor, an oil separator, and a motor shaft. • The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the variable scroll to revolve while maintaining the same posture, the volume of the space that is partitioned by both scrolls varies to perform the suction, compression, and the discharge of the refrigerant gas. • Locating the suction port directly above the scrolls enables direct suction, thus realizing improved suction efficiency. • Containing a built-in oil separator, this compressor is able to separate the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle, thus realizing a reduction in the oil circulation rate. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–13 HINT: In order ensure the proper insulation of the internal highvoltage portion of the compressor and the compressor housing, a compressor oil (ND-OIL 11) with a high level of insulation performance is used. Therefore, never use a compressor oil other than the ND-OIL 11 type compressor oil or its equivalent. Variable Scroll Fixed Scroll Oil Separator Motor Shaft Discharge Port Brushless Motor I036336E01 5. to Heater from Engine 6. I036337E01 WATER PUMP • An electrical water pump is used. This provides a stable heater performance even if the engine is stopped because of a function of the THS-ll. • A new type of electrical water pump is used in which the water flow resistance has been reduced. ROOM TEMPERATURE SENSOR AND HUMIDITY SENSOR • A humidity sensor function is used by the room temperature sensor. By enabling the detection of humidity in the vehicle interior, this function optimizes the amount of dehumidification effort during the operation of the air conditioning system. As a result, the power consumption of the compressor has been reduced and a comfortable level of humidity has been realized in the vehicle interior. • The humidity-sensing resistance film that is built into the humidity sensor absorbs and releases the humidity in the vehicle interior. During the absorption and releasing processes, the humidity-sensing resistance film expands (during the absorption of humidity) and contracts (during drying). The clearance between the carbon particles in the humidity-sensing resistance film expands and contracts during absorption and drying, thus changing the resistance between the electrodes. The air conditioning amplifier determines the humidity in the vehicle interior through the changes in the output voltage of the humidity sensor that are caused by the resistance between the electrodes. AC AC–14 AIR CONDITIONING – AIR CONDITIONING SYSTEM 7. Air Conditioning Amplifier Duty Signal BLOWER MOTOR CONTROLLER The blower motor controller controls the voltage that is output to the blower motor in accordance with the duty cycle signals that are input by the air conditioning amplifier. It is characterized by a smaller amount of heat generation than the blower controller used on the previous model. As a result, the power loss associated with the heat generation of the conventional blower linear controller has been reduced, thus realizing low fuel consumption. M+ 13 Blower Motor Controller Output Voltage (V) M- 4 30 90 Duty Ratio (%) I036338E02 8. Control Outline Fuzzy Control The fuzzy control determines the conformity levels of the temperature deviation, ambient temperature, and solar radiation by defining their respective mathematical functions. In addition, a fuzzy calculation method is used to calculate the required outlet air temperature (TAO) and the blower volume. Based on these calculations, the air conditioning amplifier effects the respective controls for the outlet air temperature, blower volume, compressor, and air outlet. Outlet Air Temp. Control AC AIR CONDITIONING AMPLIFIER The air conditioning ECU has the following controls. Air Mix Damper Control In response to the temperature control switch setting, the required outlet air temperature, evaporator temperature sensor, and engine coolant temperature sensor compensations are used by the air mix control damper control to calculate a tentative damper opening angle, through an arithmetic circuit in the air mix damper, to arrive at a target damper opening angle. AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Blower Control Air Outlet Control AC–15 Outline Blower Motor Start Up Control When the blower motor is started up, the air conditioning amplifier transmits a blower motor actuation signal with a low duty cycle ratio to the blower pulse controller, which applies a low voltage to the blower motor, in order to operate the blower motor for 3 seconds at a low speed. This is designed to protect the blower pulse controller from a sudden start-up voltage surge. Manual Control Sets the blower speed according to operation of the blower switch. Automatic Control Step Less Air Volume Control: • When the AUTO switch located on the steering pad switch is pushed, or the air conditioning screen display of the multidisplay is touched, the air conditioning amplifier automatically regulates the duty ratio to the blower pulse controller in accordance with a calculation result by the fuzzy control in order to deliver step less air volume. Warm-up Control: • When the air outlet is in the FOOT, BILEVEL, or FOOT/DEF mode, the blower will not operate until the engine coolant temperature increases above a prescribed value. When the temperature increases above a prescribed value, the blower motor operates at the LO speed. Time-Lagged Air Flow Control: • 2 types of time-lagged air flow control (in accordance with the detected by the evaporator temperature sensor) help prevent hot air from being emitted from FACE or BI-LEVEL vent. Sunlight Air Flow Control: • Controls the blower speed in accordance with the intensity of the sunlight when the air outlet mode is at FACE or BI-LEVEL. The blower speed can be adjusted in response to the signal received from the solar sensor. Manual Control Changes the air outlet in accordance with the selected position of the mode select switch. Automatic Control Mode Damper Switching Servo motor Control: • When the AUTO switch is pushed, automatic control causes the mode servo motor to rotate to a desired position in accordance with the target damper opening, which is based on the calculation of the TAO. Low-Temperature FOOT/DEF Control: • In accordance with the engine coolant temperature, ambient temperature, amount of sunlight, required outlet temperature (TAO), and vehicle speed conditions, this control automatically switches the blower outlet between the FOOT / DEF modes to prevent the window from becoming fogged when the outside air temperature is low. AC AC–16 AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Air Inlet Control Outline Manual Control Drives the air inlet servo motor according to the operation of the air inlet control switch and fixes the dampers in the FRESH or RECIRC position. Automatic Control Automatic RECIRC / FRESH Control: • When the AUTO switch is pressed, the system controls the servo motor so that the air inlet is as calculated in accordance with the TAO. DEF Mode Control: • When switching the mode switching switch to DEF mode, air conditioning amplifier turns MAX mode ON forcibly and switched to FRESH mode. • When switching the mode switching switch to FOOT / DEF mode, air conditioning amplifier switches to FRESH mode. 2-Way Flow Mode Control At the time of selecting FRESH mode, the air conditioning amplifier will judge it as 2-way flow mode when the blower outlet is set to FOOT or FOOT / DEF, the tentative air mix damper opening angle is above the specified value (MAX HOT), and either the blower volume is more than the specified volume or the vehicle speed is less than the specified speed. Half Inlet Air Mode Control At the time of selecting FRESH mode, the air conditioning amplifier will judge it as half inlet air mode when the blower outlet mode is set to FACE or BI-LEVEL and TAO is more than the specified temperature, and operates both outlet air introduction and inlet air circulation at the same time. Electric Inverter Compressor Control Compressor Speed Control • • Electrical Water Pump Control AC The air conditioning amplifier calculates target speed of the compressor based on the target evaporator temperature (which is calculated by the room temperature sensor, humidity sensor, ambient temperature sensor, and the solar sensor) and the actual evaporator temperature that is detected by the evaporator temperature sensor in order to control the compressor speed. The air conditioning amplifier calculates the target evaporator temperature, which includes corrections based on the vehicle interior humidity (which is obtained from the humidity sensor) and the windshield glass inner surface humidity (which is calculated from the humidity sensor, solar sensor, room temperature sensor, mode damper position, and wiper operation condition). Accordingly, the air conditioning amplifier controls the compressor speed to an extent that would not inhibit the proper cooling performance or defogging performance. The electrical water pump is used in order to ensure the proper heater performance while the blower motor is ON and the engine is stopped. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–17 Control Outline Engine Start Request Control To ensure the proper heater performance when the hybrid system is started at low temperatures, the air conditioning amplifier transmits an engine start request to the hybrid control ECU in accordance with the TAO, engine coolant temperature sensor signal, and ambient temperature sensor signal. PTC Heater Control When the hybrid system is operating (READY) and the blower motor is turned ON, the air conditioning amplifier turns on the PTC heater if the conditions listed below are met. Heater core integrated PTC heater • Air outlet is in the FOOT, FOOT / DEF or DEF mode. • Engine coolant temperature is below specified temperature. • Ambient temperature is below specified temperature (DEF mode). • Tentative air mix damper opening angle is above the specified value (MAX HOT). Footwell air duct integrated PTC heater • Air outlet is in the FOOT or FOOT / DEF mode. • Engine coolant temperature is below specified temperature. • Tentative air mix damper opening angle is above the specified value (MAX HOT). Electric Cooling Fan Control The air conditioning amplifier control the cooling fan in accordance with the vehicle speed signal and compressor speed signal. Rear Window Defogger Control Switches the rear defogger and outside rear view mirror heaters on for 15 minutes when the rear defogger switch is switched on. Switches them off if the switch is pressed while they are operating. Outer Temperature Indication Control Based on the signals from the ambient temperature sensor, this control calculates the outside temperature, which is then corrected in the air conditioning ECU, and shown in the multi-display. Self-Diagnosis Checks the sensor and A/C inverter in accordance with operation of the air conditioning switches, then the heater control panel displays a DTC (Diagnosis Trouble Code) to indicate if there is a malfunction or not (sensor check function). Drives the actuators through a predetermined sequence in accordance with the operation of the air conditioning switches (actuator check function). AC AC–18 AIR CONDITIONING – AIR CONDITIONING SYSTEM 9. AC ELECTRIC INVERTER COMPRESSOR CONTROL • The air conditioning amplifier calculates the target compressor speed based on the target evaporator temperature (calculated from the room temperature sensor, humidity sensor, ambient temperature sensor, and solar sensor) and the actual evaporator temperature detected by the evaporator temperature sensor. Then, the air conditioning amplifier transmits the target speed to the hybrid control ECU. The hybrid control ECU controls the A/C inverter based on the target speed data in order to control the compressor to a speed that suits the operating condition of the air conditioning system. AC–19 AIR CONDITIONING – AIR CONDITIONING SYSTEM • The air conditioning amplifier calculates the target evaporator temperature, which includes corrections based on the vehicle interior humidity (which is obtained from the humidity sensor) and the windshield glass inner surface humidity (which is calculated from the humidity sensor, solar sensor, room temperature sensor, mode damper position, and wiper operation condition). Accordingly, the air conditioning amplifier controls the compressor speed to an extent that does not inhibit the proper cooling performance or defogging performance. As a result, comfort and low fuel consumption can be realized. Electric Inverter Compressor Room Temp. Sensor Air Conditioning Amplifier Room Humidity Sensor Automatic Light Control Sensor A/C Inverter Calculates target compressor speed in accordance with various input conditions. Inverter Control Target Compressor Speed Evaporator Temp. Sensor Hybrid Control ECU Ambient Temp. Air Outlet Damper Position Sensor Wiper Switch Wiper Motor Ambient Temp. Sensor E109275E03 AC AC–20 AIR CONDITIONING – AIR CONDITIONING SYSTEM 10. MODEL POSITION AND DAMPER OPERATION Side Defroster Fresh Air 2 Center Defroster 12 11 13 Recirc. Air 14 5 1 20 21 19 6 Clean Air Filter 3 4 7 Side Defroster 8 9 10 Front Footwell Register Duct 18 151617 23 22 Rear Footwell Register Duct Center Register Side Register Blower Motor Evaporator Heater Core Side Register E125225E01 A E B F G H C K I J D L E125226E01 Function of main damper Control Damper Control Position Damper Position Indicator OFF 1, 3 Brings in fresh air. 2, 4 Brings in fresh air while circulating internal air. 2, 4 Recirculates internal air. C or I AC Air Inlet Control Damper Operation Indicator ON C or I AC–21 AIR CONDITIONING – AIR CONDITIONING SYSTEM Control Damper Air Mix Control Damper A, B or K, L Control Position Damper Position Operation - 5, 8 to 6, 9 to 7, 10 Varies mixture ratio of fresh air and recirculation air in order to regulate temperature continuously from HOT to COOL. 14, 15, 21, 22 (14, 16, 21, 22)*2 Air blows out of center registers and side registers. 14, 17, 20, 22 Air mainly blows out of center registers, side registers, and footwell register ducts. 13, 18, 19, 22 (12, 17, 19, 23)*1 Air mainly blows out of front and rear footwell register ducts. In addition, air blows out slightly from front and side defrosters, and side registers. 12, 17, 19, 22 (11, 15, 19, 23)*1 Air mainly blows out of front and side defrosters to defrost windshield. Air also blows out from front and rear footwell register ducts, and side registers. 12, 17, 19, 22 Air blows out of front and side defrosters and side registers to defrost windshield. FACE E BI-LEVEL F FOOT Mode Control Damper G FOOT/DEF H DEF D or J HINT: *1: During 2-way flow control *2: Early stage of COOL during AUTO AC AC–22 AIR CONDITIONING – AIR CONDITIONING SYSTEM 11. AIR OUTLETS AND AIR VOLUME RATIOS D D B A A D B C C C C E125224E01 Air Outlet Position Symbol Air Outlet Mode FACE BI-LEVEL FOOT AC FOOT/DEF A B C D Center Face Side Face Foot Defroster AC–23 AIR CONDITIONING – AIR CONDITIONING SYSTEM Air Outlet Position Symbol Air Outlet Mode A B C D Center Face Side Face Foot Defroster DEF HINT: 1. The circle size ({) indicates the proportion of the airflow volume. 2. The (-) indicates that the air is not blown out. 3. The (*) indicates the early stage of COOL during AUTO. AC AC–24 AIR CONDITIONING – AIR CONDITIONING SYSTEM HOW TO PROCEED WITH TROUBLESHOOTING HINT: • Use these procedures to troubleshoot the air conditioning system. • *: Use the intelligent tester. 1 VEHICLE BROUGHT TO WORKSHOP NEXT 2 CUSTOMER PROBLEM ANALYSIS (a) Confirm the problem symptoms. NEXT 3 CHECK AND CLEAR DTCS* NEXT 4 PROBLEM SYMPTOM CONFIRMATION Result Result Proceed to Symptom does not occur A Symptom occurs B B GO TO STEP 6 A 5 SYMPTOM SIMULATION NEXT 6 CHECK MULTIPLEX COMMUNICATION SYSTEM* (a) Check for the DTC outputs. Result AC Result Proceed to No multiplex DTC A Multiplex DTC output B B GO TO MULTIPLEX COMMUNICATION SYSTEM AIR CONDITIONING – AIR CONDITIONING SYSTEM 7 AC–25 CHECK CAN COMMUNICATION SYSTEM* Result Result Proceed to No CAN DTC A CAN DTC output B B GO TO CAN COMMUNICATION SYSTEM A 8 DTC CHECK (OTHER THAN MULTIPLEX DTC)* Result Result Proceed to Malfunction code A Normal code B B GO TO STEP 10 A 9 DTC CHART NEXT 10 PROBLEM SYMPTOMS TABLE NEXT 11 TERMINALS OF ECU NEXT 12 CIRCUIT INSPECTION NEXT 13 IDENTIFICATION OF PROBLEM NEXT AC AC–26 14 AIR CONDITIONING – AIR CONDITIONING SYSTEM REPAIR OR REPLACE NEXT 15 NEXT END AC CONFIRMATION TEST AC–27 AIR CONDITIONING – AIR CONDITIONING SYSTEM CUSTOMIZE PARAMETERS HINT: The following items can be customized. NOTICE: • When the customer requests a change in a function, first make sure that the function can be customized. • Be sure to make a note of the current settings before customizing. • When troubleshooting a function, first make sure that the function is set to the default setting. Air conditioning amplifier Display (Item) Default Contents Setting SET TEMP SHIFT (Set Temperature Shift) NORMAL To control with the shifted temperature against the display temperature. +2C / +1C / NORMAL / -1C / -2C AIR INLET MODE (Air Inlet Mode) AUTO In case of turning the A/C ON when you desire to make the compartment cool down quickly, this is the function to change the mode automatically to RECIRCULATED mode. MANUAL / AUTO COMPRESSOR MODE (Compressor Mode) AUTO Function to turn the A/C ON automatically by pressing the AUTO button when the blower is ON and the A/C is OFF. MANUAL / AUTO COMPRS/DEF OPER (Compressor/Air inlet DEF operation) LINK Function to turn the A/C ON automatically linking with the FRONT DEF button when the A/C is OFF. NORMAL / LINK FOOT/DEF MODE (Foot/DEF auto mode) ON Function to turn the air flow from FOOT/DEF to ON automatically when AUTO MODE is ON. OFF / ON AUTO BLOW UP (Foot/DEF automatic blow up function) ON Function to switch the blower level automatically when the defroster is ON. OFF / ON FOOT AIR LEAK (Foot air leak) ON Function to cut off the airstream felt underfoot while the vehicle is moving. OFF / ON AMBINT TMP SFT (Ambient Temperature Shift) NORMAL To control with the shifted ambient temperature against the display ambient temperature. +3C / +2C / +1C / NORMAL / -1C / -2C / -3C AC AC–28 AIR CONDITIONING – AIR CONDITIONING SYSTEM PROBLEM SYMPTOMS TABLE HINT: • Use the table below to help determine the cause of the problem symptom. The potential causes of the symptoms are listed in order of probability in the "Suspected area" column of the table. Check each symptom by checking the suspected areas in the order they are listed. Replace parts as necessary. • Inspect the fuses and relays related to this system before inspecting the suspected areas below. Air conditioning system Symptom Entire A/C system does not operate Air Flow Control: No blower operation Air Flow Control: No blower control Air Flow Control: Insufficient air output Temperature Control: No cool air comes out Temperature Control: No warm air comes out Temperature Control: Output air is warmer or cooler than set temperature or response is slow AC Suspected area 1. IG power source circuit See page AC-132 2. Air conditioning amplifier AC-28 1. Blower motor circuit AC-110 2. Air conditioning amplifier AC-28 1. Blower motor circuit AC-110 2. Air conditioning amplifier AC-28 1. Blower motor circuit AC-110 2. Air conditioning amplifier AC-28 1. Volume of refrigerant AC-136 2. Refrigerant pressure AC-136 3. Pressure switch circuit AC-59 4. Air mix damper control servo motor circuit AC-77 5. Air mix damper position sensor circuit AC-63 6. Room temperature sensor circuit AC-42 7. Room humidity sensor circuit AC-89 8. Ambient temperature sensor circuit AC-46 9. A/C inverter circuit AC-93 10. Air conditioning amplifier AC-28 11. Multiplex communication circuit MP-1 1. Air mix damper control servo motor circuit AC-77 2. Air mix damper position sensor circuit AC-63 3. Ambient temperature sensor circuit AC-42 4. Room temperature sensor circuit AC-42 5. Room humidity sensor circuit AC-89 6. Evaporator temperature sensor circuit AC-51 7. Air conditioning amplifier AC-28 8. Multiplex communication circuit MP-1 9. Heater radiator - 1. Steering pad switch circuit AC-125 2. Room temperature sensor circuit AC-42 3. Room humidity sensor circuit AC-89 4. Ambient temperature sensor circuit AC-46 5. Solar sensor circuit AC-55 6. Air mix damper control servo motor circuit AC-77 7. Air mix damper position sensor circuit AC-63 8. Air conditioning amplifier AC-28 9. Multiplex communication circuit MP-1 AC–29 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symptom Temperature Control: No temperature control (only Max. cool or Max. warm) No air inlet control No air outlet control Engine idle up does not occur, or is continuous Displayed set temperature value does not match with operation of temperature control switch Suspected area See page 1. Steering wheel pad switch circuit AC-125 2. Air mix damper control servo motor circuit AC-77 3. Air mix damper position sensor circuit AC-63 4. Air conditioning amplifier AC-28 1. Air inlet damper control servo motor circuit AC-81 2. Air inlet damper position sensor circuit AC-67 3. Air conditioning amplifier AC-28 1. Air outlet damper control servo motor circuit AC-85 2. Air outlet damper position sensor circuit AC-72 3. Air conditioning amplifier AC-28 1. A/C inverter circuit AC-93 2. Air conditioning amplifier AC-28 3. Multiplex communication circuit MP-1 1. Air conditioning amplifier AC-28 Brightness does not change when rheostat volume or light control switch is adjusted 1. Illumination light system LI-1 2. Air conditioning amplifier AC-28 Unable to access the diagnosis mode 1. Air conditioning amplifier AC-28 DTC not recorded. Set mode is cleared when power switch is turned OFF. 1. Back-up power source circuit AC-134 2. Air conditioning amplifier AC-28 1. Steering pad switch circuit AC-125 2. Air conditioning amplifier AC-28 1. Multiplex communication circuit MP-1 2. Multi-display - 3. Air conditioning amplifier AC-28 Unable to control A/C with the steering pad switch Unable to control A/C with the multi-display The heater performance is low (PTC heater does not function)* 1. PTC heater circuit AC-121 2. Heater water pump circuit AC-118 3. Air conditioning amplifier AC-28 4. Multiplex communication circuit MP-1 HINT: *: The PTC heater operation may be stopped when an electrical load is large on the entire vehicle. AC AC–30 AIR CONDITIONING – AIR CONDITIONING SYSTEM TERMINALS OF ECU A8 A7 I036314E07 1. AC CHECK AIR CONDITIONING AMPLIFIER (a) Measure the voltage and resistance of the connectors. HINT: Check from the rear of the connector while it is connected to the air conditioning amplifier. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition AIR (A8-22) - GND (A8-1) G - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: FRESH Below 1 V AIR (A8-22) - GND (A8-1) G - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: RECIRC 10 to 14 V AIF (A8-23) - GND (A8-1) P - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: RECIRC Below 1 V AIF (A8-23) - GND (A8-1) P - W-B Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: FRESH 10 to 14 V AOF (A8-16) - GND (A8-1) B - W-B Mode switch signal Power switch ON (IG) Mode switch: DEF Below 1 V AOF (A8-16) - GND (A8-1) B - W-B Mode switch signal Power switch ON (IG) Mode switch: FACE 10 to 14 V AOD (A8-24) - GND (A81) Y - W-B Mode switch signal Power switch ON (IG) Mode switch: FACE Below 1 V AOD (A8-24) - GND (A81) Y - W-B Mode switch signal Power switch ON (IG) Mode switch: DEF 10 to 14 V TPI (A7-19) - SGTPI (A74) V-L Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: RECIRC 4V TPI (A7-19) - SGTPI (A74) V-L Recirculation / Fresh switch signal Power switch ON (IG) Recirculation / Fresh switch: FRESH 1V TPM (A7-18) - SGTPM (A7-23) LG - P Mode switch signal Power switch ON (IG) Mode switch: FACE 4V TPM (A7-18) - SGTPM (A7-23) LG - P Mode switch signal Power switch ON (IG) Mode switch: DEF 1V TP (A7-20) - SGTP (A714) L - LG Temperature switch signal Power switch ON (IG) Temperature switch: Max. COOL 4V TP (A7-20) - SGTP (A714) L - LG Temperature switch signal Power switch ON (IG) Temperature switch: Max. HOT 1V SGTE (A7-5) - Body ground Y - Body ground Ground for evaporator temperature sensor Always Below 1 Ω AC–31 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition TE (A7-7) - SGTE (A7-5) B-Y Evaporator temperature sensor signal Power switch ON (IG) Evaporator temperature: 15°C (59°F) 2 to 2.4 V TE (A7-7) - SGTE (A7-5) B-Y Evaporator temperature sensor signal Power switch ON (IG) Evaporator temperature: 15°C (59°F) 1.4 to 1.8 V S5TPI (A7-3) - SGTPI (A74) B-L Power supply for air inlet damper position sensor Power switch ON (IG) 4.5 to 5.5 V AMC (A8-19) - GND (A81) B - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. HOT Below 1 V AMC (A8-19) - GND (A81) B - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. COOL 10 to 14 V AMH (A8-17) - GND (A81) R - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. COOL Below 1 V AMH (A8-17) - GND (A81) R - W-B Temperature switch Power switch ON (IG) Temperature switch: Max. HOT 10 to 14 V SGTPI (A7-4) - Body ground L - Body ground Ground for air inlet damper position sensor Always Below 1 Ω SGTPM (A7-23) - Body ground P - Body ground Ground for air outlet damper position sensor Always Below 1 Ω SGTP (A7-14) - Body ground LG - Body ground Ground for air mix damper position sensor Always Below 1 Ω S5TPM (A7-11) - SGTPM (A7-23) O-P Power supply for air outlet damper position sensor signal Power switch ON (IG) 4.5 to 5.5 V S5TP (A7-13) - SGTP (A714) P - LG Power supply for air mix damper position sensor signal Power switch ON (IG) 4.5 to 5.5 V IG (A8-5) - GND (A8-1) B - W-B Power switch signal Power switch control OFF 0V IG (A8-5) - GND (A8-1) B - W-B Power switch signal Power switch control ON (ACC) 10 to 14 V +B (A8-6) - GND (A8-1) Y - W-B Back-up power source Always 10 to 14 V MPX+ (A8-3) - GND (A81) B - W-B Terminal for BEAN Engine idling after engine warmed up Pulse generation MPX2+ (A8-11) - GND (A8-1) GR - W-B Terminal for BEAN Engine idling after engine warmed up Pulse generation GND (A8-1) - Body ground W-B - Body ground Ground for main power supply Always Below 1 Ω BLW (A8-2) - GND (A8-1) W - W-B Blower switch signal Power switch ON (IG) Blower switch ON (IG) Pulse generation (see waveform 1) S5TS (A7-12) - TS (A7-21) GR - W-B Solar sensor signal Power switch ON (IG) 0.8 to 4.3 V HR (A8-7) - GND (A8-1) B - W-B Blower switch signal Power switch ON (IG) Blower switch: OFF 10 to 14 V HR (A8-7) - GND (A8-1) B - W-B Blower switch signal Power switch ON (IG) Blower switch: ON Below 1 V TR (A7-8) - SGTR (A7-22) B-W Room temperature sensor signal Power switch ON (IG) Cabin temperature: 25°C (77°F) 1.8 to 2.2 V TR (A7-8) - SGTR (A7-22) B-W Room temperature sensor signal Power switch ON (IG) Cabin temperature: 40°C (104°F) 1.2 to 1.6 V SGTR (A7-22) - Body ground W - Body ground Ground for room temperature sensor Always Below 1 Ω AC AC–32 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: Fr. DEF Below 0.3 V ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: Rr. DEF 0.8 to 1.5 V ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: Recirculation/Fresh 2 to 2.9 V ST1 (A7-2) - SGST (A715) BR - G Steering pad switch signal Power switch ON (IG) Steering pad switch: OFF Above 4.6 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: AUTO Below 0.3 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: TEMP+ 0.8 to 1.5 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: TEMP- 2 to 2.9 V ST2 (A7-1) - SGST (A715) LG - G Steering pad switch signal Power switch ON (IG) Steering pad switch: OFF Above 4.6 V SGST (A7-15) - Body ground G - Body ground Ground for steering pad switch Always Below 1 V PSW (A7-6) - GND (A8-1) R - W-B Pressure switch signal Power switch ON (IG) Refrigerant pressure: Normal Below 1 V PSW (A7-6) - GND (A8-1) R - W-B Pressure switch signal Power switch ON (IG) Refrigerant pressure: More than 1,520 kPa (15.5 kgf/cm 2,220 psi) 10 to 14 V RH (A7-9) - GND (A8-1) R - W-B Humidity sensor signal Power switch ON (IG) Room humidity: 40% 2V RH (A7-9) - GND (A8-1) R - W-B Humidity sensor signal Power switch ON (IG) Room humidity: 60% 2.5 V S5RM (A7-10) - GND (A81) G - W-B Power supply for humidity sensor Power switch ON (IG) 4.5 to 5.5 V PTC (A7-17) - GND (A8-1) P - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: OFF Below 1 V PTC (A7-17) - GND (A8-1) P - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: LO 10 to 14 V HT-1 (A7-26) - GND (A81) BR - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: OFF Below 1 V HT-1 (A7-26) - GND (A81) BR - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: LO 10 to 14 V AC–33 AIR CONDITIONING – AIR CONDITIONING SYSTEM Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition HT-2 (A7-25) - GND (A81) L - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: OFF Below 1 V HT-2 (A7-25) - GND (A81) L - W-B PTC heater signal Power switch ON (IG) Temperature switch: Max. HOT Coolant temperature: Below 55°C (131°F) Blower switch: LO 10 to 14 V IDH (A8-18) - GND (A8-1) V - W-B DC/DC converter signal Power switch ON (IG) (Voltage normal) 10 to 14 V IDH (A8-18) - GND (A8-1) V - W-B DC/DC converter signal Power switch ON (IG) (Over voltage) Below 1 V (b) Using an oscilloscope, measure the waveform 1. Waveform 1 2 V/DIV. Item Content Symbols (Terminal No.) BLW (A8-2) - GND (A8-1) Tool Setting 2 V/DIV., 500 msec./DIV. Condition Power switch ON (IG), Blower switch LO HINT: When the blower level is increased, the duty ratio changes accordingly. GND 500 msec./DIV. I031456E18 AC AC–34 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSIS SYSTEM CG 1. DESCRIPTION (a) Air conditioning system data and the Diagnostic Trouble Codes (DTCs) can be read through the Data Link Connector 3 (DLC3) of the vehicle. When the system seems to be malfunctioning, use the intelligent tester to check for malfunctions and perform troubleshooting. 2. CHECK DLC3 The vehicle's ECM uses the ISO 15765-4 for communication protocol. The terminal arrangement of the DLC3 complies with SAE J1962 and matches the ISO 15765-4 format. SG CANH SIL 1 2 3 4 5 6 7 8 BAT 9 10 1112131415 16 CANL AC E117124E04 Symbols (Terminal No.) Terminal Description Condition Specified Condition SIL (7) - SG (5) Bus "+" line During transmission Pulse generation CG (4) - Body ground Chassis ground Always Below 1Ω SG (5) - Body ground Signal ground Always Below 1Ω BAT (16) - Body ground Battery positive Always 11 to 14 V CANH (6) - CANL (14) HIGH-level CAN bus line Power switch OFF* 54 to 67 Ω CANH (6) - Battery positive HIGH-level CAN bus line Power switch OFF* 1 MΩ or higher CANH (6) - CG (4) HIGH-level CAN bus line Power switch OFF* 3 MΩ or higher CANL (14) - Battery positive LOW-level CAN bus line Power switch OFF* 1 MΩ or higher CANL (14) - CG (4) LOW-level CAN bus line Power switch OFF* 3 MΩ or higher NOTICE: *: Before measuring the resistance, leave the vehicle as is for at least 1 minute and do not operate the power switch, any other switches or the doors. If the result is not as specified, the DLC3 may have a malfunction. Repair or replace the harness and connector. HINT: Connect the cable of the intelligent tester (with CAN VIM) to the DLC3, turn the power switch ON (IG) and attempt to use the tester. If the display indicates that a communication error has occurred, there is a problem either with the vehicle or with the tester. • If communication is normal when the tester is connected to another vehicle, inspect the DLC3 of the original vehicle. • If communication is still not possible when the tester is connected to another vehicle, the problem may be in the tester itself. Consult the Service Department listed in the tester's instruction manual. AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–35 DTC CHECK / CLEAR Intelligent Tester 1. DLC3 2. CAN VIM B127989E05 CHECK DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Read the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. CLEAR DTC (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Clear the DTC by following the prompts on the tester screen. HINT: Refer to the intelligent tester operator's manual for further details. AC AC–36 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK MODE PROCEDURE 1. AC LIST OF OPERATION METHODS By operating each of the A/C control switches as shown in the diagram below, it is possible to enter the diagnostic check mode. AC–37 AIR CONDITIONING – AIR CONDITIONING SYSTEM Turn power switch to the ON (READY) position while pressing AUTO and R/F switches simultaneously. If both AUTO switch and R/F switches are not pressed simultaneously. Indicator Check (continuous operation) TEMP- DTC Check (Sensor Check) (continuous operation) Actuator Check (continuous operation) R/F TEMP- AUTO Fr. DEF Fr. DEF TEMP- DTC Check (Sensor Check) (step operation) R/F R/F AUTO AUTO Actuator Check (step operation) TEMP- Fr. DEF Fr. DEF Cancel check mode and start A/C control. : Indicates steering switch operation R/F: Recirculation / Fresh select switch Fr. DEF: Front defogger switch E125223E01 AC AC–38 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. INDICATOR CHECK (a) Turn the power switch OFF. (b) While pressing both the AUTO and R/F (Recirculation/ Fresh) switches on the steering switch, turn the power switch from OFF to ON (READY). E072827E01 (c) The indicator check is automatically performed when activating panel diagnosis. Check that all indicators and setting displays come on and go off 4 times at 1 second intervals. Check that the buzzer sounds when the indicators come on. HINT: The sensor check is automatically started when the indicator check is completed. (d) Push the "TEMP DOWN (-)" switch to finish panel diagnosis. 2 sec. 1 sec. ON OFF I036311E01 AC AC–39 AIR CONDITIONING – AIR CONDITIONING SYSTEM DATA LIST / ACTIVE TEST 1. READ DATA LIST HINT: Using the intelligent tester's DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Read the DATA LIST by following the prompts on the tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / min.: -6.5°C (20.3°F) max.: 57.25°C (135.05°F) Actual room temperature is displayed Open in the circuit: -6.5°C (20.3°F) Short in the circuit: 57.25°C (135.05°F) AMBI TEMP SENS Ambient temperature sensor / min.: -23.3°C (-9.94°F) max.: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in the circuit: -23.3°C (9.94°F) Short: in the circuit: 65.95°C (150.71°F) EVAP TEMP Evaporator temperature sensor / min.: -29.7°C (-21.46°F) max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in the circuit: -29.7°C (21.46°F) Short in the circuit: 59.55°C (139.19°F) SOLAR SENS-P Solar sensor (Passenger side) / min.: 0 max.: 255 Increases as brightness increases Open in the circuit: 0 Short in the circuit: 255 COOLANT TEMP Engine coolant temperature / min.: 1.3°C (34.34°F) max.: 90.55°C (194.99°F) Actual engine coolant temperature is displayed while the engine is warmed up - SET TEMP-D Set temperature (Driver side) / min.: 0 max.: 255 The same contents as a setting temperature display part are displayed - ESTIMATE TEMP-D Estimated temperature (Driver side) / min.: -358.4°C (-613.12°F) max.: 358.4°C (677.12°F) Damper is at "MAX. COOL": -358.4°C (-613.12°F) Damper is at "MAX. HOT": 358.4°C (677.12°F) - A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": -10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% AC AC–40 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% HAND FREE TEL Handsfree telephone / OFF, ON - - BLOWER LEVEL Blower motor speed level / min.: Level 0 max.: 31 Increases in the range between 0 and 31 as the speed increases - AMBI TEMP Adjusted ambient temperature / min.: -30.8°C (-23.44°F) max.: 50.8°C (123.44°F) - - SET TEMP SHIFT Shift set temperature / +2C, +1C, NORMAL, -1C, -2C Customized value will be displayed - AIR INLET MODE Air inlet mode / AUTO, MANUAL Customized value will be displayed - COMPRESSOR MODE Compressor mode / AUTO, MANUAL Customized value will be displayed - COMPRS/DEF OPER Compressor/DEF operation mode / LINK, NORMAL Customized value will be displayed - FOOT AIR LEAK Foot air leak / ON, OFF Customized value will be displayed - AUTO BLOW UP Foot/DEF automatic blower up function / ON, OFF Customized value will be displayed - FOOT/DEF MODE Foot/DEF auto mode / ON, OFF Customized value will be displayed - AMBIENT TMP SFT Ambient temperature shift / +3C, +2C, +1C, NORMAL, -1C, 2C, 3C Customized value will be displayed - DESTINATION Destination/ DOMEST, USA, EUROPE, AUSTRAL, MIDEAST, NO INFO Changes with destinations - DESTINATION Destination/ DOMEST, USA, EUROPE, AUSTRAL, MIDEAST, NO INFO Changes with destinations - HUMIDITY SENS Humidity sensor / min.: 0% max.: 100% Actual room humidity is displayed - COMPRS SPD Compressor speed / min.: 0 rpm max.: 65,535 rpm Displays actual rotation speed in the range between 0 rpm and 7,500 rpm - COMPRS TARG SPD Compressor target speed / min.: 0 rpm max.: 65,535 rpm Displays target rotation speed in the range between 0 rpm and 7,500 rpm - #CODES Number of trouble codes / min.: 0 max.: 255 Number of DTCs will be displayed - AIR CONDITIONING – AIR CONDITIONING SYSTEM 2. AC–41 PERFORM ACTIVE TEST HINT: Performing the intelligent tester's ACTIVE TEST allows relays, the VSV, actuators and other items to be operated without removing any parts. Performing the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed in the ACTIVE TEST. It is possible to display the DATA LIST on the intelligent tester during the ACTIVE TEST. (a) Connect the intelligent tester (with CAN VIM) to the DLC3. (b) Turn the power switch ON (IG) and turn the intelligent tester ON. (c) Perform the ACTIVE TEST by following the prompts on the tester. Air conditioning amplifier Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR Blower motor / min.: 0 max.: 31 - AIR MIX DAMP-P Air mix damper (Passenger side) / min.: -14% max.: 113.5% - A/O MODE DAMP-D Air outlet damper position (Driver side) / min.: -14% max.: 113.5% - A/I DAMP-LINEAR Air inlet damper position (linear) / min.: -14% max.: 113.5% - COMPRS TARG SPD Compressor target speed / min.: 0 max.: 255 - DEFOGGER RLY-R Defogger relay (Rear) / OFF, ON - WATER PUMP RLY Water pump / OFF, ON - ELECTRICAL FAN Electrical fan / OFF, ON - DEFOGGER RLY-R Defogger relay (Rear) / OFF, ON - A/C MAG CLUTCH Magnetic Clutch Relay / OFF, ON - WATER PUMP RLY Water pump / OFF, ON - ELECTRICAL FAN Electrical fan / OFF, ON - AC AC–42 AIR CONDITIONING – AIR CONDITIONING SYSTEM DIAGNOSTIC TROUBLE CODE CHART HINT: When the air conditioning system function properly, DTC B1400/00 is output. Air conditioning system DTC No. AC Detection Item Trouble Area Memory*4 See page B1411*1 Room Temperature Sensor Circuit - Room temperature sensor - Wire harness between cooler room temperature sensor and air conditioning amplifier - Air conditioning amplifier (8.5 min. or more) AC-42 B1412*2 Ambient Temperature Sensor Circuit - Room temperature sensor - Wire harness between ambient temperature sensor and ECM - ECM - Multiplex communication circuit - Air conditioning amplifier (8.5 min. or more) AC-46 B1413 Evaporator Temperature Sensor Circuit - Evaporator temperature sensor - Wire harness between evaporator temperature sensor and air conditioning amplifier - Air conditioning amplifier (8.5 min. or more) AC-51 B1421*3 Solar Sensor Circuit (Passenger Side) - Solar sensor - Wire harness between solar sensor and air conditioning amplifier or body ECU - Air conditioning amplifier (8.5 min. or more) AC-55 B1423 Pressure Switch Circuit - Pressure switch - Wire harness between pressure switch and body ground - Multiplex communication circuit - Refrigerant pipe line - Air conditioning amplifier - AC-59 B1431 Air Mix Damper Position Sensor Circuit (Passenger Side) - Air mix control servo motor (air mix damper position sensor) - Wire harness between air mix control servo motor and air conditioning amplifier - Air conditioning amplifier (1 min. or more) AC-63 B1432 Air Inlet Damper Position Sensor Circuit - Air inlet control servo motor (air inlet damper position sensor) - Wire harness between air inlet control servo motor and air conditioning amplifier - Air conditioning amplifier (1 min. or more) AC-67 AC–43 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC No. Detection Item Trouble Area B1433 Air Outlet Damper Position Sensor Circuit - Air outlet control servo motor (air outlet damper position sensor) - Wire harness between air outlet control servo motor and air conditioning amplifier - Air conditioning amplifier (1 min. or more) Memory*4 See page AC-72 B1441 Air Mix Damper Control Servo Motor Circuit (Passenger Side) - Air mix control servo motor - Wire harness between air mix control servo motor and air conditioning amplifier - Air conditioning amplifier (15 sec.) AC-77 B1442 Air Inlet Damper Control Servo Motor Circuit - Air inlet control servo motor - Wire harness between air inlet control servo motor and air conditioning amplifier - Air conditioning amplifier (15 sec.) AC-81 B1443 Air Outlet Damper Control Servo Motor Circuit - Air outlet control servo motor - Wire harness between air outlet control servo motor and air conditioning amplifier - Air conditioning amplifier (15 sec.) AC-85 B1462 Room Humidity Sensor Circuit - Room humidity sensor (room temperature sensor) - Wire harness between room humidity sensor (room temperature sensor) and air conditioning amplifier - Air conditioning amplifier - AC-89 B1471 A/C Inverter High Voltage Power Resource System Malfunction - Hybrid control ECU - A/C inverter (inverter with converter) - AC-93 B1472 A/C Inverter High Voltage Output System Malfunction - Hybrid control ECU - Electric inverter compressor (w/ motor compressor) - A/C inverter (inverter with converter) - AC-96 B1473 A/C Inverter Start-up Signal System Malfunction - Wire harness between hybrid control ECU and A/ C inverter (inverter with converter) - A/C inverter (inverter with converter) - Hybrid control ECU - AC-99 B1475 A/C Inverter Cooling / Heating System Malfunction - A/C inverter (inverter with converter) - AC-101 B1476 A/C Inverter Load System Malfunction - Volume of refrigerant - Electric inverter compressor (w/ motor compressor) - Cooling fan circuit - AC-102 B1477 A/C Inverter Low Voltage Power Resource System Malfunction - A/C inverter (inverter with converter) - AC-104 AC AC–44 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC No. Detection Item Trouble Area B1498 Communication Malfunction (A/C Inverter Local) - Wire harness between hybrid control ECU and A/ C inverter (inverter with converter) - Hybrid control ECU - A/C inverter (inverter with converter) - Memory*4 See page AC-105 P0AA6-611 Hybrid Battery Voltage System Isolation Fault - Electric inverter compressor (w/ motor compressor) - A/C inverter (inverter with converter) - Compressor oil - AC-107 HINT: • *1: If the room temperature is approx. -18.6°C (-3.7 °F) or lower, DTC B1411/11 may be output even though the system is normal. • *2: If the ambient temperature is approx. -52.9°C (-61.4°F) or lower, a malfunction code may be output even though the system is normal. • *3: If the check is performed in a dark place, DTC B1421/ 21 or B1424/24 (solar sensor circuit abnormal) could be displayed. • *4: The air conditioning amplifier memorizes the DTC of the respective malfunction that has occurred for a period of the time indicated in the brackets. ACTUATOR CHECK 1. 1 sec. 1 sec. ON OFF I036313E02 AC ACTUATOR CHECK (a) Start the engine to warm it up. (b) Perform the indicator check. (c) Push the R/F (Recirculation/Fresh) switch to perform the actuator check when the sensor check is started after the indicator check. HINT: Be sure to perform the actuator check with the power switch ON (READY). (d) As the actuator check (continuous) is repeated from steps 0 to 9 at 1 second intervals, check the temperature and airflow visually and by hand. (e) If the steps are difficult to read because they change automatically, push the "Fr. DEF" switch to display the steps step by step so that they can be read easily. The items are displayed step by step each time the "Fr. DEF" switch is pushed. HINT: • The display blinks at 1 second intervals in the step operation. • The illustration indicates that code 4 is output. Push the "TEMP-" switch to finish panel diagnosis. • Push the "AUTO" switch to enter the sensor check mode. AC–45 AIR CONDITIONING – AIR CONDITIONING SYSTEM Step No. Display code Conditions Blower level Air flow vent Air inlet damper Air mix damper A/C compressor revolution speed (rpm) 1 0 0 FACE (-10.0%) FRESH (110.0%) "COOL" position (-10.0%) 0 2 1 1 FACE (-10.0%) FRESH (110.0%) "COOL" position (-10.0%) 0 3 2 17 FACE (-10.0%) FRESH (110.0%) "COOL" position (-10.0%) 7,500 4 3 17 FACE (-10.0%) RECIRCULATION (-1.0%) "COOL" position (-10.0%) 7,500 5 4 17 B/L (12%) RECIRCULATION (-1.0%) "COOL" / "HOT" (50.0% opened) 4,500 6 5 17 FOOT (49%) RECIRCULATION (-1.0%) "COOL" / "HOT" (65.0% opened) 4,500 7 6 17 FOOT (49%) RECIRCULATION (-1.0%) "HOT " position (100.0%) 4,500 8 7 17 F/D (69%) RECIRCULATION (-1.0%) "COOL" / "HOT" (65.0% opened) 4,500 9 8 17 F/D (95%) RECIRCULATION (-1.0%) "COOL" / "HOT" (90.0% opened) 4,500 10 9 31 DEF (110.0%) RECIRCULATION (-1.0%) "COOL" / "HOT" (50.0% opened) 4,500 AC AC–46 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1411 Room Temperature Sensor Circuit DESCRIPTION The room temperature sensor is installed in the instrument panel to detect the room temperature and control the heater and air conditioner "AUTO" function. The resistance of the room temperature sensor changes in accordance with the room temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies voltage (5 V) to the room temperature sensor and reads voltage changes as the resistance of the room temperature sensor changes. This sensor also sends appropriate signals to the air conditioning amplifier. The room temperature sensor is integrated with the room humidity sensor. DTC No. Detection Condition Trouble Area B1411 Open or short in room temperature sensor circuit • • • Room temperature sensor Wire harness between cooler room temperature sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Room Temperature Sensor Air Conditioning Amplifier THR Room Humidity Sensor Area Room Temperature Sensor Area GND VO S5 TR SGTR RH S5RM E125205E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (ROOM TEMP) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. AC AC–47 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note ROOM TEMP Room temperature sensor / Open in the circuit: min.: -6.5°C (20.3°F) max.: 57.25°C (135.05°F) Actual room temperature is displayed Open in the circuit: -6.5°C (20.3°F) Short in the circuit: 57.25°C (135.05°F) OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TR VOLTAGE) TR A7 SGTR (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition A7-8 (TR) - A7-22 (SGTR) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V A7-8 (TR) - A7-22 (SGTR) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V I041186E01 A HINT: As the temperature increases, the voltage decreases. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC AC–48 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT ROOM TEMPERATURE SENSOR (a) Remove the room temperature sensor. (b) Measure the resistance of the sensor. Standard resistance GND Sensor Area THR Tester Connection Condition Specified Condition 1 (THR) - 2 (GND) 10°C (50°F) 3.00 to 3.73 kΩ 1 (THR) - 2 (GND) 15°C (59°F) 2.45 to 2.88 kΩ 1 (THR) - 2 (GND) 20°C (68°F) 1.95 to 2.30 kΩ 1 (THR) - 2 (GND) 25°C (77°F) 1.60 to 1.80 kΩ 1 (THR) - 2 (GND) 30°C (86°F) 1.28 to 1.47 kΩ 1 (THR) - 2 (GND) 35°C (95°F) 1.00 to 1.22 kΩ Resistance (kΩ) 1 (THR) - 2 (GND) 40°C (104°F) 0.80 to 1.00 kΩ  1 (THR) - 2 (GND) 45°C (113°F) 0.65 to 0.85 kΩ  1 (THR) - 2 (GND) 50°C (122°F) 0.50 to 0.70 kΩ                  q%   q( Temperature 1 (THR) - 2 (GND) 55°C (131°F) 0.44 to 0.60 kΩ 1 (THR) - 2 (GND) 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph). E127529E01 NG OK AC REPLACE ROOM TEMPERATURE SENSOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 AC–49 CHECK WIRE HARNESS (ROOM TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A9 sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Room Temperature Sensor THR A9 GND Air Conditioning Amplifier Tester Connection Specified Condition A7-8 (TR) - A9-1 (THR) Below 1 Ω A7-22 (SGTR) - A9-2 (GND) Below 1 Ω A7-8 (TR) - Body ground 10 kΩ or higher A7-22 (SGTR) - Body ground 10 kΩ or higher NG A7 REPAIR OR REPLACE HARNESS AND CONNECTOR TR SGTR E125230E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–50 DTC AIR CONDITIONING – AIR CONDITIONING SYSTEM B1412 Ambient Temperature Sensor Circuit DESCRIPTION The ambient temperature sensor is installed in the front part of the condenser to detect the ambient temperature and control the heater and air conditioner "AUTO" function. The sensor connected to the ECM detects fluctuation in the ambient temperature that is used for controlling the room temperature. The sensor sends a signal to the air conditioning amplifier via the ECM. The resistance of the ambient temperature sensor changes in accordance with the ambient temperature. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The ECM applies voltage (5 V) to the ambient temperature sensor and reads voltage changes as the resistance of the ambient temperature sensor changes. The ECM sends the read signal to the air conditioning amplifier via CAN and body multiplex communications. DTC No. Detection Condition Trouble Area B1412 Open or short in ambient temperature sensor circuit • • • • • Ambient temperature sensor Wire harness between ambient temperature sensor and ECM ECM Multiplex communication circuit Air conditioning amplifier WIRING DIAGRAM Ambient Temperature Sensor ECM TAM E2 See Multiplex Communication System (CAN Bus) CANH CANL Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) AC MPX+ MPX2+ E125206E01 AC–51 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (AMBI TEMP SENS) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note AMBI TEMP SENS Ambient temperature sensor / min.: -23.3°C (-9.94°F) max.: 65.95°C (150.71°F) Actual ambient temperature is displayed Open in the circuit: -23.3°C (9.94°F) Short: in the circuit: 65.95°C (150.71°F) OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK ECM (TAM VOLTAGE) E4 E5 E7 E2 E6 TAM I036365E01 (a) Remove the ECM with connectors still connected. (b) Measure the voltage of the wire harness side connectors. Standard voltage Tester Connection Condition Specified Condition E7-21 (TAM) - E4-28 (E2) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V AC AC–52 AIR CONDITIONING – AIR CONDITIONING SYSTEM Tester Connection Condition Specified Condition E7-21 (TAM) - E4-28 (E2) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V HINT: As the temperature increases, the voltage decreases. Result A AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–53 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT AMBIENT TEMPERATURE SENSOR (a) Remove the ambient temperature sensor. (b) Measure the resistance of the sensor. Standard resistance Sensor Area Resistance (kΩ)  3.5  3.0  2.5  2.0  1.5  1.0  0.5 (50) Condition Specified Condition 1-2 10°C (50°F) 3.00 to 3.73 kΩ 1-2 15°C (59°F) 2.45 to 2.88 kΩ 1-2 20°C (68°F) 1.95 to 2.30 kΩ 1-2 25°C (77°F) 1.60 to 1.80 kΩ 1-2 30°C (86°F) 1.28 to 1.47 kΩ 1-2 35°C (95°F) 1.00 to 1.22 kΩ 1-2 40°C (104°F) 0.80 to 1.00 kΩ 1-2 45°C (113°F) 0.65 to 0.85 kΩ 1-2 50°C (122°F) 0.50 to 0.70 kΩ 1-2 55°C (131°F) 0.44 to 0.60 kΩ 1-2 60°C (140°F) 0.36 to 0.50 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decreases (see the graph).  4.0  0.0  10  Tester Connection NG  20  (68)  30   40   50  q% 60   q( REPLACE AMBIENT TEMPERATURE SENSOR (86) (104) (122) (140) Temperature °C (°F) E114516E12 OK AC AC–54 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (AMBIENT TEMPERATURE SENSOR - ECM) (a) Disconnect the A6 sensor connector. (b) Disconnect the E4 and E7 ECM connectors. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Ambient Temperature Sensor Tester Connection A6 ECM E4 E7-21 (TAM) - A6-2 Below 1 Ω E4-28 (E2) - A6-1 Below 1 Ω E7-21 (TAM) - Body ground 10 kΩ or higher E4-28 (E2) - Body ground 10 kΩ or higher NG E7 E2 TAM I036366E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR AC–55 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1413 Evaporator Temperature Sensor Circuit DESCRIPTION The evaporator temperature sensor is installed on the evaporator in the air conditioner unit to detect the cooled air temperature that has passed through the evaporator and control the air conditioning. It sends appropriate signals to the air conditioning amplifier. The resistance of the evaporator temperature sensor changes in accordance with the cooled air temperature that has passed through the evaporator. As the temperature decreases, the resistance increases. As the temperature increases, the resistance decreases. The air conditioning amplifier applies voltage (5 V) to the evaporator temperature sensor and reads voltage changes as the resistance of the evaporator temperature sensor changes. This sensor is used for frost prevention. DTC No. Detection Condition Trouble Area B1413 Open or short in evaporator temperature sensor circuit. • • • Evaporator temperature sensor Wire harness between evaporator temperature sensor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Evaporator Temperature Sensor Air Conditioning Amplifier TE SGTE E125207E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (EVAP TEMP) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note EVAP TEMP Evaporator temperature sensor / min.: -29.7°C (-21.46°F) max.: 59.55°C (139.19°F) Actual evaporator temperature is displayed Open in the circuit: -29.7°C (21.46°F) Short in the circuit: 59.55°C (139.19°F) AC AC–56 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TE VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTE A AC TE Tester Connection Condition Specified Condition A7-7 (TE) - A7-5 (SGTE) Power switch ON (IG) at 0 °C (32°F) 2.0 to 2.4 V A7-7 (TE) - A7-5 (SGTE) Power switch ON (IG) at 15°C (59°F) 1.4 to 1.8 V I041186E02 HINT: As the temperature increases, the voltage decreases. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–57 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT EVAPORATOR TEMPERATURE SENSOR (a) Remove the evaporator temperature sensor. (b) Measure the resistance of the sensor. Standard resistance Evaporator Evaporator Thermistor Condition Specified Condition 1-2 -10°C (14°F) 7.30 to 9.10 kΩ 1-2 -5°C (23°F) 5.65 to 6.95 kΩ 1-2 0°C (32°F) 4.40 to 5.35 kΩ 1-2 5°C (41°F) 3.40 to 4.15 kΩ 1-2 10°C (50°F) 2.70 to 3.25 kΩ 1-2 15°C (59°F) 2.14 to 2.58 kΩ 1-2 20°C (68°F) 1.71 to 2.05 kΩ 1-2 25°C (77°F) 1.38 to 1.64 kΩ 1-2 30°C (86°F) 1.11 to 1.32 kΩ NOTICE: • Even slightly touching the sensor may change the resistance value. Be sure to hold the connector of the sensor. • When measuring, the sensor temperature must be the same as the ambient temperature. HINT: As the temperature increases, the resistance decrease (see the graph). Sensor Area Evaporator Thermistor Resistance (kΩ)  10.0  9.0  8.0  7.0  6.0  5.0  4.0  3.0  2.0  1.0  0.0 㧙 -10  (14) Tester Connection NG 0  (32)   20 10   (68) (50) Temperature °C (°F) REPLACE EVAPORATOR TEMPERATURE SENSOR 30 q%  q( (86) E115010E15 OK AC AC–58 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (EVAPORATOR TEMPERATURE SENSOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Evaporator Temperature Sensor A11 Air Conditioning Amplifier (a) Disconnect the A11 sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A7-7 (TE) - A11-2 Below 1 Ω A7-5 (SGTE) - A11-1 Below 1 Ω A7-7 (TE) - Body ground 10 kΩ or higher A7-5 (SGTE) - Body ground 10 kΩ or higher NG A7 TE SGTE E125231E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1421 AC–59 Solar Sensor Circuit (Passenger Side) DESCRIPTION Resistance of photodiode High Low Weak Strong Strength of solar radiation E109314E08 The solar sensor is installed in the upper part of the instrument panel to detect the amount of solar radiation with a photodiode to control the heater and air conditioner "AUTO" function. It sends appropriate signals to the air conditioning amplifier. The output voltage of the solar sensor changes in accordance with the amount of solar radiation. As the amount increases, the voltage increases. As the amount decreases, the voltage decreases. The air conditioning amplifier reads voltage output from the solar sensor. DTC No. Detection Condition Trouble Area B1421 Open or short in solar sensor circuit circuit. (If the check is performed in a dark place, DTC B1421 may be displayed.) • • • Solar sensor Wire harness between solar sensor and air conditioning amplifier or body ECU Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Solar Sensor S5TS TS AC E125208E01 AC–60 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (SOLAR SENS-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note SOLAR SENS-P Solar sensor (Passenger side) / min.: 0 max.: 255 Increases as brightness increases Open in the circuit: 0 Short in the circuit: 255 OK: The display is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TS VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A7 S5TS AC TS Tester Connection Condition Specified Condition A7-12 (S5TS) - A7-21 (TS) Power switch ON (IG) 0.8 to 4.3 V HINT: • As the inspection light is moved away from the sensor, the voltage increases. • As the inspection light is moved closer to the sensor, the voltage decreases. • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. Result I041186E03 Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C AC–61 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT SOLAR SENSOR (a) Remove the solar sensor. (b) Measure the resistance of the sensor. • Connect the ohmmeter's positive (+) lead to terminal 2 and negative (-) lead to terminal 1 of the solar sensor. Standard resistance 2 1 E072857E04 Tester Connection Condition Specified condition 1-2 Sensor is subject to electric light Except ∞ Ω 1-2 Sensor is covered with a cloth ∞ Ω (No continuity) NOTICE: The connection procedure for using a digital tester such as an TOYOTA electrical tester is shown above. When using an analog tester, connect the positive (+) lead to terminal 1 and negative (-) lead to terminal 2 of the solar sensor. HINT: • As the inspection light is moved away from the sensor, the resistance increases. • Use an incandescent light for inspection. Bring it within 30 cm (11.8 in.) of the solar sensor. NG REPLACE SOLAR SENSOR OK AC AC–62 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (SOLAR SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A10 solar sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Solar Sensor A10 Air Conditioning Amplifier Specified Condition A7-12 (S5TS) - A10-1 Below 1 Ω A7-21 (TS) - A10-2 Below 1 Ω A7-12 (S5TS) - Body ground 10 kΩ or higher A7-21 (TS) - Body ground 10 kΩ or higher NG A7 S5TS Tester Connection TS E125231E02 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1423 AC–63 Pressure Switch Circuit DESCRIPTION Low-pressure Side OFF (10 kΩ or higher) High-pressure Side ON (Below 1.0 Ω) 196 kPa (2.0 kgf/cm2, 28 psi) 3,140 kPa (32.0 kgf/cm2, 455 psi) OFF (10 kΩ or higher) E113418E11 The pressure switch to detect the refrigerant pressure is located in the sight glass side of the pipe on the high-pressure side. This DTC is output when the refrigerant pressure is either significantly low (below 196 kPa (2.0 kgf/cm2, 28 psi) or significantly high (over 3,140 kPa (32.0 kgf/cm2, 455 psi). Then the pressure switch sends appropriate signals to the air conditioning amplifier. The pressure switch has built-in switches to detect high and low pressure and is turned off when either is determined to be defective. The air conditioning amplifier continuously monitors the pressure switch signal after the power switch is turned ON (IG). It stops compressor control and outputs the DTC when it detects the signal indicating that the switch is turned OFF. DTC No. Detection Condition Trouble Area B1423 When either condition below is met: • Open in pressure sensor circuit. • Abnormal refrigerant pressure: • • Below 196 kPa (2.0 kgf/cm2, 28 psi) Over 3,140 kPa (32.0 kgf/cm2, 455 psi) • • • Pressure switch Wire harness between pressure switch and body ground Multiplex communication circuit Refrigerant pipe line Air conditioning amplifier AC AC–64 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Pressure Switch PSW E125209E01 INSPECTION PROCEDURE 1 CHECK REFRIGERANT PRESSURE (a) Set the manifold gauge. (b) Read the manifold gauge pressure when these conditions are established. Test conditions: • Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) • Power switch ON (IG) • Blower speed control switch at "HI" position • Temperature control dial at "COOL" position • Air conditioning switch ON • Fully open doors Standard pressure: Pressure on high pressure side: 1.37 to 1.57 MPa (13.9 to 16.0 kgf/cm2, 198 to 228 psi) HINT: If the refrigerant pressure is below 196 kPa (2.0 kgf/cm2, 28 psi), the refrigerant amount in the air conditioning cycle may have decreased significantly for reasons such as a gas leakage. NG AC INSPECT AND REPAIR AIR CONDITIONING CYCLE AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–65 OK 2 CHECK AIR CONDITIONING OPERATION Wire Harness Side Pressure Switch P1 I040669E01 (a) Disconnect the P1 pressure switch connector. (b) Connect terminals 1 and 4 of the connector of the pressure switch on the vehicle wire harness side using a service wire. (c) Turn the power switch ON (IG). (d) Turn the air conditioning switch ON and check that the compressor is operated. (e) Check that the compressor is not operated when disconnecting terminals 1 and 4 (that were connected in the prior step). OK: Terminals 1 and 4 connected: the compressor is operated Terminals 1 and 4 disconnected: the compressor is not operated OK REPLACE PRESSURE SWITCH NG 3 CHECK WIRE HARNESS (PRESSURE SWITCH - AIR CONDITIONING AMPLIFIER AND BODY GROUND) (a) Disconnect the P1 pressure switch connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Pressure Switch P1 Tester Connection Specified Condition A7-6 (PSW) - P1-4 Below 1 Ω P1-1 - Body ground Below 1 Ω A7-6 (PSW) - Body ground 10 kΩ or higher Result Air Conditioning Amplifier Result A7 NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C A REPAIR OR REPLACE HARNESS AND CONNECTOR B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE PSW E125232E01 Proceed to AC AC–66 AIR CONDITIONING – AIR CONDITIONING SYSTEM C REPLACE AIR CONDITIONING AMPLIFIER AC AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1431 AC–67 Air Mix Damper Position Sensor Circuit (Passenger Side) DESCRIPTION Voltage (V) 4 1 0 100% Damper opening angle E109300E21 This sensor detects the position of the air mix control servo motor (air mix damper) and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air mix control servo motor. The position sensor resistance changes as the air mix control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 1 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the position sensor. DTC No. Detection Condition Trouble Area B1431 Open or short in power source circuit in air mix damper position sensor circuit. • • • Air mix control servo motor (air mix damper position sensor) Wire harness between air mix control servo motor and air conditioning amplifier Air conditioning amplifier AC AC–68 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Air Mix Control Servo Motor PT TP GND SGTP VZ S5TP E125210E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/M DAMP POS-P, TARG-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% Damper is at "MAX. HOT": 100.0% or 71.0% - OK: The displayed is as specified in the normal condition. Result AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C AC–69 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TP VOLTAGE) (a) Remove the air conditioning amplifier with its connectors still connected. (b) Change the set temperature to activate the air mix servo motor. (c) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTP TP I041186E05 Tester Connection Condition Specified Condition A7-20 (TP) - A7-14 (SGTP) Power switch ON (IG) MAX. HOT position 0.97 to 1.03 V A7-20 (TP) - A7-14 (SGTP) Power switch ON (IG) MAX. COOL position 3.97 to 4.03 V HINT: As the set temperature increases, the voltage decreases gradually without interruption. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR MIX CONTROL SERVO MOTOR (a) Remove the air mix control servo motor. (b) Measure the resistance of the servo motor. Standard resistance PT GND Tester Connection Specified Condition A15-1 (VZ) - A15-2 (GND) 4.2 to 7.8 kΩ VZ E068754E01 AC AC–70 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Measure the resistance of the servo motor. Standard resistance MAX. HOT MAX. COOL Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. COOL Position 3.6 to 6.7 kΩ A15-3 (PT) - A15-2 (GND) MAX. HOT Position 0.8 to 1.6 kΩ HINT: • Refer to the operation procedure for air mix control servo motor (see page AC-83). • As the air mix control servo motor moves from the COOL position to HOT position, the resistance decreases gradually without interruption. Resistance (kΩ) 3.6 to 6.7 Arm position NG REPLACE AIR MIX CONTROL SERVO MOTOR 0.8 to 1.6 MAX. COOL MAX. HOT E127530E01 OK 4 CHECK WIRE HARNESS (AIR MIX CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Mix Control Servo Motor VZ A15 GND (a) Disconnect the A15 servo connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection PT Air Conditioning Amplifier A7 A7-20 (TP) - A15-3 (PT) Below 1 Ω A7-14 (SGTP) - A15-2 (GND Below 1 Ω A7-13 (S5TP) - A15-1 (VZ) Below 1 Ω A7-20 (TP) - Body ground 10 kΩ or higher A7-14 (SGTP) - Body ground 10 kΩ or higher A7-13 (S5TP) - Body ground 10 kΩ or higher NG SGTP S5TP Specified Condition TP E125233E03 OK AC REPLACE AIR CONDITIONING AMPLIFIER REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1432 AC–71 Air Inlet Damper Position Sensor Circuit DESCRIPTION Voltage (V) 4 1 0 100% Damper opening angle E109300E19 This sensor detects the position of the air inlet control servo motor and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air inlet control servo motor. The position sensor's resistance changes as the air inlet control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 3 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the position sensor. DTC No. Detection Condition Trouble Area B1432 Open or short in power source circuit in air inlet damper position sensor circuit. • • • Air inlet control servo motor (air inlet damper position sensor) Wire harness between air inlet control servo motor and air conditioning amplifier Air conditioning amplifier AC AC–72 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Air Inlet Control Servo Motor PT TPI GND SGTPI VZ S5TPI E125210E04 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/I DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK: The displayed is as specified in the normal condition. Result AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B AC–73 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Proceed to OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TPI VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Change the set REC / FRS to activate the air inlet servo motor. (c) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTPI TPI I041186E06 Tester Connection Condition Specified Condition A7-19 (TPI) - A7-4 (SGTPI) Power switch ON (IG) RECIRC position 3.5 to 4.5 V A7-19 (TPI) - A7-4 (SGTPI) Power switch ON (IG) FRESH position 0.5 to 1.8 V HINT: As the air inlet servo motor is moved from REC position to FRS position, the voltage decreases gradually without interruption. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A AC AC–74 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT AIR INLET CONTROL SERVO MOTOR (a) Remove the air inlet control servo motor. (b) Measure the resistance of the servo motor. Standard resistance PT GND Tester Connection Specified Condition A14-1 (VZ) - A14-2 (GND) 4.2 to 7.8 kΩ VZ E068754E02 RECIRCULATION FRESH 3.4 to 6.2 Arm position 0.6 to 1.1 FRS E127531E01 OK AC Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) RECIRCULATION position 3.4 to 6.2 kΩ A14-3 (PT) - A14-2 (GND) FRESH position 0.6 to 1.1 kΩ HINT: • Refer to the operation procedure of the air inlet control servo motor (see page AC-87). • As the air inlet control servo motor moves from FRESH position to RECIRCULATION position, the resistance decreases gradually without interruption. Resistance (kΩ) REC (c) Measure the resistance of the servo motor. Standard resistance NG REPLACE AIR INLET CONTROL SERVO MOTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 AC–75 CHECK WIRE HARNESS (AIR INLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Inlet Control Servo Motor VZ A14 GND PT Air Conditioning Amplifier A7 (a) Disconnect the A14 servo connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A7-19 (TPI) - A14-3 (PT) Below 1 Ω A7-4 (SGTPI) - A14-2 (GND) Below 1 Ω A7-3 (S5TPI) - A14-1 (VZ) Below 1 Ω A7-19 (TPI) - Body ground 10 kΩ or higher A7-4 (SGTPI) - Body ground 10 kΩ or higher A7-3 (S5TPI) - Body ground 10 kΩ or higher NG SGTPI S5TPI REPAIR OR REPLACE HARNESS AND CONNECTOR TPI E125233E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–76 DTC AIR CONDITIONING – AIR CONDITIONING SYSTEM B1433 Air Outlet Damper Position Sensor Circuit DESCRIPTION Voltage (V) 4 1 0 100% Damper opening angle E109300E22 This sensor detects the position of the air outlet control servo motor and sends the appropriate signals to the air conditioning amplifier. The position sensor is built into the air outlet control servo motor. The potentiometer's resistance changes as the air outlet control servo motor arm moves. It outputs voltage (5 V) that is input to terminal 1 (VZ) and terminal 3 (PT) via the variable resistor, and then to the air conditioning amplifier. The air conditioning amplifier reads the arm position with the input voltage from the potentiometer. DTC No. Detection Condition Trouble Area B1433 Open or short in power source circuit in air outlet damper position sensor circuit. • • • AC Air outlet control servo motor (air outlet damper position sensor) Wire harness between air outlet control servo motor and air conditioning amplifier Air conditioning amplifier AC–77 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier Air Outlet Control Servo Motor PT TPM GND SGTPM VZ S5TPM E125210E03 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/O DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the items below in the DATA LIST, and read the displays on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0 % Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% AC AC–78 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: The displayed is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (TPM VOLTAGE) (a) Remove the air condition amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A7 SGTPM A AC TPM I041186E08 Tester Connection Condition Specified Condition A7-18 (TPM) - A7-23 (SGTPM) Power switch ON (IG) FACE position 3.97 to 4.07 V A7-18 (TPM) - A7-23 (SGTPM) Power switch ON (IG) DEF position 0.97 to 1.03 V HINT: As the air outlet servo motor is moved from the FACE position to the DEF position, the voltage decreases gradually without interruption. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AC–79 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 INSPECT AIR OUTLET CONTROL SERVO MOTOR (a) Remove the air outlet control servo motor. (b) Measure the resistance of the servo motor. Standard resistance PT GND Tester Connection Specified Condition A16-1 (VZ) - A16-2 (GND) 4.2 to 7.2 kΩ VZ E068754E03 (c) Measure the resistance of the servo motor. Standard resistance DEF FACE Tester Connection Condition Specified Condition A16-3 (PT) - A16-2 (GND) DEF position 0.6 to1.1 kΩ A16-3 (PT) - A16-2 (GND) FACE position 3.6 to 6.7 kΩ HINT: • Refer to the operation procedure for air outlet control servo motor (see page AC-91). • As the air outlet control servo motor moved from DEF position to FACE position, the resistance decreases gradually without interruption. Resistance (kΩ) 3.6 to 6.7 Arm position NG REPLACE AIR OUTLET CONTROL SERVO MOTOR 0.6 to 1.1 FACE DEF E127532E01 OK AC AC–80 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 CHECK WIRE HARNESS (AIR OUTLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Outlet Control Servo Motor VZ A16 GND PT Air Conditioning Amplifier A7 (a) Disconnect the A16 servo connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A7-18 (TPM) - A16-3 (PT) Below 1 Ω A7-23 (SGTPM) - A16-2 (GND) Below 1 Ω A7-11 (S5TPM) - A16-1 (VZ) Below 1 Ω A7-18 (TPM) - Body ground 10 kΩ or higher A7-23 (SGTPM) - Body ground 10 kΩ or higher A7-11 (S5TPM) - Body ground 10 kΩ or higher NG SGTPM S5TPM TPM E125233E02 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1441 AC–81 Air Mix Damper Control Servo Motor Circuit (Passenger Side) DESCRIPTION The air mix control servo motor (air mix damper servo) is controlled by the air conditioning amplifier. The air mix control servo motor moves the air mix damper by rotating (normal, reverse) the motor with electrical power from the air conditioning amplifier. This adjusts the mix ratio of the air that passes through the evaporator and heater core and controls the airflow temperature. Air flow temperature changes when moving the air mix damper to the target point. The target point can be detected with the air mix damper position sensor. DTC No. Detection Condition Trouble Area B1441 Air mix damper position sensor value does not change even if air conditioning amplifier assembly operates air mix servo motor. • • • Air mix control servo motor Wire harness between air mix control servo motor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Air Mix Control Servo Motor PT TP GND SGTP VZ S5TP MCOOL MHOT AMC AMH E125211E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/M DAMP POS-P, TARG-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. AC AC–82 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. COOL": 10.0% - OK: When the target position is at the "MAX. COOL" (10.0%), the actual opening angle is 19.0% or less. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 READ VALUE OF INTELLIGENT TESTER (A/M DAMP POS-P, TARG-P) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/M DAMP POS-P Air mix damper position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. HOT": 100.0% or 71.0% - A/M DAMP TARG-P Air mix damper target position (Passenger side) / min.: -14% max.: 113.5% Damper is at "MAX. HOT": 100.0% or 71.0% - OK: When the target position is at the "MAX. HOT" (100.0%), the actual opening angle is 81.0% or more. Result AC Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C AC–83 AIR CONDITIONING – AIR CONDITIONING SYSTEM B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR MIX CONTROL SERVO MOTOR (a) Remove the air mix control servo motor. (b) Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4, then check that lever turns to "MAX. HOT" position smoothly. (c) Measure the resistance of the servo motor. Standard resistance MHOT MCOOL Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. HOT position 0.8 to 1.6 kΩ (d) Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5, then check that lever turns to "MAX. COOL" position smoothly. (e) Measure the resistance of the servo motor. Standard resistance MAX. HOT MAX. COOL Tester Connection Condition Specified Condition A15-3 (PT) - A15-2 (GND) MAX. COOL position 3.6 to 6.7 kΩ NG E127533E01 REPLACE AIR MIX CONTROL SERVO MOTOR OK AC AC–84 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (AIR MIX CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Mix Control Servo Motor MHOT A15 MCOOL Air Conditioning Amplifier (a) Disconnect the A15 servo connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A8-19 (AMC) - A15-4 (MCOOL) Below 1 Ω A8-17 (AMH) - A15-5 (MHOT) Below 1 Ω A8-19 (AMC) - Body ground 10 kΩ or higher A8-17 (AMH) - Body ground 10 kΩ or higher NG A8 AMH AMC E125234E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1442 AC–85 Air Inlet Damper Control Servo Motor Circuit DESCRIPTION The air inlet control servo motor is controlled by the air conditioning amplifier and moves the air inlet control servo motor to the desired position. The air inlet control servo motor switches between "RECIRCULATION" and "FRESH" by rotating the motor (normal, reverse) with electrical power from the air conditioning amplifier. This controls intake air and switches "RECIRCULATION", "FRESH" and "HALF-RECIRCULATION". DTC No. Detection Condition Trouble Area B1442 Air outlet damper position sensor valve does not change even if air conditioning amplifier operated air outlet damper control servo motor. • • • Air inlet control servo motor Wire harness between air inlet control servo motor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Air Inlet Control Servo Motor PT TPI GND SGTPI VZ S5TPI Mrec Mfrs AIR AIF E125211E02 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/I DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON and push the intelligent tester main switch ON. AC AC–86 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "RECIRCULATION": -1.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK: When the target position is at the "RECIRCULATION" (-1.0%), the actual opening angle is 19.0% or less. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 READ VALUE OF INTELLIGENT TESTER (A/I DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier AC Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/I DAMP POS Air inlet damper position / min.: -14% max.: 113.5% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% A/I DAMP TARG Air inlet damper target position / min.: -14% max.: 113.5% Damper is at "FRESH": 110.0% Damper is at "HALFRECIRCULATION": 20.0 to 102.0% Open in the circuit: 50.0% OK: When the target position is at the "FRESH" (110.0%), the actual opening angle is 81.0% or more. AC–87 AIR CONDITIONING – AIR CONDITIONING SYSTEM Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR INLET CONTROL SERVO MOTOR (a) Remove the damper air inlet servo motor. (b) Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4 then check that the lever turns to "FRESH" position smoothly. (c) Measure the resistance of the servo motor. Standard resistance Mfrs Mrec RECIRCULATION FRESH Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) FRESH position 0.6 to 1.1 kΩ (d) Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to "RECIRCULATION" position smoothly. (e) Measure the resistance of the servo motor. Standard resistance Tester Connection Condition Specified Condition A14-3 (PT) - A14-2 (GND) RECIRCULATION position 3.4 to 6.2 kΩ NG E127534E01 REPLACE AIR INLET CONTROL SERVO MOTOR OK AC AC–88 4 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK WIRE HARNESS (AIR INLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Inlet Control Servo Motor Mfrs A14 Mrec Air Conditioning Amplifier Tester Connection Specified Condition A8-22 (AIR) - A14-4 (Mrec) Below 1 Ω A8-23 (AIF) - A14-5 (Mfrs) Below 1 Ω A8-22 (AIR) - Body ground 10 kΩ or higher A8-23 (AIF) - Body ground 10 kΩ or higher NG A8 AIF (a) Disconnect the A14 servo connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance AIR E125234E02 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1443 AC–89 Air Outlet Damper Control Servo Motor Circuit DESCRIPTION This circuit turns the servo motor and changes each damper position by receiving the signals from the air conditioning amplifier. The air outlet damper servo switches the air outlet by rotating the motor (normal, reverse) with electrical power from the air conditioning amplifier. When the AUTO switch is on, the air conditioning amplifier changes the mode between "FACE", "BILEVEL" and "FOOT" according to the temperature setting. DTC No. Detection Condition Trouble Area B1443 Air outlet damper position sensor valve does not change even if air conditioning amplifier operated air outlet damper control servo motor. • • • Air outlet control servo motor Wire harness between air outlet control servo motor and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Air Conditioning Amplifier Air Outlet Control Servo Motor PT TPM GND SGTPM VZ S5TPM MFACE MDEF AOF AOD E125211E03 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (A/O DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. AC AC–90 AIR CONDITIONING – AIR CONDITIONING SYSTEM (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Open in the circuit: 50.0% A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE": -10.0% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Open in the circuit: 50.0% OK: When the target position is at the "FACE" (-10.0%), the actual opening angle is 19.0% or less. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 READ VALUE OF INTELLIGENT TESTER (A/O DAMP POS, TARG) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier AC Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP POS Air outlet damper position / min.: -14% max.: 113.5% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% AC–91 AIR CONDITIONING – AIR CONDITIONING SYSTEM Item Measurement Item / Display (Range) Normal Condition Diagnostic Note A/O DAMP TARG Air outlet damper target position / min.: -14% max.: 113.5% Damper is at "FACE/FOOT": 12.0% Damper is at "FOOT" (Manual): 33.5% or 69.0% Damper is at "FOOT" (Auto): 49.0% or 69.0% Damper is at "FACE/DEF": 69.0% or 95.0% Damper is at "DEF": 110.0% Open in the circuit: 50.0% OK: When the target position is at the "DEF" (110.0%), the actual opening angle is 81.0% or more. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 3 INSPECT AIR OUTLET CONTROL SERVO MOTOR (a) Remove the air outlet control servo motor. (b) Connect the battery's positive (+) lead to terminal 4 and negative (-) lead to terminal 5 then check that the lever turns to "FACE" position smoothly. (c) Measure the resistance of the servo motor. Standard resistance MDEF MFACE Tester Connection Condition Specified Condition A8-3 (PT) - A8-2 (GND) FACE position 3.6 to 6.7 kΩ (d) Connect the battery's positive (+) lead to terminal 5 and negative (-) lead to terminal 4 then check that the lever turn to "DEF" position smoothly. (e) Measure the resistance of the servo motor. Standard resistance DEF FACE Tester Connection Condition Specified Condition A8-3 (PT) - A8-2 (GND) DEF position 0.6 to 1.1 kΩ NG REPLACE AIR OUTLET CONTROL SERVO MOTOR E127535E01 OK AC AC–92 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 CHECK WIRE HARNESS (AIR OUTLET CONTROL SERVO MOTOR - AIR CONDITIONING AMPLIFIER) Wire Harness Side Air Outlet Control Servo Motor MDEF A16 MFACE Air Conditioning Amplifier (a) Disconnect the A16 servo connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Tester Connection Specified Condition A8-16 (AOF) - A16-4 (MFACE) Below 1 Ω A8-24 (AOD) - A16-5 (MDEF) Below 1 Ω A8-16 (AOF) - Body ground 10 kΩ or higher A8-24 (AOD) - Body ground 10 kΩ or higher NG A8 AOF AOD E125234E03 OK REPLACE AIR CONDITIONING AMPLIFIER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AC–93 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1462 Room Humidity Sensor Circuit DESCRIPTION The room humidity sensor detects room humidity. The voltage of the room humidity sensor changes in accordance with room humidity. The air conditioning amplifier reads changes in the room humidity sensor. The room humidity sensor is integrated with room temperature sensor. DTC No. Detection Condition Trouble Area B1462 Open or short in room humidity sensor circuit • • • Room humidity sensor (room temperature sensor) Wire harness between room humidity sensor ( room temperature sensor) and air conditioning amplifier Air conditioning amplifier WIRING DIAGRAM Room Temperature Sensor Air Conditioning Amplifier THR Room Humidity Sensor Area TR GND SGTR VO Room Temperature Sensor Area RH S5 S5RM E125205E01 INSPECTION PROCEDURE 1 READ VALUE OF INTELLIGENT TESTER (HUMIDITY SENS) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the DATA LIST, and read the display on the intelligent tester. Air conditioning amplifier Item Measurement Item / Display (Range) Normal Condition Diagnostic Note HUMIDITY SENS Humidity sensor / min.: 0% max.: 100% Actual room humidity is displayed - AC AC–94 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: The displayed is as specified in the normal condition. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER A 2 CHECK AIR CONDITIONING AMPLIFIER (RH VOLTAGE) RH A7 S5RM (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage Tester Connection Condition Specified Condition A7-9 (RH) - A7-10 (S5RM) Power switch ON (IG) at 25°C (77°F) 1.8 to 2.2 V A7-9 (RH) - A7-10 (S5RM) Power switch ON (IG) at 40°C (104°F) 1.2 to 1.6 V I041186E09 A AC HINT: As the temperature increases, the voltage decreases. Result Result Proceed to NG A OK (Checking from the PROBLEM SYMPTOMS TABLE) B OK (Checking from the DTC) C B PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE C REPLACE AIR CONDITIONING AMPLIFIER AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 AC–95 INSPECT ROOM TEMPERATURE SENSOR (HUMIDITY SENSOR) S5 (a) Remove the room temperature sensor. (b) Measure the voltage of the sensor. Standard voltage: at 25°C (77°F) Humidity 40%: 1.61 to 2.24 V at 25°C (77°F) Humidity 60%: 2.26 to 2.66 V HINT: As the humidity increases, the voltage increases (see the graph). VO NG Voltage (V) REPLACE ROOM TEMPERATURE SENSOR 㪊㪅㪌 㪊㪅㪇 㪉㪅㪌 㪉㪅㪇 㪈㪅㪌 㪈㪅㪇 㪇㪅㪌 㪇 㪈㪇 㪉㪇 㪊㪇 㪋㪇 㪌㪇 㪍㪇 㪎㪇 㪏㪇 㪐㪇 㪈㪇㪇 Humidity (%) E127526E01 OK 4 CHECK WIRE HARNESS (ROOM HUMIDITY SENSOR - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A9 sensor connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Room Humidity Sensor S5 A9 VO Air Conditioning Amplifier Tester Connection Specified Condition A7-9 (RH) - A9-3 (VO) Below 1 Ω A7-10 (S5RM) - A9-4 (S5) Below 1 Ω A7-9 (RH) - Body ground 10 kΩ or higher A7-10 (S5RM) - Body ground 10 kΩ or higher NG A7 REPAIR OR REPLACE HARNESS AND CONNECTOR RH S5RM E125235E01 AC AC–96 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK REPLACE AIR CONDITIONING AMPLIFIER AC AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1471 AC–97 A/C Inverter High Voltage Power Resource System Malfunction DESCRIPTION The A/C inverter monitors the power voltage from the main battery in the self circuit. It stops compressor control and outputs the DTC when the monitored voltage is outside the specified range. The output DTC is memorized as previous trouble. Compressor control may not resume unless the power switch is turned OFF. HINT: The hybrid control system and air conditioning system output DTCs separately. Inspect DTCs following the flowchart for the hybrid control system first if any DTCs from those systems are output simultaneously. DTC No. Detection Condition Trouble Area B1471 Open or short in A/C inverter high voltage power resource system • • Hybrid control ECU A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. AC AC–98 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECM See Multiplex Communication System (CAN Bus) CANH CANL Inverter with Converter IG1 A/C (HTR) IG TOINV ETI TOECU ITE CLK CLK Power Source Control ECU DC/DC AM1 AM2 IGID GND P/I MAIN E125212E01 AC AIR CONDITIONING – AIR CONDITIONING SYSTEM AC–99 INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG GO TO HYBRID CONTROL SYSTEM OK REPLACE A/C INVERTER AC AC–100 DTC AIR CONDITIONING – AIR CONDITIONING SYSTEM B1472 A/C Inverter High Voltage Output System Malfunction DESCRIPTION The high voltage is output from the A/C inverter to the electric inverter compressor for driving the motor. Compressor control is stopped and the DTC is output if there is an open or short to ground in the output circuit. The output DTC is memorized as previous trouble. Compressor control remains stopped unless the past and current DTCs are cleared by intelligent tester. CAUTION: Wear insulated gloves and pull out the service plug grip before inspection as procedures may require disconnecting high-voltage connectors. HINT: The hybrid vehicle system and air conditioning system output DTCs separately. Inspect DTCs following the flowchart for the hybrid system first if any DTCs from those systems are output simultaneously. DTC No. Detection Condition Trouble Area B1472 Open or short in A/C inverter high voltage output system • • • Hybrid control ECU Electric inverter compressor (w/ motor compressor) A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. AC AC–101 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECM See Multiplex Communication System (CAN Bus) CANH CANL Electric Inverter Compressor Inverter with Converter OUT-W TOINV ETI OUT-V TOECU ITE OUT-U CLK CLK E125213E01 INSPECTION PROCEDURE 1 CHECK ELECTRIC INVERTER COMPRESSOR C4 OUT-U OUT-W OUT-V Electric Inverter Compressor E072789E02 (a) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (b) Disconnect the C4 electric inverter compressor connector. (c) Measure the resistance of the inverter compressor immediately after the compressor is stopped. Standard resistance Tester Connection Specified Condition C4-1 (OUT-W) - C4-2 (OUT-V) 0.5 to 0.8 Ω C4-1 (OUT-W) - C4-3 (OUT-U) 0.5 to 0.8 Ω C4-2 (OUT-V) - C4-3 (OUT-U) 0.5 to 0.8 Ω AC AC–102 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG OK REPLACE A/C INVERTER AC REPLACE ELECTRIC INVERTER COMPRESSOR AC–103 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1473 A/C Inverter Start-up Signal System Malfunction DESCRIPTION The inverter activation signal is sent to the A/C inverter from the hybrid control ECU. Compressor control is stopped and the DTC is output if there is an open or short in the signal circuit. DTC No. Detection Condition Trouble Area B1473 Open or short in A/C inverter start-up signal system • • • Wire harness between hybrid control ECU and A/C inverter (inverter with converter) A/C inverter (inverter with converter) Hybrid control ECU NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECU See Multiplex Communication System (CAN Bus) CANH CANL Inverter STB STB E125214E01 INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. AC AC–104 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK: DTCs are not output in the hybrid control system. NG GO TO HYBRID CONTROL SYSTEM OK 2 CHECK WIRE HARNESS (HYBRID CONTROL ECU - A/C INVERTER) (a) Disconnect the H11 ECU connector. (b) Disconnect the I11 inverter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Hybrid Control ECU Tester Connection Specified Condition H11-25 (STB) - I11-5 (STB) 0.5 to 0.8 Ω H11-25 (STB) - Body ground 10 kΩ or higher H11 NG STB A/C Inverter I11 STB E127536E01 OK REPLACE A/C INVERTER AC REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1475 AC–105 A/C Inverter Cooling / Heating System Malfunction DESCRIPTION The A/C inverter in the A/C inverter monitors the cooling water temperature with the temperature sensor. It stops compressor control and outputs the DTC when the monitored temperature is outside specified range (too high or too low). The hybrid system and the air conditioning system monitor the cooling water temperature separately. If DTCs referring to an inverter cooling system malfunction are output simultaneously, there may be trouble such as insufficient cooling water. If DTCs are output only for the air conditioning system, there may be an open or short in the temperature sensor circuit in the inverter. DTC No. Detection Condition Trouble Area B1475 Cooling water temperature in the inverter is outside the specified range (temperature is too high), or there is an open or short to ground in the temperature sensor circuit. A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. INSPECTION PROCEDURE 1 CHECK COOLING WATER NOTICE: Even if DTCs are output only for the air conditioning system, inspect the cooling system first and check that it is normal as there may be trouble such as insufficient cooling water. NG ADD COOLING WATER OK 2 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG GO TO HYBRID CONTROL SYSTEM OK REPLACE A/C INVERTER AC AC–106 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1476 A/C Inverter Load System Malfunction DESCRIPTION The A/C inverter stops compressor control and outputs the DTC if the rotation load is too great or too small while controlling motor rotation in the A/C inverter. HINT: Possible reasons could be as follows: Load is low when the refrigerant gas leaks, or load is too great when refrigerant gas is excessively charged, insufficient cooling performance due to condenser fan circuit trouble, or the compressor locked up. DTC No. Detection Condition Trouble Area B1476 Motor's rotation load while the compressor is operating is too great or too small. • • • Volume of refrigerant Electric inverter compressor (w/ motor compressor) Cooling fan circuit NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. INSPECTION PROCEDURE 1 CHECK COOLER CONDENSER ASSEMBLY (a) Turn the power switch OFF and ON (READY). (b) Set the A/C temperature setting to "MAX. COOL" and the blower to " LO", and turn the A/C switch ON. (c) Check operation of the condenser fan. OK: The condenser fan rotates. NG OK AC INSPECT COOLING FAN SYSTEM AC–107 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 CHECK HFC-134A (R134A) (a) Inspect refrigerant volume. (1) Check the sight glass of the cooler unit refrigerant liquid pipe E. (2) Set the vehicle according to the conditions below. Sight Glass Item Condition All Doors Fully open Temperature Setting Max. COOL Blower Speed HI A/C ON (3) Check the sight glass. I038559E03 Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* (1) Check for gas leakage and repair if necessary (2) Add refrigerant until bubbles disappear 2 No bubbles exist (DTC B1476 is output) Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty (1) Check for gas leakage with gas leak detector and repair if necessary (2) Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive (1) Discharge refrigerant (2) Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - HINT: *: Bubbles in the sight glass with room temperature higher than usual can be considered normal if cooling is sufficient. NG CHARGE REFRIGERANT OK REPLACE ELECTRIC INVERTER COMPRESSOR AC AC–108 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1477 A/C Inverter Low Voltage Power Resource System Malfunction DESCRIPTION The A/C inverter monitors the controlling power voltage in the self circuit. It stops compressor circuit and outputs the DTC when the monitored voltage is outside the specified range. The output DTC is memorized as previous trouble. The compressor control may not resume unless the power switch is turned OFF. DTC No. Detection Condition Trouble Area B1477 An open or short to ground in the inverter's controlling power voltage circuit. A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. INSPECTION PROCEDURE 1 CHECK DIAGNOSTIC TROUBLE CODE (a) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG OK REPLACE A/C INVERTER AC GO TO HYBRID CONTROL SYSTEM AC–109 AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC B1498 Communication Malfunction (A/C Inverter Local) DESCRIPTION The hybrid control ECU and A/C inverter transmit information to one another via communication line. Compressor control is stopped and the DTC is output if communication information is cut off or abnormal information occurs. The output DTC is memorized as previous trouble. DTC No. Detection Condition Trouble Area B1498 Communication line error or open between the hybrid control ECU and the A/C inverter (inverter with converter) • • • Wire harness between hybrid control ECU and A/C inverter (inverter with converter) Hybrid control ECU A/C inverter (inverter with converter) NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECU See Multiplex Communication System (CAN Bus) CANH CANL Inverter with Converter TOINV ETI TOECU ITE CLK CLK AC E125215E01 AC–110 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK WIRE HARNESS (HYBRID CONTROL ECU - INVERTER WITH CONVERTER) (a) Disconnect the H15 and H16 ECU connectors. (b) Disconnect the I11 inverter connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Hybrid Control ECU Tester Connection H16 CLK H15 ITE Specified Condition H15-24 (ETI) - I11-3 (TOINV) Below 1 Ω H16-14 (ITE) - I11-2 (TOECU) Below 1 Ω H16-17 (CLK) - I11-4 (CLK) Below 1 Ω H15-24 (ETI) - Body ground 10 kΩ or higher H16-14 (ITE) - Body ground 10 kΩ or higher H16-17 (CLK) - Body ground 10 kΩ or higher ETI NG Inverter with Converter I11 CLK REPAIR OR REPLACE HARNESS AND CONNECTOR TOECU TOINV E127537E01 OK 2 CHECK DIAGNOSTIC TROUBLE CODE (a) Connect the H15 and H16 ECU connectors. (b) Connect the I11 inverter connector. (c) Check if DTCs for the hybrid control system are output using intelligent tester. OK: DTCs are not output in the hybrid control system. NG OK REPLACE A/C INVERTER AC GO TO HYBRID CONTROL SYSTEM AIR CONDITIONING – AIR CONDITIONING SYSTEM DTC P0AA6611 AC–111 Hybrid Battery Voltage System Isolation Fault DESCRIPTION The DTC is output if there is insulation trouble with the high-voltage circuits in the air conditioning system. Insulation trouble with the electric inverter compressor or A/C inverter may be the cause. Any oil other than ND-OIL 11 may have entered the refrigeration cycle. The motor driven with high-voltage is built into the electrical compressor and is cooled directly with refrigerant. Compressor oil (ND-OIL 11) with high insulation performance is used because a leakage of electrical power may occur if regular compressor oil (ND-OIL 8) is used. NOTICE: • Electrical insulation performance may decrease significantly if even a small amount of oil other than ND-OIL 11 is used or enters the refrigeration cycle, causing the DTC to be output. • If other oil is accidentally used and a DTC is output, collect the oil in the refrigeration cycle into the compressor and replace it with ND-OIL 11 to increase the ND-OIL 11 ratio amount. • Replace the main components (evaporator, condenser, and compressor) if a large amount of oil other than ND-OIL 11 enters the system. Failing to do so may cause electrical insulation performance to remain low, causing the DTC to be output. CAUTION: Wear insulated gloves and pull out the service plug grip before inspection as procedures may require disconnecting high-voltage connectors. DTC No. Detection item Trouble Area P0AA6-611 High voltage system insulation malfunction. • • • Electric inverter compressor (w/ motor compressor) A/C inverter (inverter with converter) Compressor oil NOTICE: The A/C inverter is integrated with the inverter with converter. It is necessary to replace the PCU box if the A/C inverter (inverter with converter) needs to be replaced because the A/C inverter (inverter with converter) cannot be replaced alone. 1 CHECK A/C INVERTER Wire Harness Side C4 OUT-V OUT-W Electric Inverter Compressor OUT-U I041196E03 (a) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (b) Disconnect the C4 inverter connector. (c) Measure the resistance of the wire harness side connector immediately after the compressor is stopped. Standard resistance Tester Connection Specified Condition C4-1 (OUT-W) - Body ground 2 MΩ or higher C4-2 (OUT-V) - Body ground 2 MΩ or higher C4-3 (OUT-U) - Body ground 2 MΩ or higher NG OK REPLACE A/C INVERTER AC AC–112 2 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK ELECTRIC INVERTER COMPRESSOR (a) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (b) Disconnect the C4 compressor connector. (c) Measure the resistance of the connector. Standard resistance Wire Harness Side C4 Electric Inverter Compressor E072789E04 Tester Connection Specified Condition C4-1 - Body ground 2 MΩ or higher C4-2 - Body ground 2 MΩ or higher C4-3 - Body ground 2 MΩ or higher NG REPLACE ELECTRIC INVERTER COMPRESSOR OK 3 AC CHECK ELECTRIC INVERTER COMPRESSOR (a) Connect the electric inverter compressor connector. (b) Install the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (c) Turn the power switch ON (IG). (d) Set the A/C setting temperature to 25°C (77°F) and the blower switch LO. Then operate the compressor for 10 minutes to circulate the refrigerant cycle with refrigerant and collect as much compressor oil remaining in each component into the compressor as possible. HINT: Inspect with sufficient oil in the compressor since the insulation resistance of the compressor changes depending on the amount of oil in the compressor. (e) Turn the power switch OFF, and leave the vehicle for a night to cool down the compressor's internal temperature. NOTICE: Do not operate the compressor before inspection. HINT: • Leave the vehicle until the compressor temperature decreases below ambient temperature. (As the compressor temperature decreases below the temperature of the condenser and evaporator, more oil can be stored in the compressor.) AIR CONDITIONING – AIR CONDITIONING SYSTEM • If there is significant difference in temperature between day and night time, it will take approximately 4 hours to cool down the compressor. Remove the service plug grip. (f) Remove the service plug grip. CAUTION: Because the compressor has a high-voltage circuit, wear insulated gloves and pull out the service plug to cut the high-voltage circuit before inspection. (g) Disconnect the C4 compressor connector. (h) Measure the resistance of the connector. Standard resistance Wire Harness Side C4 Electric Inverter Compressor AC–113 E072789E04 Tester Connection Specified Condition C4-1 - Body ground 3 MΩ or higher C4-2 - Body ground 3 MΩ or higher C4-3 - Body ground 3 MΩ or higher NOTICE: If the results are out of the specified range, replace the compressor without operating. NG REPLACE ELECTRIC INVERTER COMPRESSOR OK SYSTEM IS OK AC AC–114 AIR CONDITIONING – AIR CONDITIONING SYSTEM Blower Motor Circuit DESCRIPTION Blower Level HI M3 M2 M1 LO 29 41 53 67 89 SI duty (%) A 100 (%) Duty Ratio = A+B 0 ON OFF A B 1 cycle E110709E03 The blower motor is operated by signals from the air conditioning amplifier. Blower motor speed signals are transmitted by changes in the duty ratio. Duty Ratio The duty ratio is the ratio of the period of continuity in one cycle. For example, A is the period of continuity in one cycle, and B is the period of non-continuity. The blower motor controller controls the blower motor speed. The blower motor controller reads the signal from the air conditioning amplifier and controls rotation and speed. AC AC–115 AIR CONDITIONING – AIR CONDITIONING SYSTEM WIRING DIAGRAM Blower Motor Controller Air Conditioning Amplifier SI BLW from HTR Relay +B MBlower Motor M+ GND E125222E01 INSPECTION PROCEDURE 1 PERFORM ACTIVE TEST BY INTELLIGENT TESTER (BLOWER MOTOR) (a) Connect the intelligent tester (with CAN VIM) to DLC3. (b) Turn the power switch ON (IG) and push the intelligent tester main switch ON. (c) Select the item below in the ACTIVE TEST and then check that the relay operates. Air conditioning amplifier Item Test Details / Display (Range) Diagnostic Note BLOWER MOTOR Blower motor / min.: 0 max.: 31 - Result Result Proceed to NG (Blower motor does not operate) A NG (Blower motor operate but does not change speed) B OK C B C Go to step 6 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–116 AIR CONDITIONING – AIR CONDITIONING SYSTEM A 2 INSPECT BLOWER W/ FAN MOTOR SUB-ASSEMBLY (a) Remove the cooling unit motor w/ fan. (b) Connect the battery's positive (+) lead to terminal 1 of blower motor and negative (-) lead to terminal 2. OK: Blower motor operates smoothly. Wire Harness Side B2 Blower w/ Fan Motor NG REPLACE BLOWER W/ FAN MOTOR SUBASSEMBLY E072794E01 OK 3 CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - BATTERY) (a) Disconnect the B3 controller connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side B3 Tester Connection Specified Condition B3-1 (+B) - Body ground 10 to 14 V NG +B REPAIR OR REPLACE HARNESS AND CONNECTOR E072793E01 OK 4 CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - BODY GROUND) (a) Disconnect the B3 controller connector. (b) Measure the resistance of the wire harness side connector. Standard resistance Wire Harness Side B3 GND E072793E03 OK AC Tester Connection Specified Condition B3-3 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR AIR CONDITIONING – AIR CONDITIONING SYSTEM 5 AC–117 CHECK WIRE HARNESS (BLOWER MOTOR - BLOWER MOTOR CONTROLLER) Wire Harness Side (a) Disconnect the B2 motor connector. (b) Disconnect the B4 controller connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Blower Motor B2 Blower Motor Controller Tester Connection Specified Condition B4-1 (M-) - B2-2 Below 1 Ω B4-2 (M+) - B2-1 Below 1 Ω B4-1 (M-) - Body ground 10 kΩ or higher B4-2 (M+) - Body ground 10 kΩ or higher B4 NG M+ REPAIR OR REPLACE HARNESS AND CONNECTOR M- E125236E01 OK 6 CHECK WIRE HARNESS (BLOWER MOTOR CONTROLLER - AIR CONDITIONING AMPLIFIER) (a) Disconnect the B3 controller connector. (b) Disconnect the A8 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Blower Motor Controller B3 Tester Connection Specified Condition A8-2 (BLW) - B3-2 (SI) Below 1 Ω A8-2 (BLW) - Body ground 10 kΩ or higher NG SI REPAIR OR REPLACE HARNESS AND CONNECTOR Air Conditioning Amplifier A8 BLW E127521E01 AC AC–118 AIR CONDITIONING – AIR CONDITIONING SYSTEM OK 7 CHECK BLOWER MOTOR CONTROLLER (BLW VOLTAGE) (a) Disconnect the A8 amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 Tester Connection Specified Condition B3-1 (+B) - Body ground 10 to 14 V NG BLW REPLACE BLOWER MOTOR CONTROLLER E127522E01 OK 8 CHECK AIR CONDITIONING AMPLIFIER (BLW - BODY GROUND) (a) Remove the air conditioning amplifier with its connectors still connected. (b) Turn the power switch ON (IG). (c) Turn the blower switch ON (Lo). Wire Harness Side A8 BLW E127522E01 (d) Using an oscilloscope, measure the waveform of the amplifier. OK: Waveform is as shown in the illustration. Waveform 1 2 V/DIV. Item Content Tester Connection A8-2 (BLW) - Body ground Tool Setting 2 V/DIV., 500 msec./DIV. Condition Blower switch ON (Lo) HINT: Waveform varies depending on the blower switch setting. GND NG 500 msec./DIV. I031456E19 OK AC REPLACE BLOWER MOTOR CONTROLLER REPLACE AIR CONDITIONING AMPLIFIER AC–119 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Relay Circuit DESCRIPTION The heater relay is turned on by signals from the air conditioning amplifier. It supplies power to the blower motor controller. WIRING DIAGRAM Air Conditioning Amplifier from IG1 Relay HTR GAUGE HR DC/DC HTR to Blower Motor Controller MAIN E125218E02 INSPECTION PROCEDURE 1 INSPECT FUSE (GAUGE, HTR) (a) Remove the GAUGE fuse from the driver side junction block. (b) Remove the HTR H-fuse from the engine room junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω AC AC–120 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG REPLACE FUSE OK 2 INSPECT HEATER RELAY (Marking: HTR) (a) Remove the heater relay from the driver side junction block. (b) Measure the resistance of the relay. Standard resistance 1 4 3 5 2 1 3 5 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage applied to terminals 1 and 2) 2 E127527E01 3-4 Below 1 Ω 3-5 10 kΩ or higher (When battery voltage applied to terminals 1 and 2) NG REPLACE HEATER RELAY OK 3 CHECK WIRE HARNESS (BATTERY - AIR CONDITIONING AMPLIFIER) (a) Disconnect the A8 amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch ON (IG) 10 to 14 V NG HR REPAIR OR REPLACE HARNESS AND CONNECTOR E127522E03 OK 4 CHECK AIR CONDITIONING AMPLIFIER (HR VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the connector. Standard voltage Wire Harness Side A8 AC HR E127522E03 Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch OFF Blower switch position ON Below 1 V A8-7 (HR) - Body ground Power switch ON (IG) Blower switch position ON Below 1 V AC–121 AIR CONDITIONING – AIR CONDITIONING SYSTEM Tester Connection Condition Specified Condition A8-7 (HR) - Body ground Power switch ON (IG) Blower switch position OFF 10 to 14 V NG REPLACE AIR CONDITIONING AMPLIFIER OK PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC AC–122 AIR CONDITIONING – AIR CONDITIONING SYSTEM Heater Water Pump Circuit DESCRIPTION The heater water pump sends engine coolant to the heater core while the engine is stopped to prevent heater effectiveness from becoming low. Directed by the air conditioning amplifier, hybrid control ECU operates the water pump relay and drives the heater water pump. WIRING DIAGRAM Air Conditioning Amplifier See Multiplex Communication System (BEAN Bus) MPX+ MPX2+ Hybrid Control ECU See Multiplex Communication System (CAN Bus) CANH CANL AC W/P WP Water Pump Motor from A/C (HTR) Fuse E125221E01 AC AC–123 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT INTEGRATION RELAY (UNIT C: AC W/P) (a) Remove the integration relay from the engine room junction block. NOTICE: As the integration relay is connected to the relays and fuses in the other systems, remove it with the power switch OFF. (A DTC may be output if the power switch is ON (IG). (b) Measure the resistance of the relay. Standard resistance 5 3H 4 3H 3 3H Terminal No. Specified Condition 3H-4 - 3H-5 10 kΩ or higher 3H-4 - 3H-5 Below 1 Ω (When battery voltage applied to terminals 3H-5 and 3H-3) 3H NG REPLACE INTEGRATION RELAY I041202E01 OK 2 CHECK WIRE HARNESS (HYBRID CONTROL ECU - BATTERY) (a) Install the integration relay. (b) Disconnect the H16 ECU connectors. Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side H16 WP Tester Connection Condition Specified Condition H16-5 (WP) - Body ground Power switch ON (IG) 10 to 14 V NG E127523E01 REPAIR OR REPLACE HARNESS AND CONNECTOR OK AC AC–124 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM CHECK HYBRID CONTROL ECU (WP VOLTAGE) (a) Measure the voltage of the connector. Standard voltage Hybrid Control ECU H16 WP Tester Connection Condition Specified Condition H16-5 (WP) - Body ground Heater water pump not operated 10 to 14 V H16-5 (WP) - Body ground Heater water pump operated Below 1 V NG REPLACE HYBRID CONTROL ECU I036410E02 OK 4 INSPECT HEATER WATER PUMP ASSEMBLY (a) Remove the heater water pump. (b) Connect positive (+) lead to terminal 1 of the heater water pump connector and negative (-) lead to terminal 2. OK: Heater water pump operates smoothly. NOTICE: Complete operation within 10 seconds if there is no water in the heater water pump. NG REPLACE HEATER WATER PUMP ASSEMBLY 2 1 I036418E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR AC AC–125 AIR CONDITIONING – AIR CONDITIONING SYSTEM PTC Heater Circuit DESCRIPTION The PTC heater is installed in the radiator in the heater unit on the driver and passenger's FOOT sides and operates when cooling water temperature is low and normal heater effectiveness is insufficient. The air conditioning amplifier switches the circuit in the PTC relay and operates the PTC heater when the operating conditions (cooling water temperature is below 55°C (131°F), setting temperature is MAX. HOT, air outlet damper position is FOOT or FOOT / DEF and blower switch in not OFF) are met. WIRING DIAGRAM Air Conditioning Amplifier PTC HTR 1 PTC PTC HTR1 from IG1 Relay PTC HTR 2 GAUGE HT-1 PTC HTR2 PS HTR HT-2 PS HTR DC/DC PTC Heater PTC Heater MAIN AC E125220E01 AC–126 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 INSPECT FUSE (PS HTR, PTC HTR1, PTC HTR2, GAUGE) (a) Remove the PS HTR H-fuse, PTC HTR1 and PTC HTR2 fuses from the engine room junction block. (b) Remove the GAUGE fuse from the driver side junction block. (c) Measure the resistance of the fuses. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 INSPECT PTC HEATER RELAY (Marking: PS HTR, PTC HTR 1, PTC HTR 2) (a) Remove the PS HTR, PTC HTR 1 and PTC HTR 2 heater relays from the engine room No. 2 relay block. (b) Measure the resistance of the relays. Standard resistance PS HTR 2 3 2 5 3 5 1 Tester Connection Specified Condition 3-5 10 kΩ or higher 3-5 Below 1 Ω (When battery voltage applied to terminals 1 and 2) 1 PTC HTR 1, PTC HTR 2 2 1 5 3 1 2 5 3 E127528E01 OK AC NG REPLACE PTC HEATER RELAY AC–127 AIR CONDITIONING – AIR CONDITIONING SYSTEM 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY) (a) Disconnect the A7 air conditioning amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A7 PTC HT-2 HT-1 E127524E01 Tester Connection Condition Specified Condition A7-17 (PTC) - Body ground Power switch ON (IG) 10 to 14 V A7-26 (HT-1) - Body ground Power switch ON (IG) 10 to 14 V A7-25 (HT-2) - Body ground Power switch ON (IG) 10 to 14 V NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK 4 CHECK AIR CONDITIONING AMPLIFIER (PTC, HT-1, HT-2, VOLTAGE) (a) Connect the connectors. (b) Measure the voltage of the connector. Standard voltage A7 PTC HT-1 Tester Connection Condition Specified Condition A7-17 (PTC) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF → LO (after 30 sec.) Below 1 V → 10 to 14 V A7-26 (HT-1) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF → LO (after 30 sec.) Below 1 V → 10 to 14 V A7-25 (HT-2) - Body ground Power switch ON (READY) Temperature: Max. HOT Ventilator mode: FOOT Coolant temperature: 55°C (131°F) or lower Blower switch: OFF → LO (after 30 sec.) Below 1 V → 10 to 14 V HT-2 I041186E13 HINT: • PTC operation may stop when the electric load on the vehicle is high. Perform the inspection under conditions with low electric load (such as with headlights turned OFF). • Since the 2 PTC heaters are gradually turned to the ON position, perform the inspection 30 seconds after the blower switch is turned to the LO position. AC AC–128 AIR CONDITIONING – AIR CONDITIONING SYSTEM NG REPLACE AIR CONDITIONING AMPLIFIER OK 5 INSPECT PTC HEATER (a) Disconnect the connector from the PTC heater. (b) Check the continuity between each terminal. Standard resistance Tester Connection Specified Condition P12-1 - P12-2 Continuity (0.5 kΩ or higher) P12-3 - P12-4 Continuity (0.5 kΩ or higher) NG REPLACE PTC HEATER E072666E01 OK REPAIR OR REPLACE HARNESS AND CONNECTOR AC AC–129 AIR CONDITIONING – AIR CONDITIONING SYSTEM Steering Pad Switch Circuit DESCRIPTION AUTO, TEMP UP (+), TEMP DOWN (-), Recirculation / Fresh, Fr. DEF and Rr. DEF switches are located on the steering pad switch. The resistance of the steering pad switch changes in accordance with switch operation. The air conditioning amplifier outputs voltage to the steering pad switch and reads voltage changes according to the resistance changes with switch operation. WIRING DIAGRAM Air Conditioning Amplifier Spiral Cable ST1 SGST ST2 Steering Pad Switch Cable Steering Pad Switch LH AC2 AC2 AUTO EAC Steering Pad Switch RH TEMP+ AC2 TEMPEAC EAC Front DEF AC1 AC1 Rear DEF Inlet Air AC1 E125219E01 AC AC–130 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECTION PROCEDURE 1 CHECK AIR CONDITIONING AMPLIFIER (ST1, ST2 VOLTAGE) (a) Remove the air conditioning with connectors still connected. (b) Measure the voltage of the wire harness side connectors. Standard voltage A7 SGST ST1 ST2 I041186E12 Tester Connection Condition Specified Condition A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Fr. DEF switch ON Below 0.3 V A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Rr. DEF switch ON 0.8 to 1.5 V A7-2 (ST1) - A7-15 (SGST) Power switch ON (IG) Recirculation/Fresh switch ON 2.0 to 2.9 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) AUTO switch ON Below 0.3 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) TEMP+ switch ON 0.8 to 1.5 V A7-1 (ST2) - A7-15 (SGST) Power switch ON (IG) TEMP- switch ON 2.0 to 2.9 V OK NG AC PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE AC–131 AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 INSPECT STEERING PAD SWITCH LH Connector A AC2 (a) Remove the steering pad switch LH. (b) Measure the resistance of the connectors. Standard resistance AC1 EAC Tester Connection Condition Specified Condition A2 (AC2) - B5 (AC1) Always 1,210 Ω A7 (EAC) - B6 (EAC) Always Below 1 Ω A3 (AC1) - B5 (AC1) Always Below 1 Ω A2 (AC2) - A7 (EAC) AUTO switch ON Below 1 Ω A2 (AC2) - A7 (EAC) TEMP + switch ON 300 Ω A2 (AC2) - A7 (EAC) TEMP - switch ON 1,210 Ω NG REPLACE STEERING PAD SWITCH LH Steering Pad Switch LH Connector B AC2 EAC AC1 I041198E01 OK AC AC–132 3 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT STEERING PAD SWITCH RH (a) Remove the steering pad switch RH. (b) Measure the resistance of the connector. Standard resistance Steering Pad Switch RH Tester Connection Condition Specified Condition 2 (AC1) -1 (EAC) Fr. DEF switch ON Below 1 Ω 2 (AC1) -1 (EAC) Rr. DEF switch ON 300 Ω 2 (AC1) -1 (EAC) Recirculation/Fresh switch ON 1,210 Ω NG AC1 EAC I041199E01 OK AC REPLACE STEERING PAD SWITCH RH AC–133 AIR CONDITIONING – AIR CONDITIONING SYSTEM 4 INSPECT STEERING PAD SWITCH ASSEMBLY (a) Connect the steering pad switch RH and LH to the steering pad switch cable. (b) Measure the resistance of the connector. Standard resistance Steering Pad Switch Assembly AC1 Tester Connection Condition Specified Condition 3 (AC1) - 7 (EAC) Fr. DEF switch ON Below 1 Ω 3 (AC1) - 7 (EAC) Rr. DEF switch ON 300 Ω 3 (AC1) - 7 (EAC) Recirculation/Fresh switch ON 1,210 Ω NG REPLACE STEERING PAD SWITCH ASSEMBLY EAC I039336E02 OK AC AC–134 5 AIR CONDITIONING – AIR CONDITIONING SYSTEM INSPECT SPIRAL CABLE SUB-ASSEMBLY (a) Remove the spiral cable. (b) Measure the resistance of the connectors. Standard resistance Steering Pad Switch Assembly AC2 AC1 Tester Connection Specified Condition C12-3 (EAC) - 7 (EAC) Below 1 Ω C12-9 (AC2) - 2 (AC2) Below 1 Ω C12-10 (AC1) - 3 (AC1) Below 1 Ω EAC NG C12 AC2 AC1 EAC I039337E20 OK AC REPLACE SPIRAL CABLE SUB-ASSEMBLY AIR CONDITIONING – AIR CONDITIONING SYSTEM 6 AC–135 CHECK WIRE HARNESS (STEERING PAD SWITCH - AIR CONDITIONING AMPLIFIER) (a) Disconnect the C12 steering pad connector. (b) Disconnect the A7 amplifier connector. (c) Measure the resistance of the wire harness side connectors. Standard resistance Wire Harness Side Steering Pad Switch EAC C12 Tester Connection AC1 AC2 Air Conditioning Amplifier A7 A7-2 (ST1) - C12-10 (AC1) Below 1 Ω A7-15 (SGST) - C12-3 (EAC) Below 1 Ω A7-1 (ST2) - C12-9 (AC2) Below 1 Ω A7-2 (ST1) - Body ground 10 kΩ or higher A7-15 (SGST) - Body ground 10 kΩ or higher A7-1 (ST2) - Body ground 10 kΩ or higher NG SGST Specified Condition REPAIR OR REPLACE HARNESS AND CONNECTOR ST2 ST1 E127525E01 OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–136 AIR CONDITIONING – AIR CONDITIONING SYSTEM IG Power Source Circuit DESCRIPTION This is the main power source supplied to the air conditioning amplifier when the power switch is turned ON (IG). The power source supplied is used for operating the air conditioning amplifier, servo motor, etc. WIRING DIAGRAM Air Conditioning Amplifier IG1 A/C (HTR) IG Power Source Control ECU AM1 IGID AM2 DC/DC GND P/I MAIN E125216E01 INSPECTION PROCEDURE AC 1 INSPECT FUSE (A/C (HTR)) (a) Remove the A/C (HTR) fuse from the driver side junction block. AC–137 AIR CONDITIONING – AIR CONDITIONING SYSTEM (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG REPLACE FUSE OK 2 CHECK AIR CONDITIONING AMPLIFIER (IG VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A8 IG Tester Connection Condition Specified Condition A8-5 (IG) - A8-1 (GND) Power switch ON (IG) 10 to 14 V OK GND I041186E10 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) (a) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 Tester Connection Condition Specified Condition A8-5 (IG) - Body ground Power switch ON (IG) 10 to 14 V (b) Measure the resistance of the wire harness side connector. Standard resistance IG GND E127522E05 Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–138 AIR CONDITIONING – AIR CONDITIONING SYSTEM Back-up Power Source Circuit DESCRIPTION This is the back-up power source circuit for the air conditioning amplifier. Power is supplied even when turning the power switch OFF and is used for diagnostic trouble code memory, etc. WIRING DIAGRAM Air Conditioning Amplifier ECU-B +B DC/DC MAIN GND E125217E01 INSPECTION PROCEDURE 1 INSPECT FUSE (ECU-B) (a) Remove the ECU-B fuse from the driver side junction block. (b) Measure the resistance of the fuse. Standard resistance: Below 1 Ω NG OK AC REPLACE FUSE AIR CONDITIONING – AIR CONDITIONING SYSTEM 2 AC–139 CHECK AIR CONDITIONING AMPLIFIER (+B VOLTAGE) (a) Remove the air conditioning amplifier with connectors still connected. (b) Measure the voltage of the wire harness side connector. Standard voltage A8 Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V OK +B I041186E11 PROCEED TO NEXT CIRCUIT INSPECTION SHOWN IN PROBLEM SYMPTOMS TABLE NG 3 CHECK WIRE HARNESS (AIR CONDITIONING AMPLIFIER - BATTERY AND BODY GROUND) (a) Disconnect the A8 amplifier connector. (b) Measure the voltage of the wire harness side connector. Standard voltage Wire Harness Side A8 +B Tester Connection Specified Condition A8-6 (+B) - Body ground 10 to 14 V (c) Measure the resistance of the wire harness side connector. Standard resistance GND E127522E06 Tester Connection Specified Condition A8-1 (GND) - Body ground Below 1 Ω NG REPAIR OR REPLACE HARNESS AND CONNECTOR OK REPLACE AIR CONDITIONING AMPLIFIER AC AC–136 AIR CONDITIONING – REFRIGERANT REFRIGERANT ON-VEHICLE INSPECTION 1. Sight Glass I038559E02 INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET (a) Check the sight glass of the cooler unit refrigerant liquid pipe E. (1) Set the vehicle according to the conditions below. Item Condition All doors Fully open Temperature setting MAX COLD Blower speed HI A/C switch ON (2) Check the sight glass under these conditions. Item Symptom Amount of refrigerant Corrective Actions 1 Bubbles exist Insufficient* 1. Check for gas leakage and repair if necessary 2. Add refrigerant until bubbles disappear 2 No bubbles exist (DTC 76 is output) Empty, insufficient or excessive Refer to 3 and 4 3 No temperature difference between compressor inlet and outlet Empty or nearly empty 1. Check for gas leakage and repair if necessary 2. Add refrigerant until bubbles disappear 4 Considerable temperature difference between compressor inlet and outlet Proper or excessive Refer to 5 and 6 5 Immediately after air conditioning is turned off, refrigerant remains clear Excessive 1. Discharge refrigerant 2. Remove air and supply proper amount of purified refrigerant 6 Immediately after air conditioning is turned off, refrigerant foams and then becomes clear Proper - HINT: Bubbles in the sight glass with the room temperature higher than usual can be considered normal if cooling is sufficient. 2. AC INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET (a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established. Gauge readings (Reference) Test conditions: • Temperature at the air inlet with the switch set at RECIRC is 30 to 35°C (86 to 95°F) • Blower speed control switch at "HI" position • Temperature control switch at "MAX COLD" position • A/C switch ON • Fully open doors AC–137 AIR CONDITIONING – REFRIGERANT (1) The refrigeration system functions normally Gauge reading: Low-pressure side: 0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2) High-pressure side: 1.37 to 1.57 MPa (14 to 16 kgf/cm2) (2) Moisture present in refrigeration system E050573E01 Condition: Periodically cools and then fails to cool. I022117E19 Symptoms Probable Cause Diagnosis Corrective Actions During operation, pressure on low-pressure side cycles between normal and vacuum Moisture in refrigerating system freezes at expansion valve orifice, causing a temporary stop of cycle. However, when it melts, normal state is restored. - Cooler dryer in oversaturated state Moisture in refrigeration system freezes at expansion valve orifice and blocks circulation of refrigerant 1. Replace cooler dryer 2. Remove moisture in cycle by repeatedly evacuating air 3. Supply proper amount of new refrigerant (3) Insufficient cooling Condition: Coolig system does not function effectively. I022118E11 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is low on both low and high-pressure sides - Bubbles are continuously seen through sight glass - Insufficient cooling performance Gas leakage in refrigeration system - Insufficient refrigerant - Refrigerant leaking 1. Check for gas leakage and repair if necessary 2. Supply proper amount of new refrigerant 3. If the indicated pressure value is close to 0 when connected to the gauge, create a vacuum after inspecting and repairing location of leakage AC AC–138 AIR CONDITIONING – REFRIGERANT (4) Poor circulation of refrigerant Condition: Cooling system does not function effectively. I022119E12 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure low on both low and high-pressure sides - Frost exists on pipe from cooler condenser to A/C unit Refrigerant flow is obstructed by dirt in cooler condenser core Cooler condenser core is clogged Replace cooler condenser core (5) Refrigerant does not circulate Condition: Cooling system does not function. (Sometimes it may function) I022120E11 Symptoms Probable Cause Diagnosis Corrective Actions - Vacuum is indicated on lowpressure side and very low pressure is indicated on highpressure side - Frost or condensation is seen on piping on both sides of cooler condenser core or expansion valve - Refrigerant flow is obstructed by moisture or dirt in refrigeration system - Refrigerant flow obstructed by gas leaked from cooler expansion valve Refrigerant does not circulate 1. Check expansion valve 2. Clean out dirt in cooler expansion valve by blowing air 3. Replace cooler condenser core 4. Evacuate and charge new refrigerant 5. For gas leakage from cooler expansion valve, replace cooler expansion valve (6) Refrigerant overcharged or insufficient cooling of condenser Condition: Cooling system does not function effectively. I022121E09 AC AC–139 AIR CONDITIONING – REFRIGERANT Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - No air bubbles are seen through the sight glass when compressor speed decreases - Excessive refrigerant - Insufficient cooling of cooler condenser core - Excessive refrigerant in cycle (excessive refrigerant is supplied) - Insufficient cooling of cooler condenser core 1. Clean cooler condenser core fins 2. Check cooling fan with condenser fan motor operation 3. If 1 and 2 normal, check the amount of refrigerant and supply proper amount of refrigerant (7) Air present in refrigeration system Condition: Cooling system does not function. NOTE: These gauge indications occur when the refrigeration system opens and the refrigerant is charged without vacuum purging. I022122E08 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - Low-pressure piping is too hot to touch Bubbles are seen through sight glass Air in system - Air present in refrigeration system - Insufficient vacuum purging 1. Check compressor oil to see if it is dirty or insufficient 2. Evacuate and charge new refrigerant (8) Expansion valve malfunction Condition: Insufficient Cooling I022123E13 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - Frost or large amount of condensation on piping on lowpressure side Trouble in cooler expansion valve - Excessive refrigerant in low pressure piping - Cooler expansion valve is opened too wide Replace cooler expansion valve AC AC–140 AIR CONDITIONING – REFRIGERANT (9) Defective compression in compressor Condition: Insufficient Cooling I022124E09 Symptoms Probable Cause Diagnosis Corrective Actions - Pressure is too high on both low and high-pressure sides - Pressure is too low on highpressure side Internal leak in cooler compressor - Compression failure - Leakage from damaged valve or broken sliding parts Repair or replace compressor Gauge readings (Reference) Pressure on low-pressure side MPa (kgf/cm2) 0.5 (5.0) Blower HI Zone 0.4 (4.0) 1.06 (10.80) 0.3 (3.0) 0.27 (2.75) 0.2 (2.0) 1.2 (12.23) Blower LO Zone 0.22 (2.24) 0.2 (2.03) 1.25 (12.74) 0.14 (1.42) 0.5 (5.0) Pressure on highpressure side 1.32 (13.46) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0) MPa (kgf/cm2) I030081E04 AC AIR CONDITIONING – REFRIGERANT AC–141 REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (a) Turn the A/C switch on. (b) Operate the A/C with the setting temperature at 25 °C (77°F) and the blower level at LO for 10 minutes to circulate the refrigerant, and collect compressor oil remaining in each component into the cooler compressor as much as possible. (c) Stop the engine. (d) Using SST, let the refrigerant gas out. SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) 2. CHARGE REFRIGERANT (a) Perform vacuum purging using a vacuum pump. (b) Charge refrigerant HFC-134a (R134a). Amount: 450 +-30 g (15.9 +-1.1 oz.) SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080) Amount to be charged Charge 100 g (3.53 oz.) Mean value in proper range +-50 g (+-1.8 oz.) High Pressure Overcharged Point where bubbles disappear Refrigerant Amount Sub-cool system I030082E09 NOTICE: • Do not turn the A/C on before charging refrigerant as the cooler compressor does not work properly without any refrigerant. Operating without any refrigerant causes it to overheat. AC AC–142 AIR CONDITIONING – REFRIGERANT • Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by quantity, and not with the sight glass. HINT: Prepare a service can to recharge the refrigerant if using the refrigerant gas collected with the Freon collection/recycling device because the collective rate of the device is approximately 90%. Drain Hose Gas Leak Detector N014519E04 AC 3. WARM UP COMPRESSOR (a) Turn the A/C switch on for at least 1 minute to warm up the compressor. NOTICE: Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor) to prevent damage to the compressor. 4. INSPECT LEAKAGE OF REFRIGERANT (a) After recharging the refrigerant gas, inspect leakage of refrigerant gas using a halogen leak detector. (b) (b)After recharging the refrigerant gas, prepare the vehicle for a refrigerant gas leakage check by making sure the following conditions are met. (1) The ignition switch is OFF. (2) The vehicle is in a place with good air ventilation and without any volatile gases, such as evaporated gasoline or exhaust gas. The detector is very sensitive to volatile gases. If volatile gases are unavoidable, the vehicle must be lifted up. (3) Some refrigerant remains in the refrigerant system. (4) The compressor is OFF and its pressure is approximately 392 to 588 kPa (4 to 6 kgf/cm2). (c) Bring the gas leak detector close to the drain hose with the detector's power off. HINT: • After the blower motor has stopped, leave the cooling unit as it is for more than 15 minutes. • Expose the gas leak detector sensor under the drain hose. • When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases. (d) If a gas leak is not detected on the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test. AIR CONDITIONING – REFRIGERANT AC–143 (e) Disconnect the pressure switch connector and wait for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test. AC AIR CONDITIONING – REFRIGERANT LINE AC–143 REFRIGERANT LINE HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS COOLER REFRIGERANT LIQUID PIPE E SUCTION HOSE SUB-ASSEMBLY PIPING CLAMP (QUICK JOINT) DISCHARGE HOSE SUB-ASSEMBLY 9.8 (100, 87 in.*lbf) 5.4 (55, 49 in.*lbf) ELECTRIC INVERTER COMPRESSOR ASSEMBLY CONDENSER ASSEMBLY N*m (kgf*cm, ft.*lbf) : Specified torque E118679E01 AC AC–144 AIR CONDITIONING – AIR CONDITIONING UNIT AIR CONDITIONING UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS DEFROSTER NOZZLE ASSEMBLY NO. 1 SIDE DEFROSTER NOZZLE DUCT NO. 3 HEATER TO REGISTER DUCT NO. 3 SIDE DEFROSTER NOZZLE DUCT NO. 2 HEATER TO REGISTER DUCT NO. 1 HEATER TO REGISTER DUCT PIPING CLAMP (QUICK JOINT) SUCTION HOSE SUB-ASSEMBLY COOLER REFRIGERANT LIQUID PIPE PIPING CLAMP (QUICK JOINT) O-RING O-RING NO. 1 INSTRUMENT PANEL BRACE SUB-ASSEMBLY AIR CONDITIONING UNIT ASSEMBLY Compressor oil ND-OIL 11 or equivalent ▲ BLOWER ASSEMBLY Non-reusable part AC ▲ Use repair screws (part No. 90159-70003) if the screws removed before cannot be tightened. NO. 3 AIR DUCT REAR E118680E01 AC–145 AIR CONDITIONING – AIR CONDITIONING UNIT PIPING CLAMP PIPING CLAMP DEFROSTER NOZZLE ASSEMBLY LOWER EXPANSION VALVE COVER HEATER RADIATOR UNIT SUB-ASSEMBLY AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY NO. 1 COOLER EVAPORATOR SUB-ASSEMBLY COOLER EXPANSION VALVE O-RING AIR OUTLET DAMPER SERVO MOTOR 3.5 (35, 30 in.*lbf) O-RING HEATER PIPING COVER EVAPORATOR TEMPERATURE SENSOR AIR MIX CONTROL SERVO MOTOR ASPIRATOR PIPE QUICK HEATER ASSEMBLY NO. 1 AIR DUCT N*m (kgf*cm, ft.*lbf) : Specified torque Non-reusable part Compressor oil ND-OIL 11 or equivalent AIR CONDITIONING AMPLIFIER ASSEMBLY E118681E01 AC AC–146 AIR CONDITIONING – AIR CONDITIONING UNIT REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 2. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Check SST installation direction. SST 09870-00015 HINT: Set SST so that the stopper side is on the piping clamp lock side. (b) Install SST on the piping clamp. I003838E03 (c) Push down on SST with your thumb while holding the pipe with both hands. NOTICE: Be careful not to bend the pipe. (d) Pull SST until the stopper touches the pipe. (e) Raise SST stopper and remove the piping clamp with SST from the pipe. (f) Remove the piping clamp from SST. Pull Push SST Release Lever I003839E01 (g) Disconnect the suction hose by hand or using a screwdriver. (h) Remove the 2 O-rings from the suction hose. NOTICE: • Do not apply excessive force to the suction hose. • Seal the opening of the disconnected part using vinyl tape to prevent moisture and foreign matter from entering it. Screw driver Disconnect the hose by hand I006919E11 Heater Water Hose A Heater Water Hose B AC I038565E01 3. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) SST 09870-00025 HINT: Use the same procedures described for the suction hose. 4. DISCONNECT HEATER WATER HOSE B (a) Slide the clip and disconnect the heater water hose B. NOTICE: • Do not apply excessive force to the water hose B. • Prepare a drain pan or cloth for when the cooling water leaks. AIR CONDITIONING – AIR CONDITIONING UNIT AC–147 5. DISCONNECT HEATER WATER HOSE A (a) Slide the clip and disconnect the heater water hose A. NOTICE: • Do not apply excessive force to the water hose A. • Prepare a drain pan or cloth for when the cooling water leaks. 6. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the removal procedures for the instrument panel with the passenger airbag (see page IP-5). 7. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the removal procedures for the instrument panel lower (see page IP-17). 8. REMOVE NO. 3 AIR DUCT REAR (a) Fold back the floor carpet. HINT: Fold back the floor carpet so that the No. 3 air duct rear can be removed. (b) Detach the 10 claws and then remove the No. 3 air duct rear. 9. REMOVE NO. 3 HEATER TO REGISTER DUCT (a) Remove the clip and No. 3 heater to register duct with the No. 2 side defroster nozzle duct. I038823E03 I038566E01 10. REMOVE NO. 1 HEATER TO REGISTER DUCT (a) Remove the No. 1 duct with the No. 1 side defroster nozzle duct. I038567E01 AC AC–148 AIR CONDITIONING – AIR CONDITIONING UNIT 11. REMOVE NO. 2 HEATER TO REGISTER DUCT I038568E01 12. REMOVE DEFROSTER NOZZLE ASSEMBLY (a) Remove the 2 clips. (b) Detach the 3 claws and then remove the defroster nozzle. 13. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY 14. REMOVE ECM 15. REMOVE NETWORK GATEWAY ECU I038569E03 16. REMOVE NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (a) Detach the clamp and disconnect the harness. (b) Remove the 2 bolts, nut and instrument panel brace. 17. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Remove the air conditioning amplifier (see page AC-179). I039536E01 18. REMOVE STEERING COLUMN ASSEMBLY (a) Remove the steering column (see page SR-7). AC AIR CONDITIONING – AIR CONDITIONING UNIT AC–149 19. REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Disconnect each connector and remove each clamp. Disconnect the wire harness. I038978E03 (b) Remove the 7 bolts, 2 nuts and then remove the instrument panel reinforcement with the air conditioner unit. I038973E01 AC AC–150 AIR CONDITIONING – AIR CONDITIONING UNIT 20. REMOVE AIR CONDITIONING UNIT ASSEMBLY (a) Disconnect the 5 connectors. (b) Detach the 9 clamps and disconnect the wire harness. Clamp I038974E03 (c) Remove the bolt. (d) Detach the clamp and disconnect the junction connector. : Clamp I038975E03 (e) Remove the 2 screws and air conditioning unit from the instrument panel reinforcement. I038976E01 DISASSEMBLY 1. I038977E01 AC REMOVE BLOWER ASSEMBLY (a) Remove the 2 screws. (b) Disengage the fittings with the air conditioner and then remove the blower. AIR CONDITIONING – AIR CONDITIONING UNIT AC–151 2. REMOVE DEFROSTER NOZZLE ASSEMBLY LOWER (a) Detach the 2 claws and remove the defroster nozzle lower. 3. REMOVE AIR MIX CONTROL SERVO MOTOR (a) Remove the 2 screws and air mix control servo motor. 4. REMOVE AIR OUTLET CONTROL SERVO MOTOR (a) Remove the 2 screws and disengage the claw. (b) Detach the claw and remove the air outlet control servo motor. 5. REMOVE AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (a) Remove the 2 screws and expansion valve cover. I038835E02 I038834E02 I038825E02 I038826E01 (b) Using a 4 mm hexagon wrench, remove the 2 hexagon bolts. (c) Remove the air conditioning tube. (d) Remove the 2 O-rings from the air conditioning tube assembly. AC I038827E01 AC–152 AIR CONDITIONING – AIR CONDITIONING UNIT 6. REMOVE COOLER EXPANSION VALVE (a) Remove the cooler expansion valve from the No. 1 cooler evaporator. 7. REMOVE HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Detach the clamp and disconnect the evaporator temperature sensor connector. (b) Detach the clamp and 2 claws, and remove the heater piping cover. I038828E01 : Clamp I039537E02 (c) Remove the 4 screws and 4 clamps. (d) Remove the radiator heater unit from the air conditioner radiator. NOTICE: Prepare a drain pan or cloth for when the cooling water leaks. I038830E01 8. I039539E01 AC REMOVE NO. 1 AIR DUCT (a) Remove the 2 screws and No. 1 air duct. AIR CONDITIONING – AIR CONDITIONING UNIT 9. AC–153 REMOVE QUICK HEATER ASSEMBLY (a) Remove the 4 screws and quick heater. I038833E01 10. REMOVE NO. 1 COOLER EVAPORATOR SUBASSEMBLY (a) Remove the 7 screws and No. 1 cooler evaporator from the heater case. I038832E01 (b) Remove the 2 O-rings from the No. 1 cooler evaporator. E069079E01 11. REMOVE EVAPORATOR TEMPERATURE SENSOR (a) Detach the 2 claws and remove the evaporator temperature sensor. I038987E02 REASSEMBLY 1. INSTALL EVAPORATOR TEMPERATURE SENSOR (a) Install the evaporator temperature sensor and attach the 2 claws. AC I038987E02 AC–154 AIR CONDITIONING – AIR CONDITIONING UNIT 2. E069079E01 INSTALL NO. 1 COOLER EVAPORATOR SUBASSEMBLY (a) Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the fitting surface. Install the 2 Orings to the No. 1 cooler evaporator. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the No. 1 cooler evaporator with the 7 screws. I038832E01 3. INSTALL QUICK HEATER ASSEMBLY (a) Install the quick heater with the 4 screws. 4. INSTALL NO. 1 AIR DUCT (a) Install the No. 1 air duct with the 2 screws. 5. INSTALL HEATER RADIATOR UNIT SUB-ASSEMBLY (a) Install the air conditioning radiator to the radiator heater unit. I038833E01 I039539E01 AC AIR CONDITIONING – AIR CONDITIONING UNIT AC–155 (b) Install the 4 clamps and 4 screws. I038830E01 (c) Attach the 2 claws and clamp to install the heater piping cover. (d) Attach the clamp and connect the evaporator temperature sensor connector. : Clamp I039537E02 6. INSTALL COOLER EXPANSION VALVE (a) Install the cooler expansion valve to the No. 1 cooler evaporator. 7. INSTALL AIR CONDITIONING TUBE AND ACCESSORY ASSEMBLY (a) Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the fitting surface. Install the 2 Orings to the air conditioning tube assembly. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. I038828E01 I038827E01 AC AC–156 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Install the air conditioning tube to the No. 1 cooler evaporator, placing the cooler expansion valve between them. Using a 4 mm (0.16 in.) hexagon wrench, install the 2 hexagon bolts. Torque: 3.5 N*m (35 kgf*cm, 30 in.*lbf) (c) Install the expansion cover with the 2 screws. I038826E01 8. INSTALL AIR OUTLET CONTROL SERVO MOTOR (a) Install the air outlet control servo motor and attach the claw. (b) Attach the claw and install the 2 screws. 9. INSTALL AIR MIX CONTROL SERVO MOTOR (a) Install the air mix control servo motor with the 2 screws. I038825E02 I038834E02 10. INSTALL DEFROSTER NOZZLE ASSEMBLY LOWER (a) Install the defroster nozzle lower and attach the 2 claws. I038835E02 AC AIR CONDITIONING – AIR CONDITIONING UNIT AC–157 11. INSTALL BLOWER ASSEMBLY (a) Install the blower and then attach the fittings with the air conditioner. (b) Install the 2 screws. I038977E01 INSTALLATION 1. INSTALL AIR CONDITIONING UNIT ASSEMBLY (a) Install the air conditioning unit to the instrument panel reinforcement with the 2 screws. HINT: Use repair screws (part No. 90159-70003) if the screws removed before cannot be tightened. I038976E01 (b) Attach the clamp to connect the junction connector. (c) Install the bolt. I038975E04 (d) Attach the 9 clamps to connect the instrument panel wire harness. (e) Connect the 5 connectors. 2. INSTALL INSTRUMENT PANEL REINFORCEMENT ASSEMBLY (a) Install the instrument panel reinforcement with the 7 bolts. I038974E04 AC AC–158 AIR CONDITIONING – AIR CONDITIONING UNIT (b) Install the 2 nuts to the air conditioning unit and temporarily tighten them. I038973E01 (c) Connect each connector and install each clamp. Then connect the wire harness. I038978E04 AC 3. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the air conditioning amplifier (see page AC179). 4. INSTALL STEERING COLUMN ASSEMBLY (a) Install the steering column (see page SR-12). AIR CONDITIONING – AIR CONDITIONING UNIT AC–159 5. INSTALL NO. 1 INSTRUMENT PANEL BRACE SUBASSEMBLY (a) Install the instrument panel brace with the 2 bolts and nut. (b) Attach the clamp to connect the harness. 6. FULLY TIGHTEN AIR CONDITIONING UNIT ASSEMBLY (a) Fully tighten the air conditioning unit with the 2 nuts. NOTICE: Tighten the nuts in the order indicated in the illustration. 7. INSTALL NETWORK GATEWAY ECU 8. INSTALL ECM 9. INSTALL TRANSMISSION CONTROL ECU ASSEMBLY I039536E01 (1) (2) I040423E04 10. INSTALL DEFROSTER NOZZLE ASSEMBLY (a) Install the defroster nozzle and attach the 3 claws. (b) Install the 2 clips. I038569E04 11. INSTALL NO. 2 HEATER TO REGISTER DUCT 12. INSTALL NO. 1 HEATER TO REGISTER DUCT (a) Install the duct with the No. 1 side defroster nozzle duct. 13. INSTALL NO. 3 HEATER TO REGISTER DUCT (a) Install the clip and then the duct with the No. 2 side defroster nozzle duct. I038568E01 14. INSTALL NO. 3 AIR DUCT REAR (a) Attach the 10 claws to install the No. 3 air duct rear. (b) Return the carpet to its original position. 15. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the installation procedures for the instrument panel lower (see page IP-20). AC AC–160 AIR CONDITIONING – AIR CONDITIONING UNIT 16. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the installation procedures for the instrument panel with the passenger airbag (see page IP-11). 17. CONNECT HEATER WATER HOSE A (a) Connect the heater water hose A and slide the clip. Heater Water Hose A Heater Water Hose B I038565E01 19. CONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the attached vinyl tape from the pipe's disconnected part. (b) Sufficiently apply compressor oil (ND-OIL 11) to 2 new O-rings and the pipe's connecting part. NOTICE: • Do not use any compressor oil other than NDOIL 11 (see page ). • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (c) Install the O-rings to the pipe. (d) Insert the pipe joint into the cooler unit fitting hole securely. (e) Using the piping clamp, connect the cooler unit refrigerant liquid pipe E. NOTICE: Ensure that the piping clamp is securely engaged. INCORRECT CORRECT 18. CONNECT HEATER WATER HOSE B (a) Connect the heater water hose B and slide the clip. GAP 20. CONNECT SUCTION HOSE SUB-ASSEMBLY HINT: Use the same procedures described for the cooler unit refrigerant liquid pipe E. I006878E08 21. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) 22. ADD ENGINE COOLANT (See page CO-7) 23. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) 24. WARM UP COMPRESSOR (See page AC-142) 25. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) 26. PERFORM CALIBRATION (a) Perform calibration (see page PS-13). AC AC–161 AIR CONDITIONING – BLOWER UNIT BLOWER UNIT HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS BLOWER ASSEMBLY AIR DUCT SUB-ASSEMBLY AIR INLET SERVO MOTOR CLEAN AIR FILTER BLOWER MOTOR CONTROL AIR FILTER COVER PLATE NO. 2 COOLER WIRING HARNESS SUB-ASSEMBLY BLOWER MOTOR COVER Use a repair screw (part No. 90159-70003) if the screw removed before cannot be tightened E118682E01 AC AC–162 AIR CONDITIONING – BLOWER UNIT REMOVAL 1. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the removal procedures for the instrument panel with the passenger airbag (see page IP-5). 2. REMOVE INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the removal procedures for the instrument panel lower (see page IP-17). 3. REMOVE TRANSMISSION CONTROL ECU ASSEMBLY 4. REMOVE ECM 5. REMOVE NETWORK GATEWAY ECU 6. REMOVE NO. 1 HEATER TO REGISTER DUCT 7. REMOVE AIR DUCT SUB-ASSEMBLY (a) Remove the 2 screws and air duct. 8. REMOVE BLOWER ASSEMBLY (a) Disconnect the 10 connectors. (b) Detach the 4 clamps and disconnect the wire harness. I040426E01 AC Clamp I038839E03 AIR CONDITIONING – BLOWER UNIT AC–163 (c) Remove the 3 screws, nut and blower. I038841E01 DISASSEMBLY 1. REMOVE AIR INLET SERVO MOTOR (a) Remove the 3 screws and air inlet servo motor. 2. REMOVE BLOWER MOTOR CONTROL (a) Disconnect the connector. (b) Remove the 2 screws and blower motor control. 3. REMOVE NO. 2 COOLER WIRING HARNESS SUBASSEMBLY (a) Remove the 5 screws and blower motor cover. I038843E01 I038844E01 I038845E01 (b) Remove the No. 2 cooler wiring harness from the blower with fan motor. AC I038847E01 AC–164 AIR CONDITIONING – BLOWER UNIT 4. REMOVE BLOWER WITH FAN MOTOR SUBASSEMBLY (a) Remove the 3 screws and blower with fan motor. 5. REMOVE CLEAN AIR FILTER (a) Detach the 2 claws and then remove the air filter cover plate with the clean air filter. (b) Remove the clean air filter from the air filter cover plate. I038846E01 I038848E02 REASSEMBLY 1. INSTALL CLEAN AIR FILTER (a) Install the clean air filter to the air filter cover plate. (b) Attach the 2 claws to install the air filter cover. 2. INSTALL BLOWER WITH FAN MOTOR SUBASSEMBLY (a) Install the blower with fan motor with the 3 screws. 3. INSTALL NO. 2 COOLER WIRING HARNESS SUBASSEMBLY (a) Install the No. 2 cooler wiring harness to the blower with fan motor. I038848E02 I038846E01 AC I038847E01 AIR CONDITIONING – BLOWER UNIT AC–165 (b) Install the blower motor cover with the 5 screws. I038845E01 4. INSTALL BLOWER MOTOR CONTROL (a) Install the blower motor control with the 2 screws. (b) Connect the connector. 5. INSTALL AIR INLET SERVO MOTOR (a) Install the air inlet servo motor with the 3 screws. I038844E01 I038843E01 INSTALLATION 1. INSTALL BLOWER ASSEMBLY (a) Install the blower with the 3 screws. HINT: Use a repair screw (part No. 90159-70003) if the screw (A) removed before cannot be tightened. (A) I038841E02 AC AC–166 AIR CONDITIONING – BLOWER UNIT (b) Attach the 4 clamps to connect the wire harness. (c) Connect the connectors. (d) Install the 10 connectors of the transponder key ECU. Clamp AC 2. INSTALL AIR DUCT SUB-ASSEMBLY (a) Install the air duct with the 2 screws. 3. INSTALL NO. 1 HEATER TO REGISTER DUCT 4. INSTALL NETWORK GATEWAY ECU 5. INSTALL ECU 6. INSTALL TRANSMISSION CONTROL ECU ASSEMBLY 7. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY LOWER HINT: Refer to the installation procedures for the instrument panel sub-assembly lower (see page )IP-20. 8. INSTALL INSTRUMENT PANEL SUB-ASSEMBLY WITH PASSENGER AIRBAG ASSEMBLY HINT: Refer to the installation procedures for the instrument panel with the passenger airbag assembly (see page IP11). I038839E03 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR AC–167 ELECTRIC INVERTER COMPRESSOR REMOVAL 1. REMOVE REAR NO. 2 FLOOR BOARD 2. REMOVE DECK FLOOR BOX REAR 3. REMOVE REAR NO.3 FLOOR BOARD 4. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 5. REMOVE SERVICE PLUG GRIP 6. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 7. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the discharge hose. (b) Remove the O-ring from the discharge hose. NOTICE: Seal the openings of the disconnected parts of the discharge hose and electric inverter compressor assembly using vinyl tape to prevent moisture and foreign matter from entering them. 8. DISCONNECT SUCTION HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the suction hose. (b) Remove the O-ring from the suction hose. NOTICE: Seal the openings of the disconnected parts of the suction hose and electric inverter compressor assembly using vinyl tape to prevent moisture and foreign matter from entering them. 9. REMOVE ELECTRIC INVERTER COMPRESSOR ASSEMBLY (a) Release the green-colored lock. (1) (b) Disconnect the connector. (2) (c) Detach the 3 clamps and disconnect the wire harness. NOTICE: • Wear insulated gloves when performing the procedures. • Insulate the connector by sealing it with tape. I038560E02 I038561E01 (1) (2) AC I038562E03 AC–168 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR (d) Remove the 3 bolts and electric inverter compressor. I038563E01 INSTALLATION Service Valve 1. INSPECT COMPRESSOR OIL (a) Gradually discharge inert gas (helium) from the service valve when replacing the electric inverter compressor with a new one. Drain the following amount of oil from the new electric inverter compressor before installation. Standard amount: (Oil capacity inside new electric inverter compressor 100 + 15 cc (3.52 + 0.53 fl.oz.)) (Remaining oil amount in the removed compressor assembly with the motor (with motor compressor assembly)) = (Oil amount to be removed before installation) NOTICE: • Observe the precautions on the cooler removal/installation procedures when checking the amount of compressor oil. • Because compressor oil remains in the pipes of the vehicle, if a new compressor is installed without removing the oil inside, the amount of oil becomes too great, preventing heat exchange in the refrigerant cycles and causing refrigerant failure and/or abnormal vibration. • Check for oil leakage if the remaining oil amount in the removed compressor is too low. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. 2. INSTALL ELECTRIC INVERTER COMPRESSOR ASSEMBLY (a) Temporarily install the compressor with the 2 bolts. NOTICE: Install the bolts in the order indicated in the illustration. Service Valve I039541E01 (1) AC (2) E072576E02 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR AC–169 (b) Fully install the compressor with the 2 bolts. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) NOTICE: Tighten them in the order indicated in the illustration. (2) (1) I041159E02 (c) Install the remaining bolt. Torque: 25 N*m (255 kgf*cm, 18 ft.*lbf) I041160E01 (2) (d) Connect the wire harness. NOTICE: Wear insulated gloves when performing the procedures. (1) Connect the 3 wire harness clamps. (2) Connect the connector. (1) (3) Lock the green-colored lock. (2) (1) I041121E03 3. I038561E01 INSTALL SUCTION HOSE SUB-ASSEMBLY (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the electric inverter compressor assembly. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the O-ring to the suction hose. (c) Install the suction hose with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) AC AC–170 AIR CONDITIONING – ELECTRIC INVERTER COMPRESSOR 4. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (a) Sufficiently apply compressor oil to a new O-ring and the fitting surface of the electric inverter compressor. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (b) Install the O-ring to the discharge hose. (c) Install the discharge hose with the bolt. Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf) 5. INSTALL SERVICE PLUG GRIP 6. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 7. PERFORM INITIALIZATION (a) Perform initialization (see page IN-32). NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. 8. INSTALL REAR NO. 3 FLOOR BOARD 9. INSTALL DECK FLOOR BOX REAR I038560E01 10. INSTALL REAR NO.2 FLOOR BOARD 11. CHARGE REFRIGERANT (See page AC-141) 12. WARM UP COMPRESSOR (See page AC-142) 13. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) AC AC–171 AIR CONDITIONING – CONDENSER CONDENSER HEATER AIR CONDITIONING & AIR CONDITIONING SYSTEM COMPONENTS NO. 1 INVERTER BRACKET RADIATOR SUPPORT UPPER SUCTION BRACKET 7.5 (76, 66 in.*lbf) 5.0 (51, 44 in.*lbf) HOOD LOCK ASSEMBLY RADIATOR SUPPORT SUB-ASSEMBLY UPPER LH 5.0 (51, 44 in.*lbf) 5.0 (51, 44 in.*lbf) 3.9 (40, 35 in.*lbf) RADIATOR SUPPORT SUBASSEMBLY UPPER RH ANGLE CONDENSER ASSEMBLY (WITH RECEIVER) 5.4 (55, 49 in.*lbf) DISCHARGE HOSE SUB-ASSEMBLY 3.9 (40, 35 in.*lbf) COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) 3.9 (40, 35 in.*lbf) 5.4 (55, 49 in.*lbf) COOLER DRYER O-RING CAP N*m (kgf*cm, ft.*lbf) : Specified torque 2.9 (30, 25 in.*lbf) Compressor oil ND-OIL 11 or equivalent Non-reusable part E118683E03 AC AC–172 AIR CONDITIONING – CONDENSER ON-VEHICLE INSPECTION AC 1. INSPECT COOLER CONDENSER CORE (a) If the fins of the condenser (with receiver) are dirty, clean them with water and dry them with compressed air. NOTICE: Do not damage the fins of the cooler condenser core. (b) If the fins of the condenser (with receiver) are bent, straighten them using a screwdriver or pliers. 2. INSPECT LEAKAGE OF REFRIGERANT (a) Using a halogen leak detector, check the pipe joints for gas leakage. (b) Check the tightening torque of the joint if gas leakage is detected in a pipe joint. AIR CONDITIONING – CONDENSER AC–173 REMOVAL 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See page AC-140) 2. REMOVE FRONT FENDER LINER LH (See page ET-3) 3. REMOVE FRONT FENDER LINER RH (See page ET-3) 4. REMOVE FRONT BUMPER COVER (a) Remove the front bumper cover (see page ET-3). 5. REMOVE NO. 1 INVERTER BRACKET 6. DISCONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the bolt and disconnect the discharge hose from the condenser (with receiver). (b) Remove the O-ring from the discharge hose. NOTICE: Seal the openings of the disconnected parts of the discharge hose and the condenser using vinyl tape to prevent moisture and foreign matter from entering them. 7. DISCONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the bolt and disconnect the cooler unit refrigerant liquid pipe E from the condenser (with receiver). (b) Remove the O-ring from the cooler refrigerant liquid pipe E. NOTICE: Seal the openings of the disconnected parts of the cooler unit refrigerant liquid pipe E and the condenser using vinyl tape to prevent moisture and foreign matter from entering them. 8. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY UPPER RH (a) Remove the 4 bolts and radiator support upper. I038554E01 I038555E01 I038556E01 AC AC–174 AIR CONDITIONING – CONDENSER 9. REMOVE RADIATOR SUPPORT SUB-ASSEMBLY UPPER LH (a) Remove the 4 bolts and radiator support upper. I038982E01 10. REMOVE CONDENSER ASSEMBLY WITH RECEIVER (a) Remove the 2 angles. I038557E01 (b) Remove the 2 bolts and condenser (with receiver). I038558E01 DISASSEMBLY 1. 14 mm Hexagon Wrench REMOVE COOLER DRYER (a) Using a 14 mm hexagon wrench, remove the cap from the modulator. Modulator I032993E05 (b) Remove the O-ring from the cap. AC I032475E01 AIR CONDITIONING – CONDENSER AC–175 (c) Using pliers, remove the cooler dryer. I032994E01 REASSEMBLY 1. INSTALL COOLER DRYER (a) Using pliers, install the cooler dryer to the modulator. (b) Install a new O-ring to the cap. I032994E01 (c) Sufficiently apply compressor oil (ND-OIL 11) to the O-ring and cap fitting surface. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11 (see page 55-1). • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. E055408E02 (d) Using a 14 mm hexagon wrench, install the cap to the modulator. Torque: 2.9 N*m (30 kgf*cm, 25 in.*lbf) 14 mm Hexagon Wrench Modulator I032993E05 INSTALLATION 1. INSTALL CONDENSER ASSEMBLY WITH RECEIVER (a) Install the condenser (with receiver) with the 2 bolts. Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) AC I038558E01 AC–176 AIR CONDITIONING – CONDENSER (b) Install the 2 angles to the condenser (with receiver). I038557E01 (A) (C)(A) 2. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER RH (a) Install the radiator support upper with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B 7.5 N*m (76 kgf*cm, 66 in.*lbf) for bolt C 3. INSTALL RADIATOR SUPPORT SUB-ASSEMBLY UPPER LH (a) Install the radiator support upper with the 4 bolts. Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A 3.9 N*m (40 kgf*cm, 35 in.*lbf) for bolt B 7.5 N*m (76 kgf*cm, 66 in.*lbf) for bolt C 4. CONNECT COOLER REFRIGERANT LIQUID PIPE E (TO COOLER UNIT) (a) Remove the attached vinyl tape from the disconnected parts of the cooler refrigerant liquid pipe E and condenser assembly (with receiver). (b) Install a new O-ring to the cooler refrigerant liquid pipe E. (c) Sufficiently apply compressor oil (ND-OIL 11) to the O-ring and the cooler refrigerant liquid pipe E fitting surface. Compressor oil: ND-OIL 11 or equivalent NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (B) I038556E02 (A) (C)(A) (B) I038982E02 AC AIR CONDITIONING – CONDENSER AC–177 (d) Connect the cooler refrigerant liquid pipe E to the condenser (with receiver) with the bolt. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) 5. I038555E01 CONNECT DISCHARGE HOSE SUB-ASSEMBLY (a) Remove the attached vinyl tape from the disconnected parts of the discharge hose and the condenser (with receiver). (b) Install a new O-ring to the discharge hose. (c) Sufficiently apply compressor oil (ND-OIL 11) to the O-ring and the discharge hose fitting surface. NOTICE: • Do not use any compressor oil other than NDOIL 11. • If any compressor oil other than ND-OIL 11 is used, compressor motor insulation performance may decrease, resulting in a leakage of electric power. (d) Connect the discharge hose to the condenser (with receiver) with the bolt. Torque: 5.4 N*m (55 kgf*cm, 47 in.*lbf) I038554E01 6. INSTALL NO. 1 INVERTER BRACKET 7. INSTALL FRONT BUMPER COVER (a) Install the front bumper cover (see page ET-6). 8. INSTALL FRONT FENDER LINER RH (See page ET-7) 9. INSTALL FRONT FENDER LINER LH (See page ET-7) 10. CHARGE REFRIGERANT (See page AC-141) 11. WARM UP COMPRESSOR (See page AC-142) 12. INSPECT LEAKAGE OF REFRIGERANT (See page AC-142) AC AIR CONDITIONING – HEATER WATER PUMP AC–177 HEATER WATER PUMP REMOVAL 1. Clamp DISCONNECT HEATER WATER HOSE C (a) Detach the clamp and disconnect the wire harness. I038851E02 (b) Slide the hose clip and then disconnect the heater water hose C. NOTICE: • Do not apply excessive force to the heater water hose C. • Prepare a drain pan or cloth for when the cooling water leaks. I038852E01 2. REMOVE HEATER WATER PUMP ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 bolts and then disconnect the heater water pump. I038969E01 (c) Slide the hose clip and then disconnect the heater water hose A. (d) Remove the heater water pump. NOTICE: • Do not apply excessive force to the heater water hose A. • Prepare a drain pan or cloth for when the cooling water leaks. I038968E01 INSTALLATION Groove 1. INSTALL HEATER WATER PUMP ASSEMBLY (a) Install the heater water hose A with the hose clip. NOTICE: • Ensure that the hose groove faces upwards. • Install the hose clip in the direction shown in the illustration. AC I038971E03 AC–178 AIR CONDITIONING – HEATER WATER PUMP (b) Install the heater water pump with the 2 bolts. NOTICE: Tighten them in the order indicated in the illustration. (c) Connect the connector. (1) (2) I038969E02 2. Pink Mark INSTALL HEATER WATER HOSE C (a) Install the heater water hose C with the hose clip. NOTICE: • Install the hose marking facing upwards. • Install the hose clip in the direction shown in the illustration. I038970E03 (b) Connect the wire harness and attach the clamp. I038851E03 AC 3. ADD ENGINE COOLANT (See page CO-7) 4. CHECK FOR ENGINE COOLANT LEAKS (See page CO-9) AIR CONDITIONING – AIR CONDITIONING AMPLIFIER AC–179 AIR CONDITIONING AMPLIFIER REMOVAL 1. REMOVE INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-18) 2. REMOVE NO. 3 AIR DUCT REAR 3. REMOVE AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Disconnect the connector. (b) Remove the 2 screws and air conditioning amplifier. I038972E01 INSTALLATION I038972E01 1. INSTALL AIR CONDITIONING AMPLIFIER ASSEMBLY (a) Install the air conditioning amplifier with the 2 screws. (b) Connect the connector. 2. INSTALL NO. 3 AIR DUCT REAR 3. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (See page IP-21) AC