HVAC SYSTEM (AUTO A/C)

(DIAGNOSTICS)

AC
Page
1. Basic Diagnostic Procedure ........................................................................2
2. General Description ....................................................................................3
3. Electrical Components Location..................................................................6
4. A/C Control Module I/O Signal ....................................................................8
5. Self-diagnosis............................................................................................10
6. Diagnostics for A/C System Failure ..........................................................13
7. Diagnostic Procedure for Actuators ..........................................................22
8. Diagnostic Procedure for Sensors ............................................................33
9. Symptom Related Diagnostic....................................................................43
 BASIC DIAGNOSTIC PROCEDURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

1. Basic Diagnostic Procedure

A: PROCEDURE
Step Value Yes No
1 START INSPECTIONS. Self-diagnosis operates. Go to step 2. <Ref. to AC-13, A/
1)Perform the pre-inspection. <Ref. to AC-3, C AND/OR SELF-
INSPECTION, General Description.> DIAGNOSIS SYS-
2)Perform the self-diagnosis. <Ref. to AC-10, TEMS DO NOT
OPERATION, Self-diagnosis.> OPERATE, Diag-
Does the self-diagnosis operate? nostics for A/C
System Failure.>
2 CONFIRM MALFUNCTION PART. Malfunction part can be con- Repair the mal- Go to step 3.
Confirm the malfunction part with self-diagno- firmed. function part
sis. according to each
Can the malfunction part be confirmed? diagnostics chart.
3 CHECK COMPARTMENT TEMPERATURE. Temperature changes. Go to step 4. <Ref. to AC-17,
1)Turn the A/C switch ON. COMPARTMENT
2)Set the temperature at maximum cold posi- TEMPERATURE
tion. IS NOT
3)Check the compartment temperature CHANGED OR A/
changes. C SYSTEM DOES
Is the compartment temperature changed? NOT RESPOND
QUICKLY, Diag-
nostics for A/C
System Failure.>
4 CHECK A/C SYSTEM RESPONSE. A/C syastem responds. A/C system is OK. <Ref. to AC-17,
Change the temperature setting, and check the COMPARTMENT
response of A/C system. TEMPERATURE
Does the A/C system respond quickly? IS NOT
CHANGED OR A/
C SYSTEM DOES
NOT RESPOND
QUICKLY, Diag-
nostics for A/C
System Failure.>

AC-2
 GENERAL DESCRIPTION
2. General Description
A: CAUTION
1) Never connect the battery in reverse polarity.
• The Auto A/C control module will be destroyed
instantly.
2) Do not disconnect the battery cables while the
engine is running.
• A large counter electromotive force will be gener-
ated in the alternator, and this voltage may damage
electronic parts such as A/C control module.
3) Before disconnecting the connectors of each
sensor and the A/C control module, be sure to turn
off the ignition switch.
• Otherwise, the Auto A/C control module may be
damaged.
4) Every Auto A/C-related part is a precision part.
Do not drop them.
5) Airbag system wiring harness is routed near the
A/C control panel (A/C control module) and junction
box.
CAUTION:
• All airbag system wiring harness and con-
nectors are colored yellow. Do not use electri-
cal test equipment on these circuits.
• Be careful not to damage the airbag system
wiring harness when servicing the A/C control
panel (A/C control module) and junction box.
AC-3
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
B: INSPECTION
Before performing diagnosis, check the following
items which might affect A/C system problems.
1. BATTERY
1) Measure the battery voltage and specific gravity
of electrolyte.
Standard voltage: 12 V
Specific gravity: Above 1.260
2) Check the condition of the fuses for A/C, heater
and other fuses.
3) Check the condition of the harnesses and har-
ness connectors connection.
2. ASPIRATOR HOSE
1) Turn the ignition switch to ON.
2) Turn the temperature control dail to maximum
hot position.
3) Turn the air flow control dial to “DEF” position.
4) Turn the fan speed control dial to 4th position.
5) Firmly hold a thin thread (b) in front of the in-ve-
hicle sensor suction port (a) for the auto A/C control
unit and check that the thread moves towards the
port indicating that air is being sucked into the port.
NOTE:
Ensure the thread does not get sucked into the
port.
(a)
(a)
(b)
AC-00094
6) If the thread does not move at all, remove the
lower cover <Ref. to AC-36, REMOVAL, Control
Unit.> and check for improper connection of the as-
pirator hose (a), lower cover and heater unit and
secure as necessary.
(a)
AC-00065
 GENERAL DESCRIPTION
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

3. REFRIGERANT LINE
Check contact for refrigerant line (A) and high-pres-
sure pipe.

(A)

AC-00096

4. CONTROL LINKAGE
1) Check the state of mode door linkage.
2) Check the state of air mix door linkage.
3) Check the state of intake door linkage.

AC-4
 GENERAL DESCRIPTION
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

5. CONTROL SWITCHES
Start and warm up the engine completely.
1) Inspection using switches.
No. Point to check Switch operation Judgement standard
1 Fan speed control dial Turn the fan speed control dial clockwise. Fan speed changes as dial turn.
• Outlet air: Cool
A. AUTO switch: ON • Fan speed: 4th
B. Temperature control dial maximum cold posi- • Compressor: AUTO
tion • Outlet: VENT
• Inlet: RECIRC
• Outlet air: Cool → Hot
AUTO switch and C. Turn the temperature control dial from maxi- • Fan speed: AUTO
2 temperature control mum cold position to maximum hot position grad- • Compressor: AUTO
dial ually. • Outlet: AUTO
• Inlet: AUTO
• Outlet air: Hot
• Fan speed: 4th
D. Temperature control dial maximum hot position • Compressor: AUTO
• Outlet: HEAT
• Inlet: FRESH
Air flow outlet changes from VENT → BI-
3 Mode control dial Turn the mode control dial clockwise.
LEVEL → HEAT → DEF/HEAT.
FRESH/RECIRC Air flow inlet changes from RECIRC →
4 Push the FRESH/RECIRC.
switch FRESH, or FRESH → RECIRC.
• Outlet air: AUTO
• Fan speed: AUTO
5 DEF switch Push the DEF. • Compressor: ON
• Outlet: DEF
• Inlet: FRE

2) Compressor operation inspection

No. Point to check Switch operation Judgement standard
A. A/C switch ON
1 Compressor Compressor: ON
B. Turn the fan speed control clockwise.

3) Illumination control inspection

No. Point to check Switch operation Judgement standard
A. Lighting switch ON Illumination light illuminates.
1 Illumination
B. Press the OFF switch one second or more. Illumination dimming is cancelled.

AC-5
 ELECTRICAL COMPONENTS LOCATION
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

3. Electrical Components Location

A: LOCATION
1. ENGINE COMPARTMENT

(1)

(2)

(3)

(2)

(1)

(3) (4)

AC-00097

(1) A/C compressor (3) Pressure switch

(2) A/C relay (4) Ambient sensor

AC-6
 ELECTRICAL COMPONENTS LOCATION
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

2. PASSENGER COMPARTMENT

(3)

(4)

(2)

(5)

(6)
(1)
(7)

(4)

(6)

(1)

(7)
(5)

(3)

AC-00098

(1) Mode door actuator (4) Intake door actuator (7) Air mix door actuator
(2) In-vehicle sensor (5) Blower motor
(3) Sunload sensor (6) Evaporator sensor

AC-7
 A/C CONTROL MODULE I/O SIGNAL
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

4. A/C Control Module I/O Signal

A: ELECTRICAL SPECIFICATION

10 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 16 15 14 13 12 11 10 9

To B: i49 To A: i48

AC-00099

Connector & Specified

Content Measuring condition
Terminal No. value
B9 Changes outlet from VENT to DEF.
Mode door actuator power supply *2
B8 Changes outlet from DEF to VENT.
B7 Changes air mix door from COOL to HOT.
Air mix door actuator power supply *1
B6 Changes air mix door from COOL to HOT.
B5 IGN power supply Ignition switch: ON Battery voltage
B4 Battery power supply Ignition switch: OFF, ACC, ON Battery voltage
Ignition switch: ON and under normal sunload
B3 Sunload sensor 3V
(without sunload: 5 V)
B2 Evaporator sensor Ignition switch: ON 5 V or less
Air mix door: COOL position 0.5 V
B1 Air mix door actuator P.B.R. signal
Air mix door: HOT position 4.5 V
B20 Air inlet: FRESH (other positions: 12V) 0V
B19 Intake door actuator signal Air inlet: MIX (other positions: 12 V) 0V
B18 Air inlet: RECIRC (other positions: 12 V) 0V
B17 A/C ON signal A/C: ON (A/C OFF: 0 V) 8 — 10 V
B16 Blower motor control *3 *3
When blower fan running (when blower fan not
B15 Blower fan ON signal 0V
running: 12 V)
B13 Engine coolant temperature sensor When the engine coolant is at 49°C (120°F) 8.9 V
B12 In-vehicle sensor — —
B11 Ground When there is continuity to chassis ground 0Ω
A7 Air mix door actuator P.B.R. reference voltage Ignition switch: ON 5V
BI-LEVEL, DEF 5V
A5 Mode door actuator position detection signal Outlet
VENT, HEAT, DEF/HEAT 0V
HEAT, DEF/HEAT, DEF 5V
A4 Mode door actuator position detection signal Outlet
VENT, BI-LEVEL 0V
Ignition switch: ON, light switch: ON Battery voltage
A1 Illumination power supply
Ignition switch: ON, light switch: OFF 0V
A16 Sensor ground When there is continuity to chassis ground 0Ω

AC-8
 A/C CONTROL MODULE I/O SIGNAL
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Connector & Specified

Content Measuring condition
Terminal No. value
Combination meter (ambient temperature sig-
A14 *3 *3
nal)
VENT, BI-LEVEL, HEAT 5V
A13 Mode door actuator position detection signal Outlet
DEF/HEAT, DEF 0V
VENT, DEF/HEAT 5V
A12 Mode door actuator position detection signal Outlet
BI-LEVEL, HEAT, DEF 0V
A/C: ON Battery voltage
A10 A/C cutout signal
Pressure switch operated 0V
A9 Illumination ground When there is continuity to chassis ground 0Ω
*1: Battery voltage is indicated when motor running, 0 V or battery voltage pulse signal is output when motor
stops.
*2: Battery voltage is indicated when motor running, 0 V is indicated when motor stops.
*3: Voltage can not be measured because of pulse signal.
B: SCHEMATIC
<Ref. to WI-54, SCHEMATIC, Air Conditioning
System.>

AC-9
 SELF-DIAGNOSIS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

5. Self-diagnosis
A: OPERATION
(3) (4) (5)

(2) (7)

(1) (9) (6)

(8)
AC-00250

(1) Temperature control dial (4) A/C switch (7) Rear window defogger switch
(2) OFF/BRIGHT switch (5) DEF switch (8) FRESH/RECIRC switch
(3) AUTO switch (6) Mode control dial (9) Fan speed control dial

: switch
Normal Operation

IG OFF ON
with pressing
OFF
DEF + A/C
Self-Diagnosis Mode

LED Display Check

After the LED

display AUTO
(Approx. 20sec.) FRESH / RECIRC
FRESH / RECIRC
A/C
Sensor Check Output Equipment Operation
(Sequential Operation) (Sequential Operation)
A/C
AUTO AUTO
A/C FRESH / RECIRC

Sensor Check Output Equipment Operation

(Phased Operation) (Phased Operation)
FRESH / RECIRC A/C
AUTO AUTO

AC-00242

Step Value Yes No

1 SELECT CONTROL PANEL TO SELF-DIAG- Self-diagnosis mode operates. Go to step 2. <Ref. to AC-13, A/
NOSIS MODE. C AND/OR SELF-
Start the engine while pressing DEF switch DIAGNOSIS SYS-
and A/C switch. TEMS DO NOT
Does the self-diagnosis mode operate? OPERATE, Diag-
nostics for A/C
System Failure.>

AC-10
 SELF-DIAGNOSIS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

2 CHECK LED ILLUMINATION. LED blink. Go to step 3. Go to step 5.
Make sure that three LED blink in turn on con-
trol panel (5 patterns are repeated 2 times).
Do all LED blink?
3 CHECK SENSORS MALFUNCTION. LED is turned off. Go to step 4. Confirm the com-
1)After completing the LED check or when bination of illumi-
AUTO switch is pressed, the A/C switch LED nating LEDs by
illuminates, and then the sensor check is using Sensor
started. Check Table, and
2)Check the input signal of each sensor in turn. identify the mal-
If there are any trouble for each sensor, DEF, functioning sensor
MODE and fan speed LEDs are blinked. Also before repairing.
check for each sensor is possible respectively <Ref. to AC-12,
every time AUTO switch is pressed. (At this SENSOR CHECK
time, the AUTO switch LED illuminates.) TABLE, OPERA-
3)If there is no trouble, DEF, MODE and fan TION, Self-diagno-
speed LEDs are turned off. sis.>
NOTE:
Rear window defogger LED illuminates in case
of stored malfunction but does not illuminate in
case of present malfunction.
Does each DEF, MODE and fan speed LED
turn off?
4 CHECK OPERATION OF EACH ACTUATOR, Operates according to operat- Press the OFF Refer to each diag-
COMPRESSOR AND FAN MOTOR. ing mode table. switch or turn the nostics chart for
1)Press the FRESH/RECIRC switch (FRESH/ ignition switch to actuator, compres-
RECIRC switch LED illuminates at this time.). OFF and finish the sor and fan motor,
2)Refer to OPERATING MODE TABLE to self- diagnosis and repair the mal-
check the operation of each actuator, compres- mode. functioning part as
sor and fan motor.<Ref. to AC-12, OPERAT- necessary.
ING MODE TABLE, OPERATION, Self-
diagnosis.>
Also check for each step is possible respec-
tively every time AUTO switch pressed. (At this
time, the AUTO switch LED illuminates.)
Does each actuator, compressor and fan motor
operate according to operating mode table?
5 CHECK POOR CONTACT. There is not poor contact. Replace the A/C Repair the con-
Check the A/C control module connector for control module. nector.
poor contact.
Is there a poor contact in connector?

AC-11
 SELF-DIAGNOSIS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

1. SENSOR CHECK TABLE

NOTE:
When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check
the sunload sensor at a place where sun shines directly on it.
Present Stored
Diag- Open circuit Short circuit
malfunction malfunction
nostic Checked sensor
steps MODE/FAN MODE/FAN REAR WINDOW
DEF LED DEF LED
LED LED DEFOGGER LED
VENT VENT
1 In-vehicle sensor
LED blinks LED blinks
BI-LEVEL BI-LEVEL
2 Ambient sensor
LED blinks LED blinks
HEAT HEAT
3 Evaporator sensor
LED blinks LED blinks
Turn off DEF/HEAT Illuminate DEF/HEAT Turn off Illuminate
4 Sunload sensor*1
LED blinks LED blinks
Fan speed Fan speed
5 Air mix door actuator P.B.R. 1st 1st
LED blinks LED blinks
Fan speed Fan speed
Combination meter commu-
6 2nd 2nd
nication (Ambient sensor)
LED blinks LED blinks
When all parts are in good
Turn off
condition

*1: Only present malfunction is indicated for open circuit of sunload sensor. (However, stored malfunction
can be indicated for short circuit of sunload sensor.)
2. OPERATING MODE TABLE
Step 1 2 3 4 5 6 7 8
VENT BI-LEVEL DEF/HEAT Fan speed Fan speed Fan speed Fan speed
Illuminating LED HEAT LED
LED VENT LED 1st LED 2nd LED 3rd LED 4th LED
Fan speed LO LO ML ML ML MH MH HI
Mode actuator VENT VENT VENT BI-LEVEL HEAT HEAT DEF/HEAT DEF
Intake actuator FRESH RECIRC RECIRC FRESH FRESH FRESH FRESH FRESH
FULL FULL FULL
MEDIUM MEDIUM FULL HOT FULL HOT FULL HOT
Air mix door actuator (%) COOL COOL COOL
(50%) (50%) (100%) (100%) (100%)
(0%) (0%) (0%)
Compressor OFF ON ON ON ON ON ON ON

AC-12
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

6. Diagnostics for A/C System Failure

A: A/C AND/OR SELF-DIAGNOSIS SYSTEMS DO NOT OPERATE
TROUBLE SYMPTOM:
• Switch LEDs are faulty and switches do not operate.
• Self-diagnosis system does not operate.
WIRING DIAGRAM:

IGNITION
SWITCH BATTERY
F/B NO.17 SBF-4 SBF-1

M/B NO.2

B201 : LHD B202 : RHD

LHD RHD

13

19
4 14

21

10

i40 : LHD i41 : RHD

B11
B5

B4

LHD : LHD MODEL

RHD : RHD MODEL

A: i48 B: i49 AUTO A/C CONTROL MODULE

A: i48 B: i49 B201 B202

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00149

AC-13
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK FUSE. Fuse is not blown out. Go to step 2. Replace the fuse.
1)Turn the ignition switch to OFF.
2)Remove the fuse No. 2 from main fuse box.
3)Check the condition of fuse.
Is the fuse blown out?
2 CHECK FUSE. Fuse is not blown out. Go to step 3. Replace the fuse.
1)Turn the ignition switch to OFF.
2)Remove the fuses No. 17 from fuse & relay
box.
3)Check the condition of fuse.
Is the fuse blown out?
3 CHECK A/C CONTROL MODULE POWER 10 V Go to step 4. Repair the short
CIRCUIT. circuit in harness
1)Pull out the A/C control module connector. for power supply
2)Measure the voltage between A/C control line.
module connector terminal and chassis ground
when turning ignition switch to OFF.
Connector & terminal
(i49) No. 4 (+) — Chassis ground (−):
Is the measured value more than specified
value?
4 CHECK A/C CONTROL MODULE POWER 10 V Go to step 5. Repair the short
CIRCUIT. circuit in harness
Measure the voltage between A/C control for power supply
module connector terminal and chassis ground line.
when turning ignition switch to ON.
Connector & terminal
(i49) No. 5 (+) — Chassis ground (−):
Is the measured value more than specified
value?
5 CHECK A/C CONTROL MODULE GROUND 1Ω Go to step 6. Repair the short
CIRCUIT. circuit in harness
Measure the resistance of harness between for ground line.
A/C control module and chassis ground.
Connector & terminal
(i49) No. 11 — Chassis ground:
Is the measured value less than specified
value?
6 CHECK POOR CONTACT. There is no poor contact. Repair the A/C Repair the con-
Check poor contact in A/C control module. control module. nector.
Is there poor contact in connector?

AC-14
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

B: BLOWER MOTOR IS NOT ROTATED

TROUBLE SYMPTOM:
• Blower motor is not rotated.
• Blower motor is not shifted.
WIRING DIAGRAM:

BATTERY
F/B NO.1 SBF-3 SBF-1

F/B NO.2
IGNITION
SWITCH
F/B NO.17 SBF-4

BLOWER
MOTOR RELAY 3
RHD

RHD
2 B201 i40
1
3 LHD 18 LHD
4

B50

BLOWER MOTOR
1
2 22
5
B202 i41 LHD : LHD MODEL
B87
RHD : RHD MODEL
B15
B16

A: i48 B: i49 AUTO A/C CONTROL MODULE

E

B50 B87 A: i48 B: i49

1 2 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
3 4 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20

B202 B201

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00150

AC-15
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK FUSE. Fuse is not blown out. Go to step 2. Replace the fuse.
1)Remove the No.1, No. 2 and No. 17 fuses in
fuse & relay box.
2)Check the condition of fuses.
Are any of the fuses blown out?
2 CHECK POWER SUPPLY TO BLOWER FAN 8 V (At normal temperature) Go to step 3. Repair the open
MOTOR. circuit in harness
1)Turn the ignition switch to ON. for blower fan
2)Turn the fan speed control dial clockwise. motor power sup-
3)Measure the voltage between blower fan ply line.
motor and chassis ground.
Connector & terminal
(B87) No. 1 (+) — Chassis ground (−):
Is the measured value more than specified
value?
3 CHECK BLOWER FAN MOTOR RELAY. 1Ω Go to step 4. Replace the
1)Turn the ignition switch to OFF. blower fan motor
2)Remove the blower fan motor relay. relay.
3)Connect the battery positive (+) terminal to
terminal No. 1 and ground (−) terminal to No. 3
of blower motor connector.
4)Measure the resistance between No. 2 and
No. 4 terminals.
Terminals:
No. 2 — No. 4
Is the measured value less than specified
value?
4 CHECK BLOWER FAN MOTOR. Fan motor operates. Go to step 5. Replace the
1)Disconnect the connector from blower fan blower fan motor.
motor.
2)Connect the battery positive (+) terminal to
terminal No. 1 and ground (−) terminal to No. 2
and No. 5 of blower motor connector.
3)Make sure that the blower fan motor is oper-
ated.
Does the blower fan motor operate?
5 CHECK POOR CONTACT. There is no poor contact. Repair the A/C Repair the con-
Check poor contact in A/C control module. control module. nector.
Is there poor contact in connector?

AC-16
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

C: COMPARTMENT TEMPERATURE IS NOT CHANGED OR A/C SYSTEM DOES

NOT RESPOND QUICKLY
TROUBLE SYMPTOM:
• Compartment temperature is not changed.
• A/C system does not respond quickly.
WIRING DIAGRAM FOR LHD MODEL:
F27 IGNITION
RELAY HOLDER BATTERY
SWITCH
F/B NO.17 SBF-4 SBF-1
SUB FAN FUSE 3
20A
4
F/B NO.18
MAIN FAN FUSE 1
20A
2
31
34
FAN RELAY-1 MAIN FAN MOTOR
32
30 2
33
9
5 M
FAN MODE RELAY
7
8 1
6
F17
SUB FAN MOTOR
2
28
25
FAN RELAY-2 27 M
29
26 1
18
17 F16
A/C RELAY
15
19 F2 F45
*1 : TURBO MODEL : D27
10
12
11

16
3

B100 B62 NON-TURBO MODEL : A9

PRESSURE SWITCH 2 : TURBO MODEL : D28
1
* NON-TURBO MODEL : A13
2 3 : TURBO MODEL : D17
4
B202
* NON-TURBO MODEL : A14
3
24
21
18

4 : TURBO MODEL : B3
F79
i41 * NON-TURBO MODEL : B11
COMPRESSOR
5 : TURBO MODEL : A6
*
B15
A10
B17
*21
*3
*4

*56
*

1 NON-TURBO MODEL : C11

MAGNET
CLUTCH F24
A: B134 C: B136
A: i48 B: i49
*6 : TURBO MODEL : A9
NON-TURBO MODEL : D13
B: B135 D: B137 E TB : TURBO MODEL
ENGINE AUTO A/C NA : NON-TURBO MODEL
CONTROL MODULE CONTROL MODULE

F24 F16 F79 F2 F27 A: B134 : NA

F17
1 1 2 3 4 5 6 7 8 9 5 6 7 10 15 16 17 20 25 26 27 30 35 1 2 3 4 5 6 7 8
1 2
1 3 4 10 11 12 13 14 15 16 17 18 19 20 8 11 18 21 28 31
2 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 9 12 13 14 19 22 23 24 29 32 33 34 36 24 25 26 27 28 29 30 31 32 33 34 35

B: B135 : NA C: B136 : NA D: B137 : NA A: B134 : TB B: B135 : TB

1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 17 5 6 7 8 9 10 11 12 13 8 9 10 11 12 13 14 15 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 18 19 20 21 22 23 24 25 26 14 15 16 17 18 19 20 16 17 18 19 20 21 22 20 21 22 23 24 25 26 27 28

D: B137 : TB F45 B202 A: i48 A: i49

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18 19 20 21 8 9 10 11 12 13 14 15 16 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20
22 23 24 25 26 27 28 29 30 31
AC-00151

AC-17
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

WIRING DIAGRAM FOR RHD MODEL:

F27 IGNITION
RELAY HOLDER BATTERY
SWITCH
F/B NO.17 SBF-4 SBF-1
SUB FAN FUSE 3
20A
4
F/B NO.18
MAIN FAN FUSE 1
20A
2
31
34
FAN RELAY-1 MAIN FAN MOTOR
32
30 2
33
9
5 M
FAN MODE RELAY
7
8 1
6
F17
SUB FAN MOTOR
2
28
25
FAN RELAY-2 27 M
29
26 1
18
17 F16
A/C RELAY
15
19 F2
*1 : TURBO MODEL : D27
21
22
18
19
7

16
B100 NON-TURBO MODEL : A9
PRESSURE SWITCH 2 : TURBO MODEL : D28
1
* NON-TURBO MODEL : A13
2 3 : TURBO MODEL : D17
4
B201 B202
* NON-TURBO MODEL : A14
3

21
23
3

4 : TURBO MODEL : B3
F79
i40 i41 * NON-TURBO MODEL : B11
COMPRESSOR
5 : TURBO MODEL : A6
*
B15

A10
B17
*12
*3
*4

*56
*

1 NON-TURBO MODEL : C11

MAGNET
CLUTCH F24
A: B134 C: B136
A: i48 B: i49
*6 : TURBO MODEL : A9
NON-TURBO MODEL : D13
B: B135 D: B137 E TB : TURBO MODEL
ENGINE AUTO A/C NA : NON-TURBO MODEL
CONTROL MODULE CONTROL MODULE

F24 F16 F79 F2 F27 A: B134 : NA

F17 1 2 3 4 5 6 7 8 9 10
1 5 6 7 10 15 16 17 20 25 26 27 30 35 1 2 3 4 5 6 7 8
11 12 13 14 15 16 17 18 19 20 21 22 1 2
1 3 4 8 11 18 21 28 31
2 1 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
3 4 9 12 13 14 19 22 23 24 29 32 33 34 36 24 25 26 27 28 29 30 31 32 33 34 35

B: B135 : NA C: B136 : NA D: B137 : NA A: B134 : TB B: B135 : TB

1 2 3 4 5 6 7 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 8 9
8 9 10 11 12 13 14 15 16 17 18 19 7 8 9 10 11 12 13 14 15 16 17 5 6 7 8 9 10 11 12 13 8 9 10 11 12 13 14 15 10 11 12 13 14 15 16 17 18 19
20 21 22 23 24 25 26 27 28 18 19 20 21 22 23 24 25 26 14 15 16 17 18 19 20 16 17 18 19 20 21 22 20 21 22 23 24 25 26 27 28

D: B137 : TB B201 B202 A: i48 A: i49

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20
22 23 24 25 26 27 28 29 30 31
AC-00152

AC-18
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK FUSE. No fuse blown out. Go to step 2. Replace the fuse.
1)Turn the ignition switch to OFF.
2)Remove the main fan fuse and sub fan fuse
in main fuse box.
3)Check the condition of fuse.
Is the fuse blown out?
2 CHECK THE POWER SUPPLY TO PRES- 10 V Go to step 3. Repair the har-
SURE SWITCH. ness for pressure
1)Disconnect the connector from pressure switch power sup-
switch. ply circuit.
2)Turn the ignition switch to OFF.
3)Measure the voltage between harness con-
nector and chassis ground.
Connector & terminal
(F79) No.1 (+) — Chassis ground (−):
Is the measured value more than specified
value?
3 CHECK THE HARNESS BETWEEN PRES- 1Ω Go to step 4. Repair the har-
SURE SWITCH AND A/C RELAY HARNESS. ness between A/C
1)Turn the ignition switch to OFF. relay and pres-
2)Remove the A/C relay in the main fuse box. sure switch.
3)Measure the resistance between A/C relay
and pressure switch connector.
Connector & terminal
(F27) No.17 — (F79) No.2:
Is the measured value less than specified
value?
4 CHECK THE PRESSURE SWITCH. 1Ω Go to step 5. Replace the pres-
Measure the resistance between pressure sure switch.
switch terminals.
Terminals
No. 1 — No.2:
Is the measured value less than specified
value?
5 CHECK THE A/C CUT SIGNAL CIRCUIT. 1Ω Go to step 6. Repair the har-
1)Disconnect the connector from A/C control ness between A/C
module. control module
2)Measure the resistance between A/C control and pressure
module and pressure switch connector. switch.
Connector & terminal
(i48) No.10 — (F79) No.2:
Is the measured value less than specified
value?
6 CHECK THE A/C ON SIGNAL CIRCUIT. 1Ω Go to step 7. Repair the har-
1)Disconnect the connector from engine con- ness between A/C
trol module. control module
2)Measure the resistance between engine and engine con-
control module and A/C control module con- trol module.
nector.
Connector & terminal
Turbo model
(B134) No.6 — (i49) No.17:
Non-turbo model
(B136) No.11 — (i49) No.17:
Is the measured value less than specified
value?

AC-19
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

7 CHECK A/C RELAY. Relay operates normally. Go to step 8. Replace the A/C
1)Remove the A/C relay in main fuse box. relay.
2)Check the A/C relay. <Ref. to AC-44,
INSPECTION, Relay and Fuse.>
Is the operation of the relay OK?
8 CHECK POWER SUPPLY TO MAGNET 10.5 V (At normal temperature) Go to step 9. Repair the har-
CLUTCH OF A/C COMPRESSOR. ness for power
1)Turn the ignition switch to OFF, and then con- supply line of A/C
nect the A/C relay connector and all removed compressor.
connector.
2)Start the engine, and turn A/C switch to ON.
3)Set the temperature control dial to maximum
cold position.
4)Measure the voltage between magnet clutch
harness connector and chassis ground.
Connector & terminal
(F24) No. 1 (+) — Chassis ground (−):
Is the measured value more than specified
value?
9 CHECK OPERATION OF MAIN FAN MOTOR. Fan motor operates. Go to step 14. Go to step 10.
1)Start the engine and turn the A/C switch to
ON.
2)Check the operation of main fan motor.
Does the main fan motor operate?
10 CHECK POWER SUPPLY TO MAIN FAN MO- 10 V Go to step 11. Repair the har-
TOR. ness for main fan
CAUTION: motor power sup-
Be careful not to overheat the engine during ply circuit.
repair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from main fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 100°C
(212°F).
4)Stop the engine and turn ignition switch to
ON.
5)Measure the voltage between main fan
motor harness connector and chassis ground.
Connector & terminal
Turbo engine model:
(F17) No. 2 (+) — Chassis ground (−):
Is the measured value more than specified
value?
11 CHECK GROUND CIRCUIT OF MAIN FAN 1Ω Go to step 12. Repair the har-
MOTOR. ness for main fan
1)Measure the resistance between main fan motor ground cir-
motor harness connector and chassis ground. cuit.
Connector & terminal
(F17) No. 1 — Chassis ground:
Is the measured value less than specified
value?
12 CHECK MAIN FAN MOTOR. Fan motor operates. Go to step 13. Replace the main
Connect the battery positive (+) terminal to ter- fan motor.
minal No. 2, and ground (−) terminal to termi-
nal No. 1 of main fan motor connector to
make sure that main fan motor rotate.
Does the main fan rotate?

AC-20
 DIAGNOSTICS FOR A/C SYSTEM FAILURE
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

13 CHECK POOR CONTACT IN MAIN FAN MO- There is no poor contact. Go to step 14. Repair the poor
TOR CONNECTOR. contact in main fan
Check poor contact in main fan motor harness motor connector.
connector.
Is there poor contact in connector?
14 CHECK OPERATION OF SUB FAN MOTOR. Fan motor operates. Go to step 19. Go to step 15.
1)Start the engine and turn the A/C switch to
ON.
2)Check the operation of sub fan motor.
Does the sub fan motor operate normally?
15 CHECK POWER SUPPLY TO SUB FAN MO- 10 V Go to step 16. Repair the har-
TOR. ness for sub fan
CAUTION: motor power sup-
Be careful not to overheat the engine during ply circuit.
repair.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from sub fan
motor.
3)Start the engine, and warm it up until engine
coolant temperature increases over 100°C
(212°F).
4)Stop the engine and turn ignition switch to
ON.
5)Measure the voltage between sub fan motor
harness connector and chassis ground.
Connector & terminal
(F16) No. 2 (+) — Chassis ground (−):
Is the measured value more than specified
value?
16 CHECK GROUND CIRCUIT OF SUB FAN 1Ω Go to step 17. Repair the har-
MOTOR. ness for sub fan
Measure the resistance between sub fan motor motor ground cir-
harness connector and chassis ground. cuit.
Connector & terminal
(F16) No. 1 — Chassis ground:
Is the measured value less than specified
value?
17 CHECK SUB FAN MOTOR. Fan motor rotates. Go to step 18. Replace the sub
Connect the battery positive (+) terminal to ter- fan motor.
minal No. 2, and ground (−) terminal to termi-
nal No. 1 of sub fan motor connector to make
sure that sub fan motor rotate.
Does the sub fan motor rotate?
18 CHECK POOR CONTACT IN SUB FAN MO- There is no poor contact. Go to step 19. Repair the poor
TOR CONNECTOR. contact in sub fan
Check poor contact in sub fan motor connec- motor connector.
tor.
Is there poor contact in connector?
19 CHECK POOR CONTACT IN AUTO A/C There is no poor contact. Replace the auto Repair the con-
CONTROL MODULE CONNECTOR. A/C control mod- nector.
Check poor contact in auto A/C control module ule.
connector.
Is there poor contact in connector?

AC-21
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

7. Diagnostic Procedure for Actuators

A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM:
FRESH/RECIRC mode is not changed.
WIRING DIAGRAM:

IGNITION
SWITCH BATTERY
F/B NO.17 SBF-4 SBF-1

A: i48 B: i49 AUTO A/C CONTROL

MODULE

B18
B20
B19

i41 : LHD i40 : RHD

RHD LHD
14
13
12
4
6
5

B202 : LHD B201 : RHD

LHD : LHD MODEL

RHD : RHD MODEL

1

*2
4

3
*

: LHD MODEL : 2
*1
: RHD MODEL : 1
B91
2 : LHD MODEL : 1
* INTAKE DOOR
: RHD MODEL : 2 ACTUATOR

B91 A: i48 B: i49 B202

1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11
9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22 23 24

B201

1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00153

AC-22
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK POWER SUPPLY TO INTAKE DOOR 7 V (At normal temperature) Go to step 2. Check the harness
ACTUATOR. for open or short
1)Turn the ignition switch to OFF. between intake
2)Disconnect the intake door actuator connec- door actuator and
tor. fuse.
3)Turn the ignition switch to ON.
4)Measure the voltage between intake door
actuator connector and chassis ground.
Connector & terminal
(B91) No. 4 (+) — Chassis ground (−):
Is the measured value more than specified
value?
2 CHECK HARNESS BETWEEN A/C CON- 1Ω Go to step 3. Repair the har-
TROL MODULE AND INTAKE DOOR ACTU- ness between auto
ATOR. A/C control mod-
1)Turn the ignition switch to OFF. ule and intake
2)Disconnect the auto A/C control module con- door actuator.
nector.
3)Measure the resistance between intake door
actuator connector and auto A/C control mod-
ule connector.
Connector & terminal
LHD model:
(i49) No. 18 — (B91) No. 2:
(i49) No. 20 — (B91) No. 1:
(i49) No. 19 — (B91) No. 3:
RHD model:
(i49) No. 18 — (B91) No. 1:
(i49) No. 20 — (B91) No. 2:
(i49) No. 19 — (B91) No. 3:
Is the measured value less than specified
value?
3 CHECK INTAKE DOOR ACTUATOR OPERE- Door actuator moves to Go to step 4. Replace the intake
TION. FRESH. door actuator.
1)Connect the intake door actuator connector.
2)Ground the auto A/C control module connec-
tor with a suitable wire.
3)Turn the ignition switch to ON and check
movement of intake door actuator.
Connector & terminal
(i49) No. 20 — Chassis ground:
Is the intake door actuator moved to FRESH?
4 CHECK INTAKE DOOR ACTUATOR OPERA- Door actuator moves to Replace the auto Replace the intake
TION. RECIRC. A/C control mod- door actuator.
1)Turn the ignition switch to OFF. ule.
2)Ground the auto A/C control moodule con-
nector with a suitable wire.
3)Turn the ignition switch to ON and check
movement of intake door actuator.
Connector & terminal
(i49) No. 18 — Chassis ground:
Is the intake door actuator moved to RECIRC?

AC-23
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

B: MODE DOOR ACTUATOR

TROUBLE SYMPTOM:
Air flow outlet is not changed.
WIRING DIAGRAM:

AUTO A/C CONTROL

A: i48 B: i49
MODULE

A13
A12

A16
B9

B8

A4
A5

i41
RHD LHD

15
18 10

11
8

6
7

9
17
5

4
7

9 B202

LHD : LHD MODEL

RHD : RHD MODEL

10
1

4
7
5

6
9

B77

MODE ACTUATOR

B77 A: i48 B: i49 B202

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11
9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00154

AC-24
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK POWER SUPPLY FOR AUTO A/C 12 V Go to step 2. Replace the auto
CONTROL MODULE SIDE. A/C control mod-
1)Turn the ignition switch to ON. ule.
2)Turn the mode control dial to VENT position.
3)Press the DEF switch and measure the volt-
age between auto A/C control module and
chassis ground when VENT is changed to DEF
position.
Connector & terminal
(i49) No. 9 (+) — Chassis ground (−):
Is the measured value more than specified
value?
2 CHECK POWER SUPPLY FOR ACTUATOR 7 V (At normal temperature) Go to step 3. Repair the har-
SIDE. ness between auto
1)Turn the mode control dial to VENT position. A/C control mod-
2)Press the DEF switch and measure the volt- ule and mode door
age between mode door actuator harness con- actuator.
nector and chassis ground when VENT is
changed to DEF position.
Connector & terminal
(B77) No. 1 (+) — Chassis ground (−):
Is the measured value more than specified
value?
3 CHECK POWER SUPPLY FOR AUTO A/C 12 V Go to step 4. Replace the auto
CONTROL MODULE SIDE. A/C control mod-
1)Press the DEF switch. ule.
2)Turn the mode control dial to VENT position
and measure the voltage between auto A/C
control module and chassis ground when DEF
is changed to VENT position.
Connector & terminal
(i49) No. 8 (+) — Chassis ground (−):
Is the measured value more than specified
value?
4 CHECK POWER SUPPLY FOR ACTUATOR 7 V (At normal temperature) Go to step 5. Repair the har-
SIDE. ness between auto
1)Press the DEF switch. A/C control mod-
2)Turn the mode control dial to VENT position ule and mode door
and measure the voltage between mode door actuator.
actuator harness connector and chassis
ground when DEF is changed to VENT posi-
tion.
Connector & terminal
(B77) No. 2 (+) — Chassis ground (−):
Is the measured value more than specified
value?
5 CHECK ACTUATOR. The motor operates normally. Go to step 6. Replace the mode
1)Turn the ignition switch to OFF. door actuator.
2)Disconnect the connector from mode door
actuator.
3)Connect the battery positive (+) terminal to
terminal No. 1 and ground (−) terminal to termi-
nal No. 2 of mode door actuator to make sure
that actuator operates.
4)Connect the battery positive (+) terminal to
terminal No. 2 and ground (−) terminal to termi-
nal No. 1 of mode door actuator to make sure
that actuator operates.
Does the motor operate normally?

AC-25
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

6 CHECK AUTO A/C CONTROL MODULE SIG- HEAT, D/H, DEF: 5 V, VENT, Go to step 9. Go to step 7.
NAL VOLTAGE. BI-LEVEL: 0 V
1)Turn the ignition switch to ON.
2)Turn the mode control dial and measure volt-
age between auto A/C control module harness
connector and chassis ground for each mode.
Connector & terminal
(i48) No. 4 (+) — Chassis ground (−):
Is the measured value within specified value?
7 CHECK AUTO A/C CONTROL MODULE SIG- 5V Go to step 9. Go to step 8.
NAL POWER SUPPLY.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from mode door
actuator.
3)Turn the ignition switch to ON.
4)Measure the voltage between mode door
actuator harness connector and chassis
ground.
Connector & terminal
(B77) No. 5 (+) — Chassis ground (−):
Is the measured value within specified value?
8 CHECK HARNESS BETWEEN AUTO A/C 1Ω Replace the auto Repair the har-
CONTROL MODULE AND MODE DOOR AC- A/C control mod- ness between auto
TUATOR. ule. A/C control mod-
1)Turn the ignition switch to OFF. ule and mode door
2)Disconnect the connectors from auto A/C actuator.
control module and mode door actuator.
3)Measure the resistance of harness between
auto A/C control module and mode door actua-
tor.
Connector & terminal
(i48) No. 4 (+) — Chassis ground (−):
Is the measured value less than specified
value?
9 CHECK AUTO A/C CONTROL MODULE SIG- VENT, D/H: 5 V, BI-LEVEL, Go to step 12. Go to step 10.
NAL VOLTAGE. HEAT, DEF: 0 V
1)Turn ignition switch to ON.
2)Turn the mode control dial and measure volt-
age between auto A/C control module harness
connector and chassis ground for each mode.
Connector & terminal
(i48) No. 12 (+) — Chassis ground (−):
Is the measured value within specified value?
10 CHECK AUTO A/C CONTROL MODULE SIG- 5V Go to step 12. Go to step 11.
NAL POWER SUPPLY.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from mode door
actuator.
3)Turn the ignition switch to ON.
4)Measure the voltage between mode door
actuator harness connector and chassis
ground.
Connector & terminal
(B77) No. 6, 9 (+) — Chassis ground (−):
Is the measured value within specified value?

AC-26
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

11 CHECK HARNESS BETWEEN AUTO A/C 1Ω Replace the auto Repair the har-
CONTROL MODULE AND MODE DOOR AC- A/C control mod- ness between auto
TUATOR. ule. A/C control mod-
1)Turn the ignition switch to OFF. ule and mode door
2)Disconnect the connectors from auto A/C actuator.
control module and mode door actuator.
3)Measure the resistance of harness between
auto A/C control module and mode door actua-
tor.
Connector & terminal
(i48) No. 12 — (B77) No. 6, 9:
Is the measured value less than specified
value?
12 CHECK AUTO A/C CONTROL MODULE SIG- BI-LEVEL, DEF: 5 V, VENT, Go to step 15. Go to step 13.
NAL VOLTAGE. HEAT, D/H: 0 V
1)Turn ignition switch to ON.
2)Turn the mode control dial and measure volt-
age between auto A/C control module harness
connector and chassis ground for each mode.
Connector & terminal
(i48) No. 5 (+) — Chassis ground (−):
Is the measured value within specified value?
13 CHECK AUTO A/C CONTROL MODULE SIG- 5V Go to step 15. Go to step 14.
NAL POWER SUPPLY.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from mode door
actuator.
3)Turn the ignition switch to ON.
4)Measure the voltage between mode door
actuator harness connector and chassis
ground.
Connector & terminal
(B77) No. 4, 7 (+) — Chassis ground (−):
Is the measured value within specified value?
14 CHECK HARNESS BETWEEN AUTO A/C 1Ω Replace the auto Repair the har-
CONTROL MODULE AND MODE DOOR AC- A/C control mod- ness between auto
TUATOR. ule. A/C control mod-
1)Turn the ignition switch to OFF. ule and mode door
2)Disconnect the connectors from auto A/C actuator.
control module and mode door actuator.
3)Measure the resistance of harness between
auto A/C control module and mode door actua-
tor.
Connector & terminal
(i48) No. 5 — (B77) No. 4, 7:
Is the measured value less than specified
value?
15 CHECK AUTO A/C CONTROL MODULE SIG- VENT, BI-LEVEL, HEAT: 5V, D/ Go to step 19. Go to step 16.
NAL VOLTAGE. H, DEF: 0 V
1)Turn ignition switch to ON.
2)Turn the mode control dial and measure volt-
age between auto A/C control module harness
connector and chassis ground for each mode.
Connector & terminal
(i48) No. 13 (+) — Chassis ground (−):
Is the measured value within specified value?

AC-27
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

16 CHECK AUTO A/C CONTROL MODULE SIG- 5V Go to step 18. Go to step 17.
NAL POWER SUPPLY.
1)Turn the ignition switch to OFF.
2)Disconnect the connector from mode door
actuator.
3)Turn the ignition switch to ON.
4)Measure the voltage between mode door
actuator harness connector and chassis
ground.
Connector & terminal
(B77) No. 8 (+) — Chassis ground (−):
Is the measured value within specified value?
17 CHECK HARNESS BETWEEN AUTO A/C 1Ω Replace the auto Repair the har-
CONTROL MODULE AND MODE DOOR AC- A/C control mod- ness between auto
TUATOR. ule. A/C control mod-
1)Turn the ignition switch to OFF. ule and mode door
2)Disconnect the connectors from auto A/C actuator.
control module and mode door actuator.
3)Measure the resistance of harness between
auto A/C control module and mode door actua-
tor.
Connector & terminal
(i48) No. 13 — (B77) No. 8:
Is the measured value less than specified
value?
18 CHECK ACTUATOR GROUND CIRCUIT. 1Ω Replace the mode Repair the har-
1)Turn the ignition switch to OFF. door actuator. ness between auto
2)Disconnect the connector from auto A/C con- A/C control mod-
trol module. ule and mode door
3)Measure the resistance of harness between actuator.
auto A/C control module and mode door actua-
tor.
Connector & terminal
(i48) No. 16 — (B77) No. 10:
Is the measured value less than specified
value?
19 CHECK POOR CONTACT. There is no poor contact. Repair the poor Repair the con-
Check poor contact in auto A/C control module contact in auto A/C nector.
connector. control module.
Is there poor contact in connector?

AC-28
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

C: AIR MIX DOOR ACTUATOR

TROUBLE SYMPTOM:
Outlet air temperature is not changed.
WIRING DIAGRAM FOR LHD MODEL:

AUTO A/C CONTROL

A: i48 B: i49
MODULE

A16
B1
B7
A7

B6
1

6
3
4

i65

AIR MIX DOOR

ACTUATOR

i65 A: i48 B: i49

1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
3 4 5 6 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20

AC-00106

AC-29
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

WIRING DIAGRAM FOR RHD MODEL:

AUTO A/C CONTROL

A: i48 B: i49
MODULE

A16
B1
B7
A7

B6

i41
15
10
16
6
9

B202
1

6
3
4

B293

AIR MIX DOOR

ACTUATOR

B293 A: i48 B: i49 B202

1 2 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11
3 4 5 6 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00155

AC-30
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK POWER SUPPLY TO AIR MIX DOOR Approx. 5 V Go to step 2. Replace the auto
ACTUATOR PBR. A/C control mod-
1)Turn the ignition switch to OFF. ule.
2)Disconnect the air mix door actuator connec-
tor.
3)Turn the ignition switch and AUTO switch to
ON.
4)Measure the voltage between A/C control
module connector terminals.
Connector & terminal
(i48) No. 7 (+) — (i48) No. 16 (−):
Is the measured value within specified value?
2 CHECK POWER SUPPLY TO AIR MIX DOOR 7 V (At normal temperature) Go to step 3. Replace the auto
ACTUATOR. A/C control mod-
Measure the voltage between auto A/C control ule.
module connector and chassis ground when
setting temprature control dial to FULL COOL.
Connector & terminal
(i49) No. 6 (+) — Chassis ground (−):
Is the measured value more than specified
value?
3 CHECK POWER SUPPLY TO AIR MIX DOOR 7 V (At normal temperature) Go to step 4. Replace the auto
ACTUATOR. A/C control mod-
Measure the voltage between auto A/C control ule.
module connector and chassis ground when
setting temprature control dial to FULL HOT.
Connector & terminal
(i49) No. 7 (+) — Chassis ground (−):
Is the measured value more than specified
value?
4 CHECK HARNESS BETWEEN AUTO A/C 1Ω Go to step 5. Repair the open
CONTROL MODULE AND AIR MIX DOOR circuit in harness
ACTUATOR. between auto A/C
1)Turn the A/C and ignition switch to OFF. control module
2)Disconnect the auto A/C control module con- and air mix door
nector. actuator.
3)Measure the resistance between auto A/C
control module and air mix door actuator con-
nector.
Connector & terminal
LHD model:
(i65) No. 1 — (i49) No. 1:
(i65) No. 2 — (i49) No. 7:
(i65) No. 3 — (i48) No. 16:
(i65) No. 4 — (i48) No. 7:
(i65) No. 6 — (i49) No. 6:
RHD model:
(B293) No. 1 — (i49) No. 1:
(B293) No. 2 — (i49) No. 7:
(B293) No. 3 — (i48) No. 16:
(B293) No. 4 — (i48) No. 7:
(B293) No. 6 — (i49) No. 6:
Is the measured value less than specified
value?

AC-31
 DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

5 CHECK AIR MIX DOOR ACTUATOR PBR 0.5 V (FULL COOL) — 4.5 V Go to step 6. Replace the air
SIGNAL. (FULL HOT) mix door actuator.
1)Connect the auto A/C control module and air
mix door actuator connector.
2)Turn the ignition switch and AUTO switch to
ON.
3)Change the set temprature between FULL
COOL and FULL HOT, check voltage between
auto A/C control module connector terminals.
Connector & terminal
(i49) No. 1 — (i48) No. 16 (−):
Is the measured value within specified value?
6 CHECK POOR CONTACT. There is no poor contact. Replace the auto Repair the con-
Check poor contact in the auto A/C control A/C control mod- nector.
module connector. ule.
Is there poor contact in the connector?

AC-32
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

8. Diagnostic Procedure for Sensors

A: AMBIENT SENSOR
TROUBLE SYMPTOM:
• Fan speed is not switched when the fan speed control dial is in AUTO position.
• Malfunction related to ambient sensor is indicated in self diagnosis.
WIRING DIAGRAM FOR LHD MODEL:

B: i10

COMBINATION
METER

B30

B24
i3 B25 i2
24

2
1

B38 B37

15 1 AMBIENT
14 2 SENSOR

B202 B62 F45 F78

19

i41
A14

AUTO A/C
A: i48 B: i49 CONTROL
MODULE

B: i10 A: i48 B: i49 F78

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20

B38 B202 B37 F45

1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7
10 11 12 13 14 15 16 17 18 19 20 21 12 13 14 15 16 17 18 19 20 21 22 23 24 8 9 10 11 12 13 14 15 16
22 23 24 25 26 27 28 29 30 31 32
AC-00107

AC-33
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

WIRING DIAGRAM FOR RHD MODEL:

B: i10

COMBINATION
METER

B30

B24
B25
AT MT
i2

17 13
18 14
21 16

B37

15 1 AMBIENT
14 2 SENSOR

B202 B100 F2 F78

3

i41

AT : AT MODEL

MT : MT MODEL
A14

AUTO A/C
A: i48 B: i49 CONTROL
MODULE

B: i10 A: i48 B: i49 F78

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20

i2 : AT

B202
F2 i2 : MT

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 15 16 17 18
AC-00156

AC-34
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK HARNESS BETWEEN A/C CON- 1Ω Go to step 2. Repair the har-
TROL MODULE AND COMBINATION ness between A/C
METER . control module
1)Turn the ignition switch to OFF. and combination
2)Disconnect the connectors from A/C control meter.
module and combination meter.
3)Measure the resistance of harness between
A/C control module and combination meter.
Connector & terminal
(i10) No. 30 — (i48) No. 14:
Is the measured value less than specified
value?
2 CHECK AMBIENT SENSOR CIRCUIT. Sensor circuit is normal. Go to step 3. Repair the ambi-
Check the ambient sensor circuit. <Ref. to IDI- ent sensor circuit.
11, CHECK OUTSIDE TEMPERATURE INDI-
CATOR, INSPECTION, Combination Meter
System.>
Is the ambient sensor circuit normal?
3 CHECK POOR CONTACT. There is no poor contact. Replace the A/C Repair the con-
Check poor contact in A/C control module con- control module. nector.
nector.
Is there poor contact in connector?

AC-35
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

B: IN-VEHICLE SENSOR
TROUBLE SYMPTOM:
• When turning the AUTO switch to ON, blower fan speed, outlet port and inlet port is not changed.
• Malfunction related to ambient sensor is indicated in self diagnosis.

i55 : LHD

B314 : RHD

IN-VEHICLE
SENSOR

2
RHD

LHD RHD

LHD
B202

24
9
i41
LHD

RHD
LHD

RHD

LHD LHD : LHD MODEL

RHD RHD : RHD MODEL

A16

B12

AUTO A/C
A: i48 B: i49 CONTROL
MODULE

i55 : LHD A: i48 B: i49

B202
B314 : RHD
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11
1 2 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20 12 13 14 15 16 17 18 19 20 21 22 23 24

AC-00157

AC-36
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK IN-VEHICLE SENSOR. Approx. 2.7 kΩ at 20°C (68°F) Go to step 2. Replace the in-
1)Turn the ignition switch to OFF. vehicle sensor.
2)Remove the lower cover at driver side.
3)Disconnect the connector from in-vehicle
sensor.
4)Measure the resistance between connector
terminals of in-vehicle sensor.
Terminals
No. 1 — No. 2:
Is the measured value within specified value?
2 CHECK INPUT SIGNALS FOR IN-VEHICLE Approx. 5 V Go to step 5. Go to step 3.
SENSOR.
1)Turn the ignition to ON.
2)Measure the voltage between in-vehicle sen-
sor harness connector terminals and chassis
ground.
Connector & terminal
LHD model:
(i55) No. 2 (+) — Chassis ground (−):
RHD model:
(B314) No. 2 (+) — Chassis ground (−):
Is the measured value within specified value?
3 CHECK OUTPUT SIGNALS FROM A/C CON- Approx. 5 V Go to step 4. Go to step 6.
TROL MODULE.
1)Turn the ignition switch to OFF.
2)Pull out the A/C control module.
3)Turn the ignition switch to ON.
4)Measure the voltage between A/C control
module connector terminals.
Connector & terminal
(i49) No. 12 (+) — (i48) No. 16 (−):
Is the measured value within specified value?
4 CHECK HARNESS BETWEEN A/C CON- 1Ω Go to step 5. Repair the har-
TROL MODULE AND IN-VEHICLE SENSOR. ness between A/C
1)Turn the ignition switch to OFF. control module
2)Disconnect the connectors from A/C control and in-vehicle
module. sensor.
3)Measure the resistance of harness between
A/C control module and in-vehicle sensor.
Connector & terminal
LHD model:
(i55) No. 2 — (i49) No. 12:
RHD model:
(B314) No. 2 — (i49) No. 12:
Is the measured value less than specified
value?
5 CHECK HARNESS BETWEEN A/C CON- 1Ω Go to step 6. Repair the har-
TROL MODULE AND IN-VHECLE SENSOR. ness between A/C
Measure the resistance of harness between control module
A/C control module and in-vehicle sensor. and in-vehicle
Connector & terminal sensor.
LHD model:
(i55) No. 1 — (i48) No. 16:
RHD model:
(B314) No. 1 — (i48) No. 16:
Is the measured value less than specified
value?

AC-37
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

6 CHECK POOR CONTACT. There is no poor contact. Replace the A/C Repair the con-
Check poor contact in A/C control module con- control module. nector.
nector.
Is there poor contact in connector ?

AC-38
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

C: EVAPORATOR SENSOR
WIRING DIAGRAM:

B256

EVAPORATOR
SENSOR

3
1
B202
LHD RHD

11
15 9
5
i41

LHD : LHD MODEL

RHD : RHD MODEL

A16
B2

AUTO A/C
A: i48 B: i49 CONTROL
MODULE

B256 B202 A: i48 B: i49

1 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
2 12 13 14 15 16 17 18 19 20 21 22 23 24 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20
3

AC-00158

AC-39
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK EVAPORATOR SENSOR. Approx. 2.7 kΩ at 20°C (68°F) Go to step 2. Replace the evap-
1)Turn the ignition switch to OFF. orator sensor.
2)Remove the glove box.
3)Disconnect the connector from evaporator
sensor.
4)Measure the resistance between connector
terminals of evaporator sensor.
Terminals
No. 1 — No. 2:
Is the measured value within specified value?
2 CHECK INPUT SIGNALS FOR EVAPORA- Approx. 5 V Go to step 5. Go to step 3.
TOR SENSOR.
1)Turn the ignition switch to ON.
2)Measure the voltage between evaporator
sensor harness connector terminal and chas-
sis ground.
Connector & terminal
(B256) No. 1 (+) — Chassis ground (−):
Is the measured value within specified value?
3 CHECK OUTPUT SIGNALS FROM A/C CON- Approx. 5 V Go to step 4. Go to step 6.
TROL MODULE.
1)Turn the ignition switch to OFF.
2)Pull out the A/C control module.
3)Turn the ignition switch to ON.
4)Measure the voltage between A/C control
module connector terminals.
Connector & terminal
(i49) No. 2 (+) — (i48) No. 16 (−):
Is the measured value within specified value?
4 CHECK HARNESS CONNECTOR BETWEEN 1Ω Go to step 5. Repair the har-
A/C CONTROL MODULE AND EVAPORA- ness between A/C
TOR SENSOR. control module
1)Turn the ignition switch to OFF. and evaporator
2)Disconnect the connectors from A/C control sensor.
module.
3)Measure the resistance of harness between
A/C control module and evaporator sensor.
Connector & terminal
(B256) No. 1 — (i49) No. 2:
Is the measured value less than specified
value?
5 CHECK HARNESS CONNECTOR BETWEEN 1Ω Go to step 6. Repair the har-
A/C CONTROL MODULE AND EVAPORA- ness between A/C
TOR SENSOR. control module
Measure the resistance of harness between and evaporator
A/C control module and evaporator sensor. sensor.
Connector & terminal
(B256) No. 3 — (i48) No. 16:
Is the measured value less than specified
value?
6 CHECK POOR CONTACT. There is no poor contact. Replace the A/C Repair the con-
Check poor contact in A/C control module con- control module. nector.
nector.
Is there poor contact in connector?

AC-40
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

D: SUNLOAD SENSOR
TROUBLE SYMPTOM:
• Sensor identified that sunlight is at maximum. Then, A/C system is controlled to COOL side.
• Sensor identified that sunlight is at minimum. Then, A/C system is controlled to HOT side.
NOTE:
When the sunload sensor is checked indoors or in the shade, open circuit might be indicated. Always check
the sunload sensor at a place where sun shines directly on it.
WIRING DIAGRAM:

i51

SUNLOAD
SENSOR

2
RHD

LHD

RHD

LHD

i3 i2

AT MT

17
19 7
23
22

20
B38 B37
LHD

RHD
LHD

LHD LHD : LHD MODEL

RHD
RHD RHD : RHD MODEL

AT : AT MODEL
B202
RHD LHD

20
9 15

MT : MT MODEL
12

i41
A16

B3

AUTO A/C
A: i48 B: i49 CONTROL
MODULE

i51 B38 A: i48 B: i49

1 2 1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10
10 11 12 13 14 15 16 17 18 19 20 21 9 10 11 12 13 14 15 16 11 12 13 14 15 16 17 18 19 20
22 23 24 25 26 27 28 29 30 31 32

B202 i2 : AT i2 : MT

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8
12 13 14 15 16 17 18 19 20 21 22 23 24 11 12 13 14 15 16 17 18 19 20 21 22 9 10 11 12 13 14 15 16 17 18

AC-00159
AC-00110

AC-41
 DIAGNOSTIC PROCEDURE FOR SENSORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

Step Value Yes No

1 CHECK INPUT VOLTAGE TO SUNLOAD Approx. 5 V Go to step 3. Go to step 2.
SENSOR.
1)Turn the ignition switch to ON.
2)Measure the input voltage to sunload sensor.
Connector & terminal
(i51) No. 2 (+) — Chassis ground (−):
Is the measured value within specified value?
2 CHECK HARNESS CONNECTOR BETWEEN 1Ω Go to step 3. Repair the har-
A/C CONTROL MODULE AND SUNLOAD ness between A/C
SENSOR. control module
1)Turn the ignition switch to OFF. and sunload sen-
2)Disconnect the connectors from A/C control sor.
module.
3)Measure the resistance of harness between
A/C control module and sunload sensor.
Connector & terminal
(i51) No. 2 — (i49) No. 3:
Is the measured value less than specified
value?
3 CHECK HARNESS CONNECTOR BETWEEN 1Ω Go to step 4. Repair the har-
A/C CONTROL MODULE AND SUNLOAD ness between A/C
SENSOR. control module
Measure the resistance of harness between and sunload sen-
A/C control module and sunload sensor. sor.
Connector & terminal
(i51) No. 1 — (i48) No. 16:
Is the measured value less than specified
value?
4 CHECK THE INPUT VOLTAGE TO A/C CON- Approx. 2.5 V Go to step 5. Replace the sun-
TROL MODULE. load sensor.
1)Connect the A/C control module connector.
2)Turn the ignition switch to ON.
3)Measure the voltage between A/C control
module connector terminals.
Connector & terminal
(i49) No.3 (+) — (i48) No.16 (−):
Is the measured value within specified value?
5 CHECK POOR CONTACT. There is no poor contact. Replace the A/C Repair the con-
Check poor contact in A/C control module con- control module. nector.
nector.
Is there poor contact in connector?

AC-42
 Fuse

Ground

A/C relay

sunload )
Blower fan relay
Blower fan motor
Malfunction Parts

Radiator fan relay

Radiator fan motor
Mode door actuator

Intake door actuator

Air mix door actuator
Auto A/C control module
Connector ( Poor contact )

*1 : Evaporator sensor only

temperature, evaporator and
Sensors ( In-vehicle,ambient
Compressor ( Magnet clutch )

In-vehicle sensor aspirator hose

Symptom

*1
A/C system does not operate.

Fuse is blown.
A: GENERAL DIAGNOSTICS TABLE
9. Symptom Related Diagnostic

Illumination cannot be dim.

AC-43
Blower fan does not operate or fan
speed cannot be adjusted.
Air inlet ( FRESH/RECIRC )cannot be
switched.

Air outlet cannot be switched.

Compartment temperature does not

SYMPTOM RELATED DIAGNOSTIC

increase (No hot air is discharged).

Compartment temperature does not
decrease (No cool air is discharged).
Compartment temperature is higher
than or lower than the set value.
Compartment temperature does not
quickly respond to the set value.
Radiator fan does not rotate during
A/C operation.

AC-00111
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)
 SYMPTOM RELATED DIAGNOSTIC
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

AC-44