Chapter 8 Air Conditioner System

Section 1. Summarize
F3 adopts HVAC housing assy. with the function of ventilation 、refrigeration in summer、heating and
defrosting in winter.
1. Refrigeration theory:
The refrigeration system is composed of compressor 、 evaporater 、 condensor 、 drier 、 expansion
valve、blower、control module and so on as follows:

Illustration 8-1-1

1- Condensor 2- Drier 3-Pressure switch 4- Blower

5- Evaporater 6- Expansion valve 7- Compressor
The refrigeration theory is shown as follows. The compressor which is driven by engine sucks out the
gaseous refrigerant from the evaporator, and compress the refrigerant into the condenser. The hight
pressure gaseous refrigerant go through the condenser and be liquefied there, the released heat is taken
out by the air outside the car. The high pressure gaseous refrigerant goes through the expansion valve
which has the function of throttle and the pressure is released there. The low pressure gaseous refrigerant
go through the evaporator、be gasified and absorb heat there, the refrigerated air near the evaporator is
blowed into the passenger compartment. The gaseous refrigerant was sucked out by compressor and
compressed into the condenser again. The refrigerant repeats such close circulates and takes out the heat
and refrigerates the passenger compartment to a proper tempetature.

Middle temperature Low temperature &

&high pressure Expansion low pressure liquid
Drier
liquid (1500- valve (200-500kpa, 10-
1800kpa, 70-80℃) 20℃)

Heat enter
Heat enter evaporator refrigerant
air from Condensor from air
refrigerant

High temperature Middle temperature

&high pressure gas & low pressure gas
Compressor
(1500-1800kpa, 70- (200-500kpa, 10-
80℃) 20℃)

Illustration 8-1-2

Page of chapter 8. Air conditioner1

2. Heating theory

The heating system works eith coolant from engine. It’s mainly composed of heat
exchanger、coolant pipe、blower、vent and control module. The housing heating system is integrated
with evaporator housing, the heating system use the same blower and vent together with the
refrigeration system as follows.

①Vent ②Coolant pipe ③Blower ④Heat Exchanger

Illustration 8-1-3
While the engine is running, the cooling water pumps propell the coolant which is heated through
the high temperature-cylinder into the heat exchangerthrough water pipe. Then the air is heated
through the heat exchanger and blowed into the passenger compartment or the windshield by blower to
keep the compartment warm or defrost on the windshield. Then the collant is propelled back by water
pump and repeat the circulation as follows:

High
temperature
Engine coolant

Heat
ente
Low r air
temperature Heat from
coolant exchanger here

Middle
Water temperature
Radiator pump coolant

Illustration 8-1-4

Page of chapter 8. Air conditioner2

3. Control system of air conditioner
A/C control system includes electric source
control circuit、compressor clutch control
system、security protection control circuit、data
traffic circuit and so on, mainly composed of A/C
switch、A/C controller(for manual A/C) or A/C
control module(for automatic A/C) 、evaporator
temperature sensor、refrigerant temperature
sensor、pressure switch、temperature controller
and so on. Its function is to ensure the A/C
system working effectively、 the A/C system and
the engine working safely in any condition.
1. Refrigeration temperature control:
It is mainly composed of evaporator
temperature sensor、A/C controller and
releted circuit. When the temperature in the
evaporator changes, the resistance of the
sensor changes accordingly, make the A/C
controller get the voltage signal
corresponding to the temperature, then the
signal is amplified by the amplifying circuit in
the A/C controller to control the working of
electromagnetic clutch relay: When the
electromagnetic clutch relay is switched on,
the electromagnetic clutch will joints, the
compressor start working, the temperature
will come down；When the electromagnetic
clutch relay is switched off, the
electromagnetic clutch will release, the
compressor stop working, the temperature
will raise. The A/C control system controls
the work of compressor to maintain the
refrigeration temperature in the set area.
2. The electronic injection engine controls the
work of compressor someway to alleviate the
load of the engine in some special condition:
The compressor stops working when the
engine in engine start、vehicle start、urgent
acceleration and over rotate speed
condition.
3. Security protection control:
Ensure the A/C system works normally,
monitor the pressure and temperature of the
A/C system by the pressure switch in the
drier and evaporator temperature sensor, to
carry out the security protection. The
functions as follows:
1) Low pressure protection：when the
pressure is less than 0.196±0.02 MPa，the
pressure switch（between 1-A4 and 3-
A4）will be off，the compressor clutch will
be out of power，the compressor stops
working；
2）Over pressure protectin：when the
Section 2 Layout of A/C system
Page of chapter 8. Air conditioner3
pressure is more than 3.14±0.2 MPa，the
pressure switch（between 1-A4 and 3-
A4）will be off，the compressor clutch will
be out of power，the compressor stops
working；
3）High pressure control：when the pressure
ismore than 1.77±0.1 MPa，the pressure
switch（between 2-A4 and 4-A4）will be
on，and sent the engine ECM a stimulation
signal，make the cooling fan rotates at a
high speed;
4）Low temperature protection：when the
evaporator temperature sensor detect the
temperature is less than 5℃，the
compressor clutch will be out of power，the
compressor stops working；
5）High temperature protection：when the
water temperature sensor detect the
temperature is more than 125℃，the
compressor overheat protection will be
started，the compressor clutch will be out
of power，the compressor stops working.
4. Engine cooling system (cooling fan) control:
It’s composed of water temperature sensor
engine ECM、control relays of 1#、2#、3#
fans、cooling fan、adjusting resistance of
cooling fan、condensor fan、related circuit and
so on. The engine ECM controls the on/off of
related fan control relay circuit according to
the signals of related temperature sensor and
switch to carry out the following controls:
1）When the coolant temperature is
93℃~96℃，the engine ECM makes 1#、3#
relays be electrified, the two fan motors which
is parallel connected will rotate at low speed
simultaneously.
2）When the coolant temperature is
98℃~100℃，the engine ECM makes 2#
relays be electrified, the fan motor will rotate
at high speed.
3）When the coolant temperature reachs
110℃，the warning light in the combination
instrument will be on.
4）When the A/C switch is on, the fan will rotate
at low speed no matter the coolant
temperature is low or high.
5）When pressure of the A/C refrigeratin system
ismore than 1.77±0.1 MPa，the fan will rotate
at high speed.
6）If the coolant temperature signal
isabnormal(the water temperature sensor is
damaged)，the engine ECM will consider the
engine runs in heavy load condition, the fan
will rotate at high speed.
 Compressor and
electromagnetic switch

Pressure switch

Wire connector

Condensor

Outdoor temperature sensor

Illustration 8-2-1. Layout of heating electronic control system (1)

Illustration 8-2-2. Layout of heating electronic control system (2)

Page of chapter 8. Air conditioner4

 Manual A/C control panel Automatic A/C control panel
1. Inner/outer circulation mode selecting knob 1. Blower speed adjusting knob
2. A/C switch 2. OUTSIDE TEMP button
3. Refrigeration/heating mode selecting knob 3. Temperature adjusting button
4. Blower speed adjusting knob 4. Automatic control mode button
5. Blow mode selecting knob 5. OFF button
6. Inner/outer circulation mode selecting knob
7. Blow mode selecting knob
8. Front windshield defrosting switch
9. A/C switch

Illustration 8-2-3. Structure of heating electronic control system (3)

Page of chapter 8. Air conditioner5

 Illustration 8-2-4. Disassembly of evaporator unit

Page of chapter 8. Air conditioner6

 Illustration 8-2-5. Disassembly of partial A/C component

Section 3 A/C electronic control system

Page of chapter 8. Air conditioner7
1. Control theory of automatic A/C components

Input side Execute side

1.A/C switch input
11.Temperature vent a
2.Inside temperature s dminister motor
ensor
12. Air flow administer
3.Outside temperature motor
sensor
13. Circle vent motor
4.Evaporator temperat
ure sensor
5. Water temperatures 14.Rear defroster rela
6. Light intensity senso A/C control module y
r
7. Pressure switch 15.compressor clutch
8.Temperature motor 16.Blower timing mod
position ule
9.Air flow motor positi 17.blower relay
on
18.A/C request
10.Electronic spray co
ncent 19. Self-diagnosis

2. System port voltage

2.1. A/C control system（manual）

Wire
Test port Port illustration Test condition Standard value
colour
1－body W/B grounding All the time < 1Ω
Power Input for night Ignition switch:ON，combination
2－body G 10～14V
illumination switch:Tail，All the time
3－body W/B grounding All the time < 1Ω
Drive the 4th speed th
Blower speed control knob:4
4－1 B/W-W/B of the blower < 1Ω
speed，All the time
motor
Drive the 3rd speed
Blower speed control knob:3rd
5－4 L/B-B/W of the blower < 1Ω
speed，All the time
motor
Drive the 2nd speed
Blower speed control knob:2nd
6－4 R-B/W of the blower < 1Ω
speed，All the time
motor
Drive the 1st speed of Blower speed control knob:1st
8－body L/0 < 1Ω
the blower motor speed，All the time

2.２. A/C pressure switch

Page of chapter 8. Air conditioner8

 Wire
Test port Port illustration Test condition Standard value
colour
High/low pressure signal Input
Pressure of A/C high pressure
1－body Y/B output end of pressure characteristic
pipe changes
switch curve A
2－body W/B grounding All the time < 1Ω
Electric source input for
3－body L/R High/low pressure signal of Blower runs，All the time 10～14V
pressure switch
Input
Middle pressure signal output Pressure of A/C high pressure
4－body G/B characteristic
end of pressure switch pipe changes
curve C

2.3. A/C controller（manual）

Stitch Wire
Test port Port illustration Test condition Standard value
code colour
A/C request signal output Compressor runs，All the
1－body AC1 Y/R < 1V
end time
High/low pressure signal Input
Pressure of A/C high
2－body PRS Y/B output end of pressure characteristic
pressure pipe changes
switch curve A
Evaporator temperature Input
3－13 TE B/L
sensor input end Temperature of characteristic
Evaporator temperature evaporator changes resistance table
13—3 SG W/L
sensor grounding end B
5－body GND W/B grounding All the time < 1Ω
Engine permitted signal Compressor runs，All the
7－body ACT R/L < 1V
input end time
Blower runs，press down
8－body A/C Y/B A/Cswitch signal input end 10～14V
A/C switch，All the time
10 － Control end of A/C switch A/C switch indicator light
LED G/Y —
body indicator light works
Middle pressure signal Input
11 － Pressure of A/C high
CFN- G/B output end of pressure characteristic
body pressure pipe changes
switch curve C
12 － Control end of A/C Compressor runs，All the
MGC Y/R < 1V
body electromagnetic clutch time

2.４. A/C control module（automatic）

Wire
Stitch
Test port colou Port illustration Test condition Standard value
code
r

Page of chapter 8. Air conditioner9

 Produce
Reverse buzzer
1－body BZ L Drive the reverse buzzer impulse（see 6-
sounds，All the time
C13）
Ignition Produce
Drive the reverse self-
2－body Z- V/G switch:ON，reverse radar impulse（see
diagnosis buzzer
starts 22-C13）
Electric source indicator
4－body OP G/R Indicator light control end < 3V
light works，All the time
Output end for emergency Press down the emergency
6－body HZD Y/G < 1V
signal switch，All the time
Ignition
power output end for
9－body SK P/B switch:ON，reverse radar 10-14V
reverse radar
start-up
Display control end for Reverse indicator light
13－body BK O < 3V
reverse clearance works，All the time

Wire
Stitch Standard
Test port colou Port illustration Test condition
code value
r
1－body GND W/B grounding All the time < 1Ω
Grounding end for feedback
See the stitch
2－body SGTPM Y/B resistance of blow mode Automatic A/C runs
definitionⅠ
motor
Grounding end for See the stitch
3－body SGTP Br/Y Automatic A/C runs
temperature motor definitionⅠ
feedback resistance end for See the stitch
4－body TPM L/O Automatic A/C runs
blow mode motor definitionⅠ
feedback resistance end for See the stitch
5－body TP W/L Automatic A/C runs
temperature motor definitionⅠ
Connect the feedback
See the stitch
7－body S5TPM G resistance of blow mode Automatic A/C runs
definitionⅠ
motor to +5v end
Connect the feedback
See the stitch
8－body S5TP W/R resistance of temperature Automatic A/C runs
definitionⅠ
motor to +5v end
Control end 1 for blow mode See the stitch
9－body AOF Y/B Automatic A/C runs
motor rotation direction definitionⅠ
10 － Control end 2 for blow mode See the stitch
AOD R/B Automatic A/C runs
body motor rotation direction definitionⅠ
Control end 1 for
11 － See the stitch
AMH L Temperature motor rotation Automatic A/C runs
body definitionⅠ
direction
Control end 2 for
12 － See the stitch
AMC R/W Temperature motor rotation Automatic A/C runs
body definitionⅠ
direction
Control end 1 for Fresh air
13 － See the stitch
AIR L/W inner circulation motor Automatic A/C runs
body definitionⅠ
rotation direction
Control end 2 for Fresh air
14 － See the stitch
AIF G/Y inner circulation motor Automatic A/C runs
body definitionⅠ
rotation direction
16 － CFN- G/B Connector of Middle A/C is in middle < 1V
Page of chapter 8. Air conditioner
10
 pressure、engine ECM and
body pressure, All the time
cooling fan
17 － Compressor clutch control Compressor runs, All the
MGC Y/R < 1V
body connector time
Input
18 － High/low pressure signal Pressure of A/C high
PSW Y/B characteristic
body output end of pressure switch pressure pipe changes
curve A
Ignition
19 － Electric source input of < 1V→10-
IG R/L switch:ACC→ON, All the
body ignition switch in ON position 14V
time
20 －
+B L/Y Constant power input All the time 10-14V
body
Grounding end for
Input
21－24 SGTE W/L Evaporator temperature
Temperature of characteristic
sensor signal
evaporator changes resistance
Input end for Evaporator
24－21 TE B/L table B
temperature sensor signal
Grounding end for outer
22－25 SGTAM Br/Y Input
temperature sensor signal Outer temperature
characteristic
Input end for outer changes
25－22 TAM W/G resistance D
temperature sensor signal
Grounding end for inner
23－26 SGTR Br/Y Input
temperature sensor signal Inner temperature
characteristic
Input end for inner changes
26－23 TR G/R resistance E
temperature sensor signal
Input end for light intensity
27－28 TS W/R Input
sensor signal
Light intensity changes characteristic
Grounding end for light
28－27 S5TS L/W resistance F
intensity sensor signal
Engine water temperature Input
30－31 SGTW W/G
signal grounding end Temperature of Engine characteristic
Engine water temperature coolant changes resistance
31－30 TW Y/G
signal input end table G
32 － Engine permitted signal Compressor runs，All
ACT R/L < 1V
body inputend the time
33 － Compressor runs，All
ACI Y/R A/C request signal ouput < 1V
body the time
Input impulse
signal（see
34 － Vehicle runs，All the
SPD V/W Vehicle speed signal input combination
body time
instrument
A10）
35 － Blower PWM signal output
BLC L/B Blower works —
body end
36 － Control output end of blower Blower works，All the
HR L/O < 1V
body relay time
37 － Control output end of rear Rear windshield heater
RDEF B < 1V
body windshield heater works，All the time
Ignition
39 － Electric source input for night
ILL+ G switch:ON，combination 10～14V
body illumination
switch:Tail，All the time
Electric source input for Ignition
40 － < 1V→10-
ACC W/L Ignition switch in ACC switch:OFF→ACC, All
body 14V
position the time
Section 4 Maintenance of A/C
components
1. Overhauling of the compressor belt:
(1) Remove
The location of the compressor and belt is
showed in the illustration 8-4-1.
Page of chapter 8. Air conditioner11
 Illustration 8-4-1
(a) Loosen the nut a showed in the illustration 8- Illustration 8-4-4
4-2.
2. The overhaul of the air filter
(1) Remove the glove box as showed in the
illustration 8-4-5.

Illustration 8-4-2
(b) Loosen the nut B, and remove the compressor belt
Illustration 8-4-5
(2) Installation (2) Remove the filter as showed in the illustration
(a) Install the compressor belt as showed in the 8-4-6.
illustration 8-4-3.

Illustration 8-4-3 Illustration 8-4-6

(b) Tighten the nut A to adjust the belt.
(c) Turn the nut B to adjust the belt. The (3)Remove the core and make the check, replace
distortion is 6.5~7.5mm (new), 8.0~9.0mm (old). if necessary.
Hint:
(1) New belt is indicated the belt used in 5
min.
(2) Old belt is indicated the belt used
beyond 5 min.
(3) Install the belt, check if the touch
between the belt and the pulley (showed
in the illustration 8-4-4).

Illustration 8-4-7

3. Overhaul of evaporator housing

Page of chapter 8. Air conditioner

12
1. Remove the duct system.
(1) Remove the upper duct 2) Disconnect the A/C pipe assy (showed in
① Remove the upper instrument panel. the illustration 8-4-11).
② Remove the screw as showed in the
illustration 8-4-8.

Illustration 8-4-11
Illustration 8-4-8
Use the wrenches to remove the nuts on the M16
(2) Remove the lower duct and M8 pipes.
1) Move the seat to the back. 3) Remove the snap rings from the pipe.
2) Open the carpet, remove the floor duct. Remove the snap rings from the heater inlet
(a) Remove the left floor duct as showed in the and outlet pipes
illustration 8-4-9. (showed in the illustration8-4-12).

Illustration 8-4-9 Illustration 8-4-12

(b) Remove the right floor duct as showed in the
illustration 8-4-10.
4) remove the upper instrument panel (see the
method of removing the instrument panel).
5) Remove the air flow pipe, wire harness and
other parts on the A/C unit.
6) Remove the steering wheel and steering
column (see the method of removing the
steering wheel and steering column).
7) Remove the lower instrument panel, A/C
control dashboard and the cables.
8) Loosen the screws which connect with the
beam (showed in the illustration 8-4-13).

Illustration 8-4-10

2. Remove the housing

1) Discharge the refrigerant from the A/C
Page of chapter 8. Air conditioner
13
 Illustration 8-4-16

Illustration 8-4-13 13) Remove the A/C evaporator assy.

9) Remove the beam (see the method of (1) Remove the evaporator inlet and outlet
removing the beam). cover as showed in the illustration 8-4-17.
10) Remove the three nuts showed in the
illustration 8-4-14.

Illustration 8-4-14
Illustration 8-4-17
11) Remove the nut showed in the illustration 8-
(2) Remove the two clips and expansion valve as
4-15.
showed in the illustration 8-4-17.
(3) Remove the evaporator right plate as showed
in the illustration 8-4-17.
(4) Remove the evaporator as showed in the
illustration 8-4-17.
(5) Remove the two O-sharp rings from the
evaporator core as showed in the illustration
8-4-18.

Illustration 8-4-15

12) Remove the bolt and nut showed in the

illustration 8-4-16. And then remove the A/C unit.
Illustration 8-4-18

15) Remove the heater unit

(a) Remove the heater inlet and outlet cover
and driver lower vent as showed in the
illustration 8-4-19

Page of chapter 8. Air conditioner

14

Illustration 8-4-19
(b) Remove the held snap ring as showed in
the illustration 8-4-19.
16) Remove the cooler wire harness. Disconnect
the connector, and remove the wire harness.
17) Remove the blower resistance. Remove the
two screws and the blower resistance as
showed in the illustration 8-4-20.
Illustration 8-4-20
18) Remove the blower assy with fan resistance.
Remove the 3 screws and blower assy with
motor as shown in the illustration 8-4-20.
19) Remove the thermistance.
(a) Remove the evaporator as showed in the
illustration 8-4-21.
Illustration 8-4-21
Page of chapter 8. Air conditioner
15
(b) Remove the thermistance from the plug as
showed in the illustration 8-4-21.
3. Notice for installation:
1）Install the evaporator assy.
（1）Lubricate 2 new O–sharp rings with
compressor oil (PAG56).
（2）Install 2 new O-sharp rings to the
evaporator assy as showed in the
illustration 8-4-18.
2）Install the two held snap rings and expansion
valve as showed in the illustration 8-4-17. The
torque is 3.5N.m.
3）Install the heating controller and accessories
assy.
（1）Install the inner control cable of
windshield defroster in the heater control
rod.
NOTE：
①Do not contort the cable.
②If the cable is bent; there will be problem
with the heating controller and accessories
assy.
（2）Install the inner cable of air-mix control
device in the heater control rod.
（3）Install the outer cable of air-mix control
device in the cable clip.
NOTE：
①Do not contort the cable.
②If the cable is bent, there will be problem with
the heating controller and accessories assy.
③Operate the heating control rod, check
whether the rod can stay in the inner and
outer circulation position and not to rebound.
④Pull the cable in the heater control device
assy., the outer cable shouldn’t be pulled
out.
（４）Install the inner cable of air intake control
device in the heater control rod.
（５）Install the outer cable of air intake control
device in the cable clip.
NOTE：
①Do not contort the cable.
②If the cable is bent; there will be problem with
the heating controller and accessories assy.
③Operate the heating control rod, check
whether the rod can stay in the inner and
outer circulation position and not to rebound.
④ Pull the cable in the heater control device
assy., the outer cable shouldn’t be pulled
out.
Connect the connector; install the heater control
device assy.
 Illustration 8-4-22
Put the control rod in the max. refrigeration
position，install the inner cable connector into
the control arm.
Install the outer cable into the clip, press down
the cable in the shown direction.
NOTE：
Operate the heating control rod; check whether Illustration 8-4-24
the rod can stay in the inner and outer circulation
position and not to rebound. Disassembly process:
Put the control rod in the inner circulation
position; install the inner cable connector into the
control arm.

Illustration 8-4-23
　Install the outer cable into the clip, press down
the cable in the shown direction.
NOTE：
①Do not contort the cable.
②If the cable is bent; there will be problem with
the heating controller and accessories assy. Illustration 8-4-25
③Operate the heating control rod, check （1）Remove the A/C pipe
whether the rod can stay in the inner and Seal the opening of the disconnected parts
outer circulation position and not to rebound. using vinyl tape to prevent moisture and
4）Check whether refrigerant leaks after foreign matter from entering.
installation. （2）Remove the compressor belt (showed in
the illustration 8-4-26).
4. Overhaul of compressor assy.
1. Disassembly and installation
Drain the refrigerant before disassemble the
compressor, and fill the refrigerant after
installation, then check the tension of the
compressor belt.

Illustration 8-4-26
Loosen the steering pump held bolt.
Loosen the adjusting bolt, and remove the
Page of chapter 8. Air conditioner
16
 driving belt.

（3）Remove the compressor

While do this operation, please be careful
do not spill the lubricant.
Check-up：
Check the movement of electromagnetic
clutch.

Illustration 8-4-30
While install the clutch coil to the house of
compressor, please face the bulge to the house
positioning hole.

Installation of snap ring

Illustration 8-4-27
Connect the battery positive terminal to the
connector of the electromagnetic, negative
terminal to the body of the compressor. If the
compressor is normal, there will be a “kaka”
sound. If there is not this sound, it is indicated
that there is some malfunction.

2. Disassembly and installation

Illustration 8-4-31
NOTE: Install the snap ring to make sure the
core is at the outside of it.

Installation of the locknut

Use SST to hold the electromagnetic clutch, and
then install the nut.
Adjustment of the clutch clearance (showed in
the illustration 8-4-32)

Illustration 8-4-28
Disassembly tips
Remove the locknut as shown in the illustration

Illustration 8-4-32
Check whether the clearance is in the standard
value; if necessary adjust it using the washer.
Standard value is 0.3-0.5mm.
Check
Illustration 8-4-29 Check the over-heat protecting switch as showed
Installing tips in the illustration 8-4-33.
Installation of clutch coil

Page of chapter 8. Air conditioner

17
 Illustration 8-4-35
1）Remove the radiator
Illustration 8-4-33
2）Remove the two pipes which connect to the
Put the metal part of the compressor over-heat
condenser, remove the two held screws, then
protecting switch into the engine oil, and then
remove the condenser.
heat the oil.
While the temperature is to the standard value,
3. Disassembly
ensure whether it is connected between the ports
1）Discharge the refrigerant.
of switch. (showed in the illustration 8-4-34).　
2）Remove the drier.
1) Remove the cap and filter from adjuster using
the hexagon wrench (showed in the
illustration 8-4-36).

Illustration 8-4-34
The compressor over-heat protecting switch
Connected: Less than 105℃
Disconnected: Above 130℃ ( at OFF status, at
least 125℃) Illustration 8-4-36
2) Remove the 3 O-sharp rings from the cap
5. The overhaul of the condenser assy. (showed in the illustration 8-4-36).
with the reservior
1. On-vehicle check-up
1）The check of the condenser assy.
（1）Use the air flow to clean the condenser
radiator.
（2）If the plate of radiator is distortion, please
make it straight.
2）Check whether there is leakage.
（1）Check the gas leakage using the Halogen
checking device.
（2）If there is leakage at the connector, please Illustration 8-4-37
check the tighten torque. 3) Remove the drier using the needle nose pliers
(showed in the illustration 8-4-37)
2. On-vehicle disassembly

Page of chapter 8. Air conditioner

18
 Illustration 8-4-38
4. Installation
1）Install the drier.
（1）Install the drier with the needle nose pliers
(showed in the illustration 8-4-38).
（2）Install the three new O-sharp rings
(showed in the illustration 8-4-37).
（3）Lubricate 3 new O–sharp rings with
compressor oil(PAG56).
（4）Install the cap and filter to the condenser
assy, the torque is 12N.m (showed in the
illustration 8-4-36).
2）Install the reservior condenser assy (showed
in the illustration 8-4-35).　 The blockage or leakage of refrigeration
3）Install the A/C pipe assy
（1）Connect the all parts of the condenser
assy.
（2）Lubricate the O-sharp rings and the
connectors of the pipe with compressor
oil. (PAG56).
(3)Install one O-sharp ring to the A/C pipe.
（ 4 ） Connect the A/C pipe and the reservior
condenser with the bolt, the torque is
5.4N.m.
4) Install the refrigerant outlet pipe (showed in
the illustration 8-4-38).
(1) Connect the all parts of the condenser assy.
(2) Lubricate the O-sharp rings and the
connectors of the pipe with compressor oil.
(3) Install one O-sharp ring to the A/C pipe.
(4) Connect the A/C pipe and the receiver
condenser with the bolt, the torque is 5.4N.m.
5）Refill the refrigerant. Standard amount is
580g.
6）Run the engine at the idle speed.
7）Check whether there is some leakage.
6. Replacement of the A/C amplifier:
Page of chapter 8. Air conditioner
19
Illustration 8-4-39
1. Remove
1) Remove the upper instrument panel.
2) Remove the combination instrument assy.
3) Remove the A/C amplifier assy as showed in
the illustration 8-4-39.
(1) Disconnect the connector.
(2) Remove the A/C amplifier assy.
2、Installation is in the reverse order of the
removal.
7. The overhaul of the refrigerating pipe:
1. Malfunction of refrigeratin pipe
pipes will cause bad refrigeration.
1）The pipe distortion may cause the refrigerant
flows unsmoothly or blocked.
2）If the pipe connectors are damaged or
loose,it will cause leakage.
2. Disassembly of refrigeration pipe
NOTE:
1）Use two wrenches to loose the connectors
to prevent the pipes from being damaged.
Illustration 8-4-40
Disassembly and installation of pipes
2）Jam the pipes with plugs or cloth to prevent
the pipes from being polluted inside.
3. Overhaul of refrigeration pipe
Check the following items：
1）Check whether the pipe connectors are
leak or loose, tighten them; if it still leaks
after being tightened as stated torque,
check whether the seal ring、pipes are
damaged.
2）Check whether there is
distortion、crack、damage with the pipes,
replace them if it does.
 3）If the pipes are dirty, clean them with
absolute alcohol, and install them after
dried.
NOTE：Don’t clean the pipes with
compressed air.
4. Installation of refrigeration pipe
Use two wrenches to install the refrigeratin
pipes as the stated torque. If it’s too loose, the
pipes will be bad sealed; if it’s too tight, the
thread of the connectors will be damaged.

Notice while installation：

1）Use the matched O ring, don’t let it fall off
or be damaged;
2）Coat some compressor oil on the O ring
before installation；
3）Coat some compressor oil on the pipe
Illustration 8-4-42
connectors before connect the pipes；
4. Loosen the two bolts as showed in the
4）Check the position of the pipes after illustration 8-4-43.　
installation, ensure they won’t hit other
parts.
Ensure it’s not leak after installation, vacuumize it
and fill refrigerant, test the performance of AC
system.

NOTE：
1）Seal the pipe connector after remove the
pipes to avoid the entry of moisture and dusts,
don’t use the material which will be corroded
by R134a.
2）Don’t forget to install the pipe clips while
install the pipes as the following illustration.
Illustration 8-4-43
5. Installation is in the reverse order of the
removal.

9. Disassembly of heating core

Remove the inlet/outlet pipe of heater as
following illustration:
1. Remove the heater core in the vehicle
1）Remove the lower cover of heater：

Illustration 8-4-41
8. The overhaul of the condenser fan:
1. Disconnect the connector of the condenser
fan.
2. Remove the condenser.
3. Loosen the two bolts as showed in the
illustration 8-4-42.
Illustration 8-4-44
2）Remove the lower duct in the driver side：　

Page of chapter 8. Air conditioner

20

Illustration 8-4-45
3）Remove the heater、screw of pressing plate
and screw of fix clip：　
Section 5 A/C system malfunction diagnosis
1. Diagnosis of system malfunction　
1. Check by direct observation
1. Check by direct observation with eyes
If the AC system doesn’t work or works
abnormally, there will be some symptom in
appearance. You can check the malfunction
through direct observation.
1）Carefully check whether the pipe is
brokenor there is crack or grease on the
surface of condenser and evaporator. If
there is grease on the surface of these
parts, you can check the leakage by soap
bubble, the key position is:
①connectors of pipes and valves；
② hose and its connector；
③ oil seal of compressor、front/rear
cover、seal gasket and so on；
④ scrape、distortion on the surface of
condensor、evaporator；
　2）Check the view window: check the
refrigerant through the view window of the
pipe.
Start the engine before observation, start
the AC system, keep the engine running at
a fast idle speed（1500~2000r/min）for
5min，then check the circulation statusof
the refrigerant through the view window：
①The refrigerant flows normally with a
Page of chapter 8. Air conditioner
21
Illustration 8-4-46
4）Take out the heater core：
Illustration 8-4-47
２ . Installation is in the reverse order of the
removal.
airbubble sometimes, it’s normal.
②clear&no air bubble, it indicateds that there
may be too much refrigerant or no
refrigerant. If the wind outlet duct is cool,
the refrigerant is normal; if not cold, the
refrigerant may leaked up.
③If much air bubble, it is lack of refrigerant.
3 ） Check the circuit: Whether the connection
is loose .
2. Check the malfunction by hand touch
1）Check the high pressure end of AC
refrigeratin system:
Start the AC switch，keep the compressor
working for 10~20min，touch the high pressure
end of the AC system, from the compressor
oulet→condenser→drier→expansion valve intlet,
it should feels from hot to warm.
If some parts is very hot, it may be caused
by bad heat radiation; if these parts are cold, it
may indicates that the refrigeratin system be
blocked、no refrigerant、the compressor doesn’t
work or work bad.
2）Check the low pressure end of AC
refrigeratin system:
Start the AC switch，keep the compressor
working for 10~20min，touch the low
pressure end of the AC system, from the
condenser to the compressor intlet, it
should feels from cool to cold.
If it’s not cool or frosted in some position, the
refrigeration system is abnormal.
 3）Check the temperature difference of whether the connectors of the wire is well
thecompressor outlet: connected, they should be loose or hot.
Start the AC switch，keep the compressor If the connectors are loose or hot, it may
working for 10~20min，touch the indicate that the AC system works badly because
compressor intlet and outlet, there should be of the bad conduction of the connectors.
obvious temperature difference between the 3、Check by listening
high&low pressure end of the compressor. Carefully listen whether there is abnormal
If the temperature difference isn’t obvious, there noise with the compressor, whether the
may be no refrigerant or lack of refrigerant. compressor works, to estimate whether the bad
4）Check the circuit: Check with hand refrigeratin comes from the compressor or its
circuit.
1. Check the refrigerant volume
Method: Inspect the inspecting hole on the refrigeration system pipe.
Ste Symptom Volume Remedy
p
1） Lock 1) Check the leakage of gas, if
necessary, make the repair.
Have the bubble 2) Refill the refrigerant until the bubble
is disappearing and then also refill the
refrigerant about 50g.
2) Empty, lock See the step 3) and step 4)
No bubble
or more
3） Empty 1) Check the leakage of gas, if
Non different between the input necessary, make the repair.
and output of the compressor 2) Refill the refrigerant until the bubble
is disappearing
4） Large different between the input Proper or See the step 5) and step 6)
and output of the compressor more
5） Immediately defecate after close More 1） Discharge until it is proper.
the A/C
6） Immediately bubble and then More -
defecate after close the A/C

Hint: if the refrigerant is enough, the environment temperature is high than the normal, and there is
some bubble in the inspecting hole is normal.
Test conditions:
1) Engine speed is 1500r/min
2) The blower speed control switch is at “HI” position
3) The A/C switch is on.
4) Temperature control lever is at MAX cold position.
5) All of the doors are opened.

2. Check the refrigerant pressure with manifold gauge set.

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.

(1) Test conditions:

1) Temperature at the air inlet with the switch set at RECIRC is 33~35℃.
2) Engine speed is 1500r/min.
3) The blower speed control switch is at “HI” position.
4) Temperature control level is at “COLD” position.
5) The A/C switch is on.
6) All of the doors are opened.

(a) The normal functioning refrigeration system

gauge reading is showed in the illustration 8-5-
1.
Low pressure side: 0.15~0.25MPa
High pressure side: 1.47~1.67MPa

Page of chapter 8. Air conditioner

22
 Symptom Reason Diagnosi Remedy
s
(1)Pressure Gas Insufficie (1)Check
low in both leakage in nt for gas
low and refrigerati refrigeran leakage
high on system t and
pressure or Refrigera repair if
sides shortage nt leaking necessar
(2)Insufficie fill of the y
Illustration 8-5-1 nt cooling refrigerant (2)Supply
performanc proper
e amount
(c) Moisture present in refrigeration system. It of new
is showed in the illustration 8-5-2 and table refrigeran
8-5-1. t
(d) Table 8-5-2

(e) Poor circulation of refrigerant. It is showed

in the illustration 8-5-4 and table 8-5-3.

Illustration 8-5-2

Symptom Reason Diagnosis Remedy Illustration 8-5-4

During Moisture in (1)Drier in (1)
operation, refrigeratin oversatura Replace
pressure g system ted state. the core
on low freezes at (2)Moistur of the Symptom Reason Diagnosis Remedy
pressure expansion e in drier. Pressure Refrigeran Receiver Replace
side valve refrigeratin (2) low on t flow clogged condenser
sometimes orifice g system Remove both low obstructed
become a causing a freezes at moisture and high by dirt in
vacuum temporary expansion in cycle pressure receiver
and stop of valve by sides
sometime cycle, orifice and repeated Frost on
normal however, blocks ly pipe from
when it circulation evacuati condenser
melts, of ng air. to unit
normal refrigerant. Table 8-5-3
state is
restored.
Table 8-5-1
(e) Refrigerant does not circulate. It is showed
(c) Insufficient cooling. It is showed in the in the illustration 8-5-5 and table 8-5-4.
illustration 8-5-3 and table 8-5-2.

Illustration 8-5-5

Illustration 8-5-3

Page of chapter 8. Air conditioner

23
 Table 8-5-5

Symptom Reason Diagnos Remedy

is
(1)Vacuum (1)Refriger Refrigera (1)Check (g) Air present in refrigeration system. It is
indicated on ant flow -nt the showed in the illustration 8-5-7 and table 8-5-6.
low obstructed do not expansio
pressure by circulate n valve,
side, very moisture replace if
low or dirt in necessar
pressure refrigeratin y
indicated on g system (2)Clean Illustration 8-5-7
high (2)Refriger out dirt in
pressure ant flow expansio Symptom Reason Diagnosis Reme
side obstructed n valve dy
(2)Frost or by gas by air (1) Air entered (1) Air Evacu-
dew seen leaked blowing Pressure in present in ate
on piping from (3)Evapo too high refrigerating refrigeratin air and
before and expansion rate air on both system g system supply
after valve and low and (2) new
receiver/dri supply high Insufficient refriger
er or proper pressure vacuum ant
expansion amount sides purging
valve of new (2) The
refrigera low
nt pressure
Table 8-5-4 piping too
(f) Refrigerant overcharged or insufficient hot to the
cooling of condenser. It is showed in the touch
illustration 8-5-6 and table 8-5-5. Table 8-5-6

(h) Expansion valve improperly. It is showed in

the illustration 8-5-8 and table 8-5-7.

Illustration 8-5-6
Sympto Reason Diagnosis Remedy
m
(1) (1)Ill effect (1) (1)Clean Illustration 8-5-8
Pressure of Ill effect of condenser Symptom Reason Diagnosis Remedy
too high refrigerating refrigeratin (2)Check (1) Trouble in (1) Check
on both performance -g cooling Pressure expansion Excessive expansion
low and (2)Insufficien performan- fan with too high valve refrigerant valve,
high t cooling of ce cooling on both in low replace if
pressure condenser (2)Supply fan motor low and pressure necessary
sides too much operation high piping
refrigerant (3)If (1) pressure (2)
and (2) sides Expansion
are in (1) Frost valve
normal or large opened
state, amount too wide
check of dew on
amount of piping on
refrigerant low
and pressure
supply side
proper Table 8-5-7
amount of
refrigerant
Page of chapter 8. Air conditioner
24
(i) Defective compression compressor. It is Illustration 8-5-10
showed in the illustration 8-5-9 and table 8-5-8.
(1) Discharge the refrigerant
1 Open the A/C switch.
2 The A/C is running about
5~6min while the engine is running about 1000
r/min.
3 Stop the engine.
Illustration 8-5-9 4 Discharge the refrigerant.
(2) Refill the refrigerant
Symptom Reason Diagnosis Remedy
1 Evacuate air
(1) (1) (1) Repair or
2 Refill the HFC-134a(R134a). Standard
Pressure Leakage of Damage of replace the
value: 580g.
too high the the compressor
3) Run the engine at idle speed
on low compresso compresso
4) Check the leakage of the refrigerant.
and high r r
4. Refrigerant pipe (showed in the illustration 8-
pressure (2) (2)
5-11)
sides Damage of Leakage
(2) the from valve
Refrigerant pipeline layout：
Pressure compresso damaged
too low r or broken
on high sliding
pressure parts
side
`Table 8-5-8

3． Fill the refrigerant

Illustration 8-5-11

2. Check-up of A/C electronic control system

2.1. Check-up of heating electronic control system（For automatic A/C system）

●Turn the ignition switch to the “ON” position, and at same time press down the AUTO and OFF
switches for about 5s(all of the indicators will be flashing 4 times), will enter into the checking status of
the indicator. Notice: If do not press down the AUTO and OFF switch at same time, will cancel the
checking status and enter into the A/C control status.
●After the check of the indicator, will enter into the check of the malfunction code automatically, and at
this time can read the malfunction code through the display on the control panel.
●Under the check of the malfunction code, press down the FRONT switch, will enter into the check of
the adjuster, and at this time can read the malfunction code through the display on the control panel.
Press down the OFF switch, will cancel the checking status and enter into the A/C control.
●Under the check of the adjuster, press down the AUTO switch, will enter into the check of the
malfunction code. Press down the OFF switch, will cancel the checking status and enter into the A/C
control.
●After the display, the malfunction code will be cancelled without saved automatically.

Page of chapter 8. Air conditioner

25
2.2. Table of malfunction code
Malfunction Diagnosis
code
00 Normal
Short circuit of the inner
10
temperature sensor
Open circuit of the inner
11
temperature sensor
Short circuit of the outer
20
temperature sensor
Open circuit of the outer
21
temperature sensor
Short circuit of the of the
30
evaporator sensor
Open circuit of the of the
31
evaporator sensor
Malfunction of the flow
40
mode control motor
Malfunction of the
50
temperature control motor
NOTE:
(1). If the outer or inner temperature is -40℃ or more less, although the A/C system is normal, some
malfunction codes (10, 11,,20,21) will appear
(2). If the vehicle is under dark, the malfunction codes (40) will appear.
2.3. Check the malfunction code and circuit of heating electronic control system
2.3.1. Check the malfunction codes 10, 11
●Check the circuit
Illustration 8-5-12 The checking circuit of the malfunction codes 10, 11
●Check-up process
Page of chapter 8. Air conditioner
Reason
OK
1.Malfunction of inner temperature sensor
2.Malfunction of A/C controller
3.Malfunction of the wire harness or connector between
the A/C controller and the inner temperature sensor
1. Malfunction of inner temperature sensor
2. Malfunction of A/C controller
3. Malfunction of the wire harness or connector between
the A/C controller and the inner temperature sensor
1. Malfunction of outer temperature sensor
2. Malfunction of A/C controller
3. Malfunction of the wire harness or connector between
the A/C controller and the outer temperature sensor
1. Malfunction of outer temperature sensor
2. Malfunction of A/C controller
3. Malfunction of the wire harness or connector between
the A/C controller and the outer temperature sensor
1. Malfunction of the evaporator sensor
2. Malfunction of A/C controller
3. Malfunction of the wire harness or connector between
the A/C controller and the evaporator sensor
1. Malfunction of the evaporator sensor
2. Malfunction of A/C controller
3.Malfunction of the wire harness or connector between
the A/C controller and the evaporator sensor
1. Malfunction of the flow mode control motor
2. Malfunction of A/C controller
3. Malfunction of the wire harness or connector between
the A/C controller and the floe mode control motor.
1. Malfunction of the temperature control motor
2. Malfunction of A/C controller
3. Malfunction of the wire harness or connector between
the A/C controller and the temperature control motor
26
1. Check the inner temperature sensor
Remove the inner temperature sensor; test the resistance between 1 and 2. At 20℃, the
resistance is 12.37-12.67kΩ. At 40℃, the resistance is 5.225-5.397 kΩ.
If normal, please to next step If abnormal, replace the inner temperature
sensor.
2. Check the wire harness or connector between the A/C controller and the inner
temperature sensor
（1）Disconnect the inner temperature sensor connector A19
（2）Disconnect the A/C controller connector C11
（3）Test the resistance between the port 1-A19 of the inner temperature sensor and the port A26-
C11 of A/C controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 2-A19 of the inner temperature sensor and the port 23-
C11 of A/C controller. And the resistance should be less than 1Ω.
（ 5 ） Test the resistance between the port 23-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
（ 6 ） Test the resistance between the port 26-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire
harness or the connector.

2.3.2. Check the malfunction codes 20, 21

●Check the circuit

Illustration 8-5-13 The checking circuit of the malfunction codes 20, 21

●Check-up process

1. Check the outer temperature sensor

Remove the outer temperature sensor, test the resistance between port 1 and port 2. At 20℃, the
resistance is 12.37-12.67kΩ. At 40℃, the resistance is 5.225-5.397 kΩ.
If normal, please to next step If abnormal, replace the inner temperature
sensor.
2. Check the wire harness or connector between the A/C controller and the outer temperature
sensor
（1）Disconnect the outer temperature sensor connector A1
（2）Disconnect the A/C controller connector C11
（3）Test the resistance between the port 1-A1 of the outer temperature sensor and the port 22-C11
of A/C controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 2-A1 of the outer temperature sensor and the port 25-C11
of A/C controller. And the resistance should be less than 1Ω.
（5）Test the resistance between the port 23-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
（6）Test the resistance between the port 25-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire harness

Page of chapter 8. Air conditioner

27
 or the connector.

2.3.3. Check the malfunction codes 30, 31

●Check the circuit

Illustration 8-5-14 The checking circuit of the malfunction codes 30, 31

●Check-up process
1. Check the evaporator temperature sensor
Disconnect the evaporator temperature sensor connector, test the resistance between the port 1 an d
port 2. At 10℃, the resistance is 3.101～3.359kΩ. At 20℃, the resistance is 1.964～2.106kΩ.
If normal, go to next step If abnormal, replace the evaporator temperature
sensor.
2. Check the wire harness or connector between the evaporator temperature sensor and A/C
controller.
（1）Disconnect the evaporator temperature sensor connector A18
（2）Disconnect the A/C controller connector C11
（3）Test the resistance between the port 1-A18 of the inner temperature sensor and the port 21-C11 of
A/C controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 2-A18 of the inner temperature sensor and the port 24-C11 of
A/C controller. And the resistance should be less than 1Ω.
（5）Test the resistance between the port 21-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
（6）Test the resistance between the port 24-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire harness
or the connector.

2.3.4. Check the malfunction code 40

●Check the circuit

Page of chapter 8. Air conditioner

28
 Illustration 8-5-16 The checking circuit of the malfunction code 40

●Check-up process
1. Check the A/C controller
（1）Remove A/C controller but the connector also be connected. Turn the ignition switch to the
ON position
（2）Test the voltage between the port 2-C11 and the port 7-C11 of A/C controller, the voltage is
about 5V.
（3）Test the voltage between the port 2-C11 and the port 4-C11 of A/C controller, the voltage is
3.5-4.5V while the wind outlet port is at FACE position. The voltage is 0.5-1.5V while the wind
outlet port is at DEF position.
If normal, to next step If abnormal, overhaul or replace the wire harness or the
connector.
2. Check the blow mode control motor
（1）Disconnect the blow mode control motor connector.
（2）Connect the battery positive pole to the port 5-A24, connect the battery negative pole to the
port 7-A24. The lever is turned to the DEF position.
（3）Connect the battery positive pole to the port 7-A24, connect the battery negative pole to the
port 5-A24. The lever is turned to the FACE position.
（4）Test the resistance between the port 2-A24 and the port 3-A24 of blow mode control
motor，it should be about 10kΩ. The resistance between the port 6-A24 and the port 2-A24 of that
should be 0.5～2kΩ while the wind outlet duct is in FACE position, and the resistance should be 7
～9kΩ while the duct is in DEF position.
If normal, to next step If abnormal, replace the blow mode control motor
3. Check the wire harness and connector between the blow mode control motor and A/C
controller.
（1）Disconnect the blow mode control motor connector
（2）Disconnect the A/C controller connector
（3）Test the resistance between the port 2-A24 of the blow mode control motor and the port 7-
C11 of A/C controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 3-A24 of the blow mode control motor and the port 2-
C11 of A/C controller. And the resistance should be less than 1Ω.
（5）Test the resistance between the port 5-A24 of the blow mode control motor and the port 9-
C11 of A/C controller. And the resistance should be less than 1Ω.
（6）Test the resistance between the port 6-A24 of the blow mode control motor and the port 4-
C11 of A/C controller. And the resistance should be less than 1Ω.
（7）Test the resistance between the port 7-A24 of the blow mode control motor and the port 10-
C11 of A/C controller. And the resistance should be less than 1Ω.
（8）Test the resistance between the port 7-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
（9）Test the resistance between the port 24-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
（10）Test the resistance between the port 9-C11 of A/C controller and the body. And the
Page of chapter 8. Air conditioner
29
resistance should be more than 100KΩ.（11）Test the resistance between the port 4-C11 of A/C
controller and the body. And the resistance should be more than 100KΩ.
（12）Test the resistance between the port 10-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire harness or the
connector.

2.3.5. Check the malfunction code 50

●Check the circuit

Illustration 8-5-17 The checking circuit of the malfunction code 50

●Check-up process
1. Check the A/C controller
（1）Remove the A/C controller, but the connector is connected. Turn the ignition switch to the
“ON” position
（2）Test the voltage between the port 8-C11 and port 3-C11 of the A/C controller, it should be
about 5V
（3）Test the voltage between the port 5-C11 and port 3-C11 of the A/C controller, while the
temperature selector is at coldest position, it should be 3.5～4.5V, while the temperature selector is
at hottest position, it should be 0.5～1.5V
If normal, to next step If abnormal, overhaul or replace the wire harness or the
connector.
2. Check the temperature control motor
（1）Disconnect the temperature control motor connector.
（2）Connect the port 5-A23 of the temperature control motor connector and the battery positive
terminal, port 7-A23 to the battery negative terminal,and the lever should be turned to the cold
position.
（3）Connect the port 7-A23 of the temperature control motor connector and the battery positive
terminal, port 5-A23 to the battery negative terminal,and the lever should be turned to the hot
position.
（4）Test the resistance between the port 2-A23 and the port 3-A23 of temperature control
motor，it should be about 10kΩ. The resistance between the port 6-A23 and the port 2-A23 of that
should be 0.5～2kΩ while the wind outlet duct is in cold position, and the resistance should be 7～
9kΩ while the duct is in hot position.
If normal, to next step If abnormal, replace the temperature control motor
3. Check the wire harness and connector between the temperature control motor and A/C
Page of chapter 8. Air conditioner
30
controller.
（1）Disconnect the temperature control motor connector
（2）Disconnect the A/C controller connector
（3）Test the resistance between the port 2-A23 of the temperature control motor and the port 3-
C11 of A/C controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 3-A23 of the temperature control motor and the port 8-
C11 of A/C controller. And the resistance should be less than 1Ω.
（5）Test the resistance between the port 5-A23 of the temperature control motor and the port 12-
C11 of A/C controller. And the resistance should be less than 1Ω.
（6）Test the resistance between the port 6-A23 of the temperature control motor and the port 5-
C11 of A/C controller. And the resistance should be less than 1Ω.
（7）Test the resistance between the port 7-A23 of the temperature control motor and the port 11-
C11 of A/C controller. And the resistance should be less than 1Ω.
（8）Test the resistance between the port 3-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
（9）Test the resistance between the port 8-C11 of A/C controller and the body. And the resistance
should be more than 100KΩ.
（10）Test the resistance between the port 12-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
（11）Test the resistance between the port 5-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
（12）Test the resistance between the port 11-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire harness or the
connector.

2.3.6. Check the malfunction of light intensity sensor

●Check the circuit

Illustration 8-5-18 The checking circuit of light intensity sensor

●Check-up process
1. Check the light intensity sensor
Remove the light intensity sensor, and connect the resistance 36 kΩ in series, and then connect to
the 5V source. Illuminate the sensor with sunlight（the light intensity is 30000～50000 lux），test
the voltage between the port 1 and port 2 of the light intensity sensor with digital multimeter, the
voltage should be 0.7～1.5V。
If normal, please to next step If abnormal, replace the light intensity sensor.
2. Check the wire harness or connector between the light intensity sensor and A/C
controller.
（1）Disconnect the light intensity sensor connector

Page of chapter 8. Air conditioner

31
（2）Disconnect the A/C controller connector
（3）Test the resistance between the port 1-A20 of the light intensity sensor and the port 28-C11
of A/C controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 2-A20 of the light intensity sensor and the port 27-C11
of A/C controller. And the resistance should be less than 1Ω.
（5）Test the resistance between the port 28-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
（6）Test the resistance between the port 27-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire harness or the
connector.

2.3.7. Check the malfunction of pressure switch

●Check-up process
1. Check whether the coolant leaks or is too more with pressure gauge.
If normal, to next step If abnormal, overhaul it.
2. Check the pressure switch of A/C
The pressure switch is three-state pressure switch, there are low-pressure (LP), middle-pressure
(MP), high- pressure (HP). LP and HP are in series, the ports is 1-A4 and 3-A4. The ports of MP is
2-A4 and 4-A4. The pressure of three-state pressure switch（ON/OFF）:
（1）HP：（1-A4、3-A4）OFF ≥（3.14±0.2）MPa （1-A4、3-A4）ON ≤（2.44±0.2）MPa
（2）MP：（2-A4、4-A4）ON ≥（1.77±0.1）MPa （2-A4、4-A4）OFF ≤（1.37±0.12）MPa
（3）LP：（1-A4、3-A4）OFF ≤（0.196±0.02）MPa （1-A4、3-A4）ON ≥（0.206±0.03）MPa
At normal, after fill the coolant well, the ports 1 and 3 are connected, and the ports 2 and 4 are
disconnected. If the temperature is too high or the coolant is too more, and the A/C is running, the
ports 1 and 3 are connected, and the ports 2 and 4 are connected or disconnected. Check the
connectedness of the ports 1 and 3, also the ports 2 and 4.
If normal, to step 3 If abnormal, replace the pressure switch
3. Check the wire harness and connector between pressure switch and A/C controller.
（1）Disconnect the pressure switch connector
（2）Disconnect the A/C controller connector
（3）Test the resistance between the port 1-A4 of the pressure switch and the port 18-C11 of A/C
controller. And the resistance should be less than 1Ω.
（4）Test the resistance between the port 2-A4 of the pressure switch and the body. And the
resistance should be less than 1Ω.
（5）Test the resistance between the port 3-A4 of the pressure switch and the port 3-2G of A/C
fuse. And the resistance should be less than 1Ω.（6）Test the resistance between the port 4-A4 of
the pressure switch and the port 16-C11 of A/C controller. And the resistance should be less than
1Ω.（7）Test the resistance between the port 18-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
（8）Test the resistance between the port 16-C11 of A/C controller and the body. And the
resistance should be more than 100KΩ.
If normal, replace the A/C controller. If abnormal, overhaul or replace the wire
harness or connector.

●Check the pressure switch circuit

Page of chapter 8. Air conditioner

32
 Illustration 8-5-19 The checking circuit of the pressure switch

2.3.8. Spare electrical source

●Check the circuit

Illustration 8-5-20 The circuit of the spare electrical source

●Check-up process
1. Check the 15A fuse of inner light.
Remove the 15A fuse of inner light, and check whether it has been broken off.
If normal, to next step If abnormal, replace the fuse
2. Check the A/C controller.
Remove the A/C controller but also connected, test the voltage between port A20 of the A/C
controller and the body. The voltage is 10-14V.
If normal, make next check following the if abnormal, overhaul or replace the wire
malfunction table. harness or connector.

2.3.9. IG electrical source

●Check the circuit

Illustration 8-5-21 The circuit of the IG electrical source

●Check-up process

1. Check the instrument fuse

Remove the instrument fuse in the engine relay case, check whether it has been broken off.
If normal, to next step If abnormal, replace the instrument fuse

Page of chapter 8. Air conditioner

33
2. Check the A/C controller
Remove the A/C controller but also connected, and the ignition switch in ON position, test the voltage
between port A19 of the A/C controller and the body. The voltage is 10-14V.
If normal, make next check following the malfunction if abnormal, overhaul or replace the wire
table. harness or connector.

2.3.10. ACC electrical source circuit

●Check the circuit

Illustration 8-5-22 The circuit of the ACC electrical source

●Check-up process
1. Chcek the cigar lighter fuse
Remove the 15A fuse of cigar lighter; check whether it has been broken off.
If normal, to next step If abnormal, replace the cigar lighter fuse
2. Check the A/C controller
Remove the A/C controller but also connected, and the ignition switch in ACC position, test the
voltage between port 40-C11 of the A/C controller and the body. The voltage is 10-14V.
If normal, make next check following the if abnormal, overhaul or replace the wire harness or
malfunction table. connector.

2.3.11. Rear windshield heater relay circuit

●Check the circuit

Page of chapter 8. Air conditioner

34
 Illustration 8-5-23 The circuit of the rear windshield heater relay

●Check-up process
1. Check the A/C controller
（1）Remove the A/C controller(for automatic A/C), turn the ignition switch to the OFF position, test the
voltage between port 37-C11 of the A/C controller and the body. The voltage is below 1V. Turn the
ignition switch to the ON position, The voltage between port 37-C11 of the A/C controller and the body, it
is 10-14V.
（2）Remove the A/C controller(for manual A/C), turn the ignition switch to the OFF position, test the
voltage between port 1-H5、2-H5 and the body. The voltage is below 1V. Turn the ignition switch to the
ON position, The voltage between port 1-H5、2-H5 and the body, it is 10-14V.
If normal, overhaul or replace the A/C controller、rear If abnormal, to next step
windshield heater switch
2. Check the heater replay
If normal, overhaul or replace the wire harness or If abnormal, replace the relay
connector.

2.3.12． Check the blower speed adjusting resistance (for manual A/C)

Illustration 8-5-24 The circuit of the blower speed adjusting resistance

Checkthe resistances between the ports of blower speed adjusting resistance, the resistance between
Page of chapter 8. Air conditioner
35
 the port 1-B5 and the port 2-B5 should be 1.2～1.6Ω，the resistance between the port 1-B5 and the
port 2-B5 should be 0.35～0.45Ω,the resistance between the port 1-B5 and the port 2-B5 should be
2.2～3.0Ω, or replace the blower speed adjusting resistance.

2.3.13. Check the circuit of blower motor

●Check the circuit

Illustration 8-5-25 The circuit of the blower motor

●Check-up process
1. Check blower motor
Disconnect the B4 connector of blower motor, connect the port 2-B4 of blower motor and the battery
positive pole. Connect the port 1-B4 of blower motor and the battery negative pole. And the blower
should run normally.
If normal, to next step If abnormal, overhaul or replace the blower
motor
2.Check the A/C servo
If normal, to next step If abnormal, overhaul or replace the A/C servo
3.Check the noise filter
If normal, to next step If abnormal, overhaul or replace the noise
filter
4. Check the wire harness and connector between blower speed adjusting module and battery.
If normal, make next check following the malfunction If abnormal, overhaul or replace the wire
table. harness or connector.

2.3.14. Compressor circuit

●The circuit of the compressor is showed in the illustration 8-5-26. The checking process are below.

Page of chapter 8. Air conditioner

36
 Illustration 8-5-26 The circuit of the compressor

●Check-up process
1.Check the A/C controller
Remove the A/C controller but also connected, start the engine and press down the AUTO button, test
the voltage between port 17-C11 of the A/C controller and the body. The voltage is less than 1V while
the A/C is running, and it is 10-14V while the A/C is closed.
If normal, to next step If abnormal, to step 5
2. Check the relay of the electromagnetic clutch
Remove the electromagnetic clutch relay in the engine compartment relay case, the resistance
betweenthe port B34 and B35 should be 50～95Ω, it shouldn’t be conducted between the port B62
and B36; connect the battery to the port B34 and B35, it should be conducted between the port B62
and B36.
If normal, to next step If abnormal, replace the relay of the
electromagnetic clutch
3.Check the electromagnetic clutch
Disconnect the A2 connector of electromagnetic clutch; connect the port A2 to the battery positive pole.
Connect the battery negative pole to the body. And the clutch should mesh with noise.
If normal, to next step If abnormal, replace the electromagnetic clutch
4. Check the wire harnesse and connector between compressor and relay, the wire harness and
connector between the compressor and the body.
If normal, make next check following the malfunction If abnormal, overhaul or replace the wire
table. harness or connector.
5. Check the A/C controller
Remove the connector 33-C11 of the A/C controller, turn the ignition switch to ON position, test the
voltage between port 33-C11 of the A/C controller and the body. The voltage should be 10-14V.
If normal, to next step If abnormal, overhaul or replace the A/C
controller
6.Check the engine ECM
Connect the connector 33-C11 of the A/C controller, start the engine and press down the AUTO button,
test the voltage between port 33-C11 of the A/C controller and the body. The voltage is less than 1V
while the clutch is connected, and it is 10-14V while the A/C is disconnected.
If normal, to next step If abnormal, overhaul and replace the engine ECM
7. Check the A/C controller
Start the engine and press down the AUTO button, test the voltage between port 32-C11 of the A/C
controller and the body. The voltage is less than 1V while the A/C is closed, and it is 10-14V while the
A/C is running.
If normal, to next step If abnormal, overhaul or replace the wire harness
or connector.
8. Check the wire harness and connector between A/C controller and engine ECM
If normal, replace the A/C controller If abnormal, overhaul or replace the wire harness
or connector.

Page of chapter 8. Air conditioner

37
Section 6 Technical parameters and Notice of A/C system

1. Technical parameters：

1.1. Inner temperature sensor

Temperature(℃) Lower limit of Standard value (KΩ) Upper limit of
resistance (KΩ) resistance (KΩ)
0 32.25 33.69 32.97
15 15.55 15.77 16.00
25 9.900 10.00 10.10

1.2. Outer temperature sensor

Temperature(℃) Lower limit of Standard value (KΩ) Upper limit of
resistance (KΩ) resistance (KΩ)
0 32.25 33.69 32.97
15 15.55 15.77 16.00
25 9.900 10.00 10.10

1.3. Temperature sensor of evaporator

Tempe Lower Standar Upper Tempe Lower Standar Upper

-rature limit of d value limit of - limit of d value limit of
(℃) resistanc (KΩ) resistanc rature resistanc (KΩ) resistance
e (KΩ) e (KΩ) (℃) e (KΩ) (KΩ)

1.4. Water temperature sensor（inlet pipe of heater housing）

Temperature(℃) Lower limit of Standard value(KΩ) Upper limit of

resistance(KΩ) resistance(KΩ)
0 3.996 4.163 4.288
15 2.090 2.133 2.176
25 1.372 1.400 1.428

Page of chapter 8. Air conditioner

38
1.5. Sunlight sensor
Condition Light intensity(LUX) resistance(KΩ) Error permitted
temperature(℃)
25 500 1.1 +20%
25 1000 2.1 +20%
25 1500 5.18 +20%
25 3500 7.35 +20%
25 5000 11.57 +20%
25 6500 16.98 +20%

1.6. Pressure switch

High 3.14±0.2 MPa OFF stopped
pressure 2.44±0.2 MPa ON running
Middle 1.77±0.1 MPa ON Condenser fan-high speed
pressure 1.37±0.12 MPa OFF Fan-low speed
Low 0.196±0.02 MPa OFF stopped
pressure 0.206±0.03 MPa ON running

1.7. The tighted torque of the pipe connectors and components

Positon Torque/N·m

compressor 35N·m

Inlet and outlet pipe of compressor 35N·m

Connector between evaporator and
12N·m
compressor
Connector betweencompressor and
12N·m
condensor
Connectors of other pipes 18N·m

1.8. Temperature sensor of evaperator

Temperature(℃) resistance(KΩ)
0 5.081----5.559
15 2.466---2.644
20 1.964----2.106
25 1.581----1.679
30 1.275----1.354
35 1.031----1.095

1.9. Specification of seal ring

8mm seal ringof pipe 6.80*1.78 3
16mm seal ring of pipe/expansion valve 13.80*2.40 3
12mm seal ring of compressor oulet pipe 11.00*2.40 1
Seal ring of expansion valve 6.80*1.90 1

1.10. Lubricant needed while replace the A/C pipes sepetately:

Item Capacity
condensor 35ml
evaporator 30ml
piprline 10ml
drier 10ml

Page of chapter 8. Air conditioner

39
NOTE：
1. While replace the above components together with the compressor, drain the refrigerant which
retains in the refrigerant pipe、condensor and evaporator but exceeds the stated capacity
through the compressor. No need to refill the refrigerant while there is little leakage from the
pipe connector.
2. The compressor oil is of special type, can’t be taken place of other type oil、be mixed with other
type oil, or the compressor may be damaged.
3. The compressoroil will easily absorb the moisture and be oxygenated, so it must be sealed.
4. The type of compressor oil: PAG-56
5. The oil capacity of compressor: 120ml

NOTE：
1. The maintenance for A/C system must be operated by professional technicians.
2. The maintenance area must be ventilated, don’t use the refrigerant in the close room or close
to fire. Wear the protection glass while maintenance.
3. Don’t get the refrigerant into eyes or skins. If it gets into eyes or skins, clean it with cold water,
don’t scrape it, coat Vaseline unguent on the skin. If it is serious, see the doctor as soon as
possible.
4. Don’t run the compressor if the refrigerant is not enough, avoid the compressor being burnt for
lack of refrigerant.
5. Don’t open the high pressure valve of the pressure gauge while the compressor is running, you
can only open or close the low pressure valve.
6. The refrigerant must be exclusive type for F3, mustn’t be replace or mixed with other type.
7. Total refrigerant capacity in the F3 AC system is 120ml, while the refrigerant is less than 110ml
because of leakage, it will cause excessive wear of compressor, so the service station should
refill the refrigerant according the situation.
8. The O-ring in the opened pipe must be replaced while maintenance, coat refrigerant on the seal
ring, then install it as stated torque.
9. Do the maintenance according to the technical requirement（capacity、refrigerant
type、torque ）strictly, to ensure its normal working and usage period
10. The refrigerant is easy to absorb the water, jam the nozzle at once while remove the pipe, to
avoid the entry of moisture or dust.
11. While drain the excessive refrigerant in the outlet system, don’t drain too fast,or it will drain the
compressor oil in the system.
12. Clean the air filter periodically to maintain good ventilation.
13. Check whether the surface of condenser is dirty, don’t use steam or high pressure squirt gun
to clean it, or it will be damaged, you should use fur brush to clean it.
14. Don’t fill the excessive refrigerant. If the refrigerant is excessive, it will cause bad
refrigeration、bad fuel consumption、engine overheating and such problems.

Page of chapter 8. Air conditioner

40