Aire AcondicionadoV5

Air conditioner — air conditioning system
Air Conditioner
Air conditioning system ................................................................ 13-1
Troubleshooting .......................................................................... 13-13
Drive belt .................................................................................... 13-15
Manometer ................................................................................. 13-17
Refrigeration pipeline ................................................................. 13-19
Air conditioning system .............................................................. 13-22
Air conditioner compressor assembly ........................................ 13-37
Condenser .................................................................................. 13-44
Expansion valve ......................................................................... 13-52
Blower electromotor ................................................................... 13-54
Blower resistor ............................................................................ 13-56
Thermal resistor ......................................................................... 13-57
Pressure switch .......................................................................... 13-58
Condenser fan ............................................................................ 13-61
Heater control ............................................................................. 13-66
Heater control assembly ............................................................ 13-72
Condenser fan ............................................................................ 13-75
Air filter ....................................................................................... 13-76

Air conditioning system
Precautions
1. Don’t put refrigerant in a closed room or near a
naked flame.
2. Wear eye protective device.
3. Don’t make refrigerant splash on you eyes or skin.

If the refrigerant splashes on you eyes or skin:
(a) Flush with cold water
Caution:
Don't try to wipe you eyes or skin.
(b) Wipe oil on the skin properly.
(c) See a doctor immediately.
4. Don’t heat the tank or put it close to naked flame.

5. Place refrigerant tank gently to prevent impact to
the tank.
Wrong 6. Don’t start the compressor when refrigerant level of

Right
refrigeration system is low.
If there’s not sufficient refrigerant in the refrigeration
system and the lubricating oil supply is not enough, this
may burn the compressor out. So it must pay attention
to this condition.
7. Don’t open manifold manometer valve during
compressor running process. If high-pressure valve
is opened and then refrigerant will flow reversely,
this will cause crack of cylinder. Only the
low-pressure valve is allowed to be opened or
closed.
8. Caution: Do not fill excessive refrigerant.
Filling excessive refrigerant will cause series of
problems. Such as refrigeration insufficiency, low fuel
economy and engine overheat.
9. Supplementary Restraint System (SRS)
This vehicle is equipped with a SRS system such as air
bag for driver. Any failure to follow the specified
operation procedure during maintenance will cause
opening of SRS and accidents. So the serviceman must
know vehicle precautions clearly before performing
maintenance work (including dismantling, installation,
check and replacement).
13-1
1. Check for refrigerant quantity

Peep hole Observe the refrigerant level through the peep hole in
the liquid tube.
Test condition：:
● Engine speed：: 1,500rpm
● Blower speed control switch：: “Hl” position

● A/C switch ON
● Temperature control selector：: Coolest position
● Open all the doors
refrigerant
No Problems solutions
quantity
Air bubbles in peep hole (1) Check leakage with leak
detector and repair if
necessary.
1 Insufficient
(2) Add proper amount of
refrigerant and discharge air
bubbles.
2 No air bubble in the peep hole Excessive Related to items 3 and 4
Outlet temperature of compressor is the same as inlet (1) Check leakage with leak
detector and repair if
temperature of compressor
necessary.
3 Little
(2) Add proper amount of
refrigerant to make air bubble
vanish.
An Obvious difference between compressor inlet Related to items 5 and 6
4 Normal
temperature and outlet temperature
Refrigerant in the observation becomes transparent (1) Release proper amount of
refrigerant.
immediately after closing the air conditioning system
5 Excessive (2) Add proper amount of
refrigerant after creation of
vacuum.
Refrigerant in the observation appears to be foam and
6 then transparent after closing the air conditioning Normal
system
*: If there’s not sufficient refrigerant, then air bubble in the peep hole is considered normal under the condition of
temperature higher than normal ambient temperature.
13-2
2. Check for refrigerant pressure with manifold

manometer.
Conditions and procedures of test via a manifold

manometer are taken as follows (check system failure
with manifold manometer.):
● Place the air inlet switch at “internal circulation”

position, the temperature is 30～35℃ (86～ 95°F)
● Engine speed: 1,500rpm
● Place blower speed control switch at high “Hl”
position.
● Place temperature control switch at cold position.
Tips:
Indication values of the manifold manometer will be a

little more different due to different ambient
temperatures.
(1) Performance of normal refrigeration system

Measured value:
Pressure of low-pressure side:
0.15-0.25MPa (1.5-2.5kgf/cm2)
Pressure of high-pressure side:
1. 37-1.57MPa (14-16kgf/cm2)
(2) Water in refrigeration system
State: intermittent refrigeration

followed by system non-operation
Failures in
refrigeration Possible causes Diagnosis Solutions
system
Vacuum and Moisture in the refrigeration ● the desiccant is (1) Replace the liquid
normal pressure freeze at throttle part of saturated reservoir
at low-pressure expansion valve, then the ● Moisture in the (2) Extend the vacuum
end exists refrigeration cycle is stopped refrigeration freezes at pumping time to drain
alternatively temporarily, it will return to throttle port of moisture of the system
normal when the ice melts expansion valve, and (3) Add proper amount of
blocks the refrigeration new refrigerant
cycle
13-3
(3) Insufficient of refrigerant
State: insufficient refrigeration
Failures in
Possible causes Diagnosis Solutions
refrigeration system
● Too low pressure Leakage exist in ● Insufficient (1) Check for leakage with leak detector and
of high-low refrigerant repair if necessary
some part of
pressure end
refrigeration system ● Refrigerant (2) Add proper amount of refrigerant
● Air bubble can leakage
be observed at (3) If pressure indicating value is close to zero
the peep hole when connecting refrigeration system with
manifold manometer, pump vacuum and
● Insufficient repair the leakage part after checking
refrigeration
performance
(4) Insufficient circulation of refrigerant
State: insufficient refrigeration
Failures in refrigeration
system
● Too low pressure of Dirt in the refrigerant liquid ● Refrigerant is blocked Replace the refrigerant
high-low pressure dryer blocks the flow of liquid dryer
end. refrigerant
● Frost can be seen on

the pipes from
evaporator to the
refrigerant liquid dryer
13-4
(5) No refrigerant circulation

Failures in refrigeration system Possible causes Diagnosis Solutions
● Vacuum at low-pressure end ● Moisture and dirt of the No refrigerant (1) Check for expansion
and too low pressure at refrigeration system block valve
circulation
high-pressure end flow of refrigerant
(2) Eliminate dirt in the
● Condensed frost or dew Can ● Gas leaking from expansion valve by
be seen at front-to-rear expansion valve blocks blasting air
pipeline of dryer or the flow of refrigerant
expansion valve (3) Replace liquid dryer
(4) Pump vacuum and add
proper amount of
refrigerant
(5) Replace the expansion
valve if there exists gas
leakage in it
(6) Excessive refrigerant or insufficient cooling of condenser
State: defective refrigeration
system
● Excessive pressure ● Excessive refrigerant ● Excessive refrigerant (1) Clean the condenser
on both high-low causes it to fail to in the system - add
pressure ends. display cooling excessive refrigerant. (2) Check for running
performance. condition of the
● Air bubble can’t be ● Insufficient cooling of compressor fan
observed with engine ● Insufficient cooling of condenser -
speed descending. condenser. condenser cooling fin (3) If conditions (1) and
blocked or failure. (2) are normal, check
for the refrigerant
amount and add
proper amount of
refrigerant
13-5
(7) Air exists in refrigeration system
Cautions: if adding refrigerant without pumping vacuum out after the start of refrigeration system, the manometer
reading will indicate as follows:
Possible causes Diagnosis solutions
system
● Excessive pressure Air exist in refrigeration ● Air exists in (1) Check whether
on both high-low refrigeration system. compressor oil is not
system
pressure end clean or not enough.
● Insufficient vacuum
● Low pressure pipe pumping (2) Vacuum pumping and
generate heat when it add new refrigerant.
is touched
● Air bubble is
observed from peep
hole
(8) Incorrect installation of expansion valve
State: Insufficient refrigeration
system
● Excessive pressure Expansion valve failure ● excessive opening of Check expansion valve
on both high-low expansion valve and replace it if damaged
pressure ends
● Excessive refrigerant
● Much more frost or in low-pressure pipe
dew exists on low
pressure pipe
13-6
(9) Compressor failure
State: no refrigeration
system
● Excessive pressure at ● Internal leakage of ● Compression failure Repair or replace

low-pressure end compressor compressor
● Inhalation valve
● Excessive pressure at damaged or seal
high-pressure end failure
3. Check for idle speed increasing

(a) Engine warming-up
(b) Check for idle speed increasing when it meets
conditions below
● Engine warming-up
● Place blower control switch at “Hl” position
● Air conditioner switch (A/C) “0N”
● Place transmission at neutral position
● Place temperature control switch at “cool” position
● Stabilized speed for idle speed: 700±50 rpm
Check idle controlling system if idle speed fails to meet
the specification
(c) Two-speed design for air conditioner condenser fan

of VIOS
System fan will run at low speed when air conditioning

system pressure reaches 0.196MPa
System fan will run at high speed when air conditioning
system pressure reaches 1.52MPa
13-7
4. Check for leakage of refrigerant

(a) Operation under these conditions:
● Engine stopped
● Ensure well-ventilated (or else the leak
detector will detect active gas, this gas is
gasoline vapour and exhaust gas but not
refrigerant).
● Repeat this check for two or three times
● Confirm whether refrigerant exists in the
refrigeration system, when compressor
stopped the pressure is: about 392-588kPa
(4-6kgf／cm2, 57-85psi)
(b) Put the leak detector near to exhaust pipe before
performing the test.
Tips:
● Cooling system will hold for more than 15
minutes after suspension of blower.
● Expose the leak detector sensor to exhaust
hose.
● It should ensure that leak detector won’t react
with active gas when adjacent to exhaust
hose, or else the vehicle must be lifted.
(c) If no gas leakage exists at the exhaust hose,
remove lower resistor of the refrigeration unit and
insert leak detector into refrigeration unit to check.
(d) Remove wiring harness plug to make it separate
with pressure switch for about 20 minutes, and
then put leak detector near to pressure switch to
perform check work.
(e) Put leak detector near to refrigerant pipeline to
perform check work.
13-8
Vacuum pumping
1. Connect the fast conversion connector with filling
hose
2. Remove maintenance valve cover of refrigeration
pipeline
3. Fix the manometer
(a) Close two valves of the manometer
(b) Connect the fast conversion connector with
maintenance valve
4. Discharge air from the refrigeration system

(a) Connect vacuum pump connector with vacuum
pump
(b) Connect manometer center hose with vacuum

pump
(c) Open valves of high pressure end and low
pressure end, then run the vacuum pump
(d) Indicating value of the low pressure gauge should
be 750mmHg (30in. Hg) or larger than this value for
ten minutes or ten minutes later.
Tips:
If the indicating value is 750mmHg (30in.Hg) or larger
than this value, close high pressure valve and low
pressure valve of the manometer, then close vacuum
pump, check whether leakage exists in the system and
repair if necessary.
(e) Close high pressure valve and low pressure valve
of the manometer, then close vacuum pump,
system operating mode should be kept for 5
minutes or more, check whether indicating hand
fluctuation exists for the manometer.
13-9
Refrigerant adding
1. Install cooling medium reservoir
Tips:
Push Operate according to instructions below when installing
Air
the cooling medium reservoir.
(a) Cooling medium reservoir should maintain proper

Low pressure quantities of refrigerant.
maintenance
valve (b) Connect the center hose with cooling medium
reservoir
Warning: Never open high pressure valve and low

pressure valve of the manometer.
(c) Open valve of cooling medium reservoir.

High pressure (d) Press valve center button at side of manometer,
maintenance valve
then discharge air of the center hose.
Cooling medium
reservoir
2. Check for leakage of refrigeration system

(a) Open high pressure manual valve then fill the
refrigerant
(b) Close the high pressure manual valve when
indicating value of low pressure gauge is 98kPa
(1kgf/cm2, 14psi)
(c) Check for system leakage with leak detector
Warning:
The refrigerant should be recovered no matter what
fitting part to be replaced.
Air leak detector
13-10
3. Add refrigerant to the refrigeration system

Check whether leakage exists in the refrigeration
system; if no leakage exists then fill proper amount of
refrigerant into refrigeration system.
Warning :
● Filling refrigerant into high pressure end is not
permitted when engine is in operation mode.
● Don’t open low pressure manual valve when
Low pressure filling refrigerant into refrigeration system.
maintenance
valve (a) Fully open the high pressure manual valve
(b) Fill proper amount of refrigerant according to
specification and then close the high pressure
manual valve.
Tips:
High pressure Air bubble should exist in the peep hole after filling of
maintenance valve refrigerant into refrigeration system.
(c) Other conditions for filling refrigerant into
refrigeration system
(1) Vehicle state
● Engine speed :1,500rpm
● Place the blower speed control switch at: ”Hl”
position
● Place the temperature control switch at:
coolest position
● Place the “air inlet control selection” at internal
circulation
● Fully open the door
(2) Open low pressure manual valve
Warning:
Don’t open the high pressure manual valve
(d) Fill refrigerant until the air bubble vanishes, then

check the pressure through peep hole
Proper
Insufficient
13-11
Position
Engine cabin
Main relay
Cooling fan relay No.1
Fuel pump relay
Starter relay
Heater relay
Expansion valve
Pressure switch
Cooler fan
Compressor Condenser
Combination dashboard
A/C switch
Blower switch
Magnetic clutch relay
Horn relay
Dashboard
distribution
block Engine ECU
Heater control
Front mist
assembly
light relay
Heater blower speed
replace resistance switch
Evaporator
Thermal resistor
13-12
Air conditioner — trouble shooting
Troubleshooting
Failure list
The list below will help you find the most possible causes (numbered) of the problem. Check each part according
to the order and replace the part as necessary.
Standard
Symptom Possible Cause
1. Blower fuse
2. Blower main relay
3. Blower electromotor
Blower out of operation
4. Blower resistance
5. Blower speed replace switch
6. Wiring harness
1. Engine coolant
No air
2. Heater operation assembly
1. Refrigerant volume
2. Air conditioner fuse
3. Air conditioner relay
4. Magnetic clutch
5. Compressor
Compressor out of operation
6. Pressure switch
7. Air conditioner switch
8. ECU
9. Thermal resistor
10. Wiring harness
2. Refrigerant pressure
3. Drive belt
4. Magnetic clutch
5. Compressor
No cool air 6. Pressure switch
7. Thermal resistor
8. Air conditioner switch
9. ECU
11. Wiring harness
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
Defective refrigeration 6. Expansion valve
7. Evaporator
8. Refrigeration pipeline
9. Pressure switch
10. ECU
1. Engine ECU
No idle speed increase when starting the air conditioner
2. Wiring harness
Defective air inlet control Heater operation assembly
No control model Heater operation assembly
13-13
Air conditioner — trouble shooting
Symptom Possible Cause

1. ECU-IG fuse
2. Fuse connector
3. Fan relay NO.2, NO.3
Condenser fan out of operation 4. Fan electromotor
5. ECU
6. Engine and ECU
7. Wiring harness
1. Fan relay NO. 2, NO.1
2. Pressure switch
No speed fluctuation of condenser fan 3. Condenser fan resistor
4. ECU
5. Wiring harness
* 1: Air conditioner ventilating step-up model
13-14
Air conditioner — drive belt
No. 1 V-Belt (from air conditioner compressor to crank shaft belt pulley)
Replacement
1. Remove lower cover of the engine
Nut B 2. Remove No.1 V-belt (from air conditioner

compressor to crank shaft belt pulley)
(a) Loosen nut A.
Nut A (b) Loosen nut B, remove No.1 V-belt (from air
conditioner compressor to crank shaft belt pulley).
3. Install No.1 V-belt (from air conditioner compressor

to crank shaft belt pulley)
(a) Install No.1 V-belt temporarily according to method
shown in the figure.
4. Adjust No.1 V-belt (from air conditioner compressor

to crank shaft belt pulley)
Nut B
(a) Tighten nut A.
Torque: 2.5N·m (25kgf·cm)
Nut A (b) Adjust belt tension through rotating bolt B.
Measure
Position Belt deformation:
New belt: 6.5-7.0mm
Old belt: 8.0-9.0mm
Tips:
● New belt should be one that has not been used for
five minutes on engine.
● Old belt should be one that has been used for
above 5 minutes on engine.
Right Wrong Wrong ● Install drive belt, check whether belt binding with
belt slot.
● Confirm that belt don’t slide in the pulley groove
manually.
13-15
Air conditioner — drive belt
5. Tighten No.1 V-belt (from air conditioner

compressor to crank shaft belt pulley).
(a) Tighten nut A.
Torque : 39N·m (390kgf·cm)
Nut A
13-16
Air conditioner — manometer
Manometer
Installation
1. Connection of manometer filling hose
Tighten nuts manually
Warning:
Don’t make the wrong connection of manometer filling
hose
2. Connect fast conversion connector with filling hose

Tighten nuts manually
3. Close the two manual valve of manometer
4. Remove maintenance valve cap of refrigeration
pipeline
Low pressure filling High pressure filling

hose hose
5. Connect fast conversion connector with

maintenance valve
Interface
Tips:
bushing
Push the fast conversion connector of maintenance
downwards, then slid the fast conversion connector
until it is locked.
13-17
Air conditioner — manometer
Disassembly
1. Close the two manual valve of manometer.
2. Remove fast conversion connector from
maintenance valve of refrigeration pipeline.
Tips:
Push the fast conversion connector of maintenance

upwards, and then remove fast conversion connector
from maintenance valve.
13-18
Air conditioner — refrigeration pipeline
Refrigeration pipeline
Overhaul
1. Check for loose refrigeration hose and pipe connection.
2. Check for leakage condition of refrigeration hose and pipe connection.
Check refrigerant leakage with gas leak detector.
13-19
Inhaling hose
Pipe grip
Fast
conversion
connector
Liquid line Air exhaust hose
Specified torque
13-20
Replacement
1. Discharge refrigerant from refrigeration system.
2. Replace the defective hard-tube and hose.
Cautions:
Block the vent with capping instantly to prevent moisture and dirt from entering the system.
3. Tighten bolt and nut with specified torque.
Cautions:
Other special torque is unnecessary except specified torque.
Tighten position N.m kgf.cm ft.lbf

Compressor and air
10 100 7
exhaust hose
Compressor and inhaling
10 100 7
hose
Condenser and air
5.4 55 48in.lbf
exhaust hose
Condenser and liquid
5.4 55 48in.lbf
line
4. Discharge air of the refrigeration system and fill refrigerant

Specified fill quantity: 460±15g
5. Check for refrigerant leak position

Check for refrigerant leak with gas leak detector
6. Check for operation of air conditioning system
13-21
Air conditioner — air conditioning unit
Air conditioning system
Overhaul
Check for refrigerant leak
(A) Remove door of glove box
(B) Remove blower rheostat
(C) Check for refrigerant leak with gas leak detector
Check the tightened torque of joint seam or check

evaporator if leak exist.
13-22
Air conditioner evaporator unit assembly

Components
Demister windscreen control cable subassembly
Inhaling windscreen control cable subassembly
Air mixing windscreen control cable subassembly
No.1 rear air tube
No.2 rear air tube
13-23
Upper part of dashboard
Lower part of dashboard
Reinforcement tube
Demister nozzle assembly
Air conditioner
evaporator unit
assembly
No.1 dashboard support subassembly
Specified torque
Non -reusable part
13-24
Heater and radiator

subassembly
O-ring
Cooler expansion valve
No.1 cooler evaporator

subassembly
No.1 cooler module Blower resistor
drain pipe
Heater cover
No.1 cooler wire
No.1 cooler thermal resistor
Subassembly of blower
with fan motor
Specified torque
Single-use part
Compression oil ND - oil 8 or equivalent material
13-25
Overhaul
1. Discharge refrigerant from system
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. Disconnect air conditioner pipeline assembly

(a) Remove bolt and Disconnect air conditioner
pipeline assembly.
(b) Remove two O-rings from air conditioner pipeline
assembly.
3. Disconnect heater drain pipe A (from heater unit).

(a) Hold two ends of clip with pliers and then slide the
clip (from heater unit).
Disconnect heater drain pipe A.
4. Disconnect heater water inlet pipe A
Tips:
Disconnect water inlet pipe A (from heater unit)

following the same step as that of disconnecting heater
drain pipe A.
5. Remove underside dashboard subassembly
Tips:
Refer to instruction of remove underside dashboard

subassembly.
6. Remove demister nozzle assembly.
13-26
(a) Loosen the two lock catch, and then remove clip
and demister nozzle assembly.
2 Lock catches
7. Remove No.1 dashboard subassembly
(a) Remove bolt, nut and No.1 dashboard support

subassembly.
8. Disconnect No.2 rear duct.

(a) Loosen the two lock catch then Disconnect No.2
rear duct.
2 Lock catches
9. Disconnect No.1 rear duct.

(a) Loosen the two lock catch then Disconnect No.1
rear duct.
2 Lock catches
13-27
10. Disconnect ECU

(a) Remove two bolts and Disconnect ECU.
Cautions:
● Don’t apply more force to remove the ECU
interface.
● Don’t crash with the ECU.
11. Remove demister windscreen control cable

subassembly
(a) Disconnect external cable from binding clip.
(b) Disconnect internal cable and demister windscreen
control cable subassembly.
Cautions:
● Don’t contort the cable.
● Operation of air conditioner control assembly will

Binding clip be defective with bent cable.
12. Remove air mixing windscreen control cable

subassembly
(b) Disconnect internal cable and air mixing
windscreen control cable subassembly.
Cautions:
Binding clip
be defective with bent cable.
13. Remove inhaling windscreen control cable

subassembly.
(b) Disconnect internal cable and inhaling windscreen
control cable subassembly.
Cautions:
Binding clip ● Operation of air conditioner control assembly will

13-28
14. Remove air conditioner evaporator unit assembly

(a) Loosen binding clip.
(b) Disconnect connector.
Clip
(c) Remove two bolts, five nuts and air conditioner

evaporator unit assembly.
15. Remove heater radiator unit subassembly

(a) Loosen two lock catches and remove duct
assembly.
2 Lock catch
(b) Remove bolt, binding clip and heater radiator unit

subassembly.
16. Remove No.1 cooler connection

(a) Disconnect connector and remove No.1 cooler
connection.
13-29
17. Remove fan resistor
(a) Remove two bolts and blower resistor.
18. Remove subassembly of blower with fan motor
(a) Remove three bolts and subassembly of blower

with fan motor
19. Remove heater cover

(a) Remove four lock catches and heater cover.
4 lock catches
20. Remove cooler expansion valve
(a) Remove two hexagon bolt and air conditioner

expansion valve with 5.0mm hexagon spanner.
21. Remove No.1 refrigeration thermal resistor
(a) Disengage the refrigerating mode-transfer rod.
13-30
(b) Remove twelve bolts and heater upper cover.
(c) Remove No.1 cooler thermal resistor from No.1

cooler evaporator subassembly.
22. Remove cooler evaporator subassembly

(a) Remove No.1 refrigeration evaporator
subassembly from heater lower cover.
(b) Remove two O-rings from No.1 refrigeration

evaporator subassembly.
23. Remove drain pipe of No.1 refrigeration unit
13-31
24. Install No.1 cooler evaporator subassembly

(a) Coat sufficient compression oil on the two O-rings
and expansion valve connection surface.
Compressor oil: ND-OIL8 or equivalent material
(b) Install two O-rings on No.1 cooler evaporator
subassembly.
(c) Install No.1 cooler evaporator subassembly on

heater lower cover.
25. Install No.1 cooler thermal resistor

(a) Install thermal resistor according to the method
(b) Fix heater upper cover with twelve bolts.
(c) Engage the refrigerating mode-transfer rod..
13-32
26. Install air conditioner expansion valve
(a) Install two hexagon bolts with 5.0mm hexagon

spanner.
27. Install air conditioner evaporator unit assembly

(a) Install air conditioner evaporator unit assembly with
two bolts and five nuts.
Cautions:
Tighten nuts according to order shown in the figure
when installing air conditioner evaporator unit assembly.
(b) Connect the joint.

(c) Install binding clip.
Lock catch
28. Install ECU
(a) Install ECU with two bolts.
Cautions:
● Don’t apply more force to remove the ECU

interface.
● Don’t crash with the ECU.
29. Install underside dashboard subassembly
13-33
30. Install heater control and accessory assembly

(a) Install internal cable of demister windscreen control
cable subassembly on heater control rod.
(b) Install external cable of demister windscreen
control cable subassembly on cable binding clip.
Cautions:
Tips:
● Operate the heater control button, check if it can
stop and rebound at FACE and DEF position.
● Pull cable from heater control and accessory
assembly, and external cable shouldn’t be
withdrawn.
(c) Install internal cable of air mixing windscreen

control cable subassembly on heater control rod.
(d) Install external cable of air mixing windscreen
control cable subassembly on cable binding clip.
Cautions:
Tips:
stop and rebound at FACE and DEF position.
withdrawn.
(e) Install internal cable of inhaling windscreen control

cable subassembly on heater control rod.
(f) Install external cable of inhaling windscreen control
cable subassembly on cable binding clip.
Cautions:
Tips:
stop and rebound at FRESE and RECIRC position.
withdrawn.
13-34
(g) Connect the connector, and then install heater

control and accessory assembly.
6 lock catches
(h) Place the control rod at FACE position.

(i) Install internal cable of control rod when the control
rod is placed at FACE position.
(j) Press gently according to arrow direction then
install external cable on cable binding clip.
Cautions:
Tips:
Operate the heater control button, check if it can stop
and rebound at FACE and DEF position.
(k) Place the control on DEF position.

(l) Install internal cable of control rod when the control
FACE rod is placed at DEF position.
(m) Press gently according to arrow direction then
Cautions:
DEF ● Don’t contort the cable.
Tips:
and rebound at FACE and DEF position.
(n) Place the control rod at internal circulation position.

(o) Install internal cable of control rod when the control
rod is placed at internal circulation position.
(p) Press gently according to arrow direction then
Cautions:
13-35
Tips:
and rebound at FRESE and RECIRC position.
31. Remove demister windscreen control cable

subassembly
32. Remove air mixing windscreen control cable
subassembly
33. Remove inhaling windscreen control cable
subassembly
34. Install dashboard subassembly
35. Install air conditioner pipeline assembly

(a) Coat sufficient compression oil on the two O-rings
and air conditioner pipeline assembly connection
surface.
Compressor oil: ND-OIL8 or equivalent material
(b) Install two O-rings on air conditioner pipeline
assembly.
(c) Install air conditioner pipeline assembly with bolt.
36. Fill refrigerant

SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050,07117-88060,
07117-88070, 07117-88080), 07117-48130, 07117-48140)
Fill quantity: 460±15g
37. Engine warming-up
38. Check for refrigerant leak
13-36
Air conditioner — compressor and magnetic clutch
Air conditioner compressor assembly
Components
Air conditioner wire

harness subassembly
Air conditioner support
Magnetic clutch assembly
Snap ring Air conditioner

Snap ring compressor assembly
Magnetic clutch gasket
Specified torque
One-time part
13-37
Compressor and magnetic clutch

Overhaul
1. Check for oil leakage condition of clutch bearing

2. Check for oil on platen of rotor
3. Check for noise of magnetic clutch bearing
(a) Start the engine.
(b) Check whether there exists abnormal noise of
compressor when closing air conditioner.
If abnormal noise exists then replace the magnetic

clutch.
4. Check for pick-up operation of magnetic clutch

(a) Remove plugboard part.
(b) Connect positive pole (+) of accumulator with

terminal of magnetic clutch plugboard part, then
connect negative pole with vehicle body.
(c) Check for pick-up operation of magnetic clutch.
Replace magnetic clutch under the condition of normal
pick-up operation absence.
5. Check for metal noise of platen

Check whether there exists abnormal metal noise of
platen when starting the air conditioner.
If abnormal noise exists then replace the platen.
6. Check for pressure of refrigerant

7. Check for leak condition of refrigerant directly
Check for leak condition of refrigerant with gas leak
detector.
If leakage exists then check tightened torque of

interface or replace compressor.
13-38
Disassembly
1. Drain refrigerant from the system
SST 07110-58060 (07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
2. Remove No.1 belt(from compressor to crank shaft belt pulley)
3. Disconnect No.1 refrigerant intake port

(a) Remove bolt and then Disconnect No.1 refrigerant
intake port from compressor and magnetic clutch.
(b) Remove O-ring from No.1 refrigerant intake port.
Cautions:
Seal all the openings of open part with PVC rubber belt
to prevent enter of moisture and foreign material.
4. Disconnect No.1 refrigerant outlet

(a) Remove bolt and then Disconnect No.1 refrigerant
outlet from compressor and magnetic clutch.
(b) Remove O-ring from No.1 refrigerant outlet.
Cautions:
Seal all the openings of open part with PVC rubber belt
to prevent enter of moisture and foreign material.
5. Remove lower part of right side engine
6. Remove compressor and magnetic clutch

(a) Disconnect connector.
(b) Remove four bolts, compressor and magnetic

clutch.
7. Remove magnetic clutch assembly
(a) Clamp compressor and magnetic clutch with bench

clamp.
13-39
(b) Clamp clutch hub with slip-joint pliers.

(c) Remove bolt, magnetic hub and gasket.
(d) Remove the snap ring and magnetic clutch rotor

with forceps.
(e) Remove bolt and disconnect connector.
(f) Remove the snap ring and magnetic clutch stator

with forceps.
8. Remove air conditioner control wire harness

subassembly
9. Remove support
10. Remove compressor assembly
11. Install magnetic clutch assembly

(a) Install magnetic clutch stator according to method
13-40
(b) Install new snap ring (surface with bevel should

face up) with forceps.
(c) Install bolt and connect the connector.
(d) Install magnetic clutch rotor and new snap ring

(surface with bevel should face up) with forceps.
(e) Install clutch hub and gasket.
Cautions:
Don’t modify the compound gasket of magnetic clutch

before decompounding process.
(f) Hold the magnetic clutch hub with slip-joint pliers

then install bolt.
Torque: 13N·m (133kgf·cm)
12. Check for clearance of magnetic clutch

(a) Install dial indicator and make it align with magnetic
clutch hub.
(b) Connect positive wire of accumulator with terminal
1, and then connect negative wire with ground.
Engage the clutch to measure the clearance.
Standard clearance:
0.25-0.50mm
Remove magnetic clutch hub and adjust it with shim if
measured value exceed the specified value.
Cautions:
Adjusting shim shouldn’t exceed than 3.
13-41
13. Check for compression oil

(a) Discharge refrigerant slowly from maintenance valve when replacing new compressor and magnetic clutch,
drain out all the compression oil from the new compressor and magnetic clutch before installation.
Standard:
Oil quantity of the new compressor and magnetic clutch: 80±15cc-(residual oil of the compressor and magnetic
clutch= oil discharging quantity during replace process)
Cautions:
● Refer to precautions for refrigeration disassembly when checking the compression oil quantity.
● If it is prohibited to discharge some compression oil before installing new compressor and magnetic clutch.
There will be excessive compression oil (as a result of residual oil in the vehicle pipeline), the excessive
compression oil will block heat exchange of refrigerant and then it will cause refrigerant failure.
● Check for oil leak if residual oil of old compressor and magnetic clutch is insufficient.
● Confirm the compression oil is ND-OIL8.
14. Install compressor and magnetic clutch

(a) Install compressor and magnetic clutch with four
bolts.
Torque: 25N·m
Cautions:
Install compressor and magnetic clutch and tighten
bolts according to order shown in the figure.
(b) Connect the connector.
15. Install No.1 refrigerant outlet opening

(a) Tear the wrapped PVC rubber belt from pipe
mouth.
(b) Coat sufficient compression oil on the new O-ring,
the contact surface of compressor, and magnetic
clutch.
Compression oil: ND-OIL8 or equivalent material
(c) Install O-ring on No.1 refrigerant outlet opening.
(d) Install No.1 refrigerant outlet opening onto

magnetic clutch and compressor with bolts.
16. Install No.1 refrigerant suction port
(a) Tear the wrapped PVC rubber belt from pipe
mouth.
(b) Coat sufficient compression oil on new O-ring,
contact surface of compressor and magnetic
clutch.
Compression oil: ND-OIL8 or equivalent material
13-42
(c) Install O-ring on No.1 refrigerant outlet.
(d) Install No.1 refrigerant suction port onto magnetic

clutch and compressor with bolts.
17. Install No.1 V-belt (from compressor to crankshaft belt pulley)
18. Adjust No.1 V-belt (from compressor to crankshaft belt pulley)
19. Tighten sufficient of No.1 V-belt (from compressor to crankshaft belt pulley)
20. Add refrigerant
SST 07110-58060 (07117-58060, 07117-58070, -07117-58080, 07117-58090, 07117 -78050,

07117-88060, 07117-88070, 07117-88080), 07117-48130, 07117-48140
Specified quantity: 460±15g
21. Engine warming-up
22. Check for refrigerant leak
13-43
Air conditioner — condenser
Condenser assembly with liquid reservoir
Overhaul
1. Check for condenser assembly
(a) Clean with water and dry it with compressed air if cooling fin of radiator is dirty.
Cautions:
Never damage cooling fin of condenser assembly.
(b) Pull the bended condenser cooling fin straight with screwdriver or clippers.
2. Check for condenser refrigerant leak
(a) Check for gas leak of pipeline connection part with halogen leak locator.
(b) Check the connector torque if gas leak exist at connector part.
13-44
Condenser
Overhaul
1. Check for dirt block or damage of condenser fin
● Clean with water and dry it with compressed air if fin is blocked.
Cautions:
Never damage fin of condenser assembly.
● Pull the bended condenser cooling fin straight with screwdriver or clippers.
2. Check for condenser refrigerant leak and installation of condenser
Check for gas leak of pipeline connection part with gas leak locator.
Check the connector torque if gas leak exist at connector part.
13-45
Components
Upper support of radiator
Discharge hose
Condenser
Engine hood lock O-ring
O-ring
Condenser
Liquid
Discharge line
hose
Liquid line
Condenser
Dryer
Filter
O-ring
Condenser
(ZEXEL) Capping
Specified torque
Non-reusable part
ND-8 compression oil or equivalent
Condenser (SANDEN)
13-46
Disassembly
1. Discharge refrigerant from refrigeration system
Tips:
Please follow steps below when performing installation process.
Pump air from refrigeration system.
Add refrigerant into system then check for refrigerant leak.
2. Remove discharge hose and liquid line

Torque: 5.4N·m (55kgf. cm, 48in. lbf)
Cautions:
Block the vent with capping instantly to prevent
moisture and dirt entering the system.
Tips:
Please follow steps below when perform installation
process.
Coat compression oil on the two new O-rings, and then
install them onto pipes.
3. Remove upper support of radiator

(a) Remove three installation bolts of the engine hood
lock.
(b) Remove installation bolt of center support.
(c) Remove the two installation clips of radiator
bonnet.
(d) Remove wire harness plugboard from fixed part.
(e) Remove horn bolt.
(f) Remove fixed bolts of compressor discharge pipe.
(g) Remove six bolts and radiator upper support.
13-47
4. Remove condenser
Pull out condenser upward.
Tips:
Please follow the steps below when perform installation

process.
Add compression oil into compression when replacing

condenser.
Add quantity:40cc (1.4fL. 0z)
Compression oil model: ND-8 OIL or its equivalent
13-48
Replace (ZEXEL)
Replace desiccant controller
(a) Remove controller cap and remove filter from
controller with a hexagon spanner (10mm, 0.39in.).
Hexagon
spanner
Controller
(b) Another kind of dryer

Remove two bolts then remove controller cap, remove
filter from controller.
(c) Take out desiccant with pincers
(d) Put new desiccant into controller

Cautions:
● Open PVC package of desiccant when putting
desiccant into controller.
● Make the double-deck part of desiccant face up
when putting it into controller.
(e) Insert the filter into controller
Cautions:
Make bulge of filter face to controller then insert it into

controller.
13-49
(f) Install controller cap
(1) Coat compression oil onto fine thread part of O-ring

and cap.
Compression oil model: ND-8 OIL or its equivalent
(2) Install controller cap with hexagon cap (10mn,
0.39in.).
Torque: 12.3N·m (125kgf.cm, 9ft.lbf)
It can replace desiccation liquid storage reservoir

assembly only for product of SANDEN.
13-50
Installation
Installation is in the reversed order of that of
disassembly.
13-51
Air conditioner — expansion valve
Expansion valve
Overhaul
1. Check for refrigerant quantity during refrigerant circulation process
2. Install manometer
3. Engine running
Keep the engine running at the speed of 1,500rpm shouldn’t less than five minutes.
Check high pressure indicating value of this time should be1.37-1.57MPa (14-16kgf/cm2, 199-288psi)
4. Check expansion valve
Low pressure indicating value will descend to 0kPa (0kgf/cm2, 0psi) for broken-down expansion valve.
Tips:
Check for temperature difference for inlet and outlet side of the liquid reservoir when low pressure descend to
0kPa (0kgf/ cm2 , 0psi).
13-52
Air conditioner — expansion valve
Replacement
1. Discharge refrigerant from refrigeration system
2. Remove liquid line and inhaling hose of the air
conditioner unit
3. Remove expansion valve

Left drive
(a) Remove bolt, then remove air conditioner duct and
expansion valve.
(b) Remove two bolts with hexagon spanner (5.0mm,
0. 20in.), then separate the expansion valve and
evaporator.
4. Install new expansion

(a) Coat the four O-rings with compressor oil then
install them on expansion valve.
(b) Install expansion valve and air conditioning pipe.
(c) Install two bolts with a hexagon spanner (5.0mm,
0.20in.).
Torque: 3.4N·m (35kgf.cm, 30in.lbf)
(d) Install air conditioning pipe with bolt.
5. Connect liquid line with inhaling hose

6. Fill refrigerant into the system
(a) Pump out air in the refrigeration system.
(b) Fill refrigerant into the system and check refrigerant
leak condition.
13-53
Air conditioner — blower electromotor
Blower electromotor
Check
1. Remove glove-box cover
2. Remove engine ECU
(a) Remove plugboard
(b) Remove two bolts and engine ECU
3. Remove blower electromotor
Remove three screws and blower electromotor
13-54
Air conditioner — blower electromotor
4. Check for running of blower electromotor

Standard heater
Connect positive pole (+) of accumulator with terminal 1
and connect negative pole (-) with terminal 2, then
check whether blower electromotor runs stable.
Replace blower electromotor if running process fails to

meet the specification.
5. Install blower electromotor
6. Install engine ECU
7. Install glove-box cover
13-55
Air conditioner — pressure switch
Blower resistor
Check
1. Remove glove-box cover.
2. Remove engine ECU
(a) Remove wire harness clip
(b) Remove the wire harness plugboard
(c) Remove four bolts and engine ECU
3. Remove blower resistor
(a) Remove the wire harness plugboard
(b) Remove two bolts and blower resistor
4. Check for resistance Ω of the blower resistor
Test joint Condition Specified standard

1-3 Common About 0.4Ω
Replace the blower resistor if it can’t reach the specified

range
5. Install blower resistor

6. Install engine ECU
7. Install glove-box cover
13-56
Air conditioner — thermal resistor
Thermal resistor
Check
1. Remove thermal resistor
(a) Remove wire harness plugboard
(b) Remove wire harness clip
(c) Pull out thermal resistor with screwdriver
(d) Loosen the two jaws and remove thermal resistor

from metal support
Thermometer 2. Check for resistance of thermal resistor

Water (a) Put the thermal resistor into cold water, measure
resistance at wire harness part and measure water
temperature at the same time when water
temperature changes.
Thermal resistor Dial indicator
(b) Compare the two readings in curve diagram.
Replace thermal resistance when it can’t reach the

specified range.
3. Install thermal resistor
(a) Install thermal resistor on air conditioner unit.
(b) Connect wire harness clip.
(c) Connect wire harness pulgboard.
13-57
Pressure switch
Overhaul
1. Check No.1 pressure switch

(a) Control of magnetic clutch:
Check operation of pressure switch.
(1) Install manifold instrument.
(2) Connect positive pole of ohmer with terminal 4 and
High negative pole with terminal 1.
Low pressure pressure end
end (3) Check for conduction performance of each terminal
when refrigerant changes according to the method
Replace pressure switch if operation fails to meet the
specification.
(b) Control of cooling fan
Check for operation of pressure switch.
(1) Connect positive pole of ohmer with terminal 2 and

negative pole with terminal 3.
(2) Check for conduction performance of each terminal
when refrigerant changes according to the method
Replace pressure switch if operation fails to meet the
specification.
13-58
Disassembly
1. Discharge refrigerant from refrigeration system.
Tips:
Please follow the steps below when performing installation process.
Pump out air from refrigeration system.
Fill refrigerant into the system and check leak condition of refrigerant.
Standard quantity: 460±15g
2. Remove pressure switch liquid line
Remove wire harness plugboard and pressure switch
Torque: 10N·m(100kgf. cm.7ft. lbf)
Tips:
● Hold the switch on pipeline with a open spanner

and don’t make it defective, then remove the
switch.
● Please follow the steps below when performing
installation process.
Coat new O-ring with compression oil and install it on

the pressure switch.
13-59
Installation
Installation is in the reversed order of that of disassembly.
13-60
Air conditioner — condenser fan
Condenser fan
Components
Radiator upper support
Fan electromotor
Lock Fan housing
Fan
Wire harness plugboard
13-61
Disassembly
1. Discharge the engine coolant in radiator
2. Remove radiator hose

3. Remove radiator overflow hose
4. Remove radiator upper support

(a) Remove the three installation bolts of engine hood
lock
(b) Remove installation bolts of center support
(c) Remove two installation bolts of radiator cover hole
(d) Remove wire harness plugboard from the hole part
(e) Remove the wire harness earthing screw
(f) Remove compressor exhaust pipe support (one
bolt)
(g) Remove six bolts and radiator upper support
5. Remove condenser fan

(a) Remove wire harness plugboard
(b) Remove three bolts and condenser fan.
Torque: 7.5N·m (80kgf. cm, 69in. lbf)
13-62
Disassembly
1. Remove the fan
Remove nuts and the fan
2. Remove fan electromotor
Remove three screws and fan electromotor
13-63
Installation
13-64
Installation
13-65
Air conditioner — heater control equipment
Heater control equipment
Overhaul
When checking the heater instrument panel by rotating
the control rod and panel left and right, there shall be a
“click” sound and a rebound sense.
If no “click” sound is heard and no rebound sense is felt,

then adjust control wire and heater control assembly.
13-66
Disassembly
1. Remove upper garnish panel
(a) Pull out buttons with pincers.
Tips:
Dismantle the buttons with cloth before pulling the
button.
(b) Loosen six installation clips of garnish panel with a
screwdriver, then pull out combination garnish
panel and remove connector of wire harness
plugboard.
Tips: Wrap the screwdriver end with rubber belt before
using it.
2 Remove combination instrument
3. Remove upper garnish cover of dashboard
4. Remove heater control cable
Air mixing suction valve

control cable
Air suction valve

control cable
Demister valve control cable
5. Remove heater control assembly
Loosen the two jaws and then pull out heater control
assembly.
13-67
Disassembly
1. Remove heater control cable
(a) Remove wire clip with a screwdriver and then
remove external cable.
Tips:
Wrap the screwdriver end with rubber belt before using
it.
(b) Remove internal wire of heater control assembly.
13-68
Installation
13-69
Installation
1. Install the heater control assembly
(a) Connect the connector of wire harness plugboard.
(b) Install heater operation assembly temporarily.
(c) Arrange wire path of heater control equipment
according to method shown in the figure.
Air mixing suction valve control cable
Demister valve control cable
(d) Install the two dog catches of heater control

assembly into dashboard upper hole.
2. Connect heater control cable
(a) Place the temperature control selector at “COOL”

position.
(b) Set the selection mode to face position.
13-70
(c) Adjust air mixing control cable
Put the air mixing valve control pole at “DEF” position,

and connect the internal cable with control pole pin,
hold external cable.
Information:
Push external cable in the direction of the arrow, and

then hold the clip.
(d) Adjust demister control wire
Place air inlet control rod at face position, connect

control wire and hold clip.
Tips:
Push external wire in the direction of the arrow, and

then hold the clip.
3. Install dashboard upper garnish panel

4. Install combination instrument
13-71
Air conditioner — heater control assembly
Heater control assembly composition diagram
13-72
Disassembly
1. Remove three bottoms
2. Remove inter and external air circulation buttons
3. Remove the instrument upper garnish cover
(a) Remove two bolts
(b) Disconnect the plug component
Cautions: position of latch hook
4. Remove heater control mechanism
(a) Remove two bolts
(b) Remove two jaws
(c) Disconnect the connecting wire
13-73
Installation
13-74
Condenser fan
Overhaul
1. Check for the condenser fan operation condition
Check for condenser fan running under conditions

below.
shown in the table below:
Test condition:
● Run engine
● Place blower speed switch at high ”HI” position
● Place temperature switch at “cool” position.
● A set of multi-function measure device
● Switch on air conditioner switch
Check whether condenser fan starts running when the

temperature reaches 97℃ and stops running when the
temperature descends to 93℃.
Continue the check items below if test results fail to

meet the specification above.
2. Check for the condenser fan operation condition
Remove the fan connector.
(a) Connect the accumulator and ampere meter with

condenser fan connector according to the method
(b) Check whether the fan runs stable, and observe

the readings of ampere meter at the same time.
Standard ampere meter readings:
Mark 1(80w): 6.5±1.0A at 25℃ (77°F)
Mark 2(120w): 9.8±1.0A at 25℃ (77°F)
● Replace the fan electromotor when the fan runs

unstable.
● Check the pressure switch, cooling fan relay and

water temperature switch when if it runs stable.
13-75
Air conditioner — air filter
Air filter
Replacement
1. Remove the glove-box cover
2. Replace the air filter
(a) Loosen two jaws and then pull out air filter
(b) Remove the air filter

(c) Install a new air filter
(d) Install the air filter housing onto the air conditioner
unit
3. Install the glove-box cover
13-76

Aire AcondicionadoV5

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Aire AcondicionadoV5

Uploaded by

Copyright:

Available Formats

Air conditioner — air conditioning system

Air conditioning system ................................................................ 13-1

Troubleshooting .......................................................................... 13-13

Drive belt .................................................................................... 13-15

Manometer ................................................................................. 13-17

Refrigeration pipeline ................................................................. 13-19

Air conditioning system .............................................................. 13-22

Air conditioner compressor assembly ........................................ 13-37

Condenser .................................................................................. 13-44

Expansion valve ......................................................................... 13-52

Blower electromotor ................................................................... 13-54

Blower resistor ............................................................................ 13-56

Thermal resistor ......................................................................... 13-57

Pressure switch .......................................................................... 13-58

Condenser fan ............................................................................ 13-61

Heater control ............................................................................. 13-66

Heater control assembly ............................................................ 13-72

Condenser fan ............................................................................ 13-75

Air filter ....................................................................................... 13-76

Air conditioning system

3. Don’t make refrigerant splash on you eyes or skin.

4. Don’t heat the tank or put it close to naked flame.

Wrong 6. Don’t start the compressor when refrigerant level of

1. Check for refrigerant quantity

● Engine speed：: 1,500rpm

● Blower speed control switch：: “Hl” position

2. Check for refrigerant pressure with manifold

Conditions and procedures of test via a manifold

● Place the air inlet switch at “internal circulation”

Indication values of the manifold manometer will be a

(1) Performance of normal refrigeration system

(2) Water in refrigeration system

State: intermittent refrigeration

(3) Insufficient of refrigerant

State: insufficient refrigeration

(4) Insufficient circulation of refrigerant

State: insufficient refrigeration

● Frost can be seen on

(5) No refrigerant circulation

(6) Excessive refrigerant or insufficient cooling of condenser

State: defective refrigeration

(7) Air exists in refrigeration system

(8) Incorrect installation of expansion valve

State: Insufficient refrigeration

(9) Compressor failure

● Excessive pressure at ● Internal leakage of ● Compression failure Repair or replace

3. Check for idle speed increasing

(c) Two-speed design for air conditioner condenser fan

System fan will run at low speed when air conditioning

4. Check for leakage of refrigerant

4. Discharge air from the refrigeration system

(b) Connect manometer center hose with vacuum

(a) Cooling medium reservoir should maintain proper

Warning: Never open high pressure valve and low

(c) Open valve of cooling medium reservoir.

2. Check for leakage of refrigeration system

Air leak detector

3. Add refrigerant to the refrigeration system

(d) Fill refrigerant until the air bubble vanishes, then

Magnetic clutch relay

Symptom Possible Cause

* 1: Air conditioner ventilating step-up model

1. Remove lower cover of the engine