AC-1 AIR CONDITIONING SYSTEM Page GENERAL INFORMATION . AC-2 TROUBLESHOOTING AC-6 PREPARATION ............ AC-11 USE OF MANIFOLD GAUGE SET .............. AC-13 USE OF REFRIGERANT RECOVERY MACHINE AC-14 PARTS LOCATION ... AC-15 WIRING DIAGRAM .. AC-16 DAMPERS POSITION .... AC-18 REFRIGERANT VOLUME DRIVE BELT TENSION ... IDLE-UP SPEED .......... REFRIGERANT LINES . AC-19 AC-20 AC-20 AC-21 COMPRESSOR AC-23 CONDENSER . AC-30 RECEIVER . AC-32 REAR COOLING ‘UNIT AC-33 COOL BOX . AC-41 FRONT A/C EVAPORATOR AC-43 REAR A/C EVAPORATOR ... AC-45 COOL BOX EVAPORATOR ............ AC-45 FRONT A/C EXPANSION VALVE . AC-46 REAR A/C EXPANSION VALVE .... AC-47 COOL BOX EXPANSION VALVE .. AC-47 FRONT A/C THERMISTOR .. AC-48 COOL BOX THERMISTOR AC-48 A/C CONTROL ASSEMBLY . AC-49 REAR BLOWER SWITCH AC-52 COOL BOX SWITCH ...... AC-52 PRESSURE SWITCH .......... AC-53 FRONT BLOWER MOTOR . AC-53 REAR BLOWER MOTOR ......... AC-54 COOL BOX BLOWER MOTOR AC-54 FRONT BLOWER RESISTOR AC-54 REAR A/C BLOWER RESISTOR . AC-55 HEATER MAIN RELAY ............... AC-56 BLOWER HIGH RELAY .. AC-56 A/C CUT OFF RELAY ..... AC-57 MAGNETIC CLUTCH RELAY AC-57 REAR A/C RELAY . AC-57 MAGNETIC VALVE . a AC-58 VACUUM SWITCHING VALVE (vsv) AC-59 AIR CONDITIONING AMPLIFIER AC-60 COOL BOX AMPLIFIER .... AC-61- MEMO - 2 2 po? 635O98 anna aus > anew? ° 2 aczeo7 Oil Bottle |_, Amount of il Removed ou acz808 YSTEM — GENERAL INFORMATION 3SENERAL INFORMATION {EFRIGERATION SYSTEM AC-3. AIR CONDITIONING SYSTEM — GENERAL INFORMATION Evacuation Process revention of Refrigerant Release and xcessive Quantities 10 minutes Refrigerant (CFCs) for automobile air conditioning is | or more believed to cause harm by depleting the ozone layer which helps to protect us from the ultraviolet rays of the sun. Leave for 5 minutes Therefore, it is necessary to prevent release of refrigerant to the atmosphere and to use the minimum amount when servicing the air conditioning. USE RECOVERY MACHINE TO RECOVER REFRIG. ERANT When discharging refrigerant from the system as follows, use a recovery machine to recover the re- frigerant. © Before replacing parts on the refrigerant line. Charging Cylinder nc2008 @ When moisture or air gets in the refrigerant line, e When excess refrigerant is charged. NOTICE: © — When handling the recovery machine, always follow the directions given in the instruction manual. ” After recovery, the amount of compressor oil re- moved must be measured and the same amount added to the system. 2, USE CHARGING HOSES WITH STOP VALVE WHEN INSTALLING MANIFOLD GAUGE SET To prevent release of refrigerant, using charging hoses with a stop valve when installing the manifold gauge set to the service valves on the refrigerant line. 3. TIGHTEN CONNECTION PARTS SECURELY Follow the notices about tightening connecting parts in step 6 on page AC—4. 4, PROPERLY EVACUATE AIR FROM REFRIGERANT acre SYSTEM To prevent release and wasteful use of refrigerant, evacuate air with care from refrigeration system as follows: ® Do not evacuate before recovering refrigerant in system. © Do not perform repeat evacuation of system. Evacuation | Airtight —.| Top-Up Charging |__ _] Refrigerant _..| Charging Check of Refrigerant Leak Check Refrigerant vont? USE CHARGING CYLINDER TO CHARGE PROPER AMOUNT OF REFRIGERANT To prevent excessive use of refrigerant due to ove- reharging, use a charging cylinder to charge the proper amount of refrigerant. Handling Precautions for refrigerant 1s 2. (a) (b) (ce) DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OF NEAR AN OPEN FLAME ALWAYS WEAR EYE PROTECTION BE CAREFUL THAT LIQUID REFRIGERANT DOES. NOT GET IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin: Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. Apply clean petroleum jelly to the skin. Go immediately to a physician or hospital for profes- sional treatment. CAUTION: Do not attempt to treat yourself. Handling Precautions For Refrigerant Container 1. 2. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO ITAC-4 Poisonous Gas te Gas Leak Tester 28g Recovery Machine actor +} Dust wes ; Charging Valve Compressor Oil AIR CONDITIONING SYSTEM — GENERAL INFORMATION Handling Precautions for Gas—Cylinder Type Gas Leak Tester a 2. BEFORE USING TESTER MAKE SURE THAT THERE ARE NO FLAMMABLE SUBSTANCES NEARBY BE CAREFUL NOT TO INHALE POISONOUS GAS If refrigerant gas comes in contact with flame, a poi- sonous gas is produced. During leak tests, do not inhale any gas. Precautions When Replacing Parts In Refrigerant Line 2 5. RECOVER REFRIGERANT REMOVING PARTS Using a recovery machine, recover refrigerant in system before removing the parts. NOTICE: Do not release refrigerant to atmosphere. IN SYSTEM BEFORE INSERT PLUG IMMEDIATELY IN DISCONNECTED PARTS Insert a plug immediately in the disconnected parts to Prevent the entry of moisture and dust. DO NOT REMOVE PLUG FROM NEW PARTS UNTIL IMMEDIATELY BEFORE INSTALLATION DO NOT USE BURNER FOR BENDING OR LENGT- HENING OPERATIONS ON TUBE If the tubes are heated with a burner, a layer of oxidation forms inside the tube, causing the same kind of trouble as an accumulation of dust, DISCHARGE GAS IN NEW COMPRESSOR FROM CHARGING VALVE BEFORE INSTALLING IT \f the gas in new compressor is not discharged first, compressor oil will spray out with gas when the plug is removed TIGHTEN CONNECTING PARTS SECURELY Securely tighten the connecting parts to prevent lea- king of refrigerant gas. * Apply a few drops of compressor oil to O—ring fittings for easy tightening and to prevent leaking of refrigerant gas. ® Tighten the nuts using two wrenches to avoid twisting the tube. AIR CONDITIONING SYSTEM — GENERAL INFORMATION aciece Ac2013, AC-5 * Tighten the O-ring fittings or the bolted type fittings to the specified torque. Precautions When Charging Refrigerant A, ELECTRICAL PARTS SRS AIRBAG SYSTEM DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT CYCLE If there is not enough refrigerant in the refrigerant cycle, oil lubrication will be insufficient and com- pressor burnout may occur, so take care to avoid this. DO NOT OPEN HIGH PRESSURE VALVE OF MANI- FOLD WITH COMPRESSOR OPERATING If the high pressure valve is opened, refrigerant flows in the reversedirection and could cause the charging cylinder to rupture, so open and close the low pres- sure valve only. BE CAREFUL NOT TO OVERCHARGE WITH RE- FRIGERANT IN SYSTEM If refrigerant is overcharged, it causes trouble such as insufficient cooling, poor fuel economy, engine ove- theating etc. Before removing and inspecting the electrical parts, set the ignition switch to the LOCK position and disconnect the negative (—) terminal cable from bat- tery. CAUTION: Work must not be started until after at least 30 seconds or longer from the time the negative (=) terminal cable is disconnected. Failure to carry out service operations in the correct sequence could cause the airbag system to deploy, Possibly leading to a service accidant.When removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the AB section before per- forming the operationAGS AIR CONDITIONING SYSTEM — TROUBLESHOOTING AIVCONDITIONING s¥sTEM —TROUBLESHOoTING 4°? TROUBLESHOOTING TROUBLESHOOTING seme You will find the cause of trouble more easily by properly using the table shown below. In this table, the numbers indicate the order of priority of the causes of trouble. Check each part in the order shown. If necessary, replace the part. Soe page 5 | = 4 LE 3 m3 3 : sip}. g &| | 3 as BEER el ll lalaleli allele] | FH UE sale :| |2 E #) 3l3 atiial a] |¥ 2 [fai 3 Slalala|_|é = || Ee] 2 S\ElE | |3lflz Pela) | ale elgeydiata alae aldlbalbdiiyle 28/8/31 8/8] 3/2 | 4/8 2 \2s Oo ul x e al 2 a a: Trouble $182] BIRaI E| 2 z 2/2)8) 51315) 3/ 2/2 & &]8/£| 3) E 218 2/2/38) Flelelald ¢ 3 3 Slslsl2 8| 5 5 5|3 3 5 g/s|= kl Eire 2 l@e|2|2/8|8/2|2/2/8| 2/2] 8/2/23 2|| 2] 8 2|3/e/ ae £| | 8/2/28] el 2/s/ al 2 No blower operation 2 6 5 No blower control ims No air flow mode control No air inlet control Insufficient flow air No cool air comes out = Cool air comes out intermittently Cool air comes out only at high engine | 1| 3| 2 i i a speed | | | | | Insufficient cooling Al afale | 7 | | | Front Rear | Cool box | | No warm air comes out | eT Air temp. contro! not functioning | 2] | | dha | No engine idle up when A/C switch on ) | | |AGE AIR CONDITIONING SYSTEM — TROUBLESHOOTING INSPECTION OF REFRIGERATION SYSTEM WITH MANIFOLD GAUGE SET This is a method in which the trouble is located by u: conditions are established: (a) Temperature at the air inlet with the switch set at RECIRC is 30—95°F) (b) Engine running at 2,000 rpm and blower fan speed contral switch set at high speed (c) Temperature control switch set at max cool side HINT: It should be noted that the gauge indications may vary slightly due to ambient temperature conditions, No. | Gauge reading kPa (kat/em’, psi) | Condition Probable cause Remedy LO: 147-196 (1.5-2.0, 21-28) Hi: 1,422-1,471 (14,5=15.0, 206-213) Normal cooling Normally functioning system During operation, pressure at low Pressure side sometimes becomes vacuum and sometimes normal (with Cool Box OFF) Periodically cools and then fails to cool Moisture present in (1) (2) Replace receiver Remove moisture in system through repeatedly 2 @) proper amount \ + Insufficient cooling | Insufficient refrigerent | (1) Using gas leak a toster, check for * Bubbles seen in sight peak leakage (2) Charge refrigerant to proper amount + Insufficient cooling Replace receiver 3 * Frost ontubes trom | obstructed by dirt in receiver to unit ee Acto8® 1g a manifold gauge set. (Sea “Manifold Gauge Set Installation " on page AC—13.) Read the manifold gauge pressure when the following AIR CONDITIONING SYSTEM — TROUBLESHOOTING ae No. | Gauge reading kPa (kgf/cm’, psi) Condition Probable cause Remedy Pressure too high at both low ond high pressure side Insufficient cooling of || (1) Clean condenser 4 COneeeey, (2) Check fan motor operetion | rent over charged * Insufficient cooling Chock amount of refrigerant HINT: Vent out refriger- 5 ant through gaug manifold low pressure side by gradually opening Air present in system valve a 2) Replace receiver Check compressor oil to sea if dirty or insufficient Evaci air and charge with new refrigerant + Insufficient cooling + Frost or largo amount of dew on 1 piping at low pressure side Expansion valve improperly mounted, heat sensing tube defective (Opens too wide) Check heat sensing tube installation condi Hf (1) is normal, check expansion valve Replace if defective Aco070 Vacuum indicated at low pressure side, very low pressure indicated at | + high pressure Does not cool (Cools from time to time in some cases) Allow to stand for some Refrigerant does not cireulste + Frost or dew seen on piping bofore 3 after receiver or expansion vi If caused by moisture e refer to procedures step 2 on page AC-11, ed by dirt, remove ion valve and ‘off dint by blowing If not able to remove dirt, replece valve Evacuate eir and cherge with me refrigerant to Proper amount For gas leakage from heat sensing tu replace expansion valve ACOIES HINT at No. 6 These gauge indications are shown when the refrigeration system has been opened and the refrigerant charged without evacuating air.AG*10 AIR CONDITIONING SYSTEM — TROUBLESHOOTING AIR CONDITIONING SYSTEM — PREPARATION pet = PREPARATION Condition Probable cause anne a ighbt i naan ; — ashes SST (SPECIAL SERVICE TOOLS) Insulficient compression | Repair or replace Ceo ee aaa = compressor i O7110=$8011 Air Conditioner Service Tool Set Tar see gp (07117-58010) Refrigerant Dram Service Valve (07117-78011) Refrigerant Charging Gauge = (07117-88013) Refrigerant Charging Hose Green color (07117-88022) Refrigerant Charging Hose Blue color ZS (07117-88040) Refrigerant Charging Hose Orange color (essoc5 ) Stop Valve Y 07110-58040 Charging Hose Kit If you require stop valve, plea With Stio Valve 86 order this kit. 07112-66040 Magnetic Clutch Remover 07112=76060 Magnotie Clutch Stopper 07114-84010 Snap Ring Pliers 07114-84020 Snap Ring Pliers 07117-48050 Vaccum Pump Assy Rated voltage AC220VAC-12 AIR CONDITIONING SYSTEM — PREPARATION RECOMMENDED TOOLS [ 2S (09082-00015 bial TOYOTA Electrical Tester LUBRICANT AIR CONDITIONING SYSTEM — USE OF MANIFOLD GAUGE SET Charging Hose item Capacity ce ( floz) Classification pita = Compressor oil 7 - NND OIL 6,,SUNISO No.5GS or equivalent ‘When replacing receiver 20( 07) \ Liquid Tube a ‘When replacing condencer 40-50( 13-17) Suction Tube | Paes Sy ‘When replacing evaporator 40-50 (13-17) * Charging Valve Low Pressure | \ High Pressure Charging Valve acas74 AC-13 USE OF MANIFOLD GAUGE SET MANIFOLD GAUGE SET INSTALLATION HINT: To prevent releasing refrigerant, use charging hoses with a stop valve when installing the manifold gauge set to service valves on the refrigerant line. CONNECT CHARGING HOSES WITH A STOP VALVE TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: *® Do not connect the wrong hoses to the high pres- sure and the low pressure side. © To prevent loosening the nuts, do not apply com- pressor oil to seat of the connection. CLOSE HAND VALVES OF BOTH STOP VALVES CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET REMOVE CAPS FROM SERVICE VALVES ON RE- FRIGERANT LINE CONNECT STOP VALVES TO SERVICE VALVES Tighten the nuts by hand CAUTION: * Do not connect the wrong hoses to the high pras- sure and the low pressure sides. © To prevent loosening the nuts, do not apply com- pressor oil to seat of the connection. OPEN HAND VALVES OF BOTH STOP VALVES MANIFOLD GAUGE SET REMOVAL 1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET CLOSE HAND VALVES OF BOTH STEP VALVES DISCONNECT STOP VALVES FROM SERVICE VALVES ON REFRIGERANT LINE INSTALL CAPS TO SERVICE VALVES ON REFRIG- ERANT LINEAG-14 Pressure Sone vate Rolrigeration System) Retrineration Stern] Amount if or Removed| oi ac2eo8 AIR CONDITIONING SYSTEM — USE OF REFRIGERANT RECOVERY MACHINE USE OF REFRIGERANT RECOVERY MACHINE RECOVERING OF REGRIGERANT IN REFRIGERANT SYSTEM When discharging refrigerant from the system as follows, use a recovery machine to recover the re- frigerant. Before replacing parts on the refrigerant line. When moisture or air gets in the refrigerant line. When excess refrigerant is charged. NOTICE: ° When handling the recovery machine, always follow the directions given in instruction manual. * After recovery, the amount of compressor oil re- moved must be measured and same amount added into the system. 1. INSTALL MANIFOLD GAUGE SET TO SERVICE VALVES 2. RECOVER REFRIGERANT FROM REFRIGERATION “SYSTEM (a) Connect the center hose to recovery machine. (b) Operate the recovery machine. (c) Open both high and low hand valves of manifold gauge set. 3. STOP RECOVERY MACHINE WHEN RECOVERING HAS FINISHED 4. REMOVE MANIFOLD GAUGE SET FROM SERVICE VALVES AC-15 AIR CONDITIONING SYSTEM — PARTS LOCATION Blower Motor Blower Unit Water Valve Expansion Valve Front Blower Resister Evaporator Thermistor Heater Radiator AIC Control Assembly Cool Box Amplifier Blower Motor Idle Up VSV Magnetic Valve (with Rear A/C) Expansion Valve PARTS LOCATION Condenser Receiver Sight Glass Compressor Pressure Switch Magnetic Valve (with Cool Box) Magnetic Clutch Relay AVC Cut Relay AIC Amplifier Relay Box © Rear A/C Rear AC Relay Fuse and Relay Block « Heater Relay * Front Blower High Relay * Heater CB + AC Fuse ‘Cool Box Unit Thermistor Expansion Cool Box Switch Evaporator Blower Resistor Rear Blower Switch Rear Cooling Unit Evaporator \ Blower MotorAC-17 AIR CONDITIONING SYSTEM — WIRING DIAGRAM AIR CONDITIONING SYSTEM — WIRING DIAGRAM AC-16 2 fe é = @ of cE He BH ow o He @ of o Fx © Eee MePe H eo MoM oe FoF o EEE 6 < me DHe@e fy e He Be Ho: < ira Oo < ao oO = & = ° 2 é ivew = 3ACB AIR CONDITIONING SYSTEM — DAMPERS POSITION DAMPERS POSITION AIR CONDITIONING SYSTEM — REFRIGERANT VOLUME acd REFRIGERANT VOLUME REFRIGERANT VOLUME INSPECTION 1, RUN ENGINE AT APPROX. 1,500 RPM 2. OPERATE A/C AT MAXIMUM COOLING FOR A __ Sight Giass Receiver FEW MINUTES 3. INSPECT AMOUNT OF REFRIGERANT Observe the sight glass on the liquid tube. Item Symptom Amount of refrigerant Remedy th ee ‘Chock for gas leakage with gas 1 Bubbles present in sight glass Insufficient | leak seater 2 No bubbles present in sight glass | None, sufficient or too much Refer to items 3 and 4 No temperature differance be- Evacuate and charge system. 3 ‘tween compressor inlet and Empty or nearly empty Then check for gas leakage with outlet gas leak tester Temperature between compres- 4 sor inlet and outlet is noticeably | Proper or too much Refer to items 5 and 6 different = Immediately after air condition- Discharge excess refrigerant to 5 ing is turned off, refrigerant in| Too much spaciioniamount sight glass stays clear doa When air conditioning is turned 6 off, refrigerant foams and then | Proper Refer to items 3 and 4 stays clear TO DEF Outside Air wuuuUUL 7 Air Mix =I lat inte Damper —_To SIDE DEF: Ele SIDE DEF Inside o /| s Mode mete > [52 =< ® Rear im ‘ 6 oe 80 Damper 7 | Mode useier Damper Damper Evaporator Radiator Blower Motor To FRONT TO CENTER Mode ee bast RoTEer Damper TOSIDE TOREAR TOREAR TO SIDE VENT FOOT FOOT VENT ncatos Air flow vents AIC control Dampers Pamper position position = et DEF | center | side | FRONT | REAR Air Inlet Mba ® Damesr RECIRC (0) 7 / Air Mix Won ® / Damper t t / COOL ® / Mode PEE GH? | ©@9o oO ee rooTmer Ne | ©OD@O e|[ols« + root wf | ©HSO Oo | oO Bevel NA |OO@OB, O ° ec) Oo FACE 4 | @G8E9| O QO | Rear Heat ® | @ oO Damper | (with FOOT | mode) | | | | Rr HEAT ® ° oO The size of circle (©) indicates the proportion of the air flow volume, eve Bubbles in the sight glass with ambient temperatures higher can be considered narmal if cooling is sufficient. REFRIGERANT VOLUME Specified amount: without rear A/C 950450 g (33.51.76 oz.) with rear A/C 1,200+50 g (42.32+1.76 o2.) omeraAGC-20 to Ah SA tA. Ec0003 Eeoooy oie sion. Belt tension gauge: Nippondenso BTG—20 (95506—00020) or Borroughs No.BT —-33—73F Drive belt tension: New belt 140420 lb Used belt 120+20 Ib HINT: e = ="New belt” refers to a belt which has been used less than 5 minutes on a running engine. e "Used belt” refers to a belt which has used on a running engine for 5 minutes or more. e = After installing the drive belt, check that it fits properly in the ribbed grooves. IDLE—UP SPEED IDLE—UP SPEED INSPECTION 1. WARM UP ENGINE 2. SET VEHICLE IN FOLLOWING CONDITION © Blower switch high position ¢ A/C switch on © Magnetic clutch on 3. INSPECT IDLE UP SPEED Standard: 950+50 rpm IDLE—UP SPEED ADJUSTMENT ADJUST IDLE—UP SPEED Adjust idle—up speed with the idle adjusting screw of the VSV AIR CONDITIONING SYSTEM — IOLE—UP SPEED AIR CONDITIONING SYSTEM — REFRIGERANT LINES AOS DRIVE BELT TENSION _. REFRIGERANT LINES _ DRIVE BELT TENSION INSPECTION LOCATIONS 1. MAKE SURE THAT DRIVE BELT IS INSTALLED Lanna CORRECTLY ae eons Check that the drive belt fits properly in the ribbed grooves. its ae aaa 2, INSPECT DRIVE BELT TENSION ; Using a belt tension gauge, check the drive belt ten- Liquid Tube Magnetic Valve Pressure Switch Low Pressure Charging Valve High Pressure Suction Tube Charging Valve Magnetic Valve Suction Hose Cool Box Sight Glass Receiver Condenser Discharge Hose ON-—VEHICLE INSPECTION 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBE FOR LEAKAGE Using a gas leak tester, check for leakage of refrig- erant.AG-22 AIR CONDITIONING SYSTEM — REFRIGERANT LINES REFRIGERANT LINES REPLACEMENT 1. RECOVER REFRIGERANT SYSTEM 2. REPLACE FAULTY TUBE OR HOSE HINT: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TORQUE CONNECTIONS TO SPECIFIED TORQUE NOTICE: Connections should not be torque tighter than the specified torque. Specified Torque: N-m (kgf-em, ft-lbf) IN REFRIGERATION Fieting Size Torque 0.31 in. Tube 14 (140, 10) 0.50 in. Tube 25 (230, 17) 0.62 in. Tube 33 (330, 24) Bolted Type For Compressor \ 78 For Cendonsar_/ (80, 69 in.-tb) Bolted Type ( Front AC 17 (175, 13) Evaporator) rs 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: without rear A/C 950450 g (33.51+41.76 oz.) with rear A/C 1,200+50 g (42.32+1.76 02.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak tester, check for leakage of refrig- erant. 6. INSPECT AIR CONDITIONING OPERATION AC-23 AIR CONDITIONING SYSTEM — COMPRESSOR COMPRESSOR ON-—VEHICLE INSPECTION (Magnetic Clutch) INSPECT MAGNETIC CLUTCH FOR FOLLOWING (a) Inspect the pressure plate and the rotor for signs of oil. (b) Check the clutch bearings for noise and grease leak- age, # (c) Connect the positive (+) lead from the battery to the terminal 1 on the magnetic clutch connector and the negative (—) lead to terminal 2. (d) Check that the magnetic clutch is energized. Suction Tube Low Pressure Charging 3} Valve 'S High Pressure Charging Valve ERY Acas74 (Compressor) 1. INSTALL MANIFOLD GAUGE SET See page AC—13. 2. RUN ENGINE AT APPROX. 1,500 RPM 3, INSPECT COMPRESSOR FOR FOLLOWING (a) High pressure gauge reading is not lower and low pressure gauge reading is not higher than normal (b) Check that the metallic sound. (c) Check that the leakage from shaft seal. If defects are found, replace the compressor.AC-24 Compressor Bracket AIR CONDITIONING SYSTEM — COMPRESSOR COMPRESSOR REMOVAL AIR CONDITIONING SYSTEM — COMPRESSOR MAGNETIC CLUTCH DISSEMBLY AC-25 Shatt Drive Belt | Adjusting Bolt (a) tb) RUN ENGINE AT IDLE SPEED WITH AIR CONDI- TIONING ON FOR 10 MINUTES STOP ENGINE DISCONNECT NEGATIVE CABLE FROM BATTERY DISCONNECT CLUTCH LEAD WIRE FROM WIRING HARNESS DISCHARGE REFRIGERANT FROM REFRIGERA- TION SYSTEM DISCONNECT TWO HOSES FROM COMPRESSOR SERVICE VALVES Cap the open fitting immediately to keep moisture out of the system. REMOVE COMPRESSOR Loosen the drive belt. Remove the compressor mounting bolts and the compressor, Bolt Pressure Plate @ Non-reusable part Snap Ring acter Aciaee acta63 (b) (c) REMOVE PRESSURE PLATE Using SST and a socket, remove the shaft bolt. SST 07112-76060 Install SST to the pressure plate. SST 07112-60040 Using SST and the socket, remove the pressure plate. SST 07112-76060AC-26 AIR CONDITIONING SYSTEM — COMPRESSOR — Shim © ; eee I Pressure Plate Accous cose? actess AS18685 Ac0950 (d) Remove the shims from the pressure plate. 2. REMOVE ROTOR (a) Using SST, remove the snap ring. SST 07114-84020 (b) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tap- ping on the rotor. CD] stator AIR CONDITIONING SYSTEM — COMPRESSOR AGEL (c) Remove the stator. Aconsy MAGNETIC CLUTCH ASSEMBLY 1. INSTALL STATOR Stator (a) Install the stator on the compressor. Aco9s1 (b) Using SST, install the new snap ring. SST 07114-84020 3. REMOVE STATOR (a) Disconnect the stator lead wire from the compressor housing. (b) Using SST, remove the snap ring. SST 07114-84020 (c) Connect the stator lead wires to the compressor housing. Acres 2. INSTALL ROTOR (a) Install the rotor on the compressor shaft. (b) Using SST, install the new snap ring. SST 07114-84020 cosa?AC-28 Shim OO ©) SS 2. Pressure Plate ol AC0046 Ac) 868 Thickness Gauge acie77 3. (a) (b) AIR CONDITIONING SYSTEM — COMPRESSOR INSTALL PRESSURE PLATE Put the shims to the pressure plate. Using SST and torque wrench, install the shaft bolt. SST 07112-76060 Torque: 14 N-m (140 kgf-cm, 10 ft-Ibf) CHECK CLEARANCE OF MAGNETIC CLUTCH Check the clearance between the pressure plate and rotor using thickness gauge. Standard clearance: 0.5+0.15 mm (0.020+0.0059 in.) If the clearance is not within tolerance, change the number of shims to obtain the standard clearance. AIR CONDITIONING SYSTEM — COMPRESSOR AC-29 neoat-0s COMPRESSOR INSTALLATION (See page AC—24) 1. 2. INSTALL COMPRESSOR WITH MOUNTING BOLTS INSTALL DRIVE BELT (See Inspection of Drive Belt Tension on page AC— 20.) CONNECT TWO HOSES TO COMPRESSOR SER- VICE VALVE : Torque: Discharge line 17 N-m (175 kgf-cm, 13 ft-Ibf) Suction line 17 N-m (175 kgf-cm, 13 ft-Ibf) CONNECT CLUTCH LEAD WIRE TO WIRING HAR- NESS CONNECT NEGATIVE CABLE TO BATTERY EVACUATE AIR FROM AIR CONDITIONING SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH RE- FRIGERANT AND CHECK FOR GAS LEAKAGE Spacified amount: without rear A/C 950+50 g (33.51+1.76 oz.) with rear A/C 1,200+50 g (42.32+1.76 oz.)AC-30 Condenser Bracket AIR CONDITIONING SYSTEM — CONDENSER CONDENSER ON-—VEHICLE INSPECTION aczsiT a INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. INSPECT CONDENSER FITTINGS FOR LEAKAGE Repair as necessary. CONDENSER REMOVAL DISCHARGE REFRIGERATION SYSTEM DISCONNECT DISCHARGE HOSE FROM CON- DENSER DISCONNECT LIQUID TUBE FROM RECEIVER REMOVE CONDENSER Remove the six bolts and the condenser with the brackets. ~ Condenser Bracket AIR CONDITIONING SYSTEM — CONDENSER aczs?? AC-31 CONDENSER INSTALLATION 1. 2. 3. INSTALL CONDENSER CONNECT LIQUID TUBE RECEIVER CONNECT DISCHARGE HOSE TO CONDENSER Torque: liquid tube 13 N-m (135 kgf-cm, 10 ft-lbf) Discharge hose 13 Nem (135 kgf-cm, 10 ftlbf) IF CONDENSER WAS REPLACED, ADD COMPRES- SOR OIL TO COMPRESSOR Add 40—50 ce (1.4—1.7 fl. 02.) Compressor oil: ND OIL 6, SUNISO No.5 GS or equivalent EVACUATE AIR FROM AIR CONDITIONING SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH RE- FRIGERANT ANDCHECK FOR LEAKAGE Specified amount: without rear A/C 950450 g (33.51+41.76 oz.) with rear A/C 1,200450 g (42.32£1.76 oz.)AG-32 AIR CONDITIONING SYSTEM — RECEIVER a RECEIVER ON-— VEHICLE INSPECTION AIR CONDITIONING SYSTEM — REAR COOLING UNIT REAR COOLING UNIT COOLING UNIT REMOVAL Condenser Liquid Tube Receiver INSPECT SIGHT GLASS, FUSIBLE PLUG AND FITTINGS FOR LEAKAGE Use a gas leak tester. Repair as necessary. HINT: The components parts can be replaced without removing the entire rear cooling unit. DISCONNECT NEGATIVE CABLE FROM BATTERY 2. DISCHARGE REFRIGERATION SYSTEM 3. REMOVE CENTER COVER AC2S78 é RECEIVER REMOVAL ow 4, REMOVE TUBE FITTING COVER AND COVER ON Liquid Line Tube OPPOSITE SIDE 1, DISCHARGE AIR CONDITIONING SYSTEM = 5. DISCONNECT LIQUID LINE TUBE 2. DISCONNECT TWO LIQUID TUBES FROM RECEIV- 6. DISCONNECT SUCTION TUBE ER L — 7. DISCONNECT RIGHT AND LEFT DRAIN HOSES HINT: Cap the open fittings immediately to keep HINT: Be careful that the drain does not drop. moisture out of the system. 8. DISCONNECT WIRE HARNESS GONNECTOR 3. REMOVE RECEIVER FROM RECEIVER HOLDER - Drain Hose Suction Tube c2s23 RECEIVER INSTALLATION =— 9. REMOVE COOLING UNIT (a) Remove the blind covers from the suction and register 1, INSTALL RECEIVER IN RECEIVER HOLDER pe Bie caver 4 ports. (There are two blind covers for each port.) HINT: Do not remove the blind plugs until ready for i lo (b) Remove the five bolts. connection. #1 ; 2. CONNECT TWO LIQUID TUBES TO RECEIVER 4 ‘ Torque: 13 N-m (135 kgf-cm, 10 ft-lbf) ‘ 3. IF RECEIVER WAS REPLACED, ADD COMPRESSOR 4 ’ ‘ OIL TO COMPRESSOR csv Add 20 ce (0.7 ft. 02.) Compressor oil: (c) Slide the cooling unit backward to remove it. ND OIL 6, HINT: Be careful that the drain does not drop from the SUNISO No.5 GS or equivalent en ae unit. 4. EVACUATE AIR FROM AIR CONDITIONING SYSTEM ror « 5. CHARGE AIR CONDITIONING SYSTEM WITH RE- HON FRIGERANT AND CHECK FOR GAS LEAKAGE cy Specified amount: \ without rear A/C C2525 950150 g (33.51+1.76 oz) with rear A/C 1,200+50 g (42.32+1.76 02.)AIR CONDITIONING SYSTEM — REAR COOLING UNIT COOLING UNIT DISASSEMBLY (PANASONIC type) HINT: Steps 1 to 6 can be performed without rem- oving the entire cooling unit. Accordingly, for steps 1 to 5 there is no need to discharge the refrigeration system. §—aiind cover as ey Filter Upper Unit Case Blower Resistor Evaporator Assembly Blower Motor Assembly Air Outlet Grill Lower Unit Case je Rear Blower Switch AIR CONDITIONING SYSTEM — REAR COOLING UNIT Ac2827 Ac2828 Upper Case Ac2s2e a { Blower Resistor 402530 Rear Blower Switch soai6r 1. (a) (b) (a) (b) (a) (b) AC-37 REMOVE RIGHT AND LEFT SUCTION GRILLS, REGISTER GRILLSAND FILTERS Remove the twelve screws and the grills from the lower case, Remove the filters from the lower case, REMOVE LOWER CASE Remove the nine screws from the lower case. Separate the upper and the lower cases. HINT: Empty the drain before removing the lower case. REMOVE RIGHT AND LEFT BLOWER MOTOR ASSEMBLIES Remove the three screws and disconnect the con- nector, Disengage the eight pawls and remove the blower motor assembly. REMOVE BLOWER RESISTOR Disconnect the connector, then remove the two screws and the blower resister. HINT: The register can be removed after the right suction grill is removed. REMOVE REAR BLOWER SWITCH Disconnect the connector, then remove the two screws and the rear A/C switch.AL-38 AIR CONDITIONING SYSTEM — REAR COOLING UNIT AIR CONDITIONING SYSTEM — REAR COOLING UNIT Evaporator Assembly \ acasa2 c+ Acasa Blower cot c Blower Motor Ac2834 2G Ly Heat Protective Insulator ate: See ee 6. (a) (b) (a) (b) (c) (4) AC-39 REMOVE EVAPORATOR ASSEMBLY Remove the evaporator assembly by pulling it out. COOLING UNIT ASSEMBLY (PANASONIC type) 1. ASSEMBLE BLOWER MOTOR ASSEMBLY (a) Temporarily secure the blower to the blower motor. (b) Put the blower motor unit on the blower lower case. (ce) Visually adjust the blower position so that the clear- ance between the blower and the blower case on the Clearance 402837 right side is equal to that on the left side. (d) Tighten the screw and check that the blower rotates DISASSEMBLE BLOWER MOTOR ASSEMBLY smoothly. Disengage the eight pawls of the blower case and (e) Assemble the blower upper case to the lower case. separate blower motor assembly into an upper and a 2. ASSEMBLE EVAPORATOR ASSEMBLY lower piece. (a) Connect the liquid line tube to the expansion valve, then torque the nut. Torque: 1441.0 Nm (140+10 kgf-cm, 10+0.7ft-Ibf) HINT: Connect the line as shown in the figure. (b) Connect the expansion valve to the inlet fitting of the Ac2598 evaporator. Torque: 23+ 2.0 N-m (230+ 20 kgf-em, 174 1.4ft-Ibf) Remove the screw, then remove the blower motor fp = = oe Ge (c) Connect the heat—sensing tube to the suction tube. (together with the rubber mount) and the blower (to- (d) Attach heat insulators around the expansion valve gether with the bearing). and the suction tube. HINT: You can first remove the blower motor and the blower. 402836 INSTALL EVAPORATOR TO UPPER CASE DISASSEMBLE EVAPORATOR ASSY INSTALL REAR A/C SWITCH TO LOWER CASE Remove the heat protective insulators from the ex- INSTALL RIGHT AND LEFT BLOWER MOTOR pansion valve and the suction tube. ASSEMBLIES TO UPPER CASE 6. INSTALL LOWER CASE TO UPPER CASE 7. INSTALL RIGHT AND LEFT AIR FILTERS TO LOWER CASE 8. INSTALL RIGHT AND LEFT SUCTION GRILLS, AND REGISTER GRILL TO LOWER CASE ape Remove the liquid line tube from the expansion valve. Remove the clamp, then separate the heat—sensing tube from the suction tube. Remove the expansion valve from the inlet of the ‘evaporator.AC-41 AG-40 AIR CONDITIONING SYSTEM — REAR COOLING UNIT AIR CONDITIONING SYSTEM — COOL BOX COOLING UNIT INSTALLATION a COOL BOX — COOL BOX REMOVAL 1. INSTALL REAR COOLING UNIT ON ROOF sal a (a) Fit the three pawls of the cooling unit into the roof 1. REMOVE SIDE COVERS eo groove 2, DISCONNECT NEGATIVE CABLE FROM BATTERY FRONT 3, DISCONNECT CONNECTORS 1 = 4, DISCONNECT SUCTION AND LIQUID TUBES 5. REMOVE COOL BOX MOUNTING NUTS AND COOL ncis4e vo Box (b) Install and tighten the five bolts. COOL BOX DISASSEMBLY (c) Install the four blind covers. Side Cover acasee Side Cover 2. CONNECT SUCTION TUBE TO COOLING UNIT OUTLET FITTING Torque: 23+2.0 Nm (230+20 kgf-em, 17+ 1.4ft-Ibf) 3. CONNECT LIQUID LINE TUBE TO COOLING UNIT INLET FITTING (EE Torque: 141.0 N.m (140+10 kgf-em, 10+0.7ft-Ibf) asa Thermistor 4. IF EVAPORATOR WAS REPLACED, ADD COM- PRESSOR OIL TO COMPRESSOR Add 40-50 cc (1.4—1.7 ft. oz.) Compressor oil: DENSO OIL 6, & SUNISO No.5 GS or equivalent Blower Motor 5. CONNECT RIGHT AND LEFT DRAIN HOSES 6. CONNECT NEGATIVE CABLE TO BATTERY t Amplifier 7. EVACUATE AIR FROM AIR CONDITIONING SYSTEM 8. CHARGE AIR CONDITIONING SYSTEM WITH RE- FRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: 1,200+50 g (42.32+1.76 oz.)AC-43 Berks AIR CONDITIONING SYSTEM — COOL BOx AIR CONDITIONING SYSTEM — FRONT A/C EVAPORATOR as IR GONDITIONING SYSTEM = COOL BOX 1. REMOVE COOL BOX AMPLIFIER 7 FRONT A/C EVAPORATOR 2. REMOVE UPPER CASE 7] - | EVAPORATOR REMOVAL 3, REMOVE EVAPORATOR ASSEMBLY WITH : BATTERY BLOWER MOTOR ASSEMBLY FROM LOWER CASE 1. DISCONNECT NEGATIVE CABLE FROM 4. DISASSEMBLY EVAPORATOR (a) Remove the thermistor. (b) Remove the expansion valve. 2. DISCHARGE REFRIGERATION SYSTEM 3. REMOVE AIR DUCT COOL BOX ASSEMBLY ne 4, REMOVE BLOWER 1. ASSEMBLE EVAPORATOR (a) Install the expansion valve. (b) Install the thermistor. 2. INSTALL EVAPORATOR ASSEMBLY WITH BLOWER MOTOR ASSEMBLY TO LOWER CASE 3. INSTALL UPPER CASE TO LOWER CASE 4. INSTALL AMPLIFIER 5. DISCONNECT CONNECTORS 6. DISCONNECT SUCTION AND LIQUID TUBE 7. REMOVE EVAPORATOR (a) Remove the two nuts, one bolt and the cover. (b) Remove the evaporator. COOL.BOX INSTALLATION EVAPORATOR DISASSEMBLY 1. INSTALL COOL BOX WITH MOUNTING BOLTS 2. CONNECT SUCTION AND LIQUID TUBES Torque: Suction tube 23 N-m (230 kaf-cm, 17 ft-lbf) Liquid tube 14 N.m (140 kgf-em, 10 ft-lbf) 3. CONNECT CONNECTORS 4. CONNECT NEGATIVE CABLE TO BATTERY 5. EVACUATE AIR FROM AIR CONDITIONING SYSTEM 6. CHARGE AIR CONDITIONING SYSTEM WITH RE- FRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: 1,200+50 g (42.32+1.76 02.) 7. INSTALL SIDE COVER Evaporator Thermistor Evaporator Side Cover sony 1. REMOVE THERMISTOR 2. REMOVE EXPANSION VALVE Hexagonal Wrench Expansion ‘ValveAC-44 AIR CONDITIONING SYSTEM — FRONT A/C EVAPORATOR Wrench Expansion IE Valve aczsee case} mt EVAPORATOR INSPECTION 1. INSPECT EVAPORATOR FINS BLOCKAGE If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator, 2. INSPECT FITTINGS FOR CRACKS OR SCRATCHES 8. Repair as necessary. 9. Aearo-e1 EVAPORATOR ASSEMBLY 1. INSTALL EXPANSION VALVE 10. Connect the expansion valve to the evaporator, then torque the nut. Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf) 2. INSTALL SUCTION AND LIQUID TUBES Connect the suction and liquid tubes to the evapora- tor, then torque the bolt. Torque: 5.4 N-m (55 kgf-cm, 48 in.-Ibf) 3. INSTALL THERMISTOR AIR CONDITIONING SYSTEM — COOL BOX EVAPORATOR AC-45 IF EVAPORATOR WAS REPLACED, ADD COM- PRESSOR OIL TO COMPRESSOR Add 40—50 cc (1.4—1.7 ft. oz.) Compressor oil: ND OIL 6, SUNISO No.5 GS or equivalent CONNECT NEGATIVE CABLE TO BATTERY EVACUATE AIR FROM AIR CONDITIONING SYSTEM CHARGE AIR CONDITIONING SYSTEM WITH RE- FRIGERANT AND CHECK FOR GAS LEAKAGE Specified amount: without rear A/C 950+50 g(33.51+ 1.76 oz.) with rear A/C 1,200+50 g (42.32+1.76 oz.) REAR A/C EVAPORATOR EVAPORATOR REMOVAL acorr-21 See Disassembly of Rear A/C Unit on page AC—34 or 36, EVAPORATOR INSPECTION Acoma EVAPORATOR INSTALLATION 1. INSTALL EVAPORATOR ON HEATER UNIT 2. INSTALL COVER WITH TWO NUTS AND ONE BOLT 3. CONNECT SUCTION AND LIQUID TUBE Torque: 7.8 N-m (80 kgf-cm, 69 ft-Ibf) Sea Inspection of Front A/C Evaporator on pags AC— 44, EVAPORATOR INSTALLATION See Assembly of Rear A/C Unit on page AC—35 or 39, COOL BOX EVAPORATOR acera-o1 EVAPORATION REMOVAL 4, CONNECT CONNECTORS 5. INSTALL BLOWER 6. INSTALL AIR DUCT See Disassembly of Cool Box Unit on page AC—41. EVAPORATION INSPECTION See Inspection of Front A/C Evaporator on page AC— 44, EVAPORATOR INSTALLATION See Assembly of Cool Box Unit on page AC—42.AIR CONDITIONING SYSTEM FRONT AIR CONDITIONING EXPANSION AC-46 VALVE AIR CONDITIONING SYSTEM — COOL BOX EXPANSION VALVE AC-47 FRONT AIR CONDITIONING EXPANSION VALVE ON— VEHICLE INSPECTION 1. INSPECT REFRIGERANT VOLUME See page AC—19. seorH—05 2. INSTALL MANIFOLD GAUGE SET See page AC—13, 3. FRONT A/C SWITCH ON BLOWER SWITCH TO HI 4. RUN ENGINE AT APPROX. 2,000 RPM Run the engine at 2,000 rpm for at least 5 minutes, 5. INSPECT EXPANSION VALVE If the expansion valve is clogged, the low pressure reading will drop otherwise it is OK. HINT: If the low pressure reading is normal and only the front A/C is not cooling, check for malfunction of the expansion valve. EXPANSION VALVE REMOVAL See Removal of Front A/C Evaporator on page AC— 43. EXPANSION VALVE INSTALLATION See Installation of Front A/C Evaporator on page AC —44, REAR AIR CONDITIONING EXPANSION VALVE ON VEHICLE INSPECTION Turn the rear blower switch ON and perform the same inspection as for the front A/C expansion valve. HINT:If the low pressure reading is normal and cool air is only failing to come out of the rear A/C, check fora malfunction of ‘the expansion valve. acne EXPANSION VALVE REMOVAL See Disassembly of Rear Cooling Unit on page AC— 34 or 36. EXPANSION VALVE INSTALLATION See assembly of Rear Cooling Unit on page AC— 35 or 39. COOL BOX EXPANSION VALVE ON—VEHICLE INSPECTION With the cool box switch at COOL position,perform the same inspection as for the front A/C expansion valve. HINT: First, turn the front A/C switch and rear A/C switch to OFF. EXPANSION VALVE REMOVAL Sea Disassembly of Cool Box Unit on page AC—41. EXPANSION VALVE INSTALLATION See Assembly of Cool Box Unit on page AC—42.AC-48 AIR CONDITIONING SYSTEM — COOL BOX THERMISTOR Thermometer Thermistor More than 10 cm (3.94 in.) Ohmmeter acon7s Resistance () 5,500) 5,000) 4,500] 4,000 3,500, ENG 30 32 34 36 38 40°F Temperature bec coe FRONT AIR CONDITIONING THERMISTOR THERMISTOR REMOVAL See Removal of Front A/C Evaporator on page AC— 43. THERMISTOR INSPECTION INSPECT THERMISTOR OPERATION (a) Place the thermistor in cold water. While varying the temperature of the water, measure the resistance at the connector and, at the same time, measure the temperature of the water with a thermometer. (b) Compare the two reading on the chart. If the intersection is not in the shaded area replace the thermistor. THERMISTOR INSTALLATION See Installation of Front A/C Evaporator on page AC —44, sera COOL BOX THERMISTOR THERMISTOR REMOVAL See disassembly of Cool Box Unit on page AC—41. THERMISTOR INSPECTION Check the thermistor the same way as for the front A/ C thermistor. THERMISTOR INSTALLATION See Assembly of Cool Box Unit on page AC—42. AIR CONDITIONING SYSTEM — AIR CONDITIONING CONTROL ASSEMBLY REAP AIR CONDITIONING CONTROL ASSEMBLY A/C CONTROL ASSEMBLY : Blower Speed Control AIC Switch: ‘Switch eg : ChE fei es _ BLOWER SPEED CONTROL SWITCH ~ INSPECTION INSPECT SWITCH CONTINUITY Ke Terminal 5 4 s | 6 |e [iumination | Switeh position 3] 4 OFF 4 | Lo | oo @ a es fT o+0-}-0 | swe2| HI [ [ ooo If continuity is not as specified, replace the switch. ee FRONT A/C SWITCH INSPECTION INSPECT SWITCH CONTINUITY -—9 t—o If continuity is net as specified, replace the switch.AC-50 Blower Unit Air Damper Case | FRESH Cp & AIR CONDITIONING SYSTEM — AIR CONDITIONING CONTROL ASSEMBLY A/C CONTROL LEVERS INSPECTION ~"“ INSPECT A/C CONTROL LEVERS OPERATION More the control levers left and right and check for— stiffness and binding through the full range of the levers. A/C CONTROL CABLES ADJUSTMENT 1. ADJUST AIR INLET DAMPER CONTROL GABLE Set the air inlet damper and the control lever to ” FRESH’ position, install the control cable and lock the clamp. Clamp aczse2 2. ADJUST AIR MIX DAMPER CONTROL CABLE Set the air mix damper and the control lever to ” COOL” position, install the control cable and lock the clamp. cases COOL 3. ADJUST WATER VALVE CONTROL CABLE | Set the water valve and the control lever to “COOL” | position, install the control cable and lock the clamp. | i GI © 3 ACRES 4. ADJUST MODE DAMPER CONTROL CABLE Set the mode damper and the control lever to “VENT” 7 position, install the control cable and lock the clamp. acaba AIR CONDITIONING SYSTEM — AIR CONDITIONING CONTROL ASSEMBLY ACSI 5. ADJUST REAR HEAT DAMPER CONTROL CABLE Set the rear heat damper and the control lever to “RR HEAT” position, install the control cable and lock the clamp. cases 6. ADJUST SIDE VENT DUCT CONTROL CABLE Set the side vent, duct and the mode control lever to “VENT” position, install the control cable and lock the VENT 7A NENT clamp. a “aA (Driver's Side) (Passenger's) cise?