SECTION 7B
MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
SPECIFICATIONS
A/C System Charging Capacity
Application | Eng. Type | Description |
R-134a System | FAM 2.4/HFV6 | 660 ± 20g |
| - Left Hand Drive | 2.0 DSL | 520 ± 20g |
Refrigerant Oil in A/C System | All | PAG(RL897 or EOIV) |
SP17 Compressor Specifications
Displacement (cc/rev) | 173 |
Bore x Stroke (mm) | 31.8 x 21.8 |
Number of Cylinder | 10 |
Diameter x Length (mm) | 114 x 200.5 |
Max. Allowable Speed (rpm) | 10,500 |
Weight (w/Clutch) (kg) | 6.05 |
Clutch-Standard | 12V/46W max |
Refrigerant | R134a |
Refrigerant Oil-Standard (g) | 150 |
Oil Type | PAG or equivalent |
Fastener Tightening Specifications
Application | N•m | Lb-Ft | Lb-In |
Clutch Plate and Hub Assembly Retaining Nut | 13.5 | 10 | - |
Compressor Hose Connecting Block Nut | 16 | 12 | - |
Discharge Hose Connecting Block-to-Compressor Retaining Nut | 16 | 12 | - |
Discharge Hose Connecting Block-to-Condenser Retaining Nut | 16 | 12 | - |
Expansion Valve Bolts | 10 | - | 89 |
ECM Bracket Mounting Nuts | 15 | 11 | - |
Front Compressor-to-Bracket Mounting Bolts | 23 | 17 | - |
High-Pressure Pipe-to-Evaporator Flange Connecting Block Nut | 16 | 12 | - |
High-Pressure Pipe-to-Condnser Connecting Block Nut | 14 | 10 | - |
Liquid Evaporator Pipe Clamp Bolt | 16 | 12 | - |
Pressure Relief Valve | 16 | 12 | - |
Pressure Transducer | 7 | - | 62 |
Rear Compressor-to-Bracket Mounting Bolts | 20 | 15 | - |
Rear Compressor Bracket Mouting Bolts | 23 | 17 | - |
Suction Hose Clamp Bolt | 16 | 12 | - |
Suction Hose Connecting Block Retaining Nuts | 16 | 12 | - |
Upper Condenser Mount Nuts | 4 | - | 35 |
SPECIAL TOOLS
Special Tools Table
SCHEMATIC AND ROUTING DIAGRAMS
A/C System - Typical
- Compressor
- Pressure Relief Valve
- Condenser
- Evaporator
- Expansion Valve
Manual Control A/C Diagram
DIAGNOSIS
GENERAL DIAGNOSIS
Testing the Refrigerant System
If you suspect a problem in the refrigerant system, check for the following conditions:
- Check the outer surfaces of the radiator and the condenser cores to be sure that the airflow is not blocked by dirt, leaves, or other foreign material. Check between the condenser and the radiator, as well as all outer surfaces.
- Check for restrictions or kinks in the condenser core, the hoses, and the tubes.
- Check the operation of the blower fan.
- Check all the air ducts for leaks or restrictions. Low airflow rate may indicate a restricted evaporator core.
- Check for slippage of the compressor clutch.
- Check the drive belt tension.
Insufficient Cooling "Quick Check" Procedure
Perform the following "hand-feel" procedure to get a quick idea of whether the A/C system has the proper charge of Refrigerant-134a. The air temperature must be above 21°C (70°F) for most models.
- Warm up engine. Run the engine at idle.
- Open the hood and all the doors.
- Turn the A/C switch ON.
- Set the temperature control to the full cold position.
- Set the blower speed switch on the maximum speed setting.
- "Hand-feel" the temperature of the evaporator outlet pipe. The pipe should be cold.
- Check for other problems. Refer to "Testing the Refrigerant System" in this section.
- Leak check the system. Refer to "Leak Testing the Refrigerant System" in this section. If you find a leak, discharge the system and repair the leak as required. After completing the repair, evacuate the system and charge it.
- If there is no leak, refer to "Insufficient Cooling Diagnosis" in this section.
Pressure-Temperature Relationship of R-134A
Temperature °C (°F)* | Pressure kPa (psig)* | Temperature °C (°F)* | Pressure kPa (psig)* |
-8 (17.6) | 113.1 (16.4) | 9 (48.2) | 296.2 (43.0) |
-7 (19.4) | 121.5 (17.6) | 10 (50.0) | 309.6 (44.9) |
-6 (21.2) | 130.2 (18.9) | 15 (59.0) | 383.7 (55.7) |
-5 (23.0) | 139.1 (20.2) | 20 (68.0) | 467.7 (67.8) |
-4 (24.8) | 148.4 (21.5) | 25 (77.0) | 567.5 (82.3) |
-3 (26.6) | 157.9 (22.9) | 30 (86.0) | 667.8 (96.9) |
-2 (28.4) | 167.6 (24.3) | 35 (95.0) | 785.6 (113.9) |
-1 (30.2) | 177.8 (25.8) | 40 (104.0) | 916.4 (133.0) |
0 (32.0) | 188.2 (27.3) | 45 (113.0) | 1 062.2 (154.0) |
1 (33.8) | 198.8 (28.8) | 50 (122.0) | 1 222.1 (177.2) |
2 (35.6) | 209.9 (30.4) | 55 (131.0) | 1 398.2 (202.8) |
3 (37.4) | 221.2 (32.1) | 60 (140.0) | 1 589.6 (230.5) |
4 (39.2) | 232.9 (33.8) | 65 (149.0) | 1 799.0 (260.9) |
5 (41.0) | 245.0 (35.5) | 70 (158.0) | 2 026.6 (293.9) |
6 (42.8) | 257.4 (37.3) | 75 (167.0) | 2 272.2 (329.5) |
7 (44.6) | 269.8 (39.1) | 80 (176.0) | 2 544.0 (369.0) |
8 (46.4) | 282.9 (41.0) | - | - |
* All calculated values are rounded to one decimal place.
Evaporator Range: From -7 to 7°C (19.4 to 44.6°F), the temperatures represent the gas temperatures inside the coil and not on the coil surfaces. Add 2 to 6°C (4 to 11°F) to the coil and air-off temperatures.
Condenser Range: From 45 to 70°C (113°to 158°F), the temperatures are not ambient. Add 19 to 22°C (34 to 40°C) to the ambient temperatures for proper heat transfer. Then refer to the pressure chart.
Example:
32°C (90°F) Ambient temperature + 22°C (40°F) = 54°C (130°F)Condenser temperature, which yields 1 379 kPa (200 psig), based on 50 km/h (31 mph) airflow.Leak Testing Refrigerant System
Test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the lines or the connections. Leaks are commonly found at the refrigerant fittings or at the connections. Leaks are commonly caused by the following problems:
- Improper torque.
- Damaged O-ring seals.
- Dirt or lint on the O-ring seals.
Liquid Leak Detectors
Use a liquid leak detector solution on locations such as fittings. Apply the solution to the area in question with the swab that is supplied with the solution. Look for bubbles to appear. This will indicate the existence and the location of any leak.
For areas where this is not practical, such as sections of the evaporator and the condenser, an electronic leak detector is more useful.
Electronic Leak Detectors
Follow the manufacturer's instructions for calibration, operation, and maintenance of an electronic leak detector. Battery condition is especially important to the accuracy of a portable model. Set the detector to R-134a before beginning the test.
Notice : Electronic leak detectors are sensitive to windshield washing solutions, solvents and cleaners, and certain vehicle adhesives. Surfaces must be clean to prevent false readings. Make sure that all surfaces are dry to prevent damage to the detector.
General Testing Instructions
- Follow the entire path of the refrigerant system.
- Completely circle each joint at 25 to 50 mm (1 to 2 inches) per second.
- Hold the probe tip within 6 mm (1/4 inch) of the surface.
- Do not block the air intake.
- The audible tone changes from 1 to 2 clicks per second into a solid alarm if there is a leak. Adjust the balance control to maintain 1 to 2 clicks per second.
- Test all of the following areas, even after one leak has been confirmed:
- Evaporator inlet and outlet.
- Receiver-drier inlet and outlet.
- Condenser inlet and outlet.
- Brazed and welded areas.
- Damaged areas.
- Hose couplings.
- Compressor rear head.
- All fittings and joints.
Testing Service Ports/Access Valves
The sealing caps provide protection for the service ports. Make sure that these caps are not missing or loose. Always use the correct cap for each port.
Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the evaporator core using the following procedure:
- Run the blower fan at the maximum speed setting for at least 15 minutes.
- Turn the blower OFF.
- Wait for 10 minutes.
- Remove the blower motor resistor. Refer to Section 7A, Heating and Ventilation System.
- Insert the leak detector probe as closely as possible to the evaporator core. The detector will indicate a leak with a solid alarm.
- Use a flashlight to search for refrigerant oil on the core surface.
Testing the Compressor Shaft Seal
- Blow shop air behind and in front of the compressor clutch/pulley for at least 15 seconds.
- Wait 1 to 2 minutes.
- Probe the area in front of the pulley. If the detector emits a solid alarm, there is a leak.
SP Compressor/Refrigerant System Diagnosis
Complaints about air-conditioning are typically three types: Refrigerant / Oil Leakage, Operating Noise and Insufficient Cooling.
For a proper A/C system maintenance, please refer to the following diagnosis.
