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SECTION

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE

GENERAL A/C SYSTEM SERVICE PROCEDURES

General Service Procedures

    Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System, for details of the following procedures:

SERVICEABLE COMPONENTS

Common HVAC Components

    Those components used in non-automatic systems are covered in other sections of this manual.
    Refer to Section 7A, Heating and Ventilation System for the following procedures:
    Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System, for the following procedures:

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Automatic Temperature Control Assembly

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the audio trim panel. Refer to Section 9F, Audio Systems.
  3. Remove the control assembly retaining screws.
  4. Pull out the unit to gain access to the rear.
  5. Disconnect the electrical connectors.
  6. Remove the air inlet tube.
  7. Remove the automatic temperature control assembly.

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Installation Procedure

  1. Connect the air inlet tube.
  2. Connect the electrical connectors.
  3. Position the automatic temperature control assembly and install the retaining screws.

    4. Tighten
    Tighten the control assembly retaining screws to 2.5 N•m (22 lb-in).

  4. Install the audio trim panel. Refer to Section 9F, Audio Systems.
  5. Connect the negative battery cable.

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Inlet Air Door Motor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.
  3. Remove the actuating rod by snapping the rod out of the lever with needle-nose pliers.
  4. Remove the actuating lever.
  5. Disconnect the electrical connector.
  6. Remove the motor retaining screws.
  7. Remove the motor.

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Installation Procedure

  1. Install the motor.
  2. Install the motor retaining bolts and tighten.
  3. Install the actuating lever.
  4. Install the actuating rod.
  5. Connect the electrical connector.
  6. Install the instrument panel. Refer to Section 9E, Instrumentation/Driver Information.
  7. Connect the negative battery cable.

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Mode Door Motor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the electrical connector.
  3. Remove the motor actuating rod by snapping out it out of the lever with needle-nose pliers.
  4. Remove the motor lever.
  5. Remove the motor retaining bolts.
  6. Remove the mode door motor.

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Installation Procedure

  1. Install the mode door motor.
  2. Install the motor retaining screws and tighten.
  3. Install the motor lever by pressing it onto its shaft.
  4. Install the actuating rod.
  5. Connect the electrical connector.
  6. Connect the negative battery cable.

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Temperature Door Motor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.
  3. Disconnect the electrical connector.
  4. Remove the actuating rod by snapping it out of the lever with needle-nose pliers.
  5. Remove the motor lever from its shaft by pulling the lever off.
  6. Remove the motor retaining screws.
  7. Remove the temperature door motor.

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Installation Procedure

  1. Install the temperature door motor.
  2. Install the retaining screws and tighten.
  3. Press the lever onto motor shaft.
  4. Install the actuating rod onto the lever.
  5. Connect the electrical connector.
  6. Install the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.
  7. Connect the negative battery cable.

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Duct Sensor

(Left-Hand Drive Shown, Right-Hand Drive Similar)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.
  3. Turn the sensor to release it from the aircon module.
  4. Disconnect the electrical connector.

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Installation Procedure

  1. Install the coolant temperature sensor into the aircon module and turn the sensor to lock it.
  2. Connect the electrical connector.
  3. Install the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.
  4. Connect the negative battery cable.

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Ambient Air Temperature Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the ambient air temperature sensor electrical connector.
  3. Remove the retaining nut from the bracket.
  4. Remove the ambient air temperature sensor.

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Installation Procedure

  1. Position the ambient air temperature sensor into its bracket.
  2. Install the retaining nut to the bracket.

    3. Tighten
    Tighten the ambient air temperature retaining bracket nut to 6 N•m (53 lb-in).

  3. Connect the electrical connector.
  4. Connect the negative battery cable.

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Sun Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the I/P center speaker cover. Refer to Section 9F, Audio System
  3. Gently pry up on the sun sensor to remove it.
  4. Disconnect the electrical connector.

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Installation Procedure

  1. Connect the electrical connector.
  2. Insert and press the sun sensor into position in the dash.
  3. Connect the negative battery cable.

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High-Blower Relay

Removal Procedure

  1. Disconnect the negative battery cable.
  2. The relay is located in front of the blower motor.
  3. Remove the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.
  4. Separate the relay from the connector.
  5. Remove the screws with the highblower relay.

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Installation Procedure

  1. Install the screws with the highblower relay.
  2. Connect the electrical connector.
  3. Install the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.

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Power Module

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.
  3. Disconnect the electrical connector at the resistor.
  4. Remove the screws from the resistor.
  5. Remove the resistor from the A/C module by gently pulling the resistor downward.

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Installation Procedure

  1. Install the new resistor into the heater/air distributor case assembly with the screws.

    2. Tighten
    Tighten the blower motor resistor screws to 6 N•m (53 lb-in).

  2. Connect the electrical connector at the resistor.
  3. Connect the negative battery cable.
  4. Confirm the proper performance of the blower.
  5. Install the glove box lower panel cover. Refer to Section 9E, Instrumentation/Driver Information.

UNIT REPAIR

V5 AIR CONDITIONING COMPRESSOR OVERHAUL

Compressor Overhaul

    Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System for details of the following procedures:

GENERAL DESCRIPTION AND SYSTEM OPERATION

GENERAL INFORMATION

The SP17 System

Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System,for general information details for the following:

System Components-Control

Controller

The operation of the A/C system is controlled by the switches on the control head. This console-mounted heating and ventilation system contains the following knobs and display:

Temperature Control Push Knobs

  1. Raise the temperature of the air entering the vehicle by pressing the top switch, with the red arrow pointing upward.
  2. Lower the temperature by pressing the bottom switch, with the blue arrow pointing downward.
  3. Actuate the air mix door by an electric motor.
  4. Vary the mix of the air passing through the heater core with the air bypassing the core.
Each press of a switch changes the set temperature by increments of 0.5°C (1°F). This is shown in the temperature window on the function display.

The Function Display

This is an LCD display indicating the status of the control settings selected. Starting from the left end of the display, the sections are as follows:
  1. Temperature setting - Indicates the temperature set with the temperature control knob.
  2. Auto status - Indicates whether the system is operating in the full auto mode or the manual mode.
  3. Defroster icon - Indicates manual selection of full defrost mode.
  4. Mode - Indicated by icon, the mode chosen by the system in auto (or by the operator in manual) is shown by an illumination arrow indicating the air path.
  5. A/C - A snowflake icon indicating whether the A/C is ON or OFF.
  6. Fan speed - Indicates the fan speed by illuminating a bar based on the segment at the front, for low speed, and adding additional segments in order up to the fifth, for high speed.

Eight Additional Push Knobs

  1. Full defrost - Causes the mode motors to direct all air to the windshield and aide window outlets for maximum defrosting.
  2. Air intake - Switches between fresh air intake, the default, and recirculating air. Airflow arrows on the display indicate the mode in effect.
  3. Full Auto Switch - Maintains the set temperature automatically. In this mode, the fully automatic temperature control (FATC) system controls the following:
  4. OFF Switch - Turns the automatic air conditioning and fan control off.
  5. Mode Switch - Allows manual selection of the airflow direction.
  6. A/C Switch - Allows manual selection and control of the air conditioning function.
  7. Fan Control Switch - Allows manual selection among five fan speeds.
  8. Defogger Switch - Turns on the electric defogging heater in the rear window and the outside rearview mirrors, if the vehicle is equipped with heated mirrors.

Pressure Transducer

Pressure transducer switching incorporates the functions of the high-pressure and the low-pressure cutout switches along with the fan cycling switch. The pressure transducer is located in the high-side liquid refrigerant line behind the right strut tower, between the right strut tower and the fire wall. The output from this pressure transducer goes to Engine Control Module (ECM), which controls the compressor function based on the pressure signal.

Wide-Open Throttle (WOT) Compressor Cutoff

During full-throttle acceleration, the throttle position sensor (TPS) sends a signal to the ECM, which then controls the compressor clutch.

High RPM Cutoff

As engine rpm approaches the maximum limit, the ECM will disengage the compressor clutch until the engine slows to a lower rpm.


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