Black plate (1,1)

Chassis
HEATER, AIR-CONDITIONER AND
VENTILATION

SAGA
55 HEATER, AIR CONDITIONER &
VENTILATION

Model YR 2008
English Edition RDWE-08MA010
Destination: MHR
January 2008 Printed in Malaysia

Copyright

Perusahaan Otomobil
Nasional Sdn Berhad
(Company No.: 100995-U)
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Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR-CONDITIONER AND VENTILATION CH12

Content /I

55 HEATER, AIR CONDITIONER & VENTILATION

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/1

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/1

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/2
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/2
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/2
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/2
SEALANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/3

TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/3

TROUBLESHOOTING ................................................... 55/3

TROUBLESHOOTING CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/3

MAIN FUNCTIONAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/5

THERMISTOR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/5
THERMO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/6
RESISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/6

SERVICE AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/6

SERVICE TOOLS AND GAS LEAK DETECTOR (FOR HFC 134a) . . . . . . . . . . . 55/6
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/6
HANDLING OF SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/8
PRECAUTION FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/12
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/14

EVACUATING AND CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/15

TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/15
CAUTION FOR HANDLING THE REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . 55/15
AIR-COND SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/16

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/20

RECEIVER DRIER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/20
DUAL PRESSURE SWITCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/21
PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/22

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/23

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CH12 HEATER, AIR-CONDITIONER AND VENTILATION

/II Content

REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET . . . . . 55/23

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/25

REFILLING OF OIL IN THE A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/25
REFRIGERANT LEAK REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/26
LOST CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/26
LOW CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/26
HANDLING TUBING AND FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/26
COMPRESSOR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/27
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/27
POWER RELAY CHECK ................................................ 55/27
BLOWER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/27
A/C COMPRESSOR RELAY, CONDENSER FAN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/28
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/28
AIR-COND CONTROL ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/28

AIR-COND CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/29

DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/29
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/30

COOLER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/31

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/31

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/32

REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/32
FILTER CASE ASM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/32

COOLER UNIT ASSY REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . 55/33

RESISTOR DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/34
THERMISTOR DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 55/35
CASE UPPER-CASE LOWER DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . 55/36
THERMISTOR – AMPLIFIER DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . 55/37
BLOWER MOTOR DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . 55/38
CASE INTAKE ASM DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . 55/39

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/41
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/41
REMOVAL SERVICE POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/43
INSTALLATION SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/43
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/44
COMPRESSOR MAGNETIC CLUTCH OPERATION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 55/44

REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/45

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/45
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/46
INSTALLATION SERVICE POINT ........................................ 55/46

CONDENSER AND CONDENSER FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/47

REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/47
REMOVAL SERVICE POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/49
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/49
CONDENSER FAN AND MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/49

VENTILATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/50
REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55/50

All information, illustrations and product descriptions contained in this manual are correct at time of publication. We however reserve the
right to make changes at any time without prior notice or obligation.

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HEATER, AIR-CONDITIONER AND VENTILATION CH12

Content /III
NOTE

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55 HEATER, AIR CONDITIONER & VENTILATION

/1 GENERAL INFORMATION

GENERAL INFORMATION WCH055GINFO008

The Air-Cond system uses a one -way-flow system that features high performance and low operating
noise, and includes an independent face air blowing function.
The A/C system is basically the same as the conventional system, but a new refrigerant system has
been adopted as a response to restrictions on the use of chlorofluorocarbons. Please refer to
supplier’s Air Cond Manual for detail (Pub.No RDAE-08MA100).
SAFETY PRECAUTIONS
Because R-134a refrigerant is a hydrofluorocarbon (HFC) which contains hydrogen atoms in place of
chlorine atoms, it will not cause damage to the ozone layer.
Refrigerant R-134a is transparent and colourless in both the liquid and vapour state. Since it has a
boiling point of –29.8 8C (85.64 8F), at atmospheric pressure, it will be a vapour is heavier than air,
non-flammable, and nonexplosive. The following precautions must be observed when handling R-
134a.
CAUTION
Wear safety goggles when servicing the refrigeration system.
R-134a evaporates so rapidly at normal atmospheric pressures and temperatures that it tends to
freeze anything it contacts. For this reason, extreme care must be taken to prevent any liquid
refrigerant from contacting the skin and especially the eyes. Always wear safety goggles when
servicing the refrigeration part of the A/C system. Keep a bottle of sterile mineral oil handy when
working on the refrigeration system. Should any liquid refrigerant get into the eyes, use a few drops
of mineral oil to wash them out. R-134a is rapidly absorbed by the oil. Next splash the eyes with
plenty of cold water. Call your doctor immediately even though irritation has ceased after treatment.

CAUTION
Do not heat R-134a above 40 8C (104 8F)
In most instances, moderate heat is required to bring the pressure of the refrigerant in its container
above the pressure of the system when charging or adding refrigerant.
A bucket or large pan of hot water not over 40 8C (104 8F) is all the heat required for this purpose. Do
not heat the refrigerant container with a blow torch or any other means that would raise
temperature and pressure above this temperature. Do not weld or steam clean on or near the system
components or refrigerant lines.

CAUTION
Keep R-134a containers upright when charging the system.
When metering R-134a into the refrigeration system keep the supply tank or cans in an upright
position. If the refrigerant container is on its side or upside down, liquid refrigerant will enter the
system and damage the compressor.

CAUTION
(1) The leak detector for R-134a should be used to check for refrigerant gas leaks.
(2) Do not allow liquid refrigerant to touch bright metal.
Refrigerant will tarnish bright metal and chrome surfaces, and in combination with moisture can
severely corrode all metal surfaces.

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HEATER, AIR CONDITIONER & VENTILATION 55

SPECIFICATIONS /2

SPECIFICATIONS WCH055SPECS009

GENERAL SPECIFICATIONS

Items Specifications
Air distributor assembly Type Single flow system
Air-cond control assembly Dial type
Compressor model SANDEN SD 7H15
Dual Pressure Switch High pressure switch SANDEN
ON ! OFF:
3138 kPa (446.411 psi; 947.299 in.Hg)
OFF ! ON:
2550 kPa (362.763 psi; 769.794 in.Hg)
Low pressure switch ON ! OFF: 196 kPa (27.882 psi; 59.168 in.Hg)
OFF ! ON: 221 kPa (31.439 psi; 66.715 in.Hg)
Refrigerant and quantity R-134a, Approx.
SANDEN
400 g (14.112 oz; 4 N) D 50 g (1.764 oz; 0.5 N)

SERVICE SPECIFICATIONS

Items Standard value

Idle speed 750 r/min D 100 r/min
Idle up speed SANDEN 900 r/min D 50 r/min
Blower Resistor Between terminals 1 and 2 0.29 B 10 %
Between terminals 1 and 3 0.91 B 10 %
Between terminals 1 and 4 2.48 B 10 %
Engine coolant temperature ON (continuity) Approx. 118.75 8C (245.75 8F) or less
switch (For A/C cut-off) OFF (no continuity) Approx. 115 8C (239 8F) or more (until the
temperature drop to approx.
108 8C (226.4 8F) when OFF)

LUBRICANTS

Items Specified lubricants Quantity

Compressor refrigerant unit lubricant SANDEN SP10 135 cm3 (8.237 cu.in)

SEALANT

Items Specified sealant Remark

Engine coolant temperature switch 3M Adhesive Nut Locking No. Drying sealant
threaded portion 4171 or equivalent

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55 HEATER, AIR CONDITIONER & VENTILATION

/3 SPECIAL TOOLS / TROUBLESHOOTING

SPECIAL TOOLS WCH055STOOL007

TOOLS

Tools Number Name Use

MB990784 Ornament remover Removal of Aircond assembly

DOIHC051R04017

EZT 0013 Feat belt removal To dismantle fead belt

DOIHC11AR04044

TROUBLESHOOTING WCH055TSHOT056

TROUBLESHOOTING CHECKING
Use the table below to help you find the cause of the problem. Check each part in order. If necessary,
replace these parts.

Trouble symptom Main inspection areas

A/C fuse
Main blower relay
No blower operation Blower motor
Blower speed control switch
Blower resistor
Refrigerant volume
A/C fuse
Compressor relay
Magnetic clutch relay
Magnetic clutch
Compressor
No compressor operation
Pressure switch
Thermister
A/C switch
A/C ECU
Wire harness
Water temperature sensor

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HEATER, AIR CONDITIONER & VENTILATION 55

TROUBLESHOOTING /4

Trouble symptom Main inspection areas

Refrigerant volume
Compressor relay
Magnetic clutch relay
Compressor operates intermittently Pressure switch / sensor
Magnetic clutch
Fead belt
Compressor
Condenser fan relay
No condenser fan operation Pressure switch
Condenser fan motor
Refrigerant volume
Fead belt
Magnetic clutch
Compressor
No cool air comes out
Pressure switch / sensor
Thermister
A/C ECU
A/C switch
Refrigerant volume
Fead belt
A/C ECU
Cool air comes out intermittently
Expansion valve
Evaporator
Thermister
Refrigerant volume
Fead belt
Compressor
Condenser
Cool air comes out only at high engine rpm
Receiver
Expansion valve
Evaporator
Refrigerant lines

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55 HEATER, AIR CONDITIONER & VENTILATION

/5 MAIN FUNCTIONAL COMPONENTS

Trouble symptom Main inspection areas

Refrigerant volume
Fead belt
Condenser fan relay
Condenser fan motor
Insufficient cooling Condenser
Receiver
Expansion valve
Evaporator
Refrigerant lines
A/C switch
No engine idle up when A/C switch on A/C ECU
Wire harness

MAIN FUNCTIONAL COMPONENTS

WCH055SPROC101

THERMISTOR SENSOR
The thermistor sensor, mounted on the rear of
the evaporator in the air conditioner unit,
detects temperature of the air passing through
the evaporator.

Symbol Description
A 45 mm (1.771 in)
B 24.5 mm (0.964 in) D
5 mm (0.196 in)
C Thermistor
The characteristics and electrical circuitry to the
computer are the same as those of the room
temperature sensor.

DOIMC055R07001

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HEATER, AIR CONDITIONER & VENTILATION 55

SERVICE AND REPAIR /6

THERMO AMPLIFIER
1. Electronic device containing a circuit board
and electrical components.Thermistor resis-
tance is amplified and used to control or
switch the compressor clutch on off.

Temperature Control range:

Off point 3.5 8C (38.3 8F) B 1.5 8C (34.7 8F),VR=
0k
Off point 16 8C (60.8 8F) B 2.5 8C (36.5 8F) ,VR=
5k
DOIMC055R07005
Symbol Description
A Thermo amplifier

RESISTER
2. Use circuit tester to measure the resistance
between the terminal as indicated in the
table.Checked that the measured value is at
the standard value

Symbol Description
Between terminal 1 0.29 D 10%
and 2
Between terminal 1 0.91 D 10%
and 3
DOIMC055R07002 Between terminal 1 2.48 D 10%
and 4

SERVICE AND REPAIR WCH055SPROC087

SERVICE TOOLS AND GAS LEAK DETECTOR (FOR HFC 134a)

SERVICE TOOLS
Special service tools are used for servicing the air conditioner as shown below.
For HFC 134a system, to prevent incorrect refrigerant changing and to prevent compressor oil from
getting mixed, the diameter for each joint has been changed to use quick disconnect adapter
compatible with SAE standard changing valves.
Order No. of car Air Conditioner Service Tool Set : 07110–58011.

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/7 SERVICE AND REPAIR

DOIIC055R01103

Symbol Description
A Manifold gauge
B Charging hose
C Vacuum pump adapter
D Quick disconnect adapter

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HEATER, AIR CONDITIONER & VENTILATION 55

SERVICE AND REPAIR /8

HANDLING OF SERVICE TOOLS

WCH055SPROC088

1. Connecting Manifold Gauge

CAUTION
. Always use manifold gauge for the
HFC 134a air conditioning system

Symbol Description
A Manifold gauge
B Low pressure charging hose
C Quick disconnect adapter
(Suction)
D High pressure charging
hose
E Center charging hose
F Quick disconnect adapter
(Discharge)
G Center hose

DOIIC055R01104

2. Connecting the Quick Disconnect Adapter

Push the quick disconnect adapter into the
charging valve. Then push on part ‘‘A’’ as
shown in the illustration until a click is
heard ) Connection completed

CAUTION
(1) When connecting, push carefully so the
piping doesn’t bend.
(2) When connecting the quick disconnect
adapter, if the sleeve moves before the
quick disconnect adapter connector can
be connected to the charging valve,
move back the quick sleeve to its
original position and try again.
(3) When some refrigerant remains in the
charging hose at the time of connec-
tion, it may be difficult to connect the
quick disconnect adapter. In this case,
perform the operation after removing
any residual pressure in the hose.

Symbol Description
B Sleeve
C Click
D Remove the residual pres-
DOIIC055R01105 sure by pushing the pusher

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55 HEATER, AIR CONDITIONER & VENTILATION

/9 SERVICE AND REPAIR

3. Removing the Quick Disconnect Adapter

While holding on the part ‘‘A’’ of the quick
disconnect adapter, slide part ‘‘B’’ up )
removal completed

CAUTION
After removing, make sure to cap the
charging valve.

Symbol Description
C Sleeve
D Click
4. Construction and Handling of Manifold
Gauge
By opening or closing the high and low
pressure hand valves, the following circuits
are made.

DOIIC055R01106

When low pressure valve (LO) is open and

the high pressure valve (HI) is closed.

Symbol Description
A Open
B Close

DOIIC055R01108

When the low pressure valve (LO) is closed

and the high pressure valve (HI) is open :

Symbol Description
A Close
B Open

DOIIC055R01107

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HEATER, AIR CONDITIONER & VENTILATION 55

SERVICE AND REPAIR /10

When the low pressure valve (LO) is closed

and the high pressure valve (HI) is closed :

Symbol Description
A,B Close

DOIIC055R01109

5. New Gas Leak Detector for HFC 134a

The conventional gas leak detectors such as
the halide torch type and electronic type
cannot be used to detect a gas leak of HFC
134a.
Therefore, a new gas leak detector has
been developed to detect HFC 134a.
This new gas leak detector has a higher
degree of sensitivity to the presence of HFC
134a.

Refrigerant
HFC 134a
Sens. mode
HI-SENS. 15 g (0.529 oz; 0.15 N)
to
30 g (1.058 oz; 0.3 N)
per year
R134a 40 g (1.411 oz; 0.4 N)
per year

DOIIC055R01111

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55 HEATER, AIR CONDITIONER & VENTILATION

/11 SERVICE AND REPAIR

6. Vacuum Pump Adapter

A vacuum pump can be used with HFC 134a
system by installing a vacuum pump adap-
ter.
The vacuum pump adapter has two con-
necting ports, one for HFC 134a system.
Each of these ports is connected to respec-
tive manifold gauge of HFC 134a.
The vacuum pump adapter contains an
internal magnetic valve.
A : How to use
1. Connect the center charging hose
(green) to the proper connection port.
2. Using the plug cap, plug the other
connection port
3. Evacuate the system and close the
manifold gauge.
4. Turn off the vacuum pump.
B : Magnetic Valve Operation

Symbol Description
A HFC 134a Connection port
(M10 x P1.5)
B Plug cap
DOIIC055R01112 C Magnetic valve
D Vacuum pump
The vacuum pump adapter is used to
prevent the vacuum pump oil from
flowing back into HFC 134a system.

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HEATER, AIR CONDITIONER & VENTILATION 55

SERVICE AND REPAIR /12

Without this adapter, after completing

the evacuation of the system, oil will
flow back into the manifold gauge
hose by a vacuum force in this hose
when stopping the vacuum pump.
1. When the switch of the vacuum pump
is turned on, the magnetic valve of the
adapter closes, starting the evacuation
of the system.
2. When the evacuation is completed and
the switch of the vacuum pump is
turned off, the magnetic valve opens,
thus allowing the introduction of air
into the center charging hose (green).
NOTE
Be sure to close the manifold gauge
valves immediately after evacuating
the system.
Then you may switch off the vacuum
pump.

Symbol Description
A Open
B Close
C Atomospheric pressure

DOIIC055R01113
PRECAUTION FOR SERVICE
1. When handling the refrigerant (HFC 134a),
the following precaution must be observed.
. Do not handle the refrigerant in an
enclosed area or near an open flame.
. Always wear eye protection.
. Be careful that liquid refrigerant does not
get in your eyes or on your skin.
. If the liquid refrigerant gets in your eyes or
on your skin;
– Do not rub
– Wash the area with a lot of cool water
– Apply clean petroleum jelly to the skin
– Go immediately to a physician or hospital
for professional treatment.
– Do not attempt to treat yourself.

2. When replacing parts on refrigerant line;

Symbol Description
A Recovery machine
3. Recover refrigerant before replacement of
dry parts by a recovery machine.

DOIIC055R01114

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/13 SERVICE AND REPAIR

Symbol Description
A Moisture
B Air
C Dust
D Plug
4. Insert a plug immediately in disconnected
parts to prevent entry of moisture and dust.
5. Do not leave a new condenser or receiver,
etc, lying around with the plug removed.
6. Do not use a burner for bending or
lengthening operations on tubes.
DOIIC055R01115
7. If 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.

8. Symbol Description
E Compressor oil
9. When tightening connecting parts;
. Apply a few drops of compressor oil to O-
ring fitting for easy tightening and to
prevent leaking of refrigerant gas.

DOIIC055R01116

. Symbol Description
F Over torquing
G Loosening

. Tightening the nut using two wrenches to

avoid twisting the tube.
CAUTION
Always use SP-10 for SD7415 compressor in
HFC R134a refrigerant cycle.
. Tighten the O-ring fittings or the bottled
DOIIC055R01117
type fittings to the specified torque.
10. When handling refrigerant cylinder ;
. The refrigerant cylinder must never be
heated directly.
. The refrigerant cylinder must be kept below
40 8C (104 8F)
. If warming the refrigerant cylinder with hot
water, be careful that the valve on the top
of the refrigerant cylinder is never
immersed in the water, as the water may
enter into the refrigerant cycle.
. Empty refrigerant cylinders must never be
re-used.

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SERVICE AND REPAIR /14

11. When A/C is on and the refrigerant gas is

being replenished;
. If there is not enough refrigerant gas in the
refrigerant cycle, oil lubrication becomes
insufficient and compressor burnout may
occur, so take care to avoid this.
. If the valve on the high pressure side is
opened with the engine running, the
refrigerant flows in reverse and causes the
refrigerant cylinder to rupture, so only
open and close the valve on the low
pressure side.
. If the refrigerant cylinder is inverted and
refrigerant is changed in a liquid state, the
liquid is compressed and the compressor
breaks down, so the refrigerant must be
changed in a gaseous state.
. Be careful not to change too much refrig-
erant gas, as this causes troubles such as
inadequate cooling, poor fuel economy,
engine overheating, etc.

ON-VEHICLE INSPECTION
1. Check condenser fans for blockage or
damage.
If the fins are clogged, wash them with
water.
CAUTION
Be careful not to damage the fins.

DOIHC055R04009

2. Make sure that fead belt is installed

correctly.
Check that the fead belt fits properly in the
ribbed grooves.

Symbol Description
A Correct
B Incorrect
C Incorrect

DOIIC055R01119
3. Start engine
4. Turn on A/C switch
Check that A/C operates at each position of
the blower switch.
If the blower does not operate, check the
circuit breaker.
5. Check magnetic clutch operation.
If the magnetic clutch does not engage,
check the A/C fuse.
6. Check that idle increases.

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/15 EVACUATING AND CHARGING

When the magnetic clutch engages, engine

speed should increase.
Standard idle-up RPM : 1200.
7. Check that condenser fan motor rotates
8. If there is no cooling or it is insufficient,
inspect for leakage.
If the piping connections are soiled with oil,
it indicates leakage of refrigerant. Inspect
by the gas leak detector and retighten any
loose connectors.
IMPORTANT
Retightening of pipe connecting must be
done using two wrenches to avoid twisting
of the tubing .
9. Check the amount of refrigerant.
. Operate the air conditioner under the
conditions table shown :-
NOTE
When the ambient temperature is more
than 40 8C (104 8F) and the pressure on the
high pressure gauge becomes
19 kg/cm2 (270.294 psi; 1.9 MPa) or more
with the conditions table shown, run the
engine at the idling speed to cool down the
condenser.
If the high pressure gauge of manifold
gauge still indicates too high, perform this
test in a cool place, open all car doors and
set the blower speed to LO.

Item Condition
Doors Completely open
Temperature setting Maximum cooling
Mode Face
Blower speed HI
Recirculation / Fresh air change Recirculation air
Engine speed HFC 134a ) 1500 rpm
A/C ON

EVACUATING AND CHARGING

WCH055SPROC092

TROUBLESHOOTING PROCEDURE
For Evacuating and Charging troubleshooting
procedure, please refer to Supplier’s HVAC
System Manual PUB NO.: RDAE – 08MA100.

CAUTION FOR HANDLING THE

REFRIGERANT
1. When handling refrigerant, the following
precautions must be observed.
1.1 Always wear eye protection while
handling refrigerant.

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EVACUATING AND CHARGING /16

1.2 The refrigerant cylinder must never

be heated. Store the refrigerant
cylinder below 40 8C (104 8F).
1.3 Do not handle refrigerant in an
enclosed area where it is exposed to
an open flame.
1.4 Care must be taken to protect eyes
and skin form refrigerant.
2. If refrigerant strikes eyes or skin
2.1 Do not rub the affected areas.
2.2 Splash large quantities of cool water
on the eyes or skin.
2.3 Do not attempt to treat the patient
by yourself, rush the patient to a
doctor or hospital for immediate
professional treatment.

AIR-COND SERVICE TOOL

1. Installation of Manifold Gauge
1.1 Close both the high and low hand
valves.
1.2 Connect the low pressure hose to the
low pressure charging valve and the
high pressure hose to the high pres-
sure charging valve. Tighten the hose
nuts by hand.
IMPORTANT
Do not apply compressor oil to the
seats of the connections.
DOIMC055R07006

Symbol Description
A Close
B High pressure charging valve
C Low pressure charging valve

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55 HEATER, AIR CONDITIONER & VENTILATION

/17 EVACUATING AND CHARGING

2. Evacuate Air in Refrigerant System

Symbol Description
A Open
B Air
2.1 Connect the center hose of the gauge
set to the vacuum pump inlet.
2.2 Open both the high and low hand
valves and run the vacuum pump.
If opening the low pressure hand
valve pulls the high pressure gauge
into the vacuum range, there is no
blockage in the system.
2.3 After about 20 minutes or more,
check that the low pressure gauge
indicates more than
80.0 kPa (11.38 psi; 24.15 in.Hg) of
vacuum.
If the reading is not more than
80.0 kPa (11.38 psi; 24.15 in.Hg), close
both valves and stop the vacuum
pump. Check the system for leaks
and repair as necessary.
2.4 If no leak are found, continue evac-
uating the air in the system.
2.5 Continue evacuating the air in the
DOIGC055R03001
system until the low pressure gauge
indicates a vacuum of
99.98 kPa (14.223 psi; 30.181 in.Hg).
2.6 Close both the high and low hand
valves and stop vacuum pump, then
leave the system in this condition for
five minutes or longer and check that
there is no change in the gauge
indication.

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EVACUATING AND CHARGING /18

3. Installation Connector to Gas Cylinder

3.1 Make sure cylinder up right for gas
charging.
3.2 Open the valve at the top of the
cylinder.
3.3 Press on the schrader valve on the
side of the manifold gauge set and
expel the air from inside the center
hose.
HINT:
Press on the schrader valve until
refrigerant comes out of it.

Symbol Description
A Close
B Open
C Press

DOIGC055R03002

4. Inspect Refrigeration System for Leaks.

NOTE
After evacuating the air in the system,
check the system for leakage.
4.1 Open the high pressure hand valve to
charge the system with refrigerant
vapor.
NOTE
WHEN THE REFRIGERANT CYLINDER
I S P L A C E D R I G H T S I D E U P,
REFRIGERANT WILL ENTER THE
SYSTEM AS A VAPOR.
4.2 When the low pressure gauge indi-
cates 1 kg/cm2 (14.226 psi; 0.1 MPa),
close the high pressure hand valve.
4.3 Using a gas leak detector, check the
system for leakage.
4.4 If a leak is found, repair the faulty
component or connection.

Symbol Description
A Close
B Open
C Close (LO gauge
1 kg/cm2 (14.226 psi; 0.1
DOIGC055R03003
MPa))

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55 HEATER, AIR CONDITIONER & VENTILATION

/19 EVACUATING AND CHARGING

5. Charge empty Refrigerant System with

Refrigerant (Liquid)
HINT:
This step is used to change an empty
system through the high pressure side with
refrigerant in a liquid state. When the
refrigerant cylinder is held upside down,
refrigerant will enter the system as a liquid.

Symbol Description
A Close
B Open
D Fully open

IMPORTANT
. Never run the engine when charging
the system through the high pressure
side.
. Do not open the low pressure hand
valve when the system is being
charged with liquid refrigerant.
5.1 Open the high pressure hand valve
fully and keep the refrigerant cylin-
DOIGC055R03004 der upside down.

6. Charge Partially Charged System with

Refrigerant (Vapor)
NOTE
. This step is used to charge the refriger-
ant system through the low pressure
side with the refrigerant in vapor state.
When the refrigerant cylinder is placed
rightside up, refrigerant will enter the
system as a vapor.
6.1 Install at the refrigerant cylinder to
valve.
6.2 Open the low pressure valve. Adjust
the valve, so that the low pressure
gauge does not read over
4.2 kg/cm2 (59.749 psi; 0.42 MPa).
6.3 Run the engine at fast idle and
operate the air conditioner.

Symbol Description
D Open
E Close

DOIGC055R03005

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ON-VEHICLE SERVICE /20

IMPORTANT
Be sure to keep the refrigerant
cylinder in the upright position to
prevent the liquid refrigerant from
being introduced into the refrigerant
system through the suction side,
resulting in possible damage to the
compressor.
7. Remove Manifold Gauge Set
7.1 Close both the high and low hand
valves.
7.2 Close the valve at the refrigerant
cylinder.
7.3 Turn off the engine.
7.4 Quickly disconnect the three hoses
from the service valves of the system
and the container tap valve.
7.5 Put cap nuts on the service valve
fittings.

ON-VEHICLE SERVICE WCH055SPROC089

RECEIVER DRIER TEST

1. Operate the unit and check the piping
temperature by touching the receiver drier
outlet and inlet. If there is difference in the
temperatures, the receiver drier is
restricted. Replace the receiver drier.

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/21 ON-VEHICLE SERVICE

DUAL PRESSURE SWITCH CHECK

1. Remove the dual pressure switch connector
and connect the high/low pressure side (A)
terminals located on the harness side as
shown in the illustration.
2. Install a gauge manifold to the high
pressure side service valve of the refrigerant
line. (refer to Performance Test.)
3. When the high/low pressure sides of the
dual pressure switch are at operation
pressure (ON) and there is continuity
between the respective terminals, then the
condition is normal. If there is no continu-
ity, replace the switch.

DOIMC055R07007

Items Switch position

OFF(2) ! ON(1) ON(1) ! OFF(2)
Low-pressure side (B) 225 kPa (32.008 psi; 196 kPa (27.882 psi; 59.168 in.Hg)
67.923 in.Hg)
High-pressure side (C) 2550 kPa (362.763 psi; 3140 kPa (446.696 psi; 947.903 in.Hg)
769.794 in.Hg)

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HEATER, AIR CONDITIONER & VENTILATION 55

ON-VEHICLE SERVICE /22

PERFORMANCE TEST WCH055SPROC091

1. The vehicles to be tested should be in a

place that is not in direct sun light.
2. Close the high (C) and low (B) pressure valve
of the gauge manifold, (D).
3. Connect the charging hose ‘‘G’’ (blue) to the
low pressure valve and connect the char-
ging hose ‘‘V’’ (red) to the high pressure of
the gauge manifold.
4. Install the Quick joint ‘‘O’’ (for low pressure)
to the charging hose ‘‘G’’ (blue), and
connect the Quick joint ‘‘O’’ (for high
pressure) to the charging hose ‘‘V’’ (red).
5. Connect the quick joint (for low pressure)
to the low-pressure service valve (N) and
connect the quick joint (for high pressure)
to the high-pressure service valve (W).
NOTE
The high-pressure service valve (W) is on
pipe liquid B and the low-pressure service
valve (N) is on the suction hose.
CAUTION
To connect the quick joint, press section ‘‘A’’
firmly against the service valve until a click
is heard.
When connecting, run your hand along the
DOIIC055R9015 hose while pressing to ensure that there
are no bends in the hose.

6. Start the engine.

7. Set the controls to the A/C as follows:
A/C switch: A/C–ON position
Mode selection: Face position
Temperature control: Max. cooling position
Air selection: Recirculation position
Blower switch: HI (Fast) position
8. Adjust engine speed to 1500 rpm with A/C
clutch engaged.
9. Engine should be warmed up with doors
and windows closed.
10. Insert a digital thermometer (X) in the left
center A/C outlet and operate the engine
DOIMC055R07008 for 20 minutes.
Standard Value :-
SANDEN
Ambient at 30-35 8C (86-95 8F) ) Outlet
6-8 8C (42.8-46.4 8F)
11. Note the discharge air temperature.
NOTE
If the clutch cycles, take the reading before
the clutch disengages.

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/23 INSPECTION

INSPECTION WCH055TSHOT054

REFRIGERANT SYSTEM INSPECTION WITH MANIFOLD GAUGE SET

This is a method in which the trouble is located by using a manifold gauge set.
Read the manifold gauge pressure when the following conditions are established:
 Temperature at the air inlet with the switch set at RECIRC is 30-35 8C (86-95 8F).
 Engine running at 1500 rpm D 500 rpm.
 Blower fan speed control switch set at high speed.
 Temperature control switch set at Max. cool side
HINT: IT SHOULD BE NOTED THAT THE GAUGE INDICATIONS MAY VERY SLIGHTLY DUE TO AMBIENT
TEMPERATURE CONDITIONS.
NOTE:
(1) Always recover refrigerant before removing the parts in the refrigerant line and evacuating air.
(2) Evacuate air and charge proper amount of purified refrigerant after installing the parts in the
refrigerant line.

No Gauge Reading (MPa) Condition Probable cause Remedy

LO: 0.20 B 0.05 Mpa Normal cooling Normally func- —
HI : 1.62 B 0.20 Mpa (the ready can tioning system
be achieved
after 10
min).Measure
temperature at
center
Aircond=Sanden
6-8 8C (42.8-46.4
8F)
1

DOIIC055R01062

During operation, pressure at low Periodically cools Moisture in  Replace recei-

pressure side sometimes becomes a and then fails to refrigeration sys- ver
vacuum and sometimes normal. cool tem  Remove moist-
2 ure in system
through repeat-
edly evacuating
air

DOIIC055R01063

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HEATER, AIR CONDITIONER & VENTILATION 55

INSPECTION /24

No Gauge Reading (MPa) Condition Probable cause Remedy

3 Pressure low at both low and high  Insufficient Insufficient  Check for gas
pressure sides cooling refrigerant leakage with gas
leak tester and
repair if neces-
sary

DOIIC055R01064

 Insufficient Refrigerant flow  Replace recei-

cooling obstructed by ver
 Frost on tubes dirt in receiver
from receiver to
unit
4 Pressure too high at both low and Insufficient cool- Insufficient cool-  Clean conden-
high pressure sides ing ing of condenser ser
 Check fan
motor operation
Refrigerant over-  Check amount
charged of refrigerant
 Recover refrig-
erant
 Evacuate air
and charge
proper amount
of purified
refrigerant

DOIIC055R01065

Air present in  Replace recei-

system ver
 Check compres-
sor oil to see if
dirty
 Remove air in
system through
repeatedly evac-
uating air

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/25 ON-VEHICLE SERVICE

No Gauge Reading (MPa) Condition Probable cause Remedy

5  Insufficient Expansion valve  Check heat
cooling improperly sensing tube
 Frost or large mounted, heat installation con-
amount of dew sensing tube dition If No. (1) is
on piping at low defective (Open normal
pressure side to wide)  Check expan-
sion valve and
replace if defec-
tive

DOIIC055R01065

6 Vacuum indicated at low pressure  Does not cool Refrigerant does  Check heat
side, very low pressure indicated at (Cools from time not circulate sensing tube for
high pressure to time in some gas leakage and
cases) replace expan-
 Frost or dew sion valve if
seen on piping defective, If No.
before and after (1) is normal
receiver or  Clean out dirt
expansion valve in expansion
valve by blowing
with air if not
able to remove
dirt, replace
expansion valve
DOIIC055R01066  Replace recei-
ver
7 Pressure too high at low pressure Does not cool Insufficient com-  Repair or
side, pressure too low at high pres- pression replace compres-
sure side. sor

DOIIC055R01067

ON-VEHICLE SERVICE WCH055SPROC093

REFILLING OF OIL IN THE A/C SYSTEM

Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too
much oil will increase discharge air temperature.
When a compressor is installed at the factory, it contains 135 cm3 (8.237 cu.in) of refrigerant oil. While
the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of
this oil will be trapped and retained in various parts of the system.

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HEATER, AIR CONDITIONER & VENTILATION 55

ON-VEHICLE SERVICE /26

When the following system components are changed, it is necessary to add oil to replace the oil
being removed with the component.

Compressor oil: Sanden SP10

Standard value: 135 cm3 (8.237 cu.in)

Items Quantity
Condenser 30 cm3 (1.83 cu.in)
Evaporator 30 cm3 (1.83 cu.in)
Suction hose / Discharge hose / Piping 30 cm3 (1.83 cu.in)
Receiver 30 cm3 (1.83 cu.in)

REFRIGERANT LEAK REPAIR WCH055SPROC094

LOST CHARGE
If the system has lost all charge due to a leak:
1. Evacuate the system (refer to Supplier HVAC System Manual RDAE-08MA100).
2. Charge the system with approximately 200 cm3 (12.204 cu.in) of refrigerant.
3. Check for leaks.
4. Discharge the system.
5. Repair leaks.
6. Replace receiver drier.
CAUTION
Replacement filter-drier units must be sealed while in storage. The drier used in these units will
saturate water quickly upon exposure to the atmosphere. When installing a drier, have all tools
and supplies ready for quick reassembly to avoid keeping the system open any longer than
necessary.
7. Evacuate and charge system (refer to Supplier HVAC System Manual RDAE-08MA100).
LOW CHARGE
If the system has not lost all of its refrigerant charge, locate and repair all leaks. If it is necessary to
increase the system pressure to find the leak (because of an especially low charge) add refrigerant. If
it is possible to repair the leak without discharging the refrigerant system, use the procedure for
correcting low refrigerant level.
HANDLING TUBING AND FITTINGS
Kinks in the refrigerant tubing or sharp bends in the refrigerant hose lines will greatly reduce the
capacity of the entire system. High pressures are produced in the system when it is operating.
Extreme care must be exercised to make sure that all connections are pressure tight. Dirt and
moisture can enter the system when it is opened for repair or replacement of lines or components.
The following precautions must be observed. The system must be completely discharged before
opening any fitting of connection in the refrigerant system. Open fittings with caution even after the
system has been discharged. If any pressure is noticed as a fitting is loosened, allow trapped pressure
to bleed off very slowly.
Never attempt to rebend formed lines to fit. Use the correct line for the installation you are servicing.
A good rule for the flexible hose lines is keep the radius of all bends at least 10 times the diameter of
the hose.
Sharper bends will reduce the flow of refrigerant. The flexible hose lines should be routed so that
they are at least 80 mm (3.149 in) from the exhaust manifold. It is good practice to inspect all flexible
hose lines at least once a year to make sure they are in good condition and properly routed.
Unified plumbing connections with O-rings, these O-rings are not reusable.

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COMPRESSOR NOISE WCH055SPROC095

You must first know the conditions when the noise occurs. These conditions are: weather, vehicle
speed, in gear or neutral, engine temperature or any other special conditions.
Noises that develop during A/C operation can often be misleading. For example: what sounds like a
failed front bearing or connecting rod, may be caused by loose bolts, nuts, mounting brackets, or a
loose clutch assembly. Verify accessory fead belt tension (power steering or alternator).
Improper accessory fead belt tension can cause a misleading noise when the compressor is engaged
and little or no noise when compressor is disengaged.
Speed belts are speed-sensitive. That is, at different engine speeds, and depending upon belt tension,
belt can develop unusual noises that are often mistaken for mechanical problems within the
compressor.
ADJUSTMENT
1. Select a quiet area for testing. Duplicate conditions as much as possible. Switch compressor on
and off several times to clearly identify compressor noise. To duplicate high ambient conditions
(high head pressure), restrict air flow through condenser. Install manifold gauge set to make sure
discharge pressure doesn’t exceed 2070 kPa (294.478 psi; 624.891 in.Hg).
2. Tighten all compressor mounting bolts, clutch mounting bolt, and compressor fead belt. Check to
assure clutch coil is tight (no rotation or wobble).
3. Check refrigerant hoses for rubbing or interference that can cause unusual noises.
4. Check refrigerant charge. (See Charging System )
5. Recheck compressor noise as in Step 1.
6. If noise still exists, loosen compressor mounting bolts and retorque. Repeat Step 1.
7. If noise continues, replace compressor and repeat Step 1.

POWER RELAY CHECK

BLOWER RELAY

Symbol Description
A Blower relay

DOIMC055R07003

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ON-VEHICLE SERVICE /28

A/C COMPRESSOR RELAY, CONDENSER FAN

RELAY

Symbol Description
B A/C compressor relay

REMOVAL SERVICE POINT

AIR-COND CONTROL ASSEMBLY REMOVAL
1. Remove the Air-Cond control assembly
mounting screws.
2. Disconnect the Air-Cond control harness
connector.
3. Remove the Air-Cond control assembly.

DOIMC055R07004

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/29 AIR-COND CONTROL ASSEMBLY

AIR-COND CONTROL ASSEMBLY WCH055SASSY083

DISASSEMBLY AND REASSEMBLY

DOIMC055R07009

Removal steps
1. Control Assembly,Ventilator
2. Cable aircond

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AIR-COND CONTROL ASSEMBLY /30

REMOVAL SERVICE POINT WCH055SPROC096

AIR-COND CONTROL ASSEMBLY REMOVAL

1. Remove 4 piece screw air-cond control assy.

Symbol Description
A Air-cond control assembly

DOIMC055R07010

2. Disconnect the Air-cond control harness

connector.

Symbol Description
A Connector

DOIMC055R07027

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/31 COOLER UNIT

COOLER UNIT WCH055SASSY084

REMOVAL AND INSTALLATION

DOIMC055R07011

Pre-removal and Installation

 Instrument panel refer to GROUP 52A – Instrument Panel Assembly.
 Disconnect battery
 Detach Suction pipe connection
 Detach pipe liquid. B connection
CAUTION: SRS
When removing and installing the floor console assembly from vehicles equipped with SRS, do not
let it bump against the SRS-ECU or the components.

Cooler unit removal steps

1. Cooler unit

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ON-VEHICLE SERVICE /32

ON-VEHICLE SERVICE WCH055SPROC102

REMOVAL SERVICE POINT

FILTER CASE ASM
1. Remove the glove board
2. Remove cap filter and remove filter case
ASM.

Symbol Description
A Filter case ASM
DOIMC055R07029

Printed in Malaysia 13 January 2008 Eng

 Black plate (38,1)

55 HEATER, AIR CONDITIONER & VENTILATION

/33 COOLER UNIT ASSY REMOVAL AND INSTALLATION

COOLER UNIT ASSY REMOVAL AND INSTALLATION WCH055SASSY089

DOIMC055R07032

Cooler unit assy removal steps

1. Duct ,Air Asm 10. Resistor ASM
2. Case intake assy 11. PAF Sub ASM
3. Thermo Amplifier 12. Hose Drain
4. Filter Case ASM 13. Motor ,Blower ASM
5. Cap ,filter 14. Packing,TXV cover
6. Thermister 15. Packing,TXV Seal B
7. Holder, thermister 16. Expansion Valve
8. Case upper assy 17. Pipe joint TXV ASM
9. Case Lower assy 18. Packing,PAF flange

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

COOLER UNIT ASSY REMOVAL AND INSTALLATION /34

RESISTOR DISASSEMBLY AND REASSEMBLY

DOIMC055R07012

Case lower – Support PAF - Insulator case – Resistor removal steps

1. Case lower
2. Support, PAFF
3. Insulator,case
4. Resistor

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/35 COOLER UNIT ASSY REMOVAL AND INSTALLATION

THERMISTOR DISASSEMBLY AND REASSEMBLY

DOIMC055R07013

PAF Full ASM-Thermistor-Packing removal steps

1. Packing
2. PAF, full
3. Pipe, joint
4. Thermistor
5. Expansion valve
6. Case lower

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

COOLER UNIT ASSY REMOVAL AND INSTALLATION /36

CASE UPPER-CASE LOWER DISASSEMBLY AND REASSEMBLY

DOIMC055R07014

Case Upper-Case Lower removal steps

1. Case upper
2. Case lower

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/37 COOLER UNIT ASSY REMOVAL AND INSTALLATION

THERMISTOR – AMPLIFIER DISASSEMBLY AND REASSEMBLY

DOIMC055R07015

PAF Full ASM-Thermistor-Packing removal steps

1. Case upper
2. Thermistor
3. Amplifier
4. Packing .Vent outlet
5. Packing .TXV cover

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

COOLER UNIT ASSY REMOVAL AND INSTALLATION /38

BLOWER MOTOR DISASSEMBLY AND REASSEMBLY

DOIMC055R07016

Blower Motor Drain removal steps

1. Case lower
2. Motor, blower ASM
3. Hose cooling
4. Hose , drain

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/39 COOLER UNIT ASSY REMOVAL AND INSTALLATION

CASE INTAKE ASM DISASSEMBLY AND REASSEMBLY

DOIMC055R07017

Case Intake ASM removal steps

1. Case intake
2. Door intake ASM
3. Lever main intake
4. Lever intake A
5. Lever sub intake
6. Rod intake lever joint
7. Wire clamp
8. Filter case ASM
9. Cap filter

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

COOLER UNIT ASSY REMOVAL AND INSTALLATION /40
NOTE

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/41 COMPRESSOR

COMPRESSOR WCH055SASSY085

REMOVAL AND INSTALLATION

DOIHC055R04012 @98%

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

COMPRESSOR /42

Pre-Removal Operation
 Discharging of Refrigerant (Refer to page 55/26.)
Post-Installation Operation
 Fead Belt Tension Adjustment (Refer to page 55/8.)
 Charging of Refrigerant (Refer to page 55/15.)

Compressor oil: SANDEN SP10.

PC — Piping connection
Non-reusable part
Removal steps
1. Drive tensioner assy
2. Fead belt
3. Suction hose connection
4. Discharge hose connection
5. O-ring
6. Compressor
T1 :2.2-2.6 kgm (22-26 Nm; 1.476-1.744 ft.lbs)
T2 :4.8-5.2 kgm (48-52 Nm; 3.221-3.489 ft.lbs)
T3 :2.2-2.6 kgm (22-26 Nm; 1.476-1.744 ft.lbs)
T4 :4.2-4.4 kgm (42-44 Nm; 2.818-2.952 ft.lbs)

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/43 COMPRESSOR

REMOVAL SERVICE POINTS WCH055SPROC098

FEAD BELT REMOVAL

1. Insert ratchet (A) into sqare hole on ten-
sioner arm.

DOIGC11AR03025

2. Push the ratchet (A) toward engine intake

side and pull out the fead belt from the
alternator.
SUCTION HOSE, DISCHARGE HOSE
DISCONNECTION
Plug the disconnected hose and the compressor
nipple not to let foreign materials get into
them.
CAUTION
Seal the hoses completely, otherwise the
compressor oil and receiver will absorb water
DOIGC11AR03026
vapour easily.

COMPRESSOR REMOVAL
When doing this work, be careful not to spill
the compressor oil.
INSTALLATION SERVICE POINT
COMPRESSOR INSTALLATION
If a new compressor is installed, first adjust the
amount of oil according to the procedures
described below, and then install the compres-
sor.
1. Measure the amount (X cm3) of oil within
the removed compressor.
2. Drain (from the new compressor) the
amount of oil calculated according to the
following formula, and then install the new
compressor. New compressor oil amount
135 cm3 (8.237 cu.in) – X cm3 = Y cm3.
NOTE
(1) Y cm3indicates the amount of oil in the
refrigerant line, the condenser, the
evaporator etc.
(2) When replacing the following parts at
the same times as the compressor,
subtract the rated oil amount of the
each part from Y cm3 and discharge
from the new compressor.
Quantity : <SANDEN>

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

COMPRESSOR /44

Items Quantity
Evaporator 30 cm3 (1.83 cu.in)
Condenser 30 cm3 (1.83 cu.in)
Suction 30 cm3 (1.83 cu.in)
hose
30 cm3 (1.83 cu.in)
Receiver
12.5-13.5 V

INSPECTION
COMPRESSOR MAGNETIC CLUTCH OPERATION
INSPECTION
Connect the battery (+) terminal to the com-
pressor side terminal (C), and earth the battery
(-) terminal to the body of the compressor. The
condition is normal if the sound of the mag-
netic clutch (click) can be heard.

DOIGC055R03007

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/45 REFRIGERANT LINE

REFRIGERANT LINE WCH055SASSY086

REMOVAL AND INSTALLATION

DOIMC055R07030

Pre-removal and Post-installation Operation

. Discharging and charging of Refrigerant (Refer to page 55/15).
. Front Bumper removal and installation (Refer to GROUP 51 EXTERIOR).

Compressor oil: SANDEN SP 10

PC — Piping connection
Non-reusable parts

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

REFRIGERANT LINE /46

Removal steps 9. Oil ring

1. Dual pressure switch 10. Pipe liquid B
2. Pipe liquid A 11. Oil ring
12. Clamp lamp
3. Oil ring
13. Compressor
4. Pipe suction
14. Receiver drier
5. Oil ring
15. Retainer assy
6. Hose suction
16. Bracket upper assy
7. Oil ring 17. Bracket lower assy
8. Hose discharge 18. Support bracket
19. Condenser assy
T1 :1.2-1.5 kgm (12-15 Nm; 0.805-1.006 ft.lbs)
T2 :3.0-3.5 kgm (30-35 Nm; 2.013-2.348 ft.lbs)
T3 :1.2-1.4 kgm (12-14 Nm; 0.805-0.939 ft.lbs)

REMOVAL SERVICE POINT WCH055SPROC099

HOSE SUCTION / PIPE LIQUID A / RECEIVER

DRIER ASSEMBLY DISCONNECTION
Plug the disconnected hose, the receiver, the
evaporator and the compressor nipple not to let
foreign materials get into them.
CAUTION
Seal the hoses completely, otherwise the
compressor oil and receiver will absorb water
vapour easily.

INSTALLATION SERVICE POINT

HOSE SUCTION / RECEIVER DRIER
ASSEMBLY INSTALLATION
When replacing the hose suction or receiver
assembly, refill them with a specified amount of
compressor oil, and then install them.
Compressor oil: SANDEN SP 10

Items Quantity
Suction hose 30 cm3 (1.83 cu.in)
Receiver assembly 30 cm3 (1.83 cu.in)

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/47 CONDENSER AND CONDENSER FAN MOTOR

CONDENSER AND CONDENSER FAN MOTOR WCH055SASSY087

REMOVAL AND INSTALLATION

DOIMC055R07031 @97%

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

CONDENSER AND CONDENSER FAN MOTOR /48

Pre-removal and installation

. Front bumper removal and installation (Refer to GROUP 51 EXTERIOR)
Condenser fan motor removal steps Condenser removal steps
1. Frame fan 6. Reserve tank
2. Fan motor 7. Upper insulator
3. Hose radiator lower 8. Radiator assy
4. Hose radiator upper 9. Condenser assy
5. Hose radiator condenser tank
T1 : 0.9-1.4 kgm (9-14 Nm; 0.603-0.939 ft.lbs)
T2 : 1.0-1.4 kgm (10-14 Nm; 0.671-0.939 ft.lbs)

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/49 CONDENSER AND CONDENSER FAN MOTOR

REMOVAL SERVICE POINT WCH055SPROC100

RADIATOR ASSY REMOVAL

Move the radiator to the engine side and then
lift up radiator assy to remove it.

Symbol Description
A Radiator assy

DOIMC055R07028

CONDENSER INSTALLATION
When replacing the condenser, refill it with a
specified amount of compressor oil and install it
(to the vehicle).
Compressor oil: SANDEN SP 10
Quantity: 30 cm3 (1.83 cu.in)

Symbol Description
B Condenser assy

DOIHC055R05003

INSPECTION
CONDENSER FAN AND MOTOR CHECK
Check to be sure that the condenser fan motor
operates when battery voltage is applied to
terminal 1 and terminal 2 earthed.

DOIKC055R03012

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR CONDITIONER & VENTILATION 55

VENTILATORS /50

VENTILATORS WCH055SASSY088

REMOVAL AND INSTALLATION

DOIMC055R07022

Defroster duct and distribution duct removal steps

Pre-removal and installation
. Instrument Panel removal and installation (Refer to GROUP 52A INTERIOR).
Removal steps
1. Instrument panel (Refer to GROUP 52A INTERIOR).
2. Side defroster hose assy RH
3. Side defroster hose assy LH
4. Defroster nozzle assy
5. Ventilation duct assy

Printed in Malaysia 13 January 2008 Eng

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55 HEATER, AIR CONDITIONER & VENTILATION

/51 VENTILATORS

DOIMC055R07026

Rear ventilation duct removal steps

 Rear bumper (Refer to GROUP 51 EXTERIOR).)
 Trim Outer Rear and Trim Rear End Removal (Refer to GROUP 52A INTERIOR)
1. Rear ventilation duct

Printed in Malaysia 13 January 2008 Eng

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HEATER, AIR-CONDITIONER AND VENTILATION CH12

INDEX /1

Printed in Malaysia 13 January 2008 Eng

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Content

Printed in Malaysia 13 January 2008 Eng

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SAGA Model YR 2008 English Edition RDWE-08MA010 January 2008 Printed in Malaysia