ect LEXUS SC300 1991 Service Service Manual

USE OF MANIFOLD GAUGE SET
INSTALLATION OF MANIFOLD GAUGE
SET
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.
1. CONNECT CHARGING HOSES WITH A STOP VALVE TO MANIFOLD GAUGE SET
Tighten the nuts by hand.
CAUTION:
wDo not connect the wrong hoses to the high
pressure and the low pressure sides.
w To prevent loosening the nuts, do not apply
compressor oil to seat of the connection.
2. CLOSE HAND VALVES OF BOTH STOP VALVES
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
4. REMOVE CAPS FROM SERVICE VALVES ON REFRIGERANT LINE
5. CONNECT STOP VALVES TO SERVICE VALVES Tighten the nuts by hand.
CAUTION:
wDo not connect the wrong hoses to the high
pressure and the low pressure sides.
w To prevent loosening the nuts, do not apply
compressor oil to seat of the connection.
6. OPEN HAND VALVES OF BOTH STOP VALVES
REMOVAL OF MANIFOLD GAUGE SET
1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET
2. CLOSE HAND VALVES OF BOTH STOP VALVES
3. DISCONNECT STOP VALVES FROM SERVICE VALVES ON REFRIGERANT LINE
4. INSTALL CAPS TO SERVICE VAL VES ON REFRIGERANT
LINE
±
AIR CONDITIONING SYSTEM Use of Manifold Gauge SetAC±15
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RECOVERING OF REFRIGERANT IN
REFRIGERANT SYSTEM
When discharging refrigerant from the system as follows, use
a recovery machine to recover the refrigerant.Before replacing parts on the refrigerant line.
When moisture or air gets in the refrigerant line.
When excess refrigerant is charged.
NOTICE:
w When handling the recovery machine, always follow
the directions given in instruction manual.
w After recovery, the amount of compr essor oil
removed must be measured and same am ount
added into the system.
1. INSTALL MANIFOLD GAUGE SET TO SERVICE VALVES See page AC±15
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 VA LV E S
See page AC±15
AC±16
±
AIR CONDITIONING SYSTEM Recovering of Refrigerant in Refrigerant System
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EVACUATING AIR IN
REFRIGERATION SYSTEM AND
CHARGING WITH REFRIGERANT
HINT: Before charging the system with refrigerant, be sure
carry out a complete evacuation of the system.
1. INSTALL MANIFOLD GAUGE SET TO SERVICE VALVES See page AC±15
2. EVACUATE AIR IN REFRIGERATION SYSTEM (a) Connect the center hose of the manifold gauge set to the vacuum pump.
(b) Open both the high and low hand valves and run the vacuum pump.
HINT: If opening the low pressure hand valve pulls the high
pressure gauge into the vacuum range, there is no blokage
in the system.
(c) After ten minutes or more, check that the low pressure gauge indicates 99.99 kPa (750 mmHg, 29.53 in.Hg) or
more of vacuum.
HINT: If the reading is not 99.99 kPa (750 mmHg, 29.53
in.Hg) or more of vacuum, close both the high and low hand
valves of the manifold gauge set and stop vaccum pump.
Then, check the system for leaks and repair as necessary.
(d) Close both the high and low hand valves and stop the
vacuum pump.
(e) Leave the system in this condition for five minutes or longer and check that there is no change in the gauge
indicator.
3. INSTALL CHARGING CYLINDER NOTICE: When handling the charging cylinder, always
follow the directions given in the instruction manual.
(a) Charge the proper amount of refrigerant in charging cylinder.
(b) Connect the center hose to charging cylinder. NOTICE: Do not open both high and low hand valves of
manifold guage set.
(c) Press on the schrader valve on the side of manifold gauge and expel the air inside of the center hose.
±
AIR CONDITIONING SYSTEM Evacuation Air in Refrigeration
System and Charging with RefrigerantAC±17
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4. INSPECT REFRIGERATION SYSTEM FOR LEAKSHINT: After evacuating the air in system, check the system for
leakage.
(a) Open the high pressure hand valve to charge the system with refrigerant.
(b) When the low pressure g auge indicates 98 kPa (1
kgf/cm, 14 psi), close the high pressure hand valve.
(c) Using a gas leak tester, check the system for leakage. If leak is found, repair the faulty component or connection.
5. CHARGE EMPTY REFRIGERATION SYSTEM WITH REFRIGERANT (LIQUID)
HINT: This step is used to charge an empty system through
the high pressure side with refrigerant in a liquid state.
NOTICE:
wNever run the engine when charging the system
through the high pressure side with refrigerant in a
liquid stae.
w Do not open the low pressure hand valve when the
system is being charged with liquid refrigerant.
(a) Open the high pressure hand valve fully.
(b) Charge the system with specified amount of refrigerant, then close the high pressure hand valve.
HINT:
w A fully charged system is indicated by the sight glass
being free of any bubbles.
w If the low pressure gauge does not show a reading, the
system is clogged and must be repaired.
AC±18
±
AIR CONDITIONING SYSTEM Evacuation Air in Refrigeration
System and Charging with Refrigerant
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HOW TO PROCEED WITH TROUBLESHOOTING
Perform troubleshooting in accordance with the procedure on the following page.\
[1] CUSTOMER PROBLEM ANALYSIS Using the customer problem analysis check sheet for reference, ask the c\
ustomer in as much detail as
possible about the problem. A subjective complaint such as ºpoor air conditio\
ner efficiencyº is also consid-
ered in the air conditioner complaints.
Therefore, in ºCustomer Problem Analysisº and ºProblem Symptom Confirmationº\
, check carefully to deter-
mine whether the level of performance is the actual (normal) level or whet\
her it is abnormal. Then perform
troubleshoot accordingly.
[2] CHECK AND CLEAR THE DIAGNOSTIC CODES (PRECHECK) First check the diagnostic codes to see if there are any malfunction cod\
es stored in memory. If there are
malfunction codes, make a note of them, then clear them and proceed to [3] problem \
Symptom Confirma-
tionº.
[3] PROBLEM SYMPTOM CONFIRMATION, [4] SYMPTOM SIMULATION Confirm the problem symptoms. If the problem does not reappear, be sure to simulate the problem by main-
ly checking the circuits indicated by the diagnostic code in step [2], u\
sing ºProblem Simulation Methodº.
[5] DIAGNOSTIC CODE CHECK
Check the diagnostic codes. Check for problems with the sensors or the w\
ire harness.
[6] DIAGNOSTIC CODE CHART If a malfunction code is confirmed in the diagnostic code check, proceed t\
o the check procedure indicated
by the matrix chart for each diagnostic code.
[7] MATRIX CHART OF PROBLEM SYMPTOMS
If the normal code is confirmed in the diagnostic code check, perform in\
spection in accordance with the
inspection order in the matrix chart of problem symptoms.
[8] CIRCUIT INSPECTION Proceed with diagnosis of each circuit in accordance with the inspection order c\
ofirmed in [6] and [7]. Deter-
mine whether the cause of the problem is in the sensor, actuators, wire harness and connectors, or the
ECU.
[9] ACTUATOR CHECK Check actuators for proper operation. Instructions for this diagnosis ar\
e given in the flow chart for each
circuit.
[10] REPAIRS After the cause of the problem is located, perform repairs by following the i\
nspection and replacement pro-
cedures in this manual.
[11] CONFIRMATION TEST
After completing repairs, confirm not only that the malfunction is elimi\
nated, but also perform diagnostic
code check and actuator check, etc. again to make sure the entire air condit\
ioning system is operating cor-
rectly.
AC±22
±
AIR CONDITIONING SYSTEM REPAIR INSTRUCTIONS
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DIAGNOSIS SYSTEM
Warning for A/C compressor lock
If compressor lock occurs during air conditioner operation, the
( A/C ) switch indicator on the air conditioner control assembly
starts blinking to warn the driver.
When this occurs, check for compressor lock (code 22) using diag-
nostic code check then proceed to inspect the circuit or the com-
ponent.
Compressor lock sensor circuit page AC±54.
LIST OF OPERATION METHODS
By operating each of the air conditioner control switches as shown in the \
diagram below, it is possible to enter
the diagnosis check mode. AC±26
±
AIR CONDITIONING SYSTEM Troubleshooting
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INDICATOR
1. Turn the ignition switch on while pressing the ari conditioner control
switch and REC swich
simultaneously.
2. Check that all the indicators light up and go off at 1 second intervals 4 times in succession.
3. Check that the buzzer sounds when the indicators light up in 2.
HINT:
wAfter the indicator check is ended, the diagnostic code
check begins automatically.
w Press the OFF switch when desiring to cancel the check
mode.
DIAGNOSTIC CODE CHECK (SENSOR
CHECK)
1. Perform an indicator check. After the indicator check is completed, the system enters the diagnostic code check
mode automatically.
2. Read the code displayed on the panel. Refer to the list of
codes on page AC±28 when reading the codes. (Codes are
output at the temperature display.)
If the slower display ped is desired, press the FRS
switch and change it to stepped operation. Each time the
FRS
switch is pressed, the display changes by 1 step.
HINT:
w If the buzzer sounds when a code is being read, it means
the trouble indicated by that code continues to occur.
w If the buzzer does not sound when a code is being read,
it means the trouble indicated by that code occurred ear-
lier (such as poor connector contacts, etc.)
CLEARING DIAGNOSTIC CODES
1. Pull out the DOME fuse in Relay Block No. 2 for 10 sec. or
longer to clear the memory of diagnostic codes.
2. After reinserting the fuse, check that the normal code is output.
±
AIR CONDITIONING SYSTEM TroubleshootingAC±27
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DIAGNOSTIC CODE CHART
If a malfunction code is displayed during the diagnostic code check (sens\
or check), check the circuit listed for
that code in the table below (Proceed to the page given for that circuit.)\
Code No.Diag. Code Detecting Condition
00 Normal
11 *1 Open or short in room temperature sensor circuit.
12 Open or short in ambient temperature sensor circuit.
13 Open or short in evaporator temperature sensor circuit.
14*2 Open or short in water temperature sensor circuit.
21*3 Open in solar sensor circuit.
21*3
 Short in solar sensor circuit.
22*4
 All conditions below are detected for 3 secs. or more.
 (a) Engine rpm : 450 rpm or more.
 (b) Ratio between engine and compressor rpm deviates 20% or more in c\
omparison to normal
operation.
23
 Open in pressure sensor circuit.
 Abnormal refrigerant pressure below 206 kPa (2.1 kgf/cm, 30 psi)
over 2,650 kPa (27 kgf/cm, 385 ps\
i)
31 Short to ground or power source circuit in Air Mix Damper position sens\
or circuit.
32 Short to ground or power source circuit in Air Inlet Damper position se\
nsor circuit.
33 Short to ground or power source circuit in Air Outlet Damper position s\
ensor circuit.
41 Air mix damper position sensor value does not change even if ECU operat\
es air mix servomotor.
42 Air inlet damper position sensor value does not change even if ECU oper\
ates air inlet servomotor.
43 Air outlet damper position sensor value does not change even if ECU ope\
rates air outlet
servomotor.
HINT: *1 If the room temp. is approx. ±20 °C (±4 °F) or lower, code 11 may be output even though the system
is normal.
*2 If the ambient temperature is approx. ±50 °C (±58 °F) or lower, a malfunction code may be output
even though the system is normal.
*3 If the check is being performed in a dark place, diagnostic code 21 (so\
lar sensor circuit abnormal) could be displayed.
In this case, perform diagnostic code check again while shining a light,\
such as an inspection light,
on the solar sensor.
If code 21 is still displayed, there could be trouble in the solar senso\
r circuit
AC±28
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AIR CONDITIONING SYSTEM Troubleshooting
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Trouble AreaMemory*5See page
±±±
 Room temp. Sensor
 Harness or connector between room temp. sensor and A/C control assembly\
 A/C control assemblyO
(8.5 min. or more)AC±44
 Ambient temp. sensor
 Harness or connector between ambient temp. sensor and A/C control assem\
bly
 A/C control assemblyO
(8.5 min. or more)AC±46
 Evaporator temp. sensor
 Harness or connector between evaporator temp. sensor and A/C control
assembly A/C control assemblyO
(8.5 min. or more)AC±48
 Water temp. sensor
 Harness or connector between water temp. sensor and A/C control assembl\
y
 A/C control assemblyO
(8.5 min. or more)AC±50
 Solar sensor
H b d A/C l bl
±
AC 52 Solar sensor
 Harness or connector between sensor and A/C control assembly
 A/C control assemblyOAC±52
 A/C control assemblyO
(8.5 min. or more)
 Compressor drive belt Compressor lock sensor Compressor
 Harness and connector between A/C control assembly and compressor,
 compressor lock sensor
 A/C control assembly
±AC±54
 Pressure switch
 Harness or connector between pressure switch and A/C control assembly
 Refrigerant pipe line
 A/C control assembly
±AC±56
 Air mix damper position sensor A/C control assembly
 Harness or connector between air mix damper position sensor and
A/C control assemblyO
(1 min. or more)AC±58
 Air inlet damper position sensor A/C control assembly
 Harness or connector between air inlet damper position sensor and
A/C control assemblyO
(1 min. or more)AC±62
 Air outlet damper position sensor A/C control assembly
 Harness or connector between air outlet damper position sensor and
A/C control assemblyO
(1 min. or more)AC±66
 Air mix servomotor Air mix damper position sensor
 Harness and connector between A/C control assembly and air mix position\
sensor
 Harness and connector between A/C control assembly and air mix servomot\
or.O
(15 secs. or more)AC±58
AC±60
 Air inlet servomotor Air inlet damper position sensor
 Harness and connector between A/C control assembly and air inlet positi\
on sensor.
 Harness and connector between A/C control assembly and air inlet servom\
otor.O
(15 secs. or more)AC±62
AC±64
 Air outlet servomotor Air outlet damper position sensor
 Harness and connector between A/C control assembly and air outlet posit\
ion
sensor.
 Harness and connector between A/C control assembly and air outlet servo\
motor.
 A/C control assembly
O
(15 secs. or more)AC±66
AC±68
±
AIR CONDITIONING SYSTEM TroubleshootingAC±29
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AC±68AC±70AC±72AC±74AC±76AC±78AC±80AC±82AC±84AC±90AC±92AC±96AC±98AC±10
8IN±32AC±100AC±103AC±10
4AC±12
0AC±118AC±122AC±12
5AC±126
HINT:
wIf the instruction ºProceed to next circuit inspection shown on matrix \
chartº is given in the flow chart for each
circuit, proceed to the circuit with the next highest number in the table to con\
tinue the check.
w If the trouble still reappears even though there are no abnormalities in a\
ny of the other circuits, then check
or replace the air conditioner control assembly (contains the ECU).
±
AIR CONDITIONING SYSTEM TroubleshootingAC±37
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