heater LEXUS SC400 1991 Service Repair Manual

[2] HEAT METHOD: When the problem seems to occur when the suspect area is heated.
Heat the component that is the likely cause of the malfunc-
tion with a hair dryer or similar object. Check to see if the
malfunction occurs.
NOTICE:
(1) Do not heat to more than 60°C (140 °F).
(Temperature limit that no damage is done to the
component).
(2) Do not apply heat directly to parts in the ECU.
[3] WATER SPRINKLING METHOD: When the malfunction seems to occur on a
rainy\
day or in a high±humidity condition.
Sprinkle w ater onto the vehicle and check to see if the mal-
function occurs.
NOTICE:
(1) Never sprinkle water directly into the engine compartment, but indirectly change the tempera-
ture and humidity by applying water spray onto
the radiator front surface.
(2) Never apply water directly onto the electronic components.
(Service hint)
If a vehicle is subject to water leakage, the leaked water
may contaminate the ECU. When testing a vehicle with a
water leakage problem, special caution must be used.
[4] OTHER: When the malfunction seems to occur when electrical load is excessive.
Turn on all electrical loads including the heater blower,
head lights, rear window defogger, etc. and check to see
if the malfunction occurs.
±
INTRODUCTION TITLE±NAMEIN±21
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Check voltage between terminals TW and SG of air conditioner control
assembly connector.
(1) Remove console upper panel. (See page BO±111 )
(2) Remove A/C Control Assembly with connectors
still connected.
(3) Turn ignition switch ON.
Measure voltage between terminals TW and SG of air
conditioner control assembly connector at each tem-
perature.
Voltage
at 0°C (32°F) : 2.8~3.2 V
at 40°C (104°F) : 1.8~2.2 V
at 70°C (158°F) : 0.9~1.3 V
In addition, as the temperature increases, the
voltage decreases gradually.
Proceed to next circuit inspection shown on
matrix chart (See page AC-36).However,
when Diag. code 14 is displayed, check and
repair air conditioner control assembly.
Check water temperature sensor.
(1) Remove heater unit.
(2) Remove water temperature sensor.
Measure resistance between terminals 1 and 3 of
water temperature sensor connector at each temper-
ature.
Resistance
at 0°C (32°F) : 16.5~17.5 k

at 40°C (104°F) : 2.4~2.8 k

at 70°C (158°F) : 0.7~1.0 k

In addition, as the temperature increases, the
voltage decreases gradually.
Replace water temperature sensor.
Check for open and short in harness and connector between air conditioner
control assembly and water temperature sensor (See page IN-27).
Repair or replace harness or connector.
Check and replace air conditioner control
assembly.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM TroubleshootingAC±51
WhereEverybodyKnowsYourName

Check voltage between terminals TP and SG of air conditioner control
assembly connector.
(1) Remove console upper panel.(See page BO±111).
(2) Remove A/C control assembly with connec±
tors still connected.
(3) Turn ignition switch ON.
Change the set temperature to activate the air mix
damper, and measure the voltage between termi-
nals TP and SG of air conditioner control assem-
bly connector each time when the set temperature
is changed.
Set TemperatureVoltage
Max. cool
Max. hot 3.70± 4.27 V
0.88 ± 1.16 V
In addition, as the set temperature increases,
the voltage decreases gradually without inter-
ruption.
Proceed to next circuit inspection shown on
matrix chart (See page AC-36).However,
when Diag. code 31 or 41 is displayed, check and
replace air conditioner control assembly.
Check air mix damper position sensor.
(1) Remove heater unit. (See page AC-125)
(2) Disconnect air mix servomotor assembly
connector.
Measure resistance between terminals S5 and SG of
air mix servomotor assembly connector.
Resistance:4.7~7.2 k

While operating air mix servomotor as in the
procedure on page AC-61, measure resistance
between terminals TP and SG of air mix servo-
motor assembly connector.
Position Resistance
Max. cool
Max. warm 3.76 ~ 5.76 k


0.94 ~ 1.44 k

As the air mix servomotor moves from cool side
to warm side, the resistance decreases gradually
without interruption.
Replace air mix servomotor assembly.
Check for open and short in harness and connector between air conditioner
control assembly and air mix servomotor assembly (See page IN-27).
Repair or replace harness or connector.
Check and replace air conditioner control
assembly.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM TroubleshootingAC±59
WhereEverybodyKnowsYourName

Actuator check.
(1) Warm up the engine.
(2) Set to the actuator check mode (See pageAC-30 ).
(3) Press the FRS switch and change it to step operation.
Press the FRS switch and check the
operation of the air mix damper and the condition
of the blower.
Proceed to next circuit inspection shown on
matrix chart (See page AC-36).
Check air mix servomotor.
Remove heater unit.
Connect positive
lead to terminal 4 and negative
 lead to terminal 5.
The lever turns smoothly to cool side.
Connect negative  lead to terminal 4 and positive

lead to terminal 5.
The lever turns smoothly to hot side.
Replace air mix servomotor assembly.
Check for open and short in harness and connector between air conditioner
control assembly and air mix servomotor assembly (See page IN-27).
Repair or replace harness or connector.
Check and replace air conditioner control
assembly.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM TroubleshootingAC±61
WhereEverybodyKnowsYourName

Check voltage between terminals TP1 and SG of air conditioner control
assembly connector.
(1) Remove console upper panel.(See page BO-111).
(2) Remove A/C control assembly with connec±
tors still connected.
(3) Turn ignition switch ON.
Press REC/FRS switch to change the air inlet
between fresh and recirculation air, and measure
voltage between terminals TP1 and SG of air
conditioner control assembly when the air inlet
servomotor operates.
In addition, as the air inlet servomotor is moved
from REC side to FRS side, the voltage de-
creases gradually without interruption.
Proceed to next circuit inspection shown on matrix chart
(See page AC-36).However, when Diag. code 32 or 42 is
displayed, check and replace air conditioner control assem-
bly.
Check air inlet damper position sensor.
(1) Remove heater unit. (See page AC-127)
(2) Disconnect air inlet servomotor assembly
connector.
Measure resistance between terminals S5 and SG of
air inlet servomotor assembly connector.
Resistance: 4.7~7.2 k

While operating air inlet servomotor as in the
procedure on page AC-65, measure resistance
between terminals TP1 and SG of air inlet servo-
motor assembly connector.
Resistance:
As the air inlet servomotor moves from REC side
to FRS side, the resistance decreases gradually
without interruption.
Replace air inlet servomotor assembly.
Check for open and short in harness and connector between air conditioner
control assembly and air inlet servomotor assembly (See page IN-27).
Repair or replace harness or connector.
Check and replace air conditioner control assembly.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM REPAIR INSTRUCTIONSAC±63
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Check voltage between terminals TPM and SG of air conditioner control
assembly connector.
(1) Remove console upper panel.(See page BO-111 ).
(2) Remove A/C control assembly with
connectors still connected.
(3) Turn ignition switch ON.
In addition, as the air outlet servomotor is moved
from REC side to FRS side, the voltage decreases
gradually without interruption.
Proceed to next circuit inspection shown on matrix chart
(See page AC-36).However, when Diag. code 32 or 42 is dis-
played, check and replace air conditioner control assembly.
Check air outlet damper position sensor.
(1) Remove heater unit. (See page AC-127)
(2) Disconnect air outlet servomotor assembly
connector.
Measure resistance between terminals S5 and SG of
air outlet servomotor assembly connector.
Resistance: 4.7~7.2 k

While operating air outlet servomotor as in the
procedure on page AC-69, measure resistance
between terminals TP1 and SG of air outlet servo-
motor assembly connector.
Resistance:
As the air inlet servomotor moves from DEF side
to FACE side, the resistance decreases gradually
without interruption.
Replace air outlet servomotor assembly.
Check for open and short in harness and connector between air conditioner
control assembly and air outlet servomotor assembly (See page IN-27).
Repair or replace harness or connector.
Check and replace air conditioner control assembly.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM TroubleshootingAC±67
WhereEverybodyKnowsYourName

Actuator check.
(1) Set to the actuator check mode(See page AC-30).
(2) Press the FRS switch and change it to step operation.
Press FRS switch and check the
condition of the flow.
The mode changes with the change in the tem-
perature display as shown in the table.
Proceed to next circuit inspection shown on
matrix chart (See page AC-36).
Connect positive
lead to terminal 4 and negative
 lead to terminal 5.
The lever turns smoothly to FACE position.
Remove heater unit.(See page AC-125).
Connect negative  lead to terminal 4 and positive

lead to terminal 5.
The lever moves smoothly to DEF position.
Check air outlet servomotor.
Replace air outlet servomotor.
Check for open and short in harness and connector between air conditioner control
assembly and outlet servomotor, outlet servomotor and battery, outlet servomotor and
body ground.(See page IN-27).
Repair or replace harness or connector.
Check and replace air conditioner control
assembly.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM TroubleshootingAC±69
WhereEverybodyKnowsYourName

\
\


\

\
\
Heater Main Relay Circuit
CIRCUIT DESCRIPTION
The heater main relay is switched on by signals from the air conditioner co\
ntrol assembly.
It supplies power to the blower motor.
DIAGNOSTIC CHART
Check voltage between terminals HR of air
conditioner control assembly connector
and body ground.
Check heater main relay.
Check HTR fuse.
Check and repair harness and connector
between air conditioner control assembly
and battery.
Proceed to next circuit inspection
shown on matrix chart (See page
AC-36
).
Check for short in all the harness
and components connected to
the HTR fuse (See
attached wiring diagram).
Replace heater main relay.
WIRING DIAGRAM
AC±76±
AIR CONDITIONING SYSTEM Troubleshooting
WhereEverybodyKnowsYourName

Check voltage between terminals HR of air conditioner control assem-
bly connector and body ground.
(1) Remove console upper panel.(See page BO-111 ).
(2) Remove A/C control assembly with connec±
tors still connected.
Proceed to next circuit inspection shown on ma-
trix chart (See page AC-36).
Check heater main relay.
Check continuity between each pair of terminals of
heater main relay shown below.
Measure voltage between terminals HR of air condi-
tioner control assembly and body ground when
ignition switch is on and off.
(1) Apply battery voltage between terminals 1
and 3
(2) Check continuity between each pair of ter±minal shown below.
Replace heater main relay.
Remove HTR fuse from J/B No. 1.
Check continuity of HTR fuse
Continuity
Check for short in all the harness and
components connected to the HTR fuse
See attached wiring diagram).
Check and repair harness and connector between air conditioner control \
assembly and battery.
INSPECTION PROCEDURE
±
AIR CONDITIONING SYSTEM TroubleshootingAC±77
WhereEverybodyKnowsYourName

A/C UNIT
REMOVAL OF A/C UNIT
1. RECOVER REFRIGERANT IN SYSTEMSee page AC±16
2. REMOVE ENGINE See page EM±118
3. REMOVE WATER VALVE
See page AC±127
4. REMOVE BRAKE TUBES BRACKET MOUNTING BOLTS FROM DUSH PANEL
5. REMOVE EVAPORATOR See page AC±122
6. REMOVE WATER HOSE FROM HEATER RADIATOR
7. REMOVE INSULATOR RETAINER Remove the two bolts and the retainer.
8. REMOVE INSTRUMENT PANEL REINFORCEMENT See page BO±109
9. REMOVE FLOOR CARPET See page BO±118
10. REMOVE REAR AIR DUCTS Remove the nut and the air duct.
11. REMOVE HEATER TO RESISTER NO. 3 DUCT Remove the screw and the duct.
±
AIR CONDITIONING SYSTEM A/C UnitAC±107
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