Motor TOYOTA CAMRY 1999 Service Repair Manual

I01390
Condition: Insufficient cooling
I01392
Condition: Insufficient cooling
NOTE : These gauge indica-
tions are shown when the
refrigeration system has
been opened and the refrig-
erant charged without vacu-
um purging.
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±7
2489 Author: Date:
(6) Refrigerant overcharged or insufficient cooling of
condenser
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy

Pressure too high on both low
and high pressure sides

No air bubbles seen through the
sight glass even when the engine
rpm is lowered
Unable to develop sufficient per-
formance due to excessive refrig-
eration system

Insufficient cooling of condenser
Excessive refrigerant in
cycle " refrigerant over charged

Condenser cooling " condenser
fins clogged of condenser fan
faulty
(1) Clean condenser
(2) Check condenser fan motor
operation
(3) If (1) and (2) are in normal
state, check amount of refrigerant
Charge proper amount of refriger-
ant
(7) Air present in refrigeration system
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy

Pressure too high on both low
and high pressure sides

The low pressure piping hot to
touch

Bubbles seen in sight glass
Air entered in refrigeration system

Air present in refrigeration sys-
tem

Insufficient vacuum purging
(1) Check compressor oil to see if
it is dirty or insufficient
(2) Evacuate air and charge new
refrigerant

± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±9
2491 Author: Date:
3. INSPECT IDLE±UP SPEED
(a) Warm up engine.
(b) Inspect idle±up speed when the these conditions are es-
tablished.

Warm up engine

Blower speed control switch at ºHIº position

A/C switch ON

Temperature control dial at ºCOOLº position
Magnetic clutch conditionIdle±up speed
Magnetic clutch not engaged700 ± 50 rpm
Magnetic clutch engaged700 ± 50 rpm
If idle speed is not as specified, check ISC valve and air intake
system.
4. INSPECT FOR LEAKAGE OF REFRIGERANT
(a) Perform in these conditions:

Stop engine.

Secure good ventilation (If not the gas leak detector
may react to volatile gases witch are not refrigerant,
such as evaporated gasoline and exhaust gas.)

Repeat the test 2 or 3 times.

Make sure that there is some refrigerant remaining
in the refrigeration system.
When compressor is OFF: approx. 392 ± 588 kPa
(4 ± 6 kgf/ cm
2, 57 ± 85 psi)
(b) Bring the gas leak detector close to the drain hose before
performing the test.
HINT:

After the blower motor stopped, leave the cooling unit for
more than 15 minutes.

Expose the gas leak detector sensor the under the drain
hose.

When bring the gas leak detector close to the drain hose,
make sure that the gas leak detector does not react to the
volatile gases.
If such reaction is unavoidable, the vehicle must be lifted up.
(c) If gas leak is not detected on the drain hose, remove the
blower resistor from the cooling unit. Then insert the gas
leak detector sensor into the unit and perform the test.
(d) Disconnect the connector and leave the pressure switch
for approx. 20 minutes. Then bring the gas leak detector
close to the pressure switch and perform the test.
(e) Bring the gas leak detector close to the refrigerant lines
and perform the test.

AC0LL±02
Z19146
1MZ±FE engine:
No. 1 Engine Coolant Temperature
(ECT) Switch
Compressor
Engine Room Junction Block No. 2

Engine Main Relay
(Marking: ENGINE MAIN)

No. 1 Cooling Fan Relay
(Marking: FAN NO.1)Engine Room Relay Block No. 1

Magnetic Clutch Relay
(Marking: MG CLT)

Heater Main Relay
(Marking: HTR)

No. 2 Cooling Fan Relay
(Marking: FAN NO.2)

No. 3 Cooling Fan Relay
(Marking: FAN NO.3)
5S±FE engine models:
Engine Coolant Temperature
(ECT) Switch Receiver Pressure SwitchCondenser Fan

Fan Motor1MZ±FE engine:
No. 2 Engine Coolant Temperature
(ECT) Switch
Condenser
Blower Unit A/C Unit
A/C Control Assembly

A/C Switch

Blower Speed Control Switch

Mode Switch
Air Outlet Servomotor
Heater Radiator
Thermistor
Blower ResistorBlower Motor 1MZ±FE:
A/C Amplifier Expansion Valve5S±FE engine:
ECM (Built in A/C Amplifier)
Evaporator
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±13
2495 Author: Date:
LOCATION

AC21T±01
AC±14
± AIR CONDITIONINGTROUBLESHOOTING
2496 Author: Date:
TROUBLESHOOTING
PROBLEM SYMPTOMS TABLE
Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
SymptomSuspect AreaSee page
No blower operation
4. HTR Fuse
5. Heater main relay
6. Blower motor
7. Blower resistor
8. Blower speed control switch
9. Wire harness±
AC±70
AC±63
AC±64
AC±84
±
No air temperature control1. Engine coolant volume
2. A/C control assembly±
AC±80
No air inlet control1. A/C control assemblyAC±80
No air outlet control
1. HTR Fuse
2. Air outlet servomotor
3. Mode switch±
AC±65
AC±84
No compressor operation
1. Refrigerant volume
2. A.C Fuse
3. HTR Fuse
4. Magnetic clutch relay
5. Magnetic clutch
6. Compressor
7. Pressure switch
8. Heater main relay
9. Blower speed control switch
10.A/C switch
11. *1 ECM
*
2 A/C amplifier
12.Wire harness
AC±3
±
±
AC±71
AC±39
AC±39
AC±67
AC±70
AC±84
AC±84
DI±218
AC±88
±
No compressor operates intermittently
1. Refrigerant volume
2. Condenser fan
3. Pressure switch
4. *1 ECM
*2 A/C amplifier
5. Thermistor
6. Wire harnessAC±3
AC±74
AC±67
DI±218
AC±88
AC±24
±
No cool air comes out
1. Refrigerant volume
2. Refrigerant pressure
3. Drive belt
4. Compressor lock sensor
5. Magnetic clutch
6. Compressor
7. Pressure switch
8. Thermistor
9. A/C switch
10.*1 ECM
*2 A/C amplifier
11. Wire harnessAC±3
AC±3
AC±16
AC±16
AC±39
AC±39
AC±67
AC±24
AC±84
DI±218
AC±88
±

± AIR CONDITIONINGTROUBLESHOOTING
AC±15
2497 Author: Date:
Cool air comes out only at high engine rpm
1. Refrigerant volume
2. Drive belt
3. Magnetic clutch
4. Compressor
5. Condenser
6. Condenser fan
7. Receiver
8. Expansion valve
9. Evaporator
10.Thermistor
11. Refrigerant line
12.Pressure switch
13.*
1 ECM
*2 A/C amplifier
AC±3
AC±16
AC±16
AC±39
AC±52
AC±74
AC±49
AC±59
AC±30
AC±24
AC±21
AC±67
DI±218
AC±88
No engine idle±up when A/C switch ON
1. *1 ECM
*2 A/C amplifier
2. Wire harness
DI±218
AC±88
±
Blinking of A/C indicator
1. *1 ECM
*2 A/C amplifier
2. Thermistor
3. Compressor
DI±218
AC±88
AC±24
AC±39
A/C indicator does not lights up when turn mode switch to DEF.
position
1. A/C Fuse
2. Mode switch
3. A/C switch
4. *
1 ECM
*2 A/C amplifier
5. Wire harness
±
AC±84
AC±84
DI±218
AC±88
±
No warm air comes out
1. Engine coolant volume
2. A/C control assembly
3. Heater radiator±
AC±80
AC±57
No condenser fan operation
1. CDS FAN Fuse
2. Engine main relay
3. Cooling fan relay No. 1
4. Cooling fan relay No. 2
5. Cooling fan relay No. 3
6. Condenser fan motor
7. Pressure switch
8. *
1 Engine coolant temp. switch
*2 No. 1 Engine coolant temp. switch
9. *2No. 2 Engine coolant temp. switch
10.Wire harness
±
±
AC±72
AC±72
AC±72
AC±74
AC±67
AC±92
AC±92
AC±92
±
*1: 5S±FE Engine Models
*
2: 1MZ±FE Engine Models

AC21V±01
I07050
ReinforcementInstrument Panel
No. 1 Brace
No. 2 Brace
A/C Unit
Piping Clamp
Suction Tube
Liquid Tube
Piping Clamp

O±ring
O±ring
Air Duct (Rear Foot)
Air Duct (Foot)Blower Motor
Connector Bracket
Non±reusable partWater Hose
± AIR CONDITIONINGAIR CONDITIONING UNIT
AC±25
2507 Author: Date:
COMPONENTS

I07051
Heater Protector
Heater Radiator
Pipe

Packing

O±ring

O±ring
Heater Radiator
Plate
Heater CaseGrommet

Packing
x13
Air Outlet Servomotor
Water Seal
Air Duct (Foot)
Holder
Thermistor
5.4 (55, 48)
5.4 (55, 48)

O±ring

O±ring
Tube and Accessory
Expansion Valve
Drain Hose
Insulator
Plate
Evaporator
Heater Case
N´m (kgf´cm, in:lbf) : Specified torque

Non±reusable part
AC±26
± AIR CONDITIONINGAIR CONDITIONING UNIT
2508 Author: Date:

AC21X±01
N20287
N20283
N20243
x13Water Seal
Plate
EvaporatorInsurator
N20293
± AIR CONDITIONINGAIR CONDITIONING UNIT
AC±29
2511 Author: Date:
DISASSEMBLY
1. REMOVE AIR OUTLET SERVOMOTOR
(a) Release the claw and pull out the plate.
(b) Remove the 3 screws and servomotor.
2. REMOVE HEATER RADIATOR
(a) Remove the 3 screws and 3 plates.
(b) Remove the 2 clips and heater radiator pipes.
(c) Pull out the heater radiator.
3. REMOVE THESE FOOT AIR DUCT LH
4. REMOVE EXPANSION VALVE
(a) Remove piping clamp.
(b) Remove the packings.
(c) Using a hexagon wrench (5.0 mm, 0.20 in.), remove the
2 bolts and separate the expansion valve and evaporator.
5. REMOVE EVAPORATOR
(a) Remove the grommet from the evaporator.
(b) Using a knife, cut off each packings.
HINT:
Do not reuse the packing.
(c) Remove the 13 screws and separate the heater cases,
then remove the evaporator and water seal.
(d) Release the 4 claws and remove the plate from the evap-
orator.
6. PEEL OFF THE WATER SEAL FROM HEATER UNIT
7. REMOVE THERMISTOR
Pull out the thermistor with the holders.

N20283
N20245
Pin
Pin AC±32
± AIR CONDITIONINGAIR CONDITIONING UNIT
2514 Author: Date:
(e) Lubricate 2 new O±rings with compressor oil and install
the expansion valve.
(f) Install the expansion valve with the tubes to evaporator
with the 2 bolts.
Torque: 5.4 N´m (55 kgf´cm, 48 in.´lbf)
NOTICE:
When installing the expansion valve, take care so that the
packing is not jammed with the evaporator.
(g) Peel off the remaining packing paper and apply the pack-
ing to expansion valve.
4. INSTALL HEATER RADIATOR
(a) Install the heater radiator to heater case.
(b) Install the heater radiator pipe with 2 clips.
(c) Install the 3 clamps with the 3 screws.
5. INSTALL MODE SERVOMOTOR
(a) Install the servomotor with the 3 screws.
(b) Insert the drain of the plate to the pin and install plate.

AC0LZ±02
Z19018
Connector Bracket
Glove Compartment
ECM
Foot Air Duct
No.2 Lower CoverBlower UnitCowl Side Trim
Blower Motor Connector
Blower Motor Blower Unit Case Air Inlet Damper
Control Cable
1MZ±FE engine:
A/C Amplifier
Front Door
Inside Scuff
Plate
Blower Resistor
Connecter
Blower Resistor AC±34
± AIR CONDITIONINGBLOWER UNIT
2516 Author: Date:
BLOWER UNIT
COMPONENTS