lock TOYOTA CAMRY 1999 Service Repair Manual

I01387
Condition : Periodically cools and then fails to cool
I01388
Condition: Insufficient cooling
± AIR CONDITIONINGAIR CONDITIONING SYSTEM
AC±5
2487 Author: Date:
(2) Moisture present in refrigeration system.
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy
During operation, pressure on low
pressure side sometimes become
a vacuum and sometime normal
Moisture entered in refrigeration
system freezes at expansion valve
orifice and temporarily stops cycle,
but normal state is restored after a
time when the ice melts
Drier oversaturated state

Moisture in refrigeration system
freezes at expansion valve orifice
and blocks circulation of refriger-
ant(1) Replace receiver
(2) Remove moisture in cycle
through repeatedly evacuating air
(3) Charge proper amount of new
refrigerant
(3) Insufficient cooling
Symptom seen in
refrigeration systemProbable causeDiagnosisRemedy

Pressure low on both low and
high pressure sides

Bubbles seen in sight glass con-
tinuously

Insufficient cooling performance
Gas leakage at some place in re-
frigeration system
Insufficient refrigerant in system

Refrigerant leaking
(1) Check for gas leakage with gas
leak detector and repair if neces-
sary
(2) Charge proper amount of re-
frigerant
(3) If indicated pressure value is
near 0 when connected to gauge,
create the vacuum after inspecting
and repairing the location of the
leak

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
±

AC0LN±02
Z19189
Pivot Bolt
Adjusting Bolt
Drive Belt
Pivot Bolt
Drive Belt
Adjusting Lock
Bolt
Adjusting Bolt 5S±FE:
1MZ±FE:
Adjusting Lock
Bolt
± AIR CONDITIONINGDRIVE BELT
AC±17
2499 Author: Date:
REMOVAL
REMOVE DRIVE BELT
(a) Loosen the pivot bolt and adjusting lock bolt.
Torque:
5S±FE:
Pivot bolt: 52 N´m (530 kgf´cm, 38 ft´lbf)
Adjusting lock bolt: 18 N´m (185 kgf´cm, 13 ft´lbf)
1MZ±FE:
Pivot bolt: 56 N´m (570 kgf´cm, 41 ft´lbf)
Adjusting lock bolt: 18 N´m (185 kgf´cm, 13 ft´lbf)
(b) Loosen the drive belt tension by adjusting bolt and re-
move the drive belt.

N20312
High Pressure
Charging hose Low Pressure
Charging Hose
AC0LP±02
N04392
Sleeve
± AIR CONDITIONINGMANIFOLD GAUGE SET
AC±19
2501 Author: Date:
MANIFOLD GAUGE SET
SET ON
1. CONNECT CHARGING HOSES TO MANIFOLD
GAUGE SET
Tighten the nuts by hand.
CAUTION:
Do not connect the wrong hoses.
2. CONNECT QUICK DISCONNECT ADAPTERS TO
CHARGING HOSES
Tighten the nuts by hand.
3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
4. REMOVE CAPS FROM SERVICE VALVES ON RE-
FRIGERANT LINE
5. CONNECT QUICK DISCONNECT ADAPTERS TO SER-
VICE VALVES
HINT:
Push the quick disconnect adapter onto the service valve, then
slide the sleeve of the quick disconnect adapter downward to
lock it.

AC0LQ±02
N06553
AC±20
± AIR CONDITIONINGMANIFOLD GAUGE SET
2502 Author: Date:
SET OFF
1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE
SET
2. DISCONNECT QUICK DISCONNECT ADAPTERS
FROM SERVICE VALVES ON REFRIGERANT LINE
HINT:
Slide the sleeve of the quick disconnect adapter upward to un-
lock the adapter and remove it from the service valve.
3. INSTALL CAPS TO SERVICE VALVES ON REFRIGER-
ANT LINE

AC0LT±03
± AIR CONDITIONINGREFRIGERANT LINE
AC±23
2505 Author: Date:
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
2. REPLACE FAULTY TUBE OR HOSE
NOTICE:
Cap the open fittings immediately to keep moisture or dirt out of the system.
3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE
NOTICE:
Connections should not be torqued tighter than the specified torque.
Part tightenedN´mkgf´cmft´lbf
Receiver x Liquid tube5.45548 in.´lbf
Condenser x Discharge hose101007
Condenser x Liquid tube1414010
Compressor x Discharge hose101007
Compressor x Suction hose101007
Expansion valve x Evaporator5.45548 in.´lbf
Suction line (Piping joint)3233024
Suction line (Block joint)101007
4. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT
Specified amount : 800 ± 50g (28.22 ± 1.76 oz.)
5. INSPECT FOR LEAKAGE OF REFRIGERANT
Using a gas leak detector, check for leakage of refrigerant.
6. INSPECT AIR CONDITIONING OPERATION

I03838
SST
I03839
PushSST
Pull
SST
Release
Lever
I06919
Disconnect the tube
using hand
Screw
Driver
Tube
I06878
Correct Wrong
Gap
N20281
AC±28
± AIR CONDITIONINGAIR CONDITIONING UNIT
2510 Author: Date:
(1) Inert SST to piping clamp.
HINT:
Confirm the direction of the piping clamp claw and SST using
the illustration showing on the caution label.
(2) Push down SST and release the clamp lock.
NOTICE:
Be careful not to deform the tubes, when pushing SST.
(3) Pull SST slightly and push the release lever, then re-
move the piping clamp with SST.
(4) Remove the piping clamp from SST.
(b) Disconnect the both tubes.
NOTICE:

Do not use tools like screwdriver to remove the tube.

Cap the open fittings immediately to keep moisture or
dirt out of the system.
HINT:
At the time of installation, please refer to the following item.

Lubricate 4 new O±rings with compressor oil and install
the tubes.

After connection, check the fitting for claw of the piping
clamp.
7. REMOVE A/C UNIT
(a) Disconnect the connector.
(b) Slide the floor carpet backward.
(c) Remove the rear heater duct.
(d) Remove the 2 nuts and A/C unit.

AC21Y±01
I03338
Thermometer
Ice
10 cm
(0.39 in.)
Ohmmeter
Thermistor
Z04352
(W)
5,000
0 500 1,0001,500 2,000 2,500 3,000 3,500 4,000 4,500
5 010152025(°C)
32
4150 68
77(°F) 59
AC±30
± AIR CONDITIONINGAIR CONDITIONING UNIT
2512 Author: Date:
INSPECTION
1. CHECK EVAPORATOR FINS FOR BLOCKAGE
If the fins are clogged, clean them with compressed air.
NOTICE:
Never use water to clean the evaporator.
2. CHECK FITTING FOR CRACKS OR SCRATCHES
Repair as necessary.
3. INSPECT THERMISTOR RESISTANCE
(a) Place the thermistor in cold water, and while changing the
temperature of water, measure resistance at the connec-
tor and at the same time, measure temperature of water
with a thermometer.
(b) Compare the 2 readings on the chart.
If resistance value is not as specified, replace the thermistor.

AC0M4±02
N01143
W
N01150
± AIR CONDITIONINGCOMPRESSOR AND MAGNETIC CLUTCH
AC±39
2521 Author: Date:
COMPRESSOR AND MAGNETIC
CLUTCH
ON±VEHICLE INSPECTION
1. INSPECT COMPRESSOR FOR METALLIC SOUND
(a) Start engine.
(b) Check if there is a metallic sound from the compressor
when the A/C switch is on.
If metallic sound is heard, replace the compressor assembly.
2. INSPECT REFRIGERANT PRESSURE
See ºON±VEHICLE INSPECTIONº of AIR CONDITIONING
SYSTEM on page AC±3.
3. INSPECT COMPRESSOR LOCK SENSOR RESIS-
TANCE
(a) Disconnect the connector.
(b) Measure resistance between terminals 1 and 2.
Standard resistance: 65 ± 125 W at 20 °C (68 °F)
If resistance is not as specified, replace the compressor assem-
bly.
4. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER-
ANT FROM SAFETY SEAL
Using a gas leak detector, check for leakage of refrigerant.
If there is any leakage, replace the compressor assembly.
5. CHECK FOR LEAKAGE OF GREASE FROM CLUTCH
BEARING
6. CHECK FOR SIGNS OF OIL ON PRESSURE PLATE OR
ROTOR
7. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE
(a) Start engine.
(b) Check for abnormal noise from near the compressor
when the A/C switch is OFF.
If abnormal noise is being emitted, replace the magnetic clutch.
8. INSPECT MAGNETIC CLUTCH OPERATION
(a) Disconnect the connector.
(b) Connect the positive (+) lead from the battery to terminal
4 and the negative (±) lead to the body ground.
(c) Check that the magnetic clutch is energized.
If operation is not as specified, replace the magnetic clutch.