Climate control components in passenger compartment, servicing
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- Gervase Reed
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1 Page 1 of Climate control components in passenger compartment, servicing Component electrical testing page A/C control head -E87-, removing and installing Notes: Always check DTC memory before removing E87. After replacing E87, always: - Check coding or enter new coding. - Perform basic setting. - Check DTC memory. Vehicles equipped with Nippondenso compressors must have A/C control head E87 with Part No. index "H" and higher installed to allow for correct coding. Coding E87 page 01-8.
2 Page 2 of 34 If 22 C (71 F) is always displayed after switching on the ignition regardless of the last setting, check voltage supply to E87 (terminal 30) using wiring diagram. E87 readout can be switched over from C to F and vice versa by pressing the "temperature +" and "recirculating air" buttons simultaneously. If E87 remains in operation after switching off the ignition, test cable connection to E87 connector -D- contact -1- for short circuit to positive (connection for auxiliary heater operation) using wiring diagram.
3 Page 3 of Notes: If both display fields do not light up with ignition switched on, check coding of -E87- and conduct electrical tests if necessary page For m.y. 1997, the illumination of the display field and the operating button is via light emitting diode (LED), and can not be replaced. Always refer to parts information for correct control head versions. Control heads with part number 8D should only be installed in vehicles through m.y Control heads with part number 8L should only be installed in vehicles beginning m.y A/C control head -E87- with Part No. 8D can only be installed in vehicles up to and including m.y L B A4-A/C fully automatic DXX Coding XXXXX WSC ZZZZZ M.y vehicles can only have A/C control head -E87- with the Part No. 8L up to and including Part No. index letter "C." For m.y the harness connector to A/C control head -E87- has
4 Page 4 of 34 changed (connections for illumination, terminal 58, terminal 58s). 8L D A4-A/C fully automatic DXX Coding XXXXX WSC ZZZZZ For vehicles beginning m.y there is only one A/C control head - E87- (Part No. 8L beginning with Part No. index letter "D") that can be used.
5 Page 5 of Notes: If both display fields of A/C control head -E87- (Part No. 8L beginning with Part No. index letter "D") are not illuminated when the ignition is switched on, check the voltage supply from terminal 58d (dimmer) to A/C control head -E87- page (Electrical test). If the buttons for A/C control head -E87- (Part No. 8L beginning at Part No. index letter "D") do not light up when the light is switched on, check the voltage supply from terminal 58s (illumination) to A/C control head - E87- page (Electrical test). If an A/C control head -E87- with the Part No. 8L beginning with Part No. index letter "D"is installed in a 1997 m.y. vehicle, the brightness in the switch cannot be changed page (Electrical test). If an A/C control head -E87- with Part No. 8L including Part No. index letter "C" is installed in a 1998 m.y. vehicle, the brightness in the switch cannot be changed page (Electrical test).
6 Page 6 of Removing and installing (A/C control head with double display) - Check DTC memory. CAUTION! Obtain security code for anti-theft radio. Note customer's pre-set radio stations. Disconnect battery Ground (GND) strap. Remove Radio Repair Manual, Radio, Telephone, Navigation, Repair Group 91 - Remove screws -A-. Remove center instrument panel trim Repair Manual, Body Interior, Repair Group 70 - Remove screws -B-. - Remove A/C control head.
7 Page 7 of Push back connector locks and unplug electrical connectors. - Install in reverse order of removal. Notes: After installing E87, check that shaped hose -C- of temperature sensor G56 (blower V42) is routed correctly (not kinked). When installing screws -B-, position the center trim mounts correctly. After installing E87, always confirm correct coding, perform basic setting and check DTC memory.
8 Page 8 of Removing and installing (A/C control head with single display) Removing CAUTION! Obtain security code for anti-theft radio. Note customer's pre-set radio stations. Disconnect battery Ground (GND) strap. Remove radio or radion with navigation system Repair Manual, Radio, Telephone, Navigation, Repair Group 91 - Grip control head through radio opening and slide rearward. Notes: The control head is held in the center console with 4 clips -A-. Before replacing the control head, ensure correct application (e.g. with or without knockouts for switches for seat heaters) Parts catalog
9 Page 9 of 34 Press seat heater switches -C- back into control head so that latches - B- are engaged. Make sure that the hose for the instrument panel interior temperature sensor -G56- is not kinked or otherwise closed off.
10 Page 10 of A/C control head -E87- illumination bulbs, removing and installing - Remove A/C control head page Turn bulbs 90 and remove. - Install in reverse order of removal. Notes: Always replace with bulb of the same power rating; refer to current parts information. Bulbs -A- illuminate control panel. Bulbs -B- illuminate display panels. Testing, output Diagnostic Test Mode (DTM) page
11 Page 11 of Control module for fresh air blower - J126-, removing and installing (1996) Remove glovebox and glovebox mounting Repair Manual, Body Interior, Repair Group 70 - Unplug electrical connector -A-. - Remove screw -B- and remove module in direction of arrow. - Install in reverse order of removal. Note: Electrical test page
12 Page 12 of Control module for fresh air blower - J126-, removing and installing (1997 ) - Remove fresh air blower -V2- and separate from base plate page Remove bolts -B-. - Remove control module -A- from mounting plate. Note: When installing control module, check foam seal -C-, must be used to seal mounting plate.
13 Page 13 of Fresh air blower (V2), removing and installing (1996) Remove glovebox, glovebox mounting and mounting for passenger airbag Repair Manual, Body Interior, Repair Group 70 - Remove 4 screws -A- and remove fresh air blower from heater/air conditioner assembly. - Install in reverse order of removal. Notes: The fresh air blower must be turned slightly to allow removal from heater/air conditioner assembly. Testing V2, output Diagnostic Test Mode (DTM) page Electrical test page
14 Page 14 of Fresh air blower -V2-, removing and installing (1997 ) Remove glovebox Repair Manual, Body Interior, Repair Group 70 - Remove electrical connector -B- - Remove bolts -A- and remove fresh air blower with mounting plate from heater/air conditioner assembly. Separating fresh air blower -V2- and mounting plate - Depress locking tabs -A- and -B- with screwdriver. - Separate fresh air blower from mounting plate. - Disconnect electrical harness connectors -C-.
15 Page 15 of Notes: When re-installing the fresh air blower to the mounting plate, check for correct installation position of tabs -A- and -B-. After installation check for correct fit or fresh air blower in heater/air conditioner assembly.
16 Page 16 of Sensor for outlet temperature, center - G191-, removing and installing (1997 ) Remove Radio Repair Manual, Radio, Telephone, Navigation, Repair Group 91 Remove trim for instrument panel center part Repair Manual, Body Interior, Repair Group 70 - Disconnect electrical connector -A-. - Turn sensor -B- 90 and remove.
17 Page 17 of Sensor for outlet temperature, center - G192-, removing and installing (1997 ) Remove driver side under-dash panel Repair Manual, Body Interior, Repair Group 70 - Disconnect electrical connector -A-. - Turn sensor -B- 90 and remove.
18 Page 18 of Footwell air outlets, removing and installing Remove glovebox, lower shelf on driver side and center section of instrument panel complete (trim and supports) Repair Manual, Body Interior, Repair Group 70 - Remove connection ducts between footwell and rear passenger compartment air outlets. Remove airbag control module -A- Repair Manual, "Body Interior, Repair Group 69 Remove fixture for instrument panel -B- at center tunnel Repair Manual, Body Interior, Repair Group 70 - Remove screws -C-. - Carefully remove footwell air outlet toward the passenger compartment. - Install in reverse order of removal.
19 Page 19 of Footwell/defroster flap motor -V85-, removing and installing (1996) - Remove footwell air outlet page Remove 3 screws -A-. - Separate electrical connection -B- ("red" connector housing). - Release relay lever -C- and remove flap motor. - Install in reverse order of removal. Notes: After installing, always check DTC memory page When installing flap motor, ensure that relay lever -C- is correctly positioned. Testing -V85-, output Diagnostic Test Mode (DTM) page Electrical test page
20 Page 20 of Footwell/defroster flap motor -V85-, removing and installing (1997 ) Remove driver side under dash panel Repair Manual, Body Interior, Repair Group 70 - Remove bolts -A- and -B- (for left instrument panel support). - Remove floor outlet page Disconnect electrical connector from motor. - Remove bolt -A-. - Unhook lower strap -B- of bracket with screw driver -C-. - Remove motor and unhook lever -D- (color: white).
21 Page 21 of Notes for installing: When installing flap motor, ensure that relay lever -D- is correctly positioned ( illus. A on page ). Install strap -A- (on bracket for motor) first into mounting -B- (on heater/air conditioning assembly). After installing, always check DTC memory page Testing -V85- page (output DTM). Electrical test page Wiring harness must be installed so that it does not come in contact with moving components (e.g. motor linkage). If the crank on the motor is positioned so that the lever can not be hooked in or the motor can not be installed, connect motor to the wiring harness, switch on ignition and place lever in appropriate position by activating the button for air distribution on A/C control head -E87-.
22 Page 22 of Temperature regulator flap motor -V68-, removing and installing (1996) - Remove footwell air outlet page Remove 3 screws -A-. - Separate electrical connection to flap motor ("black" connector housing). - Release relay lever -B- and remove flap motor. - Install in reverse order of removal. Notes: After installing, always check DTC memory page When installing flap motor, ensure that relay lever -B- is correctly positioned. Testing -V68-, output Diagnostic Test Mode (DTM) page Electrical test page
23 Page 23 of Temperature regulator flap motor -V68-, removing and installing (1997 ) Remove complete front section of center console Repair Manual, Body Interior, Repair Group 70 - Loosen floor outlet from the right instrument panel support page Identify and mark electrical connectors at flap motor prior to disconnecting (to prevent mix up) and remove from motor. - Remove 3 bolts -A-. - Remove motor and unhook lever -B- (color: red). Notes for installing: After installing, always check DTC memory page When installing flap motor, ensure that relay lever -B- is correctly positioned. Testing -V68- page (output DTM). Electrical test page Wiring harness must be installed so that it does not come in contact with moving components (e.g. motor linkage).
24 Page 24 of Central air flap motor -V70-, removing and installing (1996) - Remove footwell air outlet page Remove 3 screws -A-. - Separate electrical connection to flap motor ("blue" connector housing). - Release relay lever -B- and remove flap motor. - Install in reverse order of removal. Notes: After installing, always check DTC memory page When installing flap motor, ensure that relay lever -B- is correctly positioned. Testing -V70-, output Diagnostic Test Mode (DTM) page Electrical test page
25 Page 25 of Central air flap motor -V70-, removing and installing (1997 ) Remove complete front section of center console Repair Manual, Body Interior, Repair Group 70 - Loosen floor outlet from the right instrument panel support page Identify and mark electrical connectors at flap motor prior to disconnecting (to prevent mix up) and remove from motor. - Remove 3 bolts -A-. - Remove motor and unhook lever -B- (color: blue). Notes for installing: After installing, always check DTC memory page When installing flap motor, ensure that relay lever -B- is correctly positioned. Testing -V70- page (output DTM). Electrical test page Wiring harness must be installed so that it does not come in contact with moving components (e.g. motor linkage).
26 Page 26 of Fresh air/recirculating flap two-way valve -N63-, removing and installing Remove glovebox Repair Manual, Body Interior, Repair Group 70 - Remove bolt -A-. - Separate electrical connection. - Install in reverse order of removal. Notes: Connect vacuum hoses correctly (hose -B- to vacuum reservoir, hose -C- to vacuum unit). Vacuum hose layout page Testing -N63-, output Diagnostic Test Mode (DTM) page Electrical test page
27 Page 27 of Instrument panel interior temperature sensor -G56-, removing and installing Remove radio and center section of instrument panel complete (trim and supports) Repair Manual, Radio, Telephone, Navigation, Repair Group 91 and Repair Manual, Body Interior, Repair Group 70 Notes: Check temperature sensor intake -A- and intake hose -C-; air flow must not be restricted by dust or debris. Temperature sensor -B- is attached to switch mounting; replace complete unit. Electrical test page
28 Page 28 of Sunlight photo sensor -G107-, removing and installing - Carefully pry off cover -A-. - Remove screw -B-. - Remove sensor. - Separate electrical connection. - Install in reverse order of removal. Note: Testing -G107- page
29 Page 29 of Interior temperature sensor fan -V42-, removing and installing - Remove lower shelf on passenger side, radio and center section of instrument panel complete (trim and supports) Repair Manual, Electrical Equipment, Repair Group 90 and Repair Manual, Body Interior, Repair Group Remove 2 screws -A-. - Remove suction hose -C- and remove blower-b-. - Install in reverse order of removal. Notes: Check suction hose -C-; air flow must not be restricted by dust or debris. Testing -V42-, output Diagnostic Test Mode (DTM) page Electrical test page
30 Page 30 of Air flow flap motor -V71-, removing and installing (1996) - Remove heater/air conditioner assembly complete with instrument panel page Remove 3 screws -A- and remove flap motor. - Install in reverse order of removal noting the following. Notes: Markings on the gears of flap motor -B- and air flow flap -C- must be aligned (longer tooth and continuous tooth intermediate space). If lever of flap motor rests against stop D, the intake shaft through the air flow flap must be closed when the flap motor is installed (longer side of air flow flap faces in direction of travel). After installing, check DTC memory page Testing V71, output Diagnostic Test Mode (DTM) page Electrical test page
31 Page 31 of Air flow flap motor -V71-, removing and installing (1997 ) Note: Motor is installed between heater/air conditioning assembly and bulkhead and operates the air flow flap and fresh air/recirculating air flap. Remove glovebox Repair Manual, Body Interior, Repair Group 70 - Disconnect electrical connector from motor. - Remove bolts -A- and -B-. - Unhook strap -C- of bracket from heater/air conditioner assembly mounting and remove motor.
32 Page 32 of Notes for installing: After installing, always check DTC memory page Testing -V71- page (output DTM). Electrical test page Wiring harness must be installed so that it does not come in contact with moving components (Eg.: motor linkage). Metal lever -A- moves the air flow flap and is inserted in the closed guide groove -C-. Plastic lever -B- moves the fresh air/recirculating air flap, runs mostly on the rear of the curved disc and only assumes an open guide groove position when in "recirculating operation."
33 Page 33 of Fresh air intake duct temperature sensor -G89-, removing and installing (1996) - Remove heater/air conditioner assembly complete with instrument panel page Turn temperature sensor -A- 90 to remove. - Install in reverse order of removal. Notes: Testing -G89- page Electrical test page
34 Page 34 of Fresh air intake duct temperature sensor -G89-, removing and installing (1997 ) Remove glovebox Repair Manual, Body Interior, Repair Group 70 - Reach in-between heater/air conditioner assembly and bulkhead and turn sensor -B- 90 (arrow) (connector -C- remains connected). Notes: Temperature sensor -G89- is easily accessible with air flow flow flap motor -V71- removed. If sensor can not be turned: - Carefully spray contact surface of rubber grommet -B- with silicone spray. - Remove dust and pollen filter page Reach into intake and turn temperature sensor 90. After installing, always check DTC memory page Electrical test page
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