AIR CONDITIONING SYSTEM DETAILS

Pollen Removal Mode Control

1. When the pollen removal switch is pressed, the pollen removal mode control is activated. Then, the air vent is switched to the FACE MODE and recirculated pollen-free air flows around the upper body areas of the driver and front passenger.

2. When the pollen removal switch signal is received by the air conditioning amplifier assembly, the air conditioning amplifier assembly controls the No. 1 blower damper servo subassembly, air conditioning radiator damper servo and blower with fan motor sub-assembly as shown in the timing chart below.

3. This control usually operates for approximately 3 minutes. However, when the outside temperature is low, the control will operate for approximately 1 minute.

4. After this control stops operating, the air conditioning amplifier assembly controls the air conditioning system using AUTO mode.

   

Memory Call Control

1. The air conditioning amplifier assembly stores the air conditioning settings for each memory number when the power switch is turned off.

2. The main body ECU (multiplex network body ECU) converts the key ID code into a memory number, stores it and sends the converted signal to the air conditioning amplifier assembly.

3. The air conditioning amplifier assembly stores the memory number and air conditioning settings.

   

4. When the doors are unlocked, the certification ECU (smart key ECU assembly) recognizes the key ID code and sends it to the main body ECU (multiplex network body ECU).

5. Upon receiving the key ID code signal, the main body ECU (multiplex network body ECU) converts the signal into a memory number signal and sends it to the air conditioning amplifier assembly.

6. Then the air conditioning amplifier assembly recalls the stored air conditioning settings based on the memory number signal when the power switch is turned on (IG).

   

7. The following air conditioning system settings can be memorized:

   Setting		Condition
   Air Conditioning Switch		On or Off
   AUTO Switch		On or Off
   Temperature Setting	Driver	LO, 16°C to 32°C (65°F to 85°F) or HI
   	Front Passenger	LO, 16°C to 32°C (65°F to 85°F) or HI
   	Rear Passenger*	LO, 16°C to 32°C (65°F to 85°F) or HI
   Blower Fan Speed		Level 1 to 7
   Air Inlet Mode		Fresh or Recirculate
   Air Outlet Mode		Face, Bi-level, Foot, Foot and Defroster or Defroster
   Dual or 3-zone* Switch		On or Off

   
   

   • *: Models with 3-zone temperature control

   Tech Tips

   
   

   • Memory call control of the air conditioning system can be canceled or re-enabled using the Global TechStream (GTS).

   • The main body ECU (multiplex network body ECU) can store a maximum of 3 memory numbers.

   • The memory call function recalls the key ID that was recognized when the door was unlocked. This happens even when the user brings 2 keys or more, or the user uses different keys to unlock the door and to turn the power switch on (IG).

   • Using the GTS, the main body ECU (multiplex network body ECU) can be made to convert the ID numbers of different keys to a desired memory number. Therefore, all key IDs can be converted to an identical memory number, or 2 memory numbers can be divied among 3 keys.

   • For details about key ID code registration, refer to the Repair Manual.

   

Cooler Control Switch Panel

1. A cooler control switch panel, which can be used to switch the mode of the rear air conditioning system or adjust the temperature from the rear seats, is used on models with 3-zone temperature control, and is located in the rear seat center armrest.

   

   Text in Illustration

   *1

   Rear Air Conditioning Switch Section

   *2

   Cooler Control Switch Panel

Air Conditioning Unit

1. The air conditioning unit consists of the No. 1 cooler evaporator sub-assembly, No. 1 heater radiator unit sub-assembly, servo motors, evaporator temperature sensor (No. 1 cooler thermistor) and blower with fan motor sub-assembly.

2. The No. 1 cooler evaporator sub-assembly and No. 1 heater radiator unit sub-assembly are mounted transversely to achieve a compact and lightweight form.

3. A bus connector is used in the wire harness connection, which connects the servo motor to the air conditioning amplifier assembly.

   

   Text in Illustration

   *1	No. 1 Cooler Evaporator Sub-assembly	*2	No. 1 Heater Radiator Unit Sub-assembly
   	Front	-	-

4. An inside-and-outside dual air layer type air conditioning unit is used. This type of air conditioning unit introduces outside air to the upper side and circulates inside air to the lower side, thus achieving antifogging performance and ventilation loss reduction.

   

   Text in Illustration

   *1	Blower Assembly	*2	Air Conditioning Radiator Assembly
   *a	Introduces Inside Air	*b	Introduces Outside Air
   *c	Blows Inside Air	*d	Blows Outside Air
   *e	Lower Layer	*f	Upper Layer

5. Sliding doors are used for the air mix control doors (upper layer side and lower layer side) and mode control door (upper layer side), thus making the air conditioning radiator assembly more compact.

   

   Text in Illustration

   *1	Air Mix Control Door (Upper Layer Side)	*2	Air Mix Control Door (Upper Layer Side)
   *3	Mode Control Door (Upper Layer Side)	-	-

6. A mode control door (DEF) exclusive for the defroster is installed in the air conditioning radiator assembly, thus making it possible for air to be blown from the defroster nozzle even in bi-level mode.

   

   Text in Illustration

   *1	Mode Control Door (DEF)	-	-
   	To Defroster Nozzle	-	-

No. 1 Cooler Evaporator Sub-assembly

1. On models with 2GR-FXE engine, a Revolutionary super-slim Structure (RS) type evaporator is used. Placing the tanks at the top and the bottom of the evaporator and using a micropore tube construction provides the following benefits:

   
   

   • Improved heat exchange efficiency

   • More uniform temperature distribution

   • A thinner evaporator

   

   Text in Illustration

   *1	Tank	*2	Micropore Tube
   *3	Cooling Fin	-	-

2. On models with 2AR-FSE engine, an Ejector Cycle System (ECS) type No. 1 cooler evaporator is used. The ECS type No. 1 cooler evaporator is composed of a cooler expansion valve, a tank, tubes and cooling fins. For the tubes, extrusion is used so that small passages are created, helping to achieve excellent heat transmission performance and to allow for a thinner design (38 mm). In addition, reductions in the height and pitch of the fins and reductions in the thickness of the tubes are achieved, helping to promote heat transmission and to allow for thinner core materials. The result of this is a significant reduction in size and weight of the evaporator. Also, clean coat is used for the main body of the evaporator, helping to suppress development of bacteria, which may cause bad smells, and chrome-free surface treatment is used in consideration of the environment. The ejector is positioned in the ECS type No. 1 cooler evaporator top tank. The flow of the refrigerant is divided into the upwind and downwind sections as it passes through the evaporator, allowing for the ejector cycle (EJECS II)*.

   Tech Tips

   *: Ejector cycle (EJECS II) is a registered trademark owned by DENSO Corporation.

   

   Text in Illustration

   *1	Top Tank	*2	Ejector
   *3	Bottom Tank	*4	Cooling Fin
   *5	Multiple Passage Tube	-	-

3. Ejector Cycle System

   
   

   • In the conventional refrigerant cycle, liquid refrigerant gas is sent into the cooler evaporator sub-assembly using the cooler expansion valve, generating cold air. However, a rapid decrease in the refrigerant pressure forms swirls, causing energy loss.

   • In this ejector cycle, the energy loss caused by the cooler expansion valve is utilized by the operation of the ejector that injects and expands a high-pressure refrigerant, thus improving energy consumption efficiency.

     

     

4. Structure and operation of ejector

   
   

   • The ejector is composed of the nozzle, mixing and diffuser sections.

   • A high temperature and high pressure liquid refrigerant flowing from the condenser with receiver assembly is depressurized at the nozzle section and sucks in the low temperature and low pressure gaseous refrigerant from the No. 1 cooler evaporator on the downwind side. The refrigerants are mixed at the mixing section, and the flow speed is decreased at the diffuser section so that the refrigerant is pressurized and flows into the No. 1 cooler evaporator on the upwind side. This realizes the condition where the refrigerant pressure in the No. 1 cooler evaporator on the downwind side is considerably lower than that on the upwind side, creating the lower temperature conditions. Therefore, air cooled by the No. 1 cooler evaporator on the upwind side can be further cooled by the No. 1 cooler evaporator on the downwind side, thus improving the efficiency of the No. 1 cooler evaporator.

   • As a result of this, energy efficiency and cooling performance are enhanced. This allows for the reduction in the rotation speed of the electric inverter compressor, resulting in lower power consumption of the air conditioning.

     

Blower with Fan Motor Sub-assembly

1. The blower with fan motor sub-assembly has a built-in blower controller which is controlled by the air conditioning amplifier assembly.

2. A brushless motor is used for the blower with fan motor sub-assembly. This achieves low noise and better usage of space, and enhances characteristics of the blower motor, which enables blower level to be increased.

3. Along with the usage of the inside-and-outside dual air layer type air conditioning unit, a dual step type sirocco fan with an integrated upper layer fan and lower layer fan is used for the blower with fan motor sub-assembly.

   

   Text in Illustration

   *1	Upper Layer Fan	*2	Lower Layer Fan
   *3	Built-in Blower Controller	*4	Blower with Fan Motor Sub-assembly

Bus Connector

1. A bus connector is used in the wire harness connection, which connects the servo motor from the air conditioning amplifier assembly.

   

   Text in Illustration

   *1	Bus Connector	*2	Air Conditioning Harness Assembly
   	To Evaporator Temperature Sensor (No. 1 Cooler Thermistor)		To Air Conditioning Amplifier Assembly

2. The bus connector has a built-in driver IC with a position detection function that communicates with each servo motor connector and actuates the servo motor. This enables bus communication for the servo motor wire harness with a more lightweight construction and a reduced number of wires.

   

   Text in Illustration

   *A	Models with Bus Connector	*B	Models without Bus Connector
   *1	Air Conditioning Amplifier Assembly	*2	Bus Connector
   *3	Communication Driver IC	*4	Servo Motor
   *5	Communication IC	*6	CPU
   *7	Driver IC	-	-

Servo Motor

1. In contrast to the previous type that detects the position by way of a potentiometer voltage, the pulse pattern type servo motor detects the relative position by way of the 2-bit on/off signals.

2. The forward and reverse revolutions of this motor are detected by way of 2 phases, A and B, which output 4 types of patterns. The air conditioning amplifier assembly counts the number of pulse patterns in order to determine the stopped position.

   

Clean Air Filter (Air Refiner Element)

1. An air refiner element is used, which can remove odors from the cabin and exhaust gases. Activated charcoal is used for odor reduction, and the life of the air refiner has been prolonged by reducing the amount of desorbing odor which has been already absorbed once. In addition, the fixing material used to adhere activated charcoal to the air refiner element has been optimized and pressure loss reduction has been aimed for in the activated charcoal layer, thus enabling a finer non-woven fabric to achieve removal of micro particles such as pollen.

   

   Text in Illustration

   *1	Non-woven Fabric (Upper Flow Side)	*2	Fixing Material (in Sheet Form)
   *3	Non-woven Fabric (Lower Flow Side)	*4	Fixing Material (in Particle Form)
   *5	Activated Charcoal	*6	Air Refiner Element
   *7	Case	*8	Blower Assembly
   *a	Filter Cross-section	*b	Airflow

Cooler Condenser Assembly

1. A Multi-Flow (MF) type condenser is used. The cooler condenser assembly consists of 2 cooling portions: a condensing portion and a super-cooling portion. These portions are integrated with a gas-liquid separator (modulator). This cooler condenser assembly uses a sub-cool cycle that offers excellent heat-exchange performance.

2. In the sub-cool cycle, after the refrigerant passes through the condensing portion of the condenser, both the liquid refrigerant and the gaseous refrigerant that could not be liquefied are cooled again in the super-cooling portion. Thus, the refrigerant is sent to the evaporator in an almost completely liquefied state.

   

   Text in Illustration

   *1	Modulator	*2	Cooler Dryer
   *3	Filter	-	-
   	Condensing Portion		Super-cooling Portion
   	Gaseous Refrigerant		Liquid Refrigerant

   Tech Tips

   The point at which the air bubbles disappear in the refrigerant of the sub-cool cycle is lower than the proper amount of refrigerant with which the system must be filled. Therefore, if the system is recharged with refrigerant based on the point at which the air bubbles disappear, the amount of refrigerant would be insufficient. As a result, the cooling performance of the system would be affected. Overcharging the system with refrigerant will also lead to reduced performance. For the proper method of verifying the amount of refrigerant and for instructions on how to recharge the system with refrigerant. For details, refer to the Repair Manual.

   

Compressor with Motor Assembly

1. Along with the installation of the hybrid system, an ES27 type electric inverter compressor that is driven by a motor is used. The basic construction and operation of this compressor is the same as an ordinary scroll compressor, except that it is driven by an electric motor.

2. The A/C inverter is integrated with the compressor.

3. The electric motor is actuated by 3-phase alternating current created from the direct current (244.8 V) supplied to the A/C inverter. As a result, the air conditioning system is actuated without depending on the operation of the engine, thus realizing a comfortable air conditioning system and low fuel consumption.

4. Due to the use of an electric inverter compressor, the compressor speed can be controlled at the required speed calculated by the air conditioning amplifier assembly. Thus, the cooling and dehumidification performance and power consumption have been optimized.

5. Low-moisture permeation hoses are used for the suction and discharge hoses at the compressor in order to minimize the entry of moisture into the refrigeration cycle.

6. The compressor is supplied with high-voltage direct current, and it uses high-voltage alternating current internally. If an open or short circuit occurs in the compressor, the hybrid vehicle control ECU will cut off the A/C inverter circuit.

   

   Text in Illustration

   *1	A/C Inverter	*2	Discharge Hose Port
   *3	Suction Hose Port	-	-

7. The electric inverter compressor consists of a spirally wound fixed scroll and variable scroll that form a pair, a brushless motor, an oil separator, a motor shaft and A/C inverter.

8. The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the variable scroll to revolve while maintaining the same posture, the volume of the space that is partitioned by both scrolls varies to perform the suction, compression, and the discharge of the refrigerant gas.

9. Locating the suction port directly above the scrolls enables direct suction, thus realizing improved suction efficiency.

10. Containing a built-in oil separator, this compressor is able to separate the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle, thus realizing a reduction in the oil circulation rate.

11. This inverter converts the HV battery nominal voltage of DC 244.8 V into AC and supplies power to operate the compressor.

    

    Text in Illustration

    *1	A/C Inverter	*2	Discharge Port
    *3	Motor Shaft	*4	Variable Scroll
    *5	Fixed Scroll	*6	Oil Separator
    *7	Brushless Motor	*8	Electric Inverter Compressor
    *9	HV Battery	*10	Current Sensor
    *11	Power Supply Circuit	*12	Gate Drive Circuit
    *13	Temperature Sensor	*14	Voltage Sensor
    *15	Power Management Control ECU	*16	Input/Output Interface
    *17	CPU	*18	System Protection Control Circuit
    *a	From Battery	-	-

    Note

    In order ensure proper insulation of the internal high-voltage portion of the compressor and the compressor housing, this model has adopted compressor oil (ND11) with a high level of insulation performance. Therefore, never use compressor oil other than the ND11 type compressor oil or its equivalent.

Heater Water Pump Assembly (Heater Accessory Assembly)

1. A heater water pump assembly (heater accessory assembly) is used to circulate coolant for the heater core in the air conditioning system. This provides a stable heater performance even if the engine is stopped due to the hybrid control system.

2. A heater water pump with reduced water flow resistance is used.

   

   Text in Illustration

   *a

   To Heater

   *b

   From Engine

Mode Position and Door Operation

Mode Position and Door Operation

Control Door	Operation Position*1		Door Position	Operation
Air Inlet Control Door	FRESH		A2, B1	Brings in fresh air.
	RECIRCULATION		A1, B2	Recirculates internal air.
Inside-and-outside Dual Air Layer Control Door	- (Auto Control)		C1 - C2	Separates or integrates the upper layer and lower layer in response to the control conditions to control the inside-and-outside dual air layers.
Air Mix Control Door	MAX COLD to MAX HOT Temperature Setting		D1 - D2*2 E1 - E2*3 F1 - F2*4 G1 - G2*5 H1 - H2*6	Varies the mixture ratio of warm air and cool air in order to continuously regulate the temperature between hot and cold.
Mode Control Door (for All Seat Control Modes)		FACE	J1, K1, L1, M1, N3, O1, I3, I2*7	Air blows out of the front center register, side register and console box register.
		BI-LEVEL	J2, K2, L2, M2, N2, O2, I3, I2*7	Air blows out of the front center register, side register, console box register and front and rear footwell register ducts. Air may blow out from the center defroster and side defroster depending on the cabin environment (I2).
		FOOT	J3, K3, L3, M3, N2, O3, I2	Air blows out of the front footwell register and rear footwell register ducts. In addition, air blows out slightly from the front center register, side register and console box register. Air blows out slightly from the center defroster and side defroster.
		FOOT AND DEFROSTER	J3, K3, L2, M2, N2, O2, I1	Defrosts the windshield through the center defroster and side defroster, while air is also blown out from the front footwell register and rear footwell register ducts. In addition, air blows out slightly from the front center register, side register and console box register.
		DEFROSTER	J4, K4, L1, M1, O1, I1	Defrosts the windshield through the center defroster and side defroster ducts.
Mode Control Door (for Front Seat Control Modes*8)		FACE	J1, K1, L1, M1, N1, O1, I3, I2*7	Air blows out of the front center register and side register
		BI-LEVEL	J2, K2, L2, M2, N1, O1, I3, I2*7	Air blows out of the front center register, side register and front footwell register ducts. Air may blow out from the center defroster and side defroster depending on the cabin environment (I2).
		FOOT	J3, K3, L3, M3, N1, O1, I2	Air blows out of the front footwell register. In addition, air blows out slightly from the front center register and side register. Air blows out slightly from the center defroster and side defroster.
		FOOT AND DEFROSTER	J3, K3, L2, M2, N1, O1, I1	Defrosts the windshield through the center defroster and side defroster, while air is also blown out from the front footwell register. In addition, air blows out slightly from the front center register and side register.
		DEFROSTER	J4, K4, L1, M1, N1, O1, I1	Defrosts the windshield through the center defroster and side defroster ducts.
Mode Control Door (for Driver Seat Control Modes*9)		FACE	J1, K4, L1, M1, N1, O1, I3, I2*7	Air blows out of the driver side front center register and side register.
		BI-LEVEL	J2, K4, L2, M1, N1, O1, I3, I2*7	Air blows out of the driver side front center register, side register and front footwell register ducts. Air may blow out from the center defroster and side defroster depending on the cabin environment (I2).
		FOOT	J3, K4, L3, M1, N1, O1, I2	Air blows out of the driver side front footwell register. In addition, air blows out slightly from the front driver side center register and side register. Air blows out slightly from the center defroster and side defroster.
		FOOT AND DEFROSTER	J3, K4, L2, M1, N1, O1, I1	Defrosts the windshield through the center defroster and side defroster, while air is also blown out from the front driver side footwell register. In addition, air blows out slightly from the front driver side center register and side register.

Air Outlets and Airflow Volume (for All Seat Control Modes)

Indication	Mode	Face			Footwell		Defroster
		Center	Side	Rear	Front	Rear	Center	Side
		A	B	C	D	E	F	G
	FACE-U*1				-	-	-	-
							*3	*3
	FACE-L*1						-	-
							*3	*3
	FACE-R*1, *2				-	-	-	-
							*3	*3
	BI-LEVEL*1, *2						*3, *4	*3, *4
	FOOT-D*1
	FOOT-R*1, *2
	FOOT-F*1
	FOOT AND DEFROSTER *1, *2
	DEFROSTER *1, *2	-	-	-	-	-

Air Outlets and Airflow Volume (for Front Seat Control Modes)

Indication	Mode	Face			Footwell		Defroster
		Center	Side	Rear	Front	Rear	Center	Side
		A	B	C	D	E	F	G
	FACE-U*1			-	-	-	-	-
							*3	*3
	FACE-L*1			-		-	-	-
							*3	*3
	FACE-R*1, *2			-	-	-	-	-
							*3	*3
	BI-LEVEL*1, *2			-		-	*3, *4	*3, *4
	FOOT-D*1			-		-
	FOOT-R*2			-		-
	FOOT-F*1			-		-
	FOOT AND DEFROSTER *1, *2			-		-
	DEFROSTER *1, *2	-	-	-	-	-

Air Outlets and Airflow Volume (for Driver Seat Control Modes)

Indication	Mode	Face (Only for Driver Side)			Footwell (Only for Driver Side)		Defroster
		Center	Side	Rear	Front	Rear	Center	Side
		A	B	C	D	E	F	G
	FACE-U*1			-	-	-	-	-
							*3	*3
	FACE-L*1			-		-	-	-
							*3	*3
	FACE-R*1, *2			-	-	-	-	-
							*3	*3
	BI-LEVEL*1, *2			-		-	*3, *4	*3, *4
	FOOT-D*1			-		-
	FOOT-R*1, *2			-		-
	FOOT-F*1			-		-
	FOOT AND DEFROSTER *1, *2			-		-

[nanoe] Generator Operation

1. The [nanoe] generator (No. 1 ion generator sub-assembly) gathers moisture in the air, generates [nanoe] by applying a high level of electric voltage and emits it from the driver side center register to the cabin.

2. Electrodes and a Peltier device are installed in the [nanoe] generator. The electrodes cooled by applying current to the Peltier device generate [nanoe] by applying a high level of electric voltage to water drops created by dew condensation.

   

   Text in Illustration

   *1	Counter Electrode	*2	Electrode
   *3	Peltier Device	*4	Heatsink
   *5	[nanoe] Generator (No. 1 Ion Generator Sub-assembly)	*6	Electron
   *7	Water	-	-
   *a	[nanoe] Generation Portion	*b	Image of [nanoe]