AIR CONDITIONING SYSTEM

Air Conditioning Unit Assembly

1. The air conditioning unit assembly consists of the No.1 cooler evaporator sub-assembly, 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 heater radiator unit sub-assembly have been positioned horizontally in the unit, and the air conditioning unit assembly has been made smaller.

   

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   *1

   No.1 Cooler Evaporator Sub-assembly

   *2

   Heater Radiator Unit Sub-assembly

No.1 Cooler Evaporator Sub-assembly

1. A Revolutionary super-slim Structure (RS) type evaporator is used. Placing the tanks at the top and the bottom of the evaporator and adopting a micropore tube construction has provided the following benefits:

   
   

   • Improved heat exchange efficiency

   • More uniform temperature distribution

   • A thinner evaporator

     

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

Blower Motor Control (Models with Automatic Air Conditioning System)

1. The blower motor control has internal circuitry that uses electrical current to change the signal from the air conditioning control assembly (air conditioning ECU) and to change the speed of the blower with fan motor sub-assembly.

   

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   *1	Blower Motor Control	*2	Temperature Fuse
   *a	To Air Conditioning Control Assembly (Air Conditioning ECU)	*b	To Blower with Fan Motor Sub-assembly

Blower Resistor (Models with Manual Air Conditioning System)

1. The blower resistor is a resistor that changes the speed of the blower with fan motor sub-assembly, and it has a temperature fuse installed in it.

   

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   *1

   Blower Resistor

   *2

   Temperature Fuse

Servo Motor (Models with Automatic Air Conditioning System)

1. A No.1 blower damper servo sub-assembly, No.1 air conditioning radiator damper servo sub-assembly, No.3 air conditioning radiator damper servo sub-assembly (driver), and No.3 air conditioning radiator damper servo sub-assembly (passenger) have been adopted.

   

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   *1	No.3 Air Conditioning Radiator Damper Servo Sub-assembly (Driver)	*2	No.1 Air Conditioning Radiator Damper Servo Sub-assembly
   *3	No.3 Air Conditioning Radiator Damper Servo Sub-assembly (Passenger)	*4	No.1 Blower Damper Servo Sub-assembly

2. The No.1 blower damper servo sub-assembly receives an activation signal from the air conditioning control panel for its internal/fresh air select switch, whereupon it causes motor rotation and opens or closes the internal/fresh air door through a link.

   

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   *1	Recirculated Air	*2	Fresh Air
   *3	Internal air contact	*4	Moving contact
   *5	Fresh air contact	*6	Motor

3. In the No.1 air conditioning radiator damper servo sub-assembly, the air conditioning control assembly (air conditioning ECU) causes the servo motor to rotate to a particular position due to action taken to change the mode of the air conditioning control assembly or by automatic control, causing the mode door to open or close through a link.

4. The actual position of the mode door is measured by a potentiometer installed in the No.1 air conditioning radiator damper servo sub-assembly, and the change in resistance caused by the change in door position is fed back into the air conditioning control assembly (air conditioning ECU) as a change in voltage.

   

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   *1	DEF	*2	F/D
   *3	FOOT	*4	B/L
   *5	FACE	*6	Potentiometer
   *7	Motor	-	-

5. In the No.3 air conditioning radiator damper servo sub-assembly, the air conditioning control assembly (air conditioning ECU) causes the servo motor to rotate to a particular position due to action taken to set the temperature or by automatic control, causing the air mix door to open or close through a link.

6. The actual position of the air mix door is measured by a potentiometer installed in the No.3 air conditioning radiator damper servo sub-assembly (driver), and the change in resistance caused by the change in door position is fed back into the air conditioning control assembly (air conditioning ECU) as a change in voltage.

   

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   *1	Max Cool	*2	Max Hot
   *3	Potentiometer	*4	Motor

Clean Air Filter

1. The adoption of a high-performance fine-dust clean air filter that uses electret* fibers provides pleasant air inside the vehicle through its ability to remove pollen, dust and other micron-sized particles as well as diesel carbon and other sub-micron particles that get inside the vehicle interior.

   
   

   • *: Electret: a material that produces a semi-permanent external electric field

   

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   *1	Clean Air Filter	*2	Large Foreign Object Filter Layer
   *3	Electret Layer	*4	Air Flow

   Tech Tips

   The filter should be replaced regularly in order to maintain its dust collection capacity.

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.

   

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   *1	Gaseous Refrigerant	*2	Condensing Portion
   *3	Modulator	*4	Super-cooling Portion
   *5	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.

   

   *1	Proper Charge Amount
   *2	High Pressure
   *3	Point at which Bubbles Disappear
   *4	Amount of Refrigerant

Compressor with Magnet Clutch

1. A compact and high performance scroll compressor with oil separator has been adopted.

   

2. The scroll compressor with oil separator consists of a spirally wound fixed scroll and rotating scroll that from a pair, and oil separator, and a magnetic clutch.

   The fixed scroll is integrated with the housing. Because the rotation of the shaft causes the rotating 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.

   A pin is attached behind the rotating scroll to prevent the autorotation of the rotating scroll, allowing it only to revolve.

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

   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.

   

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   *1	Fixed Scroll	*2	Rotating Scroll
   *3	Pins	*4	Shaft
   *5	Discharge Port	-	-

3. A CS (Centrifugal with Shutter) type oil separator has been adopted to reduce the circulation rate of the compressor oil that is intermixed with the refrigerant and circulates in the refrigeration cycle.

   This oil separator is provided with a cylindrical pipe in the separator case, enabling the refrigerant gas that has been discharged through the discharge gas inlet to be separated into refrigerant gas and oil through centrifugal force, and minimizing the outflow of the oil to the discharge service port. As a result, the oil circulation rate has been reduced and makes energy savings possible.

   

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   *1	Cooler Condenser Assembly and Modulator	*2	Cooler Expansion Valve
   *3	Refrigerant Gas + Compressor Oil	*4	No.1 Cooler Evaporator Sub-assembly
   *5	Oil	*6	Compressor with Magnet Clutch
   *7	Oil Separator	-	-
   *a	Oil Circulation Ratio of 4%	*b	Oil Circulation Ratio of 1%

Mode Position and Door Operation

Control Door	Operation Position		Door Position	Operation
Air Inlet Control Door	FRESH		A	Brings in fresh air. (The internal air recirculates partially.)
	RECIRCULATION		B	Recirculates internal air.
Air Mix Control Door	MAX COLD to MAX HOT Temperature Setting		C - D (C' - D')	Varies the mixture ratio of warm air and cool air in order to regulate the temperature continuously between hot and cold.
Mode Control Door		FACE	E, H	Air blows out of the center register and side register ducts.
		BI-LEVEL	F, H	Air blows out of the center register, side register and footwell register ducts.
		FOOT	G, I	Air blows out of the footwell register and side register ducts. In addition, air blows out slightly from the front defroster and side defroster.
		FOOT AND DEFROSTER	G, J	Defrosts the windshield through the front defroster, side defroster and side register ducts, while air is also blown out from the footwell register ducts.
		DEFROSTER	G, K	Defrosts the windshield through the front defroster, side defroster and side register ducts.

Air Outlets and Airflow Volume

Indication	Mode	Face		Footwell	Defroster
		Center	Side		Front	Side
		A	B	C	D	E
	FACE			-	-	-
	BI-LEVEL				-	-
	FOOT	-
	FOOT AND DEFROSTER	-
	DEFROSTER	-		-

The size of the circle ○ indicates the proportion of airflow volume.