AIR INTAKE MODE DOES NOT CHANGE [FULL-AUTO AIR CONDITIONER]

DESCRIPTION

• Air intake mode does not change when switching REC/FRESH mode

POSSIBLE CAUSE

• ROOM 15 A fuse malfunction

• Open or short circuit in wiring harness between battery positive terminal and climate control unit

• Open or short circuit in wiring harness between climate control unit and each actuator / sensor

• Open or short circuit in wiring harness between climate control unit and air intake actuator position sensor

• Climate control unit connector malfunction or poor connection

• Air intake actuator connector malfunction or poor connection

• Air intake actuator malfunction

• Air intake link malfunction

• Climate control unit malfunction

• Air intake door malfunction

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, inspect to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

Step	Inspection		Action
1	INSPECT FUSE • Switch the ignition off. • Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Remove the ROOM 15 A fuse. • Is the fuse normal?	Yes	Go to the next step.
1		No	If the fuse is blown: • Refer to the wiring diagram and verify whether or not there is a common connector between ROOM 15 A fuse and climate control unit terminal. If there is a common connector: ― Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground. ― Repair or replace the malfunctioning part. If there is no common connector: ― Repair or replace the wiring harness which has a short to ground. • Replace the fuse. If the fuse is damaged: • Replace the fuse. Then go to Step 22.
2*	INSPECT TO SEE WHETHER MALFUNCTION (OPEN CIRCUIT) IS IN B+ SIGNAL WIRING HARNESS (BETWEEN FUSE BLOCK AND CLIMATE CONTROL UNIT) OR ELSEWHERE • Disconnect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Switch the ignition ON (engine off or on). • Measure voltage at the following terminal (wiring harness-side). ― Climate control unit terminal 1U • Is the voltage B+?	Yes	Go to the next step.
2*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and fuse block terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for an open circuit. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 22.
3*	INSPECT TO SEE WHETHER MALFUNCTION IS IN BLOWER UNIT OR AIR INTAKE ACTUATOR • Switch the ignition off. • Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Connect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Switch the ignition ON (engine off or on). • Measure and record voltage at the following terminal (wiring harness-side) when air intake mode at RECIRCULATE and FRESH. ― Climate control unit terminal 1D • Is voltage normal?	Yes	Go to Step 21.
3*		No	Go to the next step.
4*	INSPECT TO SEE WHETHER MALFUNCTION IS IN POSITION SENSOR OR ELSEWHERE • Measure voltage at the following terminal (wiring harness-side) when airflow mode at VENT and DEFROSTER. ― Climate control unit terminal 1B • Is voltage normal?	Yes	Go to Step 7.
4*		No	Go to the next step.
5*	INSPECT TO SEE WHETHER MALFUNCTION (SHORT TO POWER SUPPLY OR GROUND) IS IN POSITION SENSOR POWER SUPPLY OR ELSEWHERE • Measure voltage at the following terminal (wiring harness-side). ― Climate control unit terminal 1C • Is voltage approx. 5 V?	Yes	Go to the next step.
5*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and each actuator / sensor terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 22.
6*	INSPECT TO SEE WHETHER MALFUNCTION (SHORT TO POWER SUPPLY) IS IN POSITION SENSOR GROUND OR ELSEWHERE • Measure voltage at the following terminal (wiring harness-side). ― Climate control unit terminal 1Q • Is voltage below 1.0 V?	Yes	Refer to wiring diagram and inspect for open circuit following. • Between climate control unit terminal 1C and junction point to actuators / sensors (position sensor power supply). • Between climate control unit terminal 1Q and junction point to actuators / sensors (position sensor ground). Repair or replace the malfunctioning part or wiring harness. Go to Step 22.
6*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and each actuator / sensor terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 22.
7*	INSPECT TO SEE WHETHER MALFUNCTION (SHORT TO POWER SUPPLY) IS IN WIRING HARNESS (AIR INTAKE POSITION SIGNAL) OR ELSEWHERE • Is voltage B+, at Step 3?	Yes	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to power supply. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to power supply. Go to Step 22.
7*		No	Go to the next step.
8	INSPECT CLIMATE CONTROL UNIT CONNECTOR CONNECTION CONDITION • Switch the ignition off. • Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Inspect the climate control unit connector engagement and connection condition. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Is the connector normal?	Yes	Go to the next step.
8		No	Reconnect the climate control unit connector properly. Go to Step 22.
9	INSPECT CLIMATE CONTROL UNIT CONNECTOR TERMINAL CONDITION • Disconnect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Inspect the connector and terminals (corrosion, damage, pin disconnection). • Are the connector and terminals normal?	Yes	Go to the next step.
9		No	Repair/replace the connector or terminal. Go to Step 22.
10	INSPECT AIR INTAKE ACTUATOR CONNECTOR CONNECTION CONDITION • Inspect the air intake actuator connector engagement and connection condition. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Is the connector normal?	Yes	Go to the next step.
10		No	Reconnect the air intake actuator connector properly. Go to Step 22.
11	INSPECT AIR INTAKE ACTUATOR CONNECTOR TERMINAL CONDITION • Disconnect the air intake actuator connector. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Inspect the connector and terminals (corrosion, damage, pin disconnection). • Are the connector and terminals normal?	Yes	Go to the next step.
11		No	Repair/replace the connector or terminal. Go to Step 22.
12*	INSPECT TO SEE WHETHER MALFUNCTION (LACK OF CONTINUITY) IS IN WIRING HARNESS (AIR INTAKE POSITION SIGNAL) OR ELSEWHERE • Inspect for continuity between the following terminals (wiring harness-side): ― Climate control unit terminal 1D — air intake actuator terminal D • Is there continuity?	Yes	Go to the next step.
12*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 22.
13*	INSPECT TO SEE WHETHER MALFUNCTION (SHORT TO GROUND) IS IN WIRING HARNESS (AIR INTAKE POSITION SIGNAL) OR ELSEWHERE • Inspect for continuity between the following terminal (wiring harness-side) and body ground: ― Climate control unit terminal 1D • Is there continuity?	Yes	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 22.
13*		No	Go to the next step.
14*	INSPECT TO SEE WHETHER MALFUNCTION (OPEN CIRCUIT) IS IN POSITION SENSOR POWER SUPPLY OR ELSEWHERE • Inspect for continuity between the following terminal (wiring harness-side) and junction point to other actuators / sensors (position sensor power supply). L.H.D.: ― Air intake actuator terminal C R.H.D.: ― Air intake actuator terminal E • Is there continuity?	Yes	Go to the next step.
14*		No	Refer to the wiring diagram and verify whether or not there is a common connector between air intake actuator terminal and junction point to other actuators / sensor terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for an open circuit. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 22.
15*	INSPECT TO SEE WHETHER MALFUNCTION (OPEN CIRCUIT) IS IN POSITION SENSOR GROUND OR ELSEWHERE • Inspect for continuity between the following terminal (wiring harness-side) and junction point to other actuators / sensors (position sensor ground). L.H.D.: ― Air intake actuator terminal E R.H.D.: ― Air intake actuator terminal C • Is there continuity?	Yes	Go to the next step.
15*		No	Refer to the wiring diagram and verify whether or not there is a common connector between air intake actuator terminal and junction point to other actuators / sensor terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for an open circuit. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has an open circuit. Go to Step 22.
16*	INSPECT TO SEE WHETHER MALFUNCTION IS IN AIR INTAKE ACTUATOR OR WIRING HARNESS (BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) • Connect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Switch the ignition ON (engine off or on). • Measure voltage at the following terminals (wiring harness-side). L.H.D.: ― Air intake actuator terminal B (RECIRCULATE mode motor drive signal) ― Air intake actuator terminal A (FRESH mode motor drive signal) R.H.D.: ― Air intake actuator terminal A (RECIRCULATE mode motor drive signal) ― Air intake actuator terminal B (FRESH mode motor drive signal) • Are voltages normal?	Yes	Go to Step 20.
16*		No	Go to the next step.
17*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Switch the ignition off. • Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Disconnect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) • Inspect for continuity between the following terminals (wiring harness-side): L.H.D.: ― Climate control unit terminal 2F — air intake actuator terminal B (RECIRCULATE mode motor drive signal) ― Climate control unit terminal 2H — air intake actuator terminal A (FRESH mode motor drive signal) R.H.D.: ― Climate control unit terminal 2F — air intake actuator terminal A (RECIRCULATE mode motor drive signal) ― Climate control unit terminal 2H — air intake actuator terminal B (FRESH mode motor drive signal) • Is there continuity?	Yes	Go to the next step.
17*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 22.
18*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO B+ BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.) • Switch the ignition ON (engine off or on). • Measure voltage at the following terminals (wiring harness-side). ― Climate control unit terminal 2F (RECIRCULATE mode motor drive signal) ― Climate control unit terminal 2H (FRESH mode motor drive signal) • Are voltages approx. 0 V?	Yes	Go to the next step.
18*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to power supply. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to power supply. Go to Step 22.
19*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO GROUND BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Switch the ignition off. • Inspect for continuity between the following terminals (wiring harness-side) and body ground: ― Climate control unit terminal 2F (RECIRCULATE mode motor drive signal) ― Climate control unit terminal 2H (FRESH mode motor drive signal) • Is there continuity?	Yes	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to ground. Go to Step 22.
19*		No	Go to the next step.
20	INSPECT AIR INTAKE ACTUATOR • Inspect air intake actuator. (See AIR INTAKE ACTUATOR INSPECTION [FULL-AUTO AIR CONDITIONER].) • Is air intake actuator normal?	Yes	Replace the climate control unit. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) Go to Step 22.
20		No	Replace the air intake actuator. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) Then go to Step 22.
21	INSPECT AIR INTAKE LINK • Inspect air intake links. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) ― Is grease on link? ― Are links securely and properly installed? ― Are links free of obstructions and hindrances? • Are the above items normal?	Yes	Inspect the air intake doors. (See BLOWER UNIT DISASSEMBLY/ASSEMBLY.) • If any doors are cracked or damaged, replace them. • If any doors are not installed securely and properly. Install them in proper positions. • If there are any obstructions, remove them. Go to the next step.
21		No	Apply grease to links. If any links are damaged, replace malfunctioning part. Then go to the next step.
22	VERIFY THAT MALFUNCTION SYMPTOM DOES NOT RECUR AFTER REPAIR • Does the air intake mode change smoothly?	Yes	Troubleshooting completed. Explain repairs to customer.
22		No	Recheck malfunction symptoms, then repeat from Step 1 if the malfunction recurs.