AIR INTAKE MODE DOES NOT CHANGE [MANUAL AIR CONDITIONER]

id0703c2700500


Climate Control Unit With RECIRCULATE/FRESH Lever Type

DESCRIPTION
•  Air intake mode does not change when switching REC/FRESH mode.
POSSIBLE CAUSE
•  Air intake wire, clamp malfunction
•  Climate control unit air intake control lever malfunction
•  A/C unit air intake door malfunction


Diagnostic procedure

STEP

INSPECTION

ACTION
1
VERIFY AIR INTAKE WIRE FROM A/C UNIT IS POSITIONED SECURELY AND CORRECTLY
•  Is the air intake wire securely installed in the correct position in relation to the A/C unit air intake links?
Yes
Go to the next step.
No
Adjust the air intake wire or install securely in the correct position, then go to Step 5.
2
INSPECT CLIMATE CONTROL UNIT
•  Remove the air intake wire from A/C unit.
•  Inspect climate control unit air intake control lever operation.
•  Does the air intake lever move smoothly?
Yes
Go to the next step.
No
Repair or replace the climate control unit, then go to Step 5.
3
INSPECT AIR INTAKE DUCT
•  Is there any foreign material or obstruction in the air intake door?
Yes
Remove obstruction, then go to Step 5.
No
Go to the next step.
4
INSPECT AIR INTAKE DOOR
•  Is the air intake door securely and properly installed?
Yes
Inspect the air intake door for cracks or damage, then go to the next step.
No
Install the air intake door securely in the proper position, then go to the next step.
5
CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR
•  Does the air intake mode change smoothly?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if the malfunction recurs.


Climate Control Unit With RECIRCULATE/FRESH Switch Type (With Mechanical Lock Type Air Intake Actuator)

DESCRIPTION
•  Air intake mode does not change when switching REC/FRESH mode
POSSIBLE CAUSE
•  INTERIOR 15 A fuse malfunction
•  ROOM 25 A fuse malfunction
•  Air intake actuator malfunction
•  Open or short circuit in wiring harness between climate control unit and air intake actuator
•  Climate control unit connector malfunction or poor connection
•  Air intake actuator connector malfunction or poor connection
•  Climate control unit malfunction
•  Air intake link malfunction
•  Air intake door malfunction
•  Restriction in blower unit

•  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.
Note
•  The climate control unit controls the air intake mode when the airflow mode is in DEFROSTER so that it is fixed at FRESH mode. At this time, the airflow mode cannot be changed from FRESH to RECIRCULATE even if the REC switch is pressed, but this does not indicate a malfunction.

Diagnostic Procedure

Step

Inspection

Action
1
INSPECT FUSE
•  Switch the ignition off.
•  Disconnect the negative battery cable.
•  Remove the ROOM 25 A fuse and INTERIOR 15 A fuse.
•  Is the fuse normal?
Yes
Go to the next step.
No
If the fuse is blown:
•  Refer to the wiring diagram and verify whether or not there is a common connector between ROOM 25 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 13.
2
INSPECT AIR INTAKE ACTUATOR CONNECTOR CONNECTION CONDITION
•  Inspect the air intake actuator connector engagement and connection condition.
•  Is the connector normal?
Yes
Go to the next step.
No
Reconnect the air intake actuator connector properly.
Go to Step 13.
3
INSPECT AIR INTAKE ACTUATOR CONNECTOR TERMINAL CONDITION
•  Disconnect the air intake actuator connector.
•  Inspect the connector and terminals (corrosion, damage, pin disconnection).
•  Are the connector and terminals normal?
Yes
Go to the next step.
No
Repair/replace the connector or terminal.
Go to Step 13.
4*
INSPECT TO SEE WHETHER MALFUNCTION IS IN AIR INTAKE ACTUATOR OR ELSEWHERE
•  Air intake actuator connector disconnected.
•  Switch the ignition ON (engine off or on).
•  Measure voltage at the following terminal (wiring harness-side).
L.H.D.
―  Air intake actuator terminal A (RECIRCULATE motor drive signal)
―  Air intake actuator terminal F (FRESH motor drive signal)
R.H.D.
―  Air intake actuator terminal F (RECIRCULATE motor drive signal)
―  Air intake actuator terminal A (FRESH motor drive signal)
•  Are voltages normal?
Yes
Go to the next step.
No
Go to Step 6.
5
INSPECT AIR INTAKE ACTUATOR
•  Inspect air intake actuator.
•  Is it normal?
Yes
Go to the Step 11.
No
Replace the air intake actuator, then go to Step 13.
(See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
6
INSPECT CLIMATE CONTROL UNIT CONNECTOR CONNECTION CONDITION
•  Inspect the climate control unit connector engagement and connection condition.
•  Is the connector normal?
Yes
Go to the next step.
No
Reconnect the climate control unit connector properly.
Go to Step 13.
7
INSPECT CLIMATE CONTROL UNIT CONNECTOR TERMINAL CONDITION
•  Disconnect the climate control unit connector.
•  Inspect the connector and terminals (corrosion, damage, pin disconnection).
•  Are the connector and terminals normal?
Yes
Go to the next step.
No
Repair/replace the connector or terminal.
Go to Step 13.
8*
INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO POWER SUPPLY BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE
•  Climate control unit and air intake actuator connectors disconnected.
•  Connect the negative battery cable.
•  Switch the ignition ON (engine off or on).
•  Measure voltage at the following terminal (wiring harness-side).
―  Climate control unit terminal B
―  Climate control unit terminal A
•  Are voltages approx. 0 V?
Yes
Go to the next step.
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 13.
9*
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.
•  Disconnect the negative battery cable.
•  Climate control unit and air intake actuator connectors disconnected.
•  Inspect for continuity between the following terminals (wiring harness-side) and body ground:
―  Climate control unit terminal B
―  Climate control unit terminal A
•  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 13.
No
Go to the next step.
10*
INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY OR OPEN BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE
•  Climate control unit and air intake actuator connectors disconnected.
•  Inspect for continuity between the following terminals (wiring harness-side):
L.H.D.
―  Climate control unit terminal B — air intake actuator terminal A
―  Climate control unit terminal A — air intake actuator terminal F
R.H.D.
―  Climate control unit terminal B — air intake actuator terminal F
―  Climate control unit terminal A — air intake actuator terminal A
•  Is there continuity?
Yes
Replace the climate control unit, then go to Step 13.
(See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
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 13.
11
INSPECT AIR INTAKE LINK
•  Inspect the air intake link.
―  Is there grease on link?
―  Are the links securely and properly installed?
―  Are the links free of obstructions and hindrances?
•  Are the above items normal?
Yes
Go to the next step.
No
Apply grease to the links. If any the links are damaged, replace the air intake actuator, then go to Step 13.
(See BLOWER UNIT DISASSEMBLY/ASSEMBLY.)
12
INSPECT TO SEE WHETHER MALFUNCTION IS IN CLIMATE CONTROL UNIT OR AIR INTAKE DOOR
•  Inspect the blower unit air intake door.
―  Is the door free of obstructions, cracks, and damage?
―  Are the doors securely and properly installed?
•  Are the above items normal?
Yes
Go to the next step.
No
Remove obstruction, or install the doors in the proper position. If any doors are cracked or damaged, replace them, then go to the next step.
13
CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR
•  Does the air intake mode change smoothly?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if the malfunction recurs.


Climate Control Unit With RECIRCULATE/FRESH Switch Type (With Potentiometer Type Air Intake Actuator)

DESCRIPTION
•  Air intake mode does not change when switching REC/FRESH mode
POSSIBLE CAUSE
•  ROOM 25 A fuse malfunction
•  INTERIOR 15 A fuse malfunction
•  Air intake actuator malfunction
•  Open or short circuit in wiring harness between climate control unit and air intake actuator
•  Climate control unit connector malfunction or poor connection
•  Air intake actuator connector malfunction or poor connection
•  Climate control unit malfunction
•  Air intake link malfunction
•  Air intake door malfunction
•  Restriction in blower unit

•  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.
Note
•  The climate control unit controls the air intake mode when the airflow mode is in DEFROSTER so that it is fixed at FRESH mode. At this time, the airflow mode cannot be changed from FRESH to RECIRCULATE even if the REC switch is pressed, but this does not indicate a malfunction.

Diagnostic Procedure

Step

Inspection

Action
1
INSPECT FUSE
•  Switch the ignition off.
•  Disconnect the negative battery cable.
•  Remove the ROOM 25 A fuse and INTERIOR 15 A fuse.
•  Is the fuse normal?
Yes
Go to the next step.
No
If the fuse is blown:
•  Refer to the wiring diagram and verify whether or not there is a common connector between ROOM 25 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 13.
2*
INSPECT TO SEE WHETHER MALFUNCTION IS IN BLOWER UNIT OR AIR INTAKE ACTUATOR
•  Connect the negative battery cable.
•  Switch the ignition ON (engine off or on).
•  Measure voltage at the following terminal (wiring harness-side) when air intake mode at RECIRCULATE and FRESH.
―  Climate control unit terminal E
•  Is voltage normal?
Yes
Go to Step 11.
No
Go to the next step.
3
INSPECT AIR INTAKE ACTUATOR CONNECTOR CONNECTION CONDITION
•  Switch the ignition off.
•  Disconnect the negative battery cable.
•  Inspect the air intake actuator connector engagement and connection condition.
•  Is the connector normal?
Yes
Go to the next step.
No
Reconnect the air intake actuator connector properly.
Go to Step 13.
4
INSPECT AIR INTAKE ACTUATOR CONNECTOR TERMINAL CONDITION
•  Disconnect the air intake actuator connector.
•  Inspect the connector and terminals (corrosion, damage, pin disconnection).
•  Are the connector and terminals normal?
Yes
Go to the next step.
No
Repair/replace the connector or terminal.
Go to Step 13.
5
INSPECT AIR INTAKE ACTUATOR
•  Inspect air intake actuator.
•  Is it normal?
Yes
Go to the next step.
No
Replace the air intake actuator, then go to Step 13.
(See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
6
INSPECT CLIMATE CONTROL UNIT CONNECTOR CONNECTION CONDITION
•  Inspect the climate control unit connector engagement and connection condition.
•  Is the connector normal?
Yes
Go to the next step.
No
Reconnect the climate control unit connector properly.
Go to Step 13.
7
INSPECT CLIMATE CONTROL UNIT CONNECTOR TERMINAL CONDITION
•  Disconnect the climate control unit connector.
•  Inspect the connector and terminals (corrosion, damage, pin disconnection).
•  Are the connector and terminals normal?
Yes
Go to the next step.
No
Repair/replace the connector or terminal.
Go to Step 13.
8*
INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO POWER SUPPLY BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE
•  Climate control unit and air intake actuator connectors disconnected.
•  Connect the negative battery cable.
•  Switch the ignition ON (engine off or on).
•  Measure voltage at the following terminal (wiring harness-side).
―  Climate control unit terminal C
―  Climate control unit terminal E
―  Climate control unit terminal J
―  Climate control unit terminal A
―  Climate control unit terminal B
•  Are voltages approx. 0 V?
Yes
Go to the next step.
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 / evaporator temperature 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 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 13.
9*
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.
•  Disconnect the negative battery cable.
•  Climate control unit and air intake actuator connectors disconnected.
•  Inspect for continuity between the following terminals (wiring harness-side) and body ground:
―  Climate control unit terminal C
―  Climate control unit terminal E
―  Climate control unit terminal A
―  Climate control unit terminal B
•  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 13.
No
Go to the next step.
10*
INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY OR OPEN BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE
•  Climate control unit and air intake actuator connectors disconnected.
•  Inspect for continuity between the following terminals (wiring harness-side):
L.H.D.:
―  Climate control unit terminal C — air intake actuator terminal E
―  Climate control unit terminal E — air intake actuator terminal D
―  Climate control unit terminal J — air intake actuator terminal C
―  Climate control unit terminal A — air intake actuator terminal F
―  Climate control unit terminal B — air intake actuator terminal A
R.H.D.:
―  Climate control unit terminal C — air intake actuator terminal C
―  Climate control unit terminal E — air intake actuator terminal D
―  Climate control unit terminal J — air intake actuator terminal E
―  Climate control unit terminal A — air intake actuator terminal A
―  Climate control unit terminal B — air intake actuator terminal F
•  Is there continuity?
Yes
Replace the climate control unit, then go to Step 13.
(See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
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 13.
11
INSPECT AIR INTAKE LINK
•  Inspect the air intake link.
―  Is there grease on link?
―  Are the links securely and properly installed?
―  Are the links free of obstructions and hindrances?
•  Are the above items normal?
Yes
Go to the next step.
No
Apply grease to the links. If any the links are damaged, replace the air intake actuator, then go to Step 13.
(See BLOWER UNIT DISASSEMBLY/ASSEMBLY.)
12
INSPECT TO SEE WHETHER MALFUNCTION IS IN CLIMATE CONTROL UNIT OR AIR INTAKE DOOR
•  Inspect the blower unit air intake door.
―  Is the door free of obstructions, cracks, and damage?
―  Are the doors securely and properly installed?
•  Are the above items normal?
Yes
Go to the next step.
No
Remove obstruction, or install the doors in the proper position. If any doors are cracked or damaged, replace them, then go to the next step.
13
CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR
•  Does the air intake mode change smoothly?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if the malfunction recurs.