A/C-HEATER SYSTEM - AUTOMATIC

1988 Toyota Celica

1988 Automatic A/C-Heater Systems

Celica

* PLEASE READ THIS FIRST *

CAUTION: When discharging air conditioning system, use only approved
refrigerant recovery/recycling equipment. Make every attempt
to avoid discharging refrigerant into the atmosphere.

DESCRIPTION
The automatic temperature control system consists of
electronically controlled A/C components that provided automatic
temperature control of vehicle’s interior.

OPERATION

AMBIENT TEMPERATURE SENSOR

Ambient sensor is a thermistor that determines temperature of
surrounding outside air and sends appropriate signals to amplifier.
This signal is compared against signals from in-car temperature
sensor.

COOLANT TEMPERATURE SWITCH

Switch senses coolant temperature at heater core. Information
is then sent to A/C amplifier to adjust amount of warm air that enters
vehicle’s interior.

SOLAR SENSOR
Solar sensor functions as a monitor of sunlight. It senses
amount of sunlight entering vehicle interior, and then signals power
servo to adjust air temperature according to preselected temperature.

TROUBLE SHOOTING

NO BLOWER OPERATION
Problem may be due to the following condition(s): blown
fuses, faulty heater relay, faulty blower motor or resistor, faulty
power transistor, faulty blower fan relay or blower switch, faulty A/C
control assembly, faulty wiring, bad ground, air vent mode control
servo, or system amplifier.

NO COOL AIR
Problem may be due to the following condition(s): blown
fuses, incorrect refrigerant charge, incorrect A/C compressor belt
tension, faulty magnetic clutch relay, faulty pressure switch or A/C
compressor, faulty A/C control assembly, faulty/plugged receiver-
drier, faulty/plugged condenser, faulty/plugged expansion valve or
evaporator, faulty thermistor or A/C amplifier, faulty wiring or bad
ground.
 NO WARM AIR
Problem may be due to the following condition(s): A/C
control cable out of adjustment, faulty heater valve, faulty air mix
servomotor, faulty A/C amplifier or system amplifier (push-button
type), faulty wiring or bad ground.

INTERMITTENT COOL AIR

Problem may be caused by the following condition(s):
incorrect refrigerant charge, slipping A/C compressor belt, faulty
magnetic clutch, or plugged/faulty expansion valve or evaporator.

COOL AIR ONLY AT HIGH SPEED

Problem may be caused by the following condition(s):
incorrect refrigerant charge, slipping A/C compressor belt, faulty A/C
compressor, plugged condenser, or faulty A/C fan motor or fan relay.

INSUFFICIENT COOLING
Problem may be caused by the following condition(s):
incorrect refrigerant charge (including air or excessive oil in
system), slipping A/C compressor belt, out-of-adjustment A/C control
cable, clogged condenser, faulty A/C compressor, faulty A/C fan or
relay, faulty expansion valve, faulty A/C control assembly, faulty air
mix servomotor, faulty wire harness connections or wiring.

NO BLOWER CONTROL
Problem may be due to the following condition(s): power
transistor faulty, blower resistor, heater main relay or blower fan
relay faulty, faulty A/C control assembly,blown fuses, faulty wire
harness connections or wiring.

INSUFFICIENT COOL AIR VELOCITY

Problem may be caused by the following condition(s): faulty
blower motor, blocked air inlet, clogged/frosted evaporator, or air
leakage from evaporator case or air duct.

TESTING

A/C AMPLIFIER
Disconnect amplifier. Check continuity or battery voltage on
wiring harness connector following test conditions specified in A/C
AMPLIFIER TEST chart. See Fig. 1. If circuit resistance/voltage
readings are correct, replace A/C amplifier.

A/C AMPLIFIER TEST TABLE

Terminal (1) Test Specified
Connection Condition Value

14-Ground ............. ..... ............... Continuity

1-14 .............. A/C Switch On ...... Battery Voltage
1-14 ............. A/C Switch Off ........... No Voltage
6-14 .............. A/C Switch On ...... Battery Voltage
6-14 ............. A/C Switch Off ........... No Voltage
2-9 ................... ..... ...................... ( 2)
13-14 .............. Ignition On ....... Battery Voltage
13-14 ............. Ignition Off ............ No Voltage
4-14 ............... Ignition On ....... Battery Voltage
4-14 .............. Ignition Off ............ No Voltage
10-14 ............... Engine On ............ 10-14 Volts
10-14 .............. Engine Off ............. No Voltage
18-14 .............. Ignition On ....... Battery Voltage
18-14 ............. Ignition Off ............ No Voltage
7-14 ............... Ignition On ....... Battery Voltage
7-14 .............. Ignition Off ............ No Voltage
8-14 ............... Ignition On ....... Battery Voltage
8-14 .............. Ignition Off ............ No Voltage
5-14 ............... Ignition On ....... Battery Voltage
5-14 .............. Ignition Off ............ No Voltage
16-9 .................. ..... ........... About 115 Ohms

(1) - Temperature to MAX COOL.

 "HI"
 blower speed.
(2) - About 1500 ohms at 77 F (25 C).

Fig. 1: A/C Amplifier Connector Identification

Courtesy of Toyota Motor Sales, U.S.A., Inc.

A/C COMPRESSOR
Clutch
Inspect pressure plate and rotor for signs of oil leaks.
Check clutch bearings for noise and loss of lubricant. Using an
ohmmeter, measure the resistance of stator coil between clutch lead
wire and
 ground
 (A/C compressor body). Reading should be 3.4-3.8 ohms
at 68 F (20 C). If reading is incorrect, replace A/C compressor
clutch.

RPM Sensor
Using an ohmmeter, measure the resistance between connector

terminals
 of RPM sensor lead. Reading should be 100-130 ohms at 68 F
(20 C). If reading is incorrect, replace RPM sensor.
Fig. 2: Automatic A/C-Heater System Components
Courtesy of Toyota Motor Sales, U.S.A., Inc.

A/C TEMPERATURE CONTROL SYSTEM

 1) Remove glove compartment and reinforcement. Disconnect
White single terminal connectors at the heater assembly. Connect
Green/Black test connector to single White/Red male terminal
connector.  
2) Place temperature control lever at 77 F (25 C). Start and
run engine at idle. Depress "AUTO" fan speed control switch. Verify
that guide plate on servo motor is located at "O" mark. See Fig. 3.
3) If lower edge of guide plate is over "R", disconnect
wiring harness from system amplifier. Install adjustment lead
(terminal No. 10) into terminal No. 9 until position is correct. Put
adjustment lead in terminal No. 10.
4) If lower edge of guide plate is over "W", disconnect
wiring harness from system amplifier. Install adjustment lead
(terminal No. 10) into terminal No. 2 until position is correct. Put
adjustment lead in terminal No. 10.
5) Reconnect wiring harness to system amplifier. Unplug check
connector from wiring harness. Plug in White/Red connector. Install
reinforcement and glove compartment.

Fig. 3: A/C Temperature Control System Test

Courtesy of Toyota Motor Sales, U.S.A., Inc.

AMBIENT TEMPERATURE SENSOR

Check ambient temperature sensor resistance.
 Sensor 
resistance
 may vary from 1700 ohms at 77 F (25 C) to 620 ohms at 122 F
(50 C).

IN-CAR TEMPERATURE SENSOR

If an open exists in in-car temperature sensor circuit,
system will operate at maximum heating. If sensor circuit has a short,
system will operate at
 maximum
 cooling. Sensor resistance
  may vary
from 1700 ohms at 77 F (25 C) to 620 ohms at 122 F (50 C).

SOLAR SENSOR
Unplug solar sensor connector and check sensor continuity. If
no continuity exists, replace solar sensor.

REFRIGERANT PRESSURE SWITCHES

Dual Pressure Switch

Check refrigerant pressure. Pressure must be  more  than 30 psi
(2.1 kg/cm ) when ambient temperature is more than 32 F (0 C). Charge
A/C system if necessary. Using an ohmmeter, check continuity between
terminals of dual pressure switch. Ohmmeter must indicate zero ohms.
If continuity exist, replace switch.

High Pressure Switch

Disconnect high pressure switch lead from wiring harness.
Using an ohmmeter, check continuity between terminals of high pressure
switch. Ohmmeter reading must be zero ohms. If continuity exists,
replace switch.

A/C COMPRESSOR CLUTCH RELAY

1) Remove A/C compressor clutch relay. Check that continuity
exists between terminals No. 1 and 2. See Fig. 4. No continuity should
exist between terminals No. 3 and 4, and terminals No. 1 and 4. If
continuity is not as specified, replace relay.
2) If continuity is okay, apply battery voltage across
terminals No. 1 and 2. With voltage across relay, continuity should
exist between terminals No. 3 and 4. No continuity should exist
between terminals No. 1 and 4. If relay operation is not as specified,
replace relay.

Fig. 4: A/C Compressor Clutch Relay Test

Courtesy of Toyota Motor Sales, U.S.A., Inc.

CONDENSER FAN RELAYS

 No. 1 Condenser Fan Relay
1) Remove relay. Check for battery voltage between body
ground and terminals No. 2 and 6 at wiring connector. Check for ground
connection between body ground and terminal No. 3 at wiring connector.
2) Check for continuity between relay terminals No. 2 and 6,
and between terminals No. 1 and 3. No continuity should exist between
terminals No. 1 and 4. See Fig. 5. If continuity is not as specified,
replace relay.
3) If continuity is okay, apply battery voltage across
terminals No. 2 and 6. With voltage across relay, continuity should
exist between terminals No. 1 and 4. No continuity should exist
between terminals No. 1 and 3. If relay operation is not as specified,
replace relay.

No. 2 Condenser Fan Relay

1) Remove relay. Check for battery voltage between body
ground and terminals No. 1 and 4 at wiring connector. Check for
continuity between relay terminals No. 1 and 4. No continuity should
exist between terminals No. 2 and 4. If continuity is not as
specified, replace relay.
2) If continuity is okay, apply battery voltage across
terminals No. 1 and 4. See Fig. 5. With voltage across relay,
continuity should exist between terminals No. 2 and 3. If relay
operation is not as specified, replace relay.

Fig. 5: Condenser Fan Relay Connector Identification

Courtesy of Toyota Motor Sales, U.S.A., Inc.

CONDENSER FAN MOTOR

 3S-GE Engine
1) Fan motor operates according to coolant temperature and
A/C mode switch position. See 3S-GE ENGINE CONDENSER FAN MOTOR
SPECIFICATIONS table.
2) Unplug condenser fan motor connector. Using ammeter and
jumper wires, apply battery voltage to connector. Motor should operate
smoothly and draw 6.0-7.4 amps. If not, replace condenser fan motor.

3S-GE ENGINE CONDENSER FAN MOTOR SPECIFICATIONS TABLE

A/C Switch A/C Coolant
  Temp. Fan Motor
Position Clutch F ( C) Speed

Off ............ Off ..... 194 (90) or Less ...... Off

On ............. Off ..... 194 (90) or More ...... High
On ............. On ...... 194 (90) or Less ...... Low
On ............. On .. (1) 194 (90) or More ..... High


(1) - With specified temperature or with refrigerant
pressure at 220 psi (15.5 kg/cm ) or more.




























































3S-FE Engine
1) Fan motor operates according to coolant temperature and
A/C mode switch position. See 3S-FE ENGINE CONDENSER FAN MOTOR
SPECIFICATIONS table.
2) Unplug condenser fan motor connector. Using ammeter and
jumper wires, apply battery voltage to connector. Motor should operate
smoothly and draw 6.0-7.4 amps. If not, replace condenser fan motor.

3S-FE ENGINE CONDENSER FAN MOTOR SPECIFICATIONS TABLE

A/C Switch A/C Coolant
  Temp. Fan Motor
Position Clutch F ( C) Speed

Off ........... Off ..... 194 (90) or Less ....... Off

Off ........... Off ..... 194 (90) or More ....... Off
On ............ Off ..... 194 (90) or Less ....... Off
On ............ Off ..... 194 (90) or More ...... High
On ............. On ..... 194 (90) or Less ....... Low
On ............. On .. (1) 194 (90) or More ...... High


(1) - With specified temperature or with refrigerant
pressure at 220 psi (15.5 kg/cm ) or more.

HEATER A/C CONTROLS

A/C Indicator Light
Disconnect electrical connector at control panel. Connect
jumper lead from battery positive terminal to terminal No. B5. Connect
jumper lead from battery negative terminal to terminal No. B2. With
A/C control switch pushed in, check that indicator light is lit. See
Fig. 6

A/C Switch
Disconnect electrical connector at control panel. Using an
ohmmeter, check that continuity exists across terminals No. B5 and B6,
and terminals No. B6 and B2 with A/C switch in the on position. There
should be no continuity when A/C switch is off. See Fig. 6

Blower Switch
Detach multi-pin terminal from blower switch. Use ohmmeter to
check for continuity between terminals at different switch positions.
If continuity is not as shown, replace blower switch. See BLOWER
SWITCH CONTINUITY table. See Fig. 6.

BLOWER SWITCH CONTINUITY TABLE

Application/ Terminal
Switch Position Continuity

"OFF" ..................................... None

"LO" ................................... A16-B23
"I" ........................... A16-B23, A16-B24
"II" .......................... A16-B23, B23-B20
"HI" .......................... A16-B23, B23-B19

Fig. 6: Control Panel Connector Identification

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Thermister
Disconnect negative battery cable. Remove glove compartment
and under cover. Using an ohmmeter, measure resistance
  at thermistor
connector. Resistance should be 1500 ohms at 77 F (25 C). If reading
is not as indicated, replace thermister

Air Vent Control Switch

Disconnect electrical connector at control panel. Using an
ohmmeter, check continuity across terminals at all switch positions.
See AIR VENT CONTROL SWITCH CONTINUITY table. See
Fig. 6

AIR VENT CONTROL SWITCH CONTINUITY TABLE

Switch Position Terminal Continuity

"AUTO" .................................. A16-A5

"FACE" ................................. A16-A12
"BI-LEVEL" ............................. A16-A17
"FOOT" .................................. A16-A6
"FOOT/DEF" ............................. A16-A13
"DEF" .................................. A16-A11


















































Air-Mix Control Switch
1) Disconnect electrical connector at control panel. Using an
ohmmeter, check resistance across terminals No. A1 and A10. See
Fig. 6.
2) With temperature control lever at maximum cool position,
ohmmeter should read infinity. With lever in center, ohmmeter should
read 1.3-1.7 ohms. With lever in maximum warm position, ohmmeter
should read zero ohm.

Recirc/Fresh Control Switch

1) Connect a battery positive jumper lead to terminal No. A2.
Connect battery negative jumper lead to terminal No. A16. Recirc
indicator light should come on. If light does not come on, replace
switch. Remove battery jumper leads. See Fig. 6.
2) Set recirc/fresh switch to fresh position. Using an
ohmmeter, check that continuity exists across terminals No. A15 and
A16. Check that no continuity exists across terminals No. A14 and A16.
3) Set recirc/fresh switch to recirc position. Check that
continuity exists across terminals No. A14 and A16. Check that no
continuity exists across terminals No. A15 and A16. If recirc/fresh
control switch operation is not as specified, replace switch.

Air Vent Servo Motor

Detach multi-pin terminal from air vent servo motor. Connect
a battery positive jumper lead to terminal No. 1. Connect battery
negative jumper lead to terminal No. 2. Use ohmmeter or circuit tester
to check for continuity between terminals. If continuity is not as
shown, replace air vent servo motor. See AIR VENT SERVO MOTOR
CONTINUITY table. See Fig. 7.

AIR VENT SERVO MOTOR CONTINUITY TABLE

Switch Position Terminal Continuity

"FACE" .................................... None

"BI-LEVEL" ........................... 10-4, 4-5
"FOOT" ............................... 10-6, 6-5
"FOOT/DEF" ..................... 6-5, 10-9, 6-10
"DEF" ..................... 6-4, 4-3, 6-11, 11-9


















































Fig. 7: Air Vent Servo Motor Connector
Courtesy of Toyota Motor Sales, U.S.A., Inc.

Air-Mix Servo Motor

1) Disconnect air-mix servo motor connector. Connect a
battery positive jumper lead to terminal No. 2. Connect battery
negative jumper lead to terminal No. 8. Check that servo motor lever
moves smoothly from warm to cool. Reverse battery jumper leads. Servo
motor lever should move smoothly to warm position. See Fig. 8.
2) Connect an ohmmeter across terminals No. 13 and 15. While
operating servo motor in step 1), check resistance. When servo motor
is in cool position, ohmmeter should read 1800-2000 ohms. When in warm
position, ohmmeter should read 150-250 ohms. If servo motor fails
tests in either step, replace servo motor.

Fig. 8: Air-Mix Servo Motor Connector

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Recirc/Fresh Servo Motor

1) Disconnect recirc/fresh servo motor connector. Connect a
battery positive jumper lead to terminal No. 1. Connect battery
negative jumper lead to terminal No. 2. Servo motor lever should move
smoothly from fresh to recirc. See Fig. 9.
2) Move battery negative jumper lead to terminal No. 3. Servo
motor lever should move smoothly from recirc to fresh. If servo motor
operation is not as specified, replace servo motor.

Fig. 9: Recirc/Fresh Servo Motor Connector

Courtesy of Toyota Motor Sales, U.S.A., Inc.

Blower Auto Speed (Relay A)

1) Using an ohmmeter, check that continuity exists across
terminals No. 5 and 7. Check that no continuity exists across
terminals No. 3 and 4. See Fig. 10.
2) Using battery jumper leads, connect positive jumper lead
to terminal No. 5 and negative jumper lead to terminal No. 7. Using an
ohmmeter, check that continuity exists across terminals No. 3 and 4.
If readings are not as specified, replace relay.

Blower Auto Speed (Relay B)

1) Using an ohmmeter, check that continuity exists across
terminals No. 5 and 8. Check that no continuity exists across
terminals No. 2 and 3. See Fig. 10.
2) Using battery jumper leads, connect positive jumper lead
to terminal No. 5 and negative jumper lead to No. 8. Using an
ohmmeter, check that continuity exists across terminals No. 2 and 3.
If readings are not as specified, replace relay.

Blower Auto Speed (Relay C)

1) Using an ohmmeter, check that continuity exists across
terminals No. 5 and 6. Check that no continuity exists across
terminals No. 1 and 3. See Fig. 10.
2) Using battery jumper leads, connect positive jumper lead
to terminal No. 5 and negative jumper lead to No. 6. Using an
ohmmeter, check that continuity exists across terminals No. 1 and 3.
If readings are not as specified, replace relay.

Fig. 10: Blower Speed Control Relay Connector

Courtesy of Toyota Motor Sales, U.S.A., Inc.

VACUUM SWITCHING VALVE

 1) Remove Vacuum Switching Valve (VSV) from vacuum tank.
Apply battery voltage to VSV terminals. See Fig. 11. Blow into pipe
"A". Air should come out of pipe "B".
2) Disconnect battery. Blow into pipe "A". Air should come
out of filter, and not out of pipe "B". If VSV operation is not as
specified, replace valve. If operation is okay, go to next step.
3) Using an ohmmeter, check for continuity between each
terminal of VSV and VSV mounting bracket (ground). No continuity
should exist. If continuity exists, replace valve.
4) Using an ohmmeter, check for open circuit between VSV 
terminals.
 Resistance between terminals should be 38-43 ohms at 68 F
(20 C). If resistance is not as specified, replace valve.

Fig. 11: Vacuum Switching Valve Test

Courtesy of Toyota Motor Sales, U.S.A., Inc.

COOLANT TEMPERATURE SWITCH

 Remove coolant temperature switch from heater case. Unplug

coolant
 temperature switch connector. Immerse switch in 59-77 F (15-
25 C) water. Continuity should
 exist
 between terminals No. 1 and 3.
Immerse switch in 95-113 F (35-45 C) water. Continuity should exist
between terminals No. 2 and 4.

NOTE: Terminal No. 1 and 2 are near connector lock tab. Terminal
No. 3 and 4 are opposite tab (flat portion of connector).

REMOVAL & INSTALLATION

COMPRESSOR
Removal & Installation
1) Start and run engine with A/C on for 10 minutes.
Disconnect battery cables and remove battery. Disconnect A/C
compressor leads from wiring harness. Discharge A/C system using
approved refrigerant recovery/recycling equipment.
2) Disconnect hoses from compressor and cap all openings.
Loosen drive belt, remove compressor mounting bolts and A/C
compressor. To install, reverse removal procedure. Charge A/C system
and check for leaks.

RECEIVER-DRIER
Removal & Installation
Discharge A/C system using approved refrigerant
recovery/recycling equipment. Disconnect lines from top of receiver-
drier and cap all openings. Remove receiver-drier from holder. To
install, reverse removal procedure. If receiver-drier is replaced, add
.7 ounces of refrigerant oil to receiver-drier. Charge A/C system and
check for leaks.

CONDENSER
Removal & Installation
1) Discharge A/C system using approved refrigerant
recovery/recycling equipment. Remove grille and under cover. Remove
center brace and horn. Disconnect discharge hose, suction hose, liquid
line, and suction hose from condenser. Cap all openings. Remove
condenser.
2) To install, reverse removal procedure. If receiver-drier
is replaced, add 1.4-1.7 ounces of refrigerant oil to receiver-drier.
Charge A/C system and check for leaks.

A/C AMPLIFIER, THERMISTOR, EXPANSION VALVE & EVAPORATOR

Removal
1) Disconnect negative battery cable. Discharge A/C system
using approved refrigerant recovery/recycling equipment. Disconnect
suction hose from outlet fitting. Disconnect liquid line from inlet
fitting. Cap all openings.
2) Remove grommets from inlet and outlet fittings. Remove
glove box and reinforcement. Unplug connector and remove evaporator
housing. Remove connectors from lower evaporator case.
3) Remove 3 clips, 5 screws, upper case, thermistor holder,
lower case, and A/C amplifier. See Fig. 12. Remove evaporator.
Disconnect liquid line from inlet fitting of expansion valve. Remove
packing and heat sensing tube from suction hose of evaporator. Remove
expansion valve.

Installation
 To install, reverse removal procedure. If evaporator is
replaced, add 1.4-1.7 ounces of refrigerant oil to evaporator. Charge
A/C system and check for leaks.

Fig. 12: Exploded View of Evaporator Assembly

Courtesy of Toyota Motor Sales, U.S.A., Inc.

A/C SYSTEM SPECIFICATIONS

A/C SYSTEM SPECIFICATIONS TABLE




























































Application Specification

System Type ............................... Cycling Clutch

Compressor Type .................. Nippondenso 10-Cylinder
R-12 Capacity .................................. 21-27 oz.
Normal System Pressure 
Low Side .................... 21-28 psi (1.5-2.0 kg/cm  )
High Side ............... 206-213 psi (14.5-15.0 kg/cm )
Drive Belt Deflection ................................ ( 1)

(1) - Belt deflection is 165-175 lbs. using belt tension

gauge. Belt deflection is 120-130 lbs. for used belt.

WIRING DIAGRAMS

Fig. 13: Auto. A/C-Heater System Wiring Diagram (1 of 2)

Fig. 14: Auto. A/C-Heater System Wiring Diagram (2 of 2)