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Diagnostic Procedure for Actuators


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                  DIAGNOSTIC PROCEDURE FOR ACTUATORS
                                                                                    HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

7. Diagnostic Procedure for Actuators
A: INTAKE DOOR ACTUATOR
TROUBLE SYMPTOM:
FRESH/RECIRC mode is not changed.
WIRING DIAGRAM:


                                   IGNITION
                                    SWITCH                                                 BATTERY
                       F/B NO.17                         SBF-4                   SBF-1




                                                        i49       AUTO A/C CONTROL
                                                                  MODULE




                                                                  18
                                                                       20
                                                                            19




                                                                                    i41
                                                                  14
                                                                       13
                                                                            12




                                                                                   B202
                                                              4

                                                                  2
                                                                       1
                                                                            3




                                                                  B91

                                                           INTAKE DOOR
                                                             ACTUATOR




                     B91                                  i49     (GRAY)                                B202


                   1 2 3 4                    1 2 3 4 5 6 7 8 9 10                        1 2 3 4 5            6 7 8 9 10 11
                                              11 12 13 14 15 16 17 18 19 20               12 13 14 15 16 17 18 19 20 21 22 23 24




                                                                                                                                   AC-00800




                                                     AC-21
                     DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

                        Step                                       Check                     Yes                 No
1      CHECK POWER SUPPLY TO INTAKE DOOR              Is the voltage more than 7 V    Go to step 2.      Check the harness
       ACTUATOR.                                      (At normal temperature)?                           for open or short
       1) Turn the ignition switch to OFF.                                                               between intake
       2) Disconnect the intake door actuator con-                                                       door actuator and
       nector.                                                                                           fuse.
       3) Turn the ignition switch to ON.
       4) Measure the voltage between intake door
       actuator connector and chassis ground.
         Connector & terminal
           (B91) No. 4 (+) -- Chassis ground (-):
2      CHECK HARNESS BETWEEN A/C CON-                 Is the resistance less than 1   Go to step 3.      Repair the open
       TROL MODULE AND INTAKE DOOR ACTU-              ?                                                  circuit in harness
       ATOR.                                                                                             between auto A/C
       1) Turn the ignition switch to OFF.                                                               control module
       2) Disconnect the auto A/C control module                                                         and intake door
       connector.                                                                                        actuator.
       3) Measure the resistance between intake
       door actuator connector and auto A/C control
       module connector.
         Connector & terminal
           (i49) No. 18 -- (B91) No. 2:
           (i49) No. 20 -- (B91) No. 1:
           (i49) No. 19 -- (B91) No. 3:
3      CHECK INTAKE DOOR ACTUATOR OPERE-              Is the intake door actuator     Go to step 4.      Replace the intake
       TION.                                          moved to FRESH?                                    door actuator.
       1) Connect the intake door actuator connec-
       tor.
       2) Ground the auto A/C control module con-
       nector with a suitable wire.
       3) Turn the ignition switch to ON and check
       movement of intake door actuator.
         Connector & terminal
           (i49) No. 20 -- Chassis ground:
4      CHECK INTAKE DOOR ACTUATOR OPERA-              Is the intake door actuator     Replace the auto   Replace the intake
       TION.                                          moved to RECIRC?                A/C control mod-   door actuator.
       1) Turn the ignition switch to OFF.                                            ule.
       2) Ground the auto A/C control module con-
       nector with a suitable wire.
       3) Turn the ignition switch to ON and check
       movement of intake door actuator.
         Connector & terminal
           (i49) No. 18 -- Chassis ground:




                                                       AC-22
                            DIAGNOSTIC PROCEDURE FOR ACTUATORS
                                                                                                            HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

B: MODE DOOR ACTUATOR
TROUBLE SYMPTOM:
Air flow outlet is not changed.
WIRING DIAGRAM:



                                                                                       AUTO A/C CONTROL
                                                        A:    i48      B:   i49
                                                                                       MODULE




                                                                                                    A13
                                                                                        A12




                                                                                                          A16
                                                             B9

                                                                  B8




                                                                                  A4
                                                                       A5




                                                                                                                i41



                                                                                                          15
                                                             10

                                                                  11
                                                                       8


                                                                                  6
                                                                                        7


                                                                                                    9           B202
                                                                                                          10
                                                             1

                                                                  2

                                                                       4
                                                                            7
                                                                                  5

                                                                                        6
                                                                                              9

                                                                                                    8




                                                                                B77

                                                                       MODE ACTUATOR




            B77   (BROWN)               i48   (GRAY)                                          i49   (GRAY)                              B202


    1 2 3 4 5 6 7 8 9 10       1 2 3 4 5 6 7 8                                                                         1 2 3 4 5            6 7 8 9 10 11
                                                                            1 2 3 4 5 6 7 8 9 10
                               9 10 11 12 13 14 15 16                                                                  12 13 14 15 16 17 18 19 20 21 22 23 24
                                                                            11 12 13 14 15 16 17 18 19 20




                                                                                                                                                                AC-00801




                                                                        AC-23
                       DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

                        Step                                           Check                    Yes             No
1      CHECK POWER SUPPLY FOR AUTO A/C                    Is the voltage more than 12 V? Go to step 2.   Replace the auto
       CONTROL MODULE SIDE.                                                                              A/C control mod-
       1) Turn the ignition switch to ON.                                                                ule.
       2) Turn the mode control dial to VENT posi-
       tion.
       3) Press the DEF switch and measure the
       voltage between auto A/C control module and
       chassis ground when VENT is changed to DEF
       position.
         Connector & terminal
           (i49) No. 9 (+) -- Chassis ground (-):
2      CHECK POWER SUPPLY FOR ACTUATOR                    Is the voltage more than 7 V   Go to step 3.   Repair the open
       SIDE.                                              (At normal temperature)?                       circuit in harness
       1) Turn the mode control dial to VENT posi-                                                       between auto A/C
       tion.                                                                                             control module
       2) Press the DEF switch and measure the                                                           and mode door
       voltage between mode door actuator harness                                                        actuator.
       connector terminal and chassis ground when
       VENT is changed to DEF position.
         Connector & terminal
           (B77) No. 1 (+) -- Chassis ground (-):
3      CHECK POWER SUPPLY FOR AUTO A/C                    Is the voltage more than 12 V? Go to step 4.   Replace the auto
       CONTROL MODULE SIDE.                                                                              A/C control mod-
       1) Press the DEF switch.                                                                          ule.
       2) Turn the mode control dial to VENT position
       and measure the voltage between auto A/C
       control module and chassis ground when DEF
       is changed to VENT position.
         Connector & terminal
           (i49) No. 8 (+) -- Chassis ground (-):
4      CHECK POWER SUPPLY FOR ACTUATOR                    Is the voltage more than 7 V   Go to step 5.   Repair the open
       SIDE.                                              (At normal temperature)?                       circuit in harness
       1) Press the DEF switch.                                                                          between auto A/C
       2) Turn the mode control dial to VENT position                                                    control module
       and measure the voltage between mode door                                                         and mode door
       actuator harness connector terminal and chas-                                                     actuator.
       sis ground when DEF is changed to VENT
       position.
         Connector & terminal
           (B77) No. 2 (+) -- Chassis ground (-):
5      CHECK ACTUATOR.                                    Does the motor operate nor-    Go to step 6.   Replace the mode
       1) Turn the ignition switch to OFF.                mally?                                         door actuator.
       2) Disconnect the connector from mode door
       actuator.
       3) Connect the battery positive (+) terminal to
       terminal No. 1 and ground (-) terminal to termi-
       nal No. 2 of mode door actuator to make sure
       that actuator operates.
       4) Connect the battery positive (+) terminal to
       terminal No. 2 and ground (-) terminal to termi-
       nal No. 1 of mode door actuator to make sure
       that actuator operates.




                                                           AC-24
                    DIAGNOSTIC PROCEDURE FOR ACTUATORS
                                                                         HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

                       Step                                        Check                   Yes                  No
6    CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage the value shown Go to step 9.       Go to step 7.
     NAL VOLTAGE.                                    in the followings?
     1) Turn the ignition switch to ON.              HEAT, D/H, DEF: Approx. 5 V,
     2) Turn the mode control dial and measure       VENT, BI-LEVEL: Approx. 0 V
     voltage between auto A/C control module har-
     ness connector terminal and chassis ground
     for each mode.
       Connector & terminal
         (i48) No. 4 (+) -- Chassis ground (-):
7    CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage approx. 5 V?     Go to step 9.      Go to step 8.
     NAL POWER SUPPLY.
     1) Turn the ignition switch to OFF.
     2) Disconnect the connector from mode door
     actuator.
     3) Turn the ignition switch to ON.
     4) Measure the voltage between mode door
     actuator harness connector terminal and chas-
     sis ground.
       Connector & terminal
         (B77) No. 5 (+) -- Chassis ground (-):
8    CHECK HARNESS BETWEEN AUTO A/C                  Is the resistance less than 1   Replace the auto   Repair the open
     CONTROL MODULE AND MODE DOOR AC-                ?                               A/C control mod-   circuit in harness
     TUATOR.                                                                         ule.               between auto A/C
     1) Turn the ignition switch to OFF.                                                                control module
     2) Disconnect the connectors from auto A/C                                                         and mode door
     control module and mode door actuator.                                                             actuator.
     3) Measure the resistance of harness
     between auto A/C control module and mode
     door actuator.
       Connector & terminal
         (i48) No. 4 -- (B77) No. 5:
9    CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage the value    Go to step 12.         Go to step 10.
     NAL VOLTAGE.                                    shown in the followings?
     1) Turn ignition switch to ON.                  VENT, D/H: Approx. 5 V, BI-
     2) Turn the mode control dial and measure       LEVEL, HEAT, DEF: Approx.
     voltage between auto A/C control module har-    0V
     ness connector terminal and chassis ground
     for each mode.
       Connector & terminal
         (i48) No. 12 (+) -- Chassis ground (-):
10   CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage approx. 5 V?     Go to step 12.     Go to step 11.
     NAL POWER SUPPLY.
     1) Turn the ignition switch to OFF.
     2) Disconnect the connector from mode door
     actuator.
     3) Turn the ignition switch to ON.
     4) Measure the voltage between mode door
     actuator harness connector terminal and chas-
     sis ground.
       Connector & terminal
         (B77) No. 6 (+) -- Chassis ground (-):
         (B77) No. 9 (+) -- Chassis ground (-):




                                                      AC-25
                      DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

                         Step                                       Check                     Yes                   No
11     CHECK HARNESS BETWEEN AUTO A/C                  Is the resistance less than 1   Replace the auto   Repair the open
       CONTROL MODULE AND MODE DOOR AC-                ?                               A/C control mod-   circuit in harness
       TUATOR.                                                                         ule.               between auto A/C
       1) Turn the ignition switch to OFF.                                                                control module
       2) Disconnect the connectors from auto A/C                                                         and mode door
       control module and mode door actuator.                                                             actuator.
       3) Measure the resistance of harness
       between auto A/C control module and mode
       door actuator.
         Connector & terminal
           (i48) No. 12 -- (B77) No. 6:
           (i48) No. 12 -- (B77) No. 9:
12     CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage the value shown Go to step 15.      Go to step 13.
       NAL VOLTAGE.                                    in the followings?
       1) Turn ignition switch to ON.                  BI-LEVEL, DEF: Approx. 5 V,
       2) Turn the mode control dial and measure       VENT, HEAT, D/H: Approx. 0 V
       voltage between auto A/C control module har-
       ness connector and chassis ground for each
       mode.
         Connector & terminal
           (i48) No. 5 (+) -- Chassis ground (-):
13     CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage approx. 5 V?     Go to step 15.     Go to step 14.
       NAL POWER SUPPLY.
       1) Turn the ignition switch to OFF.
       2) Disconnect the connector from mode door
       actuator.
       3) Turn the ignition switch to ON.
       4) Measure the voltage between mode door
       actuator harness connector terminal and chas-
       sis ground.
         Connector & terminal
           (B77) No. 4 (+) -- Chassis ground (-):
           (B77) No. 7 (+) -- Chassis ground (-):
14     CHECK HARNESS BETWEEN AUTO A/C                  Is the resistance less than 1   Replace the auto   Repair the open
       CONTROL MODULE AND MODE DOOR AC-                ?                               A/C control mod-   circuit in harness
       TUATOR.                                                                         ule.               between auto A/C
       1) Turn the ignition switch to OFF.                                                                control module
       2) Disconnect the connectors from auto A/C                                                         and mode door
       control module and mode door actuator.                                                             actuator.
       3) Measure the resistance of harness
       between auto A/C control module and mode
       door actuator.
         Connector & terminal
           (i48) No. 5 -- (B77) No. 4:
           (i48) No. 5 -- (B77) No. 7:
15     CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage the value shown Go to step 19.      Go to step 16.
       NAL VOLTAGE.                                    in the followings?
       1) Turn ignition switch to ON.                  VENT, BI-LEVEL, HEAT:
       2) Turn the mode control dial and measure       Approx. 5V D/H, DEF: Approx.
       voltage between auto A/C control module har-    0V
       ness connector terminal and chassis ground
       for each mode.
         Connector & terminal
           (i48) No. 13 (+) -- Chassis ground (-):




                                                        AC-26
                    DIAGNOSTIC PROCEDURE FOR ACTUATORS
                                                                         HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

                     Step                                         Check                     Yes                 No
16   CHECK AUTO A/C CONTROL MODULE SIG-              Is the voltage approx. 5 V?     Go to step 18.     Go to step 17.
     NAL POWER SUPPLY.
     1) Turn the ignition switch to OFF.
     2) Disconnect the connector from mode door
     actuator.
     3) Turn the ignition switch to ON.
     4) Measure the voltage between mode door
     actuator harness connector and chassis
     ground.
      Connector & terminal
        (B77) No. 8 (+) -- Chassis ground (-):
17   CHECK HARNESS BETWEEN AUTO A/C                  Is the resistance less than 1   Replace the auto   Repair the open
     CONTROL MODULE AND MODE DOOR AC-                ?                               A/C control mod-   circuit in harness
     TUATOR.                                                                         ule.               between auto A/C
     1) Turn the ignition switch to OFF.                                                                control module
     2) Disconnect the connectors from auto A/C                                                         and mode door
     control module and mode door actuator.                                                             actuator.
     3) Measure the resistance of harness
     between auto A/C control module and mode
     door actuator.
      Connector & terminal
        (i48) No. 13 -- (B77) No. 8:
18   CHECK ACTUATOR GROUND CIRCUIT.                  Is the resistance less than 1   Replace the mode Repair the open
     1) Turn the ignition switch to OFF.             ?                               door actuator.   circuit in harness
     2) Disconnect the connector from auto A/C                                                        between auto A/C
     control module.                                                                                  control module
     3) Measure the resistance of harness                                                             and mode door
     between auto A/C control module and mode                                                         actuator.
     door actuator.
      Connector & terminal
        (i48) No. 16 -- (B77) No. 10:
19   CHECK POOR CONTACT.                             Is there poor contact in con-   Repair the con-    Repair the poor
     Check poor contact in auto A/C control module   nector?                         nector.            contact in auto A/C
     connector.                                                                                         control module.




                                                      AC-27
                      DIAGNOSTIC PROCEDURE FOR ACTUATORS
HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

C: AIR MIX DOOR ACTUATOR
TROUBLE SYMPTOM:
Outlet air temperature is not changed.
WIRING DIAGRAM:



                                                                                AUTO A/C CONTROL
                                                     A:   i48   B:   i49
                                                                                MODULE




                                                                                 A16
                                                                B1
                                                                     B7
                                                                           A7


                                                                                       B6
                                                                1

                                                                     2




                                                                                       6
                                                                                 3
                                                                           4




                                                                          i65

                                                                AIR MIX DOOR
                                                                 ACTUATOR




         i65                    A:   i48   (GRAY)                               B:     i49   (GRAY)


       1     2              1 2 3 4 5 6 7 8                          1 2 3 4 5 6 7 8 9 10
       3 4 5 6              9 10 11 12 13 14 15 16                   11 12 13 14 15 16 17 18 19 20




                                                                                                      AC-00802




                                                                 AC-28
                   DIAGNOSTIC PROCEDURE FOR ACTUATORS
                                                                         HVAC SYSTEM (AUTO A/C) (DIAGNOSTICS)

                      Step                                        Check                     Yes               No
1   CHECK POWER SUPPLY TO AIR MIX DOOR               Is the voltage approx. 5 V?     Go to step 2.     Replace the auto
    ACTUATOR PBR.                                                                                      A/C control mod-
    1) Turn the ignition switch to OFF.                                                                ule.
    2) Disconnect the air mix door actuator con-
    nector.
    3) Turn the ignition switch and AUTO switch to
    ON.
    4) Measure the voltage between A/C control
    module connector terminals.
     Connector & terminal
        (i48) No. 7 (+) -- (i48) No. 16 (-):
2   CHECK POWER SUPPLY TO AIR MIX DOOR               Is the voltage more than 7 V    Go to step 3.     Replace the auto
    ACTUATOR.                                        (At normal temperature)?                          A/C control mod-
    Measure the voltage between auto A/C control                                                       ule.
    module connector terminal and chassis ground
    when setting temperature control dial to FULL
    COOL.
     Connector & terminal
        (i49) No. 6 (+) -- Chassis ground (-):
3   CHECK POWER SUPPLY TO AIR MIX DOOR               Is the voltage more than 7 V    Go to step 4.     Replace the auto
    ACTUATOR.                                        (At normal temperature)?                          A/C control mod-
    Measure the voltage between auto A/C control                                                       ule.
    module connector terminal and chassis ground
    when setting temperature control dial to FULL
    HOT.
     Connector & terminal
        (i49) No. 7 (+) -- Chassis ground (-):
4   CHECK HARNESS BETWEEN AUTO A/C                   Is the resistance less than 1   Go to step 5.     Repair the open
    CONTROL MODULE AND AIR MIX DOOR                  ?                                                 circuit in harness
    ACTUATOR.                                                                                          between auto A/C
    1) Turn the A/C and ignition switch to OFF.                                                        control module
    2) Disconnect the auto A/C control module                                                          and air mix door
    connector.                                                                                         actuator.
    3) Measure the resistance between auto A/C
    control module and air mix door actuator con-
    nector.
     Connector & terminal
        (i65) No. 1 -- (i49) No. 1:
        (i65) No. 2 -- (i49) No. 7:
        (i65) No. 3 -- (i48) No. 16:
        (i65) No. 4 -- (i48) No. 7:
        (i65) No. 6 -- (i49) No. 6:
5   CHECK AIR MIX DOOR ACTUATOR PBR                  Is the voltage 0.5 V (FULL Go to step 6.          Replace the air
    SIGNAL.                                          COOL) -- 4.5 V (FULL HOT)?                        mix door actuator.
    1) Connect the auto A/C control module and
    air mix door actuator connector.
    2) Turn the ignition switch and AUTO switch to
    ON.
    3) Change the set temperature between FULL
    COOL and FULL HOT, check voltage between
    auto A/C control module connector terminals.
     Connector & terminal
        (i49) No. 1 (+) -- (i48) No. 16 (-):
6   CHECK POOR CONTACT.                              Is there poor contact in the    Repair the con-   Replace the auto
    Check poor contact in the auto A/C control       connector?                      nector.           A/C control mod-
    module connector.                                                                                  ule.




                                                      AC-29



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