Heating Air Conditioning. Air Conditioning System (For Automatic Air Conditioning System) Air Conditioning Compressor Magnetic Clutch Circuit

Vehicle Interior. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

Heating Air Conditioning. Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

DESCRIPTION

WIRING DIAGRAM

INSPECTION PROCEDURE

READ VALUE USING INTELLIGENT TESTER (A/C SIGNAL)

INSPECT MAGNET CLUTCH RELAY

CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY)

CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY

INSPECT COOLER COMPRESSOR ASSEMBLY

CHECK HARNESS AND CONNECTOR (COOLER COMPRESSOR ASSEMBLY - MAGNET CLUTCH RELAY)

CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - ECM)

CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY

CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - ECM)

CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY

AIR CONDITIONING SYSTEM (for Automatic Air Conditioning System) - Air Conditioning Compressor Magnetic Clutch Circuit

DESCRIPTION

The air conditioning amplifier assembly outputs the magnet clutch on request signal to the ECM. The ECM sends a magnet clutch on permission signal to the air conditioning amplifier assembly. The air conditioning amplifier assembly turn the magnet clutch on based on the signal.

WIRING DIAGRAM

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25.Heating Air Conditioning.Air Conditioning System (For Automatic Air Conditioning System).Air Conditioning System (For Automatic Air Conditioning System) Air Conditioning Compressor Magnetic Clutch Circuit

INSPECTION PROCEDURE

NOTICE:

Inspect the fuses for circuits related to this system before performing the following inspection procedure.

1.READ VALUE USING INTELLIGENT TESTER (A/C SIGNAL)

Use the Data List to check if the magnet clutch on request signal is functioning properly (HILUX_TGN26 RM000003R7K00GX.html).

ECM
Tester Display	Measurement Item/Range	Normal Condition	Diagnostic Note
A/C Signal	Magnet clutch on request signal / ON or OFF	ON: A/C switch on OFF: A/C switch off	Check this item with the engine idling and the blower switch on (LO level).

OK:: Display is as specified in normal condition.

Go to step 9

OK

2.INSPECT MAGNET CLUTCH RELAY

Remove the magnet clutch relay (HILUX_TGN26 RM000003ZPW018X.html).

Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Tester Connection
Condition
Specified Condition
3 - 5
Battery voltage is not applied to terminals 1 and 2
10 kΩ or higher
Battery voltage is applied to terminals 1 and 2
Below 1 Ω

REPLACE MAGNET CLUTCH RELAY (HILUX_TGN26 RM000003ZPW018X.html)

OK

3.CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - BATTERY)

Disconnect the G94 air conditioning amplifier assembly connector.

Measure the voltage according to the value(s) in the table below.
Standard Voltage:
Tester Connection
Switch Condition
Specified Condition
G94-13 (MGC) - Body ground
Ignition switch ON
11 to 14 V
Ignition switch off
Below 1 V
Text in Illustration
*a
Front view of wire harness connector
(to Air Conditioning Amplifier Assembly)

Text in Illustration
*a	Front view of wire harness connector (to Air Conditioning Amplifier Assembly)

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

4.CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY

Remove the air conditioning amplifier assembly with its connectors still connected (HILUX_TGN26 RM000001K3A024X.html).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Condition	Specified Condition
G94-13 (MGC) - Body ground	Engine idling A/C switch on (magnet clutch on permitted)	Below 1 V
G94-13 (MGC) - Body ground	Engine idling A/C switch off or on (magnet clutch not on permitted)	11 to 14 V

Text in Illustration
*a	Component with harness connected (Air Conditioning Amplifier Assembly)

Go to step 7

OK

5.INSPECT COOLER COMPRESSOR ASSEMBLY

Hilux. Tgn26, 36 Kun25, 26, 35, 36 Ggn25

Remove the cooler compressor assembly.
1. for 1KD-FTV: HILUX_TGN26 RM0000012JZ038X.html.
2. for 2TR-FBE: HILUX_TGN26 RM0000012JZ036X.html.
3. for 1GR-FE: HILUX_TGN26 RM0000012JZ02PX.html.

Apply battery voltage to the magnet clutch and check operation of the magnet clutch.
OK:
Measurement Connection
Specified Condition
Battery positive (+) → Terminal 1
Battery negative (-) → Ground wire
Magnet clutch engages
Result
Result
Proceed to
OK
A
NG (for 1KD-FTV)
B
NG (for 2TR-FBE)
C
NG (for 1GR-FE)
D

REPLACE COOLER COMPRESSOR ASSEMBLY (HILUX_TGN26 RM0000012JZ038X.html)

REPLACE COOLER COMPRESSOR ASSEMBLY (HILUX_TGN26 RM0000012JZ036X.html)

REPLACE COOLER COMPRESSOR ASSEMBLY (HILUX_TGN26 RM0000012JZ02PX.html)

A

6.CHECK HARNESS AND CONNECTOR (COOLER COMPRESSOR ASSEMBLY - MAGNET CLUTCH RELAY)

Disconnect the C33 cooler compressor assembly connector.

Remove the magnet clutch relay (HILUX_TGN26 RM000003ZPW018X.html).

Measure the voltage according to the value(s) in the table below.
Standard Voltage:
Tester Connection
Switch Condition
Specified Condition
G71-5 - Body ground
Ignition switch ON
11 to 14 V
Ignition switch off
Below 1 V

Measure the resistance according to the value(s) in the table below.
Standard Resistance:
Tester Connection
Condition
Specified Condition
G71-3 - C33-1
Always
Below 1 Ω
G71-3 - Body ground
Always
10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

PROCEED TO NEXT SUSPECTED AREA SHOWN IN PROBLEM SYMPTOMS TABLE (HILUX_TGN26 RM0000045E301VX.html)

7.CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - ECM)

Disconnect the G94 air conditioning amplifier assembly connector.

Disconnect the G38*1, G148*2, G156*3, G146*4, or G154*5 ECM connectors.
1. *1: for 1KD-FTV except DPF and i-ART
2. *2: for 1KD-FTV for DPF
3. *3: for 1KD-FTV for i-ART
4. *4: for 2TR-FBE
5. *5: for 1GR-FE

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
for 1KD-FTV except DPF and i-ART
Tester Connection
Condition
Specified Condition
G94-7 (ACT) - G38-19 (ACT)
Always
Below 1 Ω
G94-7 (ACT) - Body ground
Always
10 kΩ or higher
for 1KD-FTV for DPF
Tester Connection
Condition
Specified Condition
G94-7 (ACT) - G148-13 (ACT)
Always
Below 1 Ω
G94-7 (ACT) - Body ground
Always
10 kΩ or higher
for 1KD-FTV for i-ART
Tester Connection
Condition
Specified Condition
G94-7 (ACT) - G156-13 (ACT)
Always
Below 1 Ω
G94-7 (ACT) - Body ground
Always
10 kΩ or higher
for 2TR-FBE
Tester Connection
Condition
Specified Condition
G94-7 (ACT) - G146-21 (ACT)
Always
Below 1 Ω
G94-7 (ACT) - Body ground
Always
10 kΩ or higher
for 1GR-FE
Tester Connection
Condition
Specified Condition
G94-7 (ACT) - G154-25 (ACT)
Always
Below 1 Ω
G94-7 (ACT) - Body ground
Always
10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

8.CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY

Remove the air conditioning amplifier assembly with its connectors still connected (HILUX_TGN26 RM000001K3A024X.html).

Measure the voltage according to the value(s) in the table below.

Standard Voltage:

Tester Connection	Condition	Specified Condition
G94-7 (ACT) - Body ground	Engine idling Blower switch on (LO level) A/C switch on (magnet clutch on)	11 to 14 V
G94-7 (ACT) - Body ground	Engine idling Blower switch on (LO level) A/C switch off or on (magnet clutch off)	Below 1 V

Text in Illustration
*a	Component with harness connected (Air Conditioning Amplifier Assembly)

Result
Result	Proceed to
OK	A
NG (for 1KD-FTV)	B
NG (for 2TR-FBE)	C
NG (for 1GR-FE)	D

REPLACE ECM (HILUX_TGN26 RM0000013Z001IX.html)

REPLACE ECM (HILUX_TGN26 RM000000VW2024X.html)

REPLACE ECM (HILUX_TGN26 RM000000VW202SX.html)

REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY (HILUX_TGN26 RM000001K3A024X.html)

9.CHECK HARNESS AND CONNECTOR (AIR CONDITIONING AMPLIFIER - ECM)

Disconnect the G94 air conditioning amplifier assembly connector.

Disconnect the G38*1, G148*2, G156*3, G146*4, or G154*5 ECM connectors.
1. *1: for 1KD-FTV except DPF and i-ART
2. *2: for 1KD-FTV for DPF
3. *3: for 1KD-FTV for i-ART
4. *4: for 2TR-FBE
5. *5: for 1GR-FE

Measure the resistance according to the value(s) in the table below.

Standard Resistance:
for 1KD-FTV except DPF and i-ART
Tester Connection
Condition
Specified Condition
G94-21 (AC1) - G38-18 (AC1)
Always
Below 1 Ω
G94-21 (AC1) - Body ground
Always
10 kΩ or higher
for 1KD-FTV for DPF
Tester Connection
Condition
Specified Condition
G94-21 (AC1) - G148-10 (AC1)
Always
Below 1 Ω
G94-21 (AC1) - Body ground
Always
10 kΩ or higher
for 1KD-FTV for i-ART
Tester Connection
Condition
Specified Condition
G94-21 (AC1) - G156-10 (AC1)
Always
Below 1 Ω
G94-21 (AC1) - Body ground
Always
10 kΩ or higher
for 2TR-FBE
Tester Connection
Condition
Specified Condition
G94-21 (AC1) - G146-19 (AC1)
Always
Below 1 Ω
G94-21 (AC1) - Body ground
Always
10 kΩ or higher
for 1GR-FE
Tester Connection
Condition
Specified Condition
G94-21 (AC1) - G154-24 (AC1)
Always
Below 1 Ω
G94-21 (AC1) - Body ground
Always
10 kΩ or higher

REPAIR OR REPLACE HARNESS OR CONNECTOR

OK

10.CHECK AIR CONDITIONING AMPLIFIER ASSEMBLY

Remove the air conditioning amplifier assembly with its connectors still connected (HILUX_TGN26 RM000001K3A024X.html).

Measure the voltage according to the value(s) in the table below.
Standard Voltage:
Tester Connection
Condition
Specified Condition
G94-21 (AC1) - Body ground
Engine idling
Blower switch on (LO level)
A/C switch on
Below 1 V
Engine idling
Blower switch on (LO level)
A/C switch off
11 to 14 V
Text in Illustration
*a
Component with harness connected
(Air Conditioning Amplifier Assembly)
Result
Result
Proceed to
OK (for 1KD-FTV)
A
OK (for 2TR-FBE)
B
OK (for 1GR-FE)
C
NG
D

REPLACE ECM (HILUX_TGN26 RM000000VW2024X.html)

REPLACE ECM (HILUX_TGN26 RM000000VW202SX.html)

REPLACE AIR CONDITIONING AMPLIFIER ASSEMBLY (HILUX_TGN26 RM000001K3A024X.html)

REPLACE ECM (HILUX_TGN26 RM0000013Z001IX.html)

Tester Connection	Switch Condition	Specified Condition
G94-13 (MGC) - Body ground	Ignition switch ON	11 to 14 V
G94-13 (MGC) - Body ground	Ignition switch off	Below 1 V

Measurement Connection	Specified Condition
Battery positive (+) → Terminal 1 Battery negative (-) → Ground wire	Magnet clutch engages

Result	Proceed to
OK (for 1KD-FTV)	A
OK (for 2TR-FBE)	B
OK (for 1GR-FE)	C
NG	D