How To Fix Toyota Camry Limp Mode

Front

Evaporator

Structure Evaporator Body

Heater Core

Evaporator

Evaporator

Rooftop Unit And Evaporator Location

Heater Core

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Heater Core

Top View

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Heater Core

A compact, lightweight, and highly efficient SFA (Straight Flow Aluminum)-II type heater core is used.

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Evaporator

A semi-center location air conditioning unit, in which the evaporator and heater core are placed in the vehicle's longitudinal direction, is used. As a result, the air conditioning unit has been made compact and lightweight.

► A revolutionary super-slim structure evaporator is used.

► By placing the tanks at the top and the bottom of the evaporator unit and adopting a micropore tube construction, the following effects have been realized:

a) The heat exchanging efficiency has been improved.

b) The temperature distribution has been made more uniform.

c) The evaporator has been made thinner. 58 mm (2.3 in.) A 38 mm (1.5 in.)

► The evaporator body has been coated with a type of resin that contains an antibacterial agent in order to minimize the source of foul odor and the propagation of bacteria. The substrate below this coating consists of a chromate-free layer to help protect the environment.

Mixing Resin Air BlowerRailway Drainage Systems

Evaporator Temp. Sensor

Evaporator temp. sensor detects the temperature of the cool air immediately past the evaporator in the form of resistance changes, and outputs it to the A/C ECU.

Blower Motor

The blower motor has an in-built blower controller, and is controlled with the duty control from the A/C ECU.

BUS Connector

► A BUS connector is used in the wire harness connection that connects the servo motor from the A/C ECU.

BUS Connector

To Air Mix Servo Motor (For Driver)

BUS Connector

To Air Inlet Servo Motor

Evaporator Temp. Sensor iM^c

Evaporator Temp. Sensor

BUS Connector-

To Air Vent Servo Motor

BUS Connector-

To Air Vent Servo Motor

BUS Connector To Air Mix Servo Motor (For Front Passenger)

BUS Connector To Air Mix Servo Motor (For Front Passenger)

► The BUS connector has a built-in communication/drive IC which communicates with each servo motor connector, actuates the servo motor, and has a position detection function. This enables bus communication for the servo motor wire harness, for a more lightweight construction and a reduced number of wires.

A/C ECU

Communication IC

Communication/Drive IC

BUS Connector

With BUS Connector

Servo Motor

1

—0^0-

Drive IC

Drive IC

Servo Motor

Without BUS Connector

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285BE44

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Servo Motor

The pulse pattern type servo motor consists of a printed circuit board and servo motor. The printed circuit board has three contact points, and transmits to the A/C ECU two ON-OFF signals for the difference of the pulse phase. The smart connector detects the damper position and movement direction with this signal.

Contact Points

Conduction Portion

Conduction Portion

Engine 2gr Repair

Printed-circuit Board

Conduction Portion Contact Points

Printed-circuit Board

GND B

Conduction Portion Contact Points

Printed-circuit Board

GND B

How Clean Servo Motor Camry

1 Rotation

1 Rotation

Printed-circuit Board

285BE46

Clean Air Filter

A micro dust and pollen filter is used. This filter excels in the removal of dust and pollen. The filter is made of polyester. Thus, it can be disposed of easily as a non hazardous combustible material, a feature that is provided in consideration of the environment.

Large Foreign Object Filter L

► The filter used on U.S.A. models should be changed at 30,000 miles. (cleaning interval: 15,000 miles).

► The filter used on Canadian package models should be changed at 16,000 km. (cleaning interval: 8,000 km).

► The filter used on Mexican package models should be changed at 30,000 km under normal conditions (cleaning interval: 10,000 km). Under dusty conditions, the filter should be changed at 15,000 km (cleaning interval: 5,000 km).

However, observation of these guidelines should depend on the usage conditions (or environment).

Electr

(Microscopic foreign object filtration)

Large Foreign Object Filter L

Multi Flow Condenser

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Service Tip y

3. Condenser

► A MF (Multi-Flow) type condenser is used. The condenser consists of two cooling portions: a condensing portion and a super-cooling portion, and gas-liquid separator (modulator) are integrated together. This condenser uses a sub-cool cycle that offers excellent heat-exchange performance.

► In the sub-cool cycle, after the refrigerant passes through the condensing portion of the condenser, both the liquid refrigerant and the gaseous refrigerant that could not be liquefied are cooled again in the super-cooling portion. Thus, the refrigerant is sent to the evaporator in an almost completely liquefied state.

Gaseous Refrigerant

Liquid Refrigerant

Gaseous Refrigerant

Liquid Refrigerant

Super-Cooling Portion

Modulator

Super-Cooling Portion

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Service Tip-

The point at which the air bubbles disappear in the refrigerant of the sub-cool cycle is lower than the proper amount of refrigerant with which the system must be filled. Therefore, if the system recharged with refrigerant based on the point at which the air bubbles disappear, the amount of refrigerant would be insufficient. As a result, the cooling performance of the system will be affected. If the system is overcharged with refrigerant, this will also lead to a reduced performance.

For the proper method of verifying the amount of the refrigerant and for instructions on how to recharge the system with refrigerant, see the 2007 Camry Repair Manual (Pub. No. RM0250U).

High Pressure

Properly Recharged Amount

Point in which Bubbles Disappear

Amount of Refrigerant

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4. A/C Compressor General

► The A/C compressor is a continuously variable capacity type in which its capacity can be varied in accordance with the cooling load of the air conditioning.

► This compressor consists of the A/C pulley, shaft, lug plate, swash plate, piston, shoe, crank chamber, cylinder, and solenoid valve.

► The A /C pulley with built-in magnetic clutch and the lock sensor that detects whether the magnetic clutch is locked are installed on models with the 2GR-FE engine.

► The DL (Damper Limiter) type A/C pulley is installed on models with the 2AZ-FE engine.

► A solenoid valve that adjusts the suction pressure so that the compressor capacity can be controlled as desired is provided.

► The internal valve is provided on models with 2AZ-FE engine to improve the A/C compressor durability under the high speed and large thermal load conditions. The internal valve is integrated into the solenoid valve.

Crank Chamber

Swash Plate

Lug Plate

A/C Pulley ► Magnetic Clutch

Piston

Crank Chamber

Swash Plate

Lug Plate

Piston

A/C Pulley ► Magnetic Clutch

Mr2 Rpm Diagram

Cylinder

Solenoid Valve

Lock Sensor Shaft

Lock Sensor Shaft

A/C Compressor for Models with 2GR-FE Engine

Cylinder

Solenoid Valve

Lock Sensor (Only for Models with 2GR-FE Engine)

The lock sensor sends A/C pulley speed signals to the A/C ECU. The A/C ECU determines whether the magnetic clutch is locked or not by using those signals and engine speed signals.

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Solenoid Valve Operation

► The crank chamber is connected to the discharge passage. A solenoid valve is provided between the discharge passage (LO pressure) and the discharge passage (HI pressure).

► The solenoid valve operates under duty cycle control in accordance with the signals from A/C ECU.

Suction

Suction

Crank Chamber

Evac Suction Pressure

Discharge Pressure (HI)

Discharge Pressure (LO) Discharge Pressure (HI)

Crank Chamber

"7/

Piston

» Crank Chamber Discharge Pressure

Discharge Pressure (HI)

Discharge Pressure (LO) Discharge Pressure (HI)

Crank Chamber Pressure Suction Pressure

Solenoid Valve (2GR-FE Engine)

Solenoid Valve (2AZ-FE Engine)

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► When the solenoid valve closes (solenoid coil is energized), a difference in pressure is created and the pressure in the crank chamber decreases. Then, the pressure that is applied to the right side of the piston becomes greater than the pressure that is applied to the left side of the piston. This compresses the spring and tilts the swash plate. As a result, the piston stroke increases and the discharge capacity increases.

Crank Chamber Pressure + Spring Force

Suction

Suction

Discharge

Discharge Pressure

Crank Chamber Pressure + Spring Force

Piston Stroke: Large

A/C ECU

Discharge

Discharge Pressure

Piston Stroke: Large

A/C ECU

Solenoid Valve (2GR-FE Engine)

Solenoid Valve (2AZ-FE Engine)

► When the solenoid valve opens (solenoid coil is not energized), the difference in pressure disappears. Then, the pressure that is applied to the left side of the piston becomes the same as the pressure that is applied to the right side of the piston. Thus, the spring elongates and eliminates the tilt of the swash plate. As a result, there is no piston stroke and the discharge capacity is reduced.

Suction

Suction

1991 Camry 2az Crankshaft Pulley
(2AZ-FE Engine)

Internal Valve Operation (Only for Models with 2AZ-FE Engine)

The internal valve operates when the A/C compressor speed has increased rapidly, the A/C compressor speed is high, or when thermal load has suddenly changed. As a result, the A/C compressor capacity is reduced, increasing the durability of the A/C compressor.

A/C ECU

Crank Chamber Pressure

Discharge Pressure ■

Discharge Pressure Crank Chamber Pressure

A/C ECU

Crank Chamber Pressure

Discharge Pressure ■

Discharge Pressure Crank Chamber Pressure

Internal Valve

Internal Valve

Solenoid Valve (2AZ-FE Engine)

DL type A/C Pulley (Only for Models with 2AZ-FE Engine)

This pulley contains a damper to absorb the torque fluctuations of the engine and a limiter mechanism to protect the drive belt in case the compressor locks. In the event that the compressor locks, the limiter mechanism causes the spoke portion of the pulley to break, thus separating the pulley from the compressor.

Spoke Portion

Spoke Portion

Great Circle Astrology

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a do

Limiter Mechanism

Damper

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5. A/C Pressure Sensor

A/C pressure sensor detects the refrigerant pressure and outputs it to the A/C ECU in the form of voltage changes.

6. Room Temp. Sensor and Outside Temp. Sensor

► The room temperature sensor detects the room temperature based on changes in the resistance of its built-in thermistor and sends a signal to the A/C ECU. This sensor is used on models with automatic air conditioning.

► The outside temperature sensor detects the outside temperature based on changes in the resistance of its built-in thermistor and sends a signal to the A/C ECU.

7. Solar Sensor

► The solar sensor consists of a photo diode, two amplifier circuits for the solar sensor, and a frequency converter circuit for the light control sensor. This sensor is used on models with automatic air conditioning.

► A solar sensor detects (in the form of changes in the current that flows through the built-in photo diode) the changes in the amount of sunlight from the LH and RH sides (2 directions) and outputs these sunlight strength signals to the A/C ECU.

LH Side RH Side

LH Side RH Side

Ecu Internal Circuit
Internal circuit of the solar sensor

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8. Plasmacluster™ Generator General

► A PlasmaclusterTM generator is provided inside the air duct of the side register on the driver seat side to improve the air quality and comfort in the cabin.

► This generator is controlled by the A/C ECU and operates in conjunction with the blower motor.

Behind the Combination Meter

Side Register

Side Register

Avensis Amplifier

NOTE:

► The PlasmaclusterTM generator uses a high voltage, which is hazardous. Therefore, if the PlasmaclusterTM generator requires repairs, be sure to have them done at a Toyota dealer.

► Do not apply any type of spray (such as a cleaning solvent or hair spray) or stick any foreign matter into the PlasmaclusterTM ion outlet, as this could cause improper operation or a malfunction.

► After use, dust may accumulate around the side register on the driver seat side. If this occurs, press the OFF switch on the heater control panel to stop the blower motor before cleaning the area.

► It is normal for the PlasmaclusterTM generator to emit a slight sound during operation. This sound is created when electrons collide with the electrode while PlasmaclusterTM ions are being generated.

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Operation

The PlasmaclusterTM generator produces positive and negative ions from the water molecules (H2O) and oxygen molecules (O2) in the air, and emits them into the air. These ions reduce airborne germs.

Positive Ions

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• SYSTEM CONTROL 1. General

The air conditioning system has the following controls.

Control

Outline

A/C

Neural Network Control

[See page BE-60]

This control is capable of effecting complex control by artificially simulating the information processing method of the nervous system of living organisms in order to establish a complex input/output relationship that is similar to a human brain.

Manual Control

The A /C ECU controls the damper positions (air inlet control damper, air mix control damper and mode control damper) and blower speed in accordance with the positions of the switches (temperature control switch, blower switch, mode select switch and air inlet control switch).

Outlet Air Temp. Control

Based on the temperature set at the temperature control switch, the neural network control calculates the outlet air temperature based on the input signals from various sensors.

The temperature settings for the driver and front passenger are controlled independently in order to provide separate vehicle interior temperatures for the right and left sides of the cabin. Thus, air conditioning that accommodates the occupants' preferences has been realized.

Blower Control

Controls the blower motor in accordance with the airflow volume that has been calculated by the neural network control based on the input signals from various sensors.

Automatically switches the air outlets in accordance with the outlet mode that has been calculated by the neural network control based on the input signals from various sensors.

Air Outlet Control

In accordance with the engine coolant temperature, outside air temperature, amount of sunlight, required blower, outlet temperature, and vehicle speed conditions, this control automatically switches the blower outlet to FOOT/DEF mode to prevent the windows from becoming fogged when the outside air temperature is low.

Air Inlet Control

Automatically controls the air inlet control damper to achieve the calculated required outlet air temperature.

Compressor Control

Through the calculation of the target evaporator temperature based on various sensor signals, the A/C ECU optimally controls the discharge capacity by regulating the opening extent of the A/C compressor solenoid valve.

The A/C ECU compares the A/C pulley speed signals, which are transmitted by the lock sensor located on the A/C compressor, with the engine speed signals, which are transmitted by the ECM (crankshaft position sensor). When the A/C ECU determines that the A/C pulley is locked, it turns off the magnetic clutch. (Only for models with 2GR-FE engine)

MAX A/C Control

When the temperature control switch is in the MAX A/C position, the A/C ECU turns the compressor on and activates the servomotor (air inlet) to set the air inlet control damper to the RECIRC position, improving the cooling efficiency.

Rear Window Defogger Control [See page BE-172]

Switches the rear defogger and outside rear view mirror heaters on for 15 minutes when the rear defogger button is pressed. Switches them off if the button is pressed again while they are operating.

Outside Temperature Indication Control

Calculates the outside temperature using signals transmitted by the outside temperature sensor. Calculated values are corrected by the A/C ECU and then indicated on the multi-information display.

Self-Diagnosis [See page BE-61]

A DTC (Diagnostic Trouble Code) is stored in the memory when the A/C ECU detects a problem with the air conditioning system.

2. Neural Network Control

► In previous automatic air conditioning systems, the A/C ECU determined the required outlet air temperature and blower air volume in accordance with the calculation formula that has been obtained based on information received from the sensors. However, because the senses of a person are rather complex, a given temperature is sensed differently, depending on the environment in which the person is situated. For example, a given amount of solar radiation can feel comfortably warm in a cold climate, or extremely uncomfortable in a hot climate. Therefore, as a technique for effecting a higher level of control, a neural network is used in the automatic air conditioning system. With this technique, the data that has been collected under varying environmental conditions is stored in the A/C ECU. The A/C ECU can then effect control to provide enhanced air conditioning comfort.

► The neural network control consists of neurons in the input layer, intermediate layer, and output layer. The input layer neurons process the input data of the outside temperature, the amount of sunlight, and the room temperature based on the outputs of the switches and sensors, and output them to the intermediate layer neurons. Based on this data, the intermediate layer neurons adjust the strength of the links among the neurons. The sum of these is then calculated by the output layer neurons in the form of the required outlet temperature, solar correction, target airflow volume, and outlet mode control volume. Accordingly, the A/C ECU controls the servo motors and blower motor in accordance with the control volumes that have been calculated by the neural network control.

Toyota Camry Dimention

I i : Neural Network Operation Range

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I i : Neural Network Operation Range

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