BODY ELECTRICAL AIR CONDITIONER BE-13

AIR CONDITIONER

DESCRIPTION

1. General

The new Hilux has an air conditioner system with the following equipment.

Thailand, Central
General
Destinations Philippines, Australia and South
Countries
Malaysia America
2TR-FE,
Engine All 1KD-FTV All All
1GR-FE
Single,
Cab Type All All Double All All
Extra
Manual A/C Option Option

Manual Cooler Standard*

Conventional Standard Option Standard

Heater
With PTC Standard

*: Except KUN15R-TRMDYT3

The heater control panel is the rotary switch type. A rotating cable control mechanism has been
adopted to make the control unit more compact.
The air conditioner unit has been made compact and lightweight by placing the evaporator and the
heater core horizontally, above and below in the unit, and adopting a film type slide door for the air
mix door.
A compact, lightweight, and highly efficient straight flow (full-path flow) aluminum heater core has
been adopted.
The PTC (Positive Temperature Coefficient) heater system contains a PTC heater that heats the air
that has passed through the heater core to ensure the proper heater performance.
A multi-tank supper-slim structure evaporator has been adopted on Central and South American
model.
A revolutionary-slim structure evaporator has been adopted on all except Central and South American
model.
A compact, lightweight, and low-noise swash plate type compressor has been adopted.
BE-14 BODY ELECTRICAL AIR CONDITIONER

Performance
Central and South Except Central and
Destinations
America South America
Heat Output
W 5,200

Air Flow
Heater m3/h 320
Volume
Power
W Less than 190 Less than 170
Consumption
Heat Output
PTC Heater W 450

Cooling
W 4,800
Capacity
Air conditioner Air Flow
m3/h 470
or Cooler Volume
Power
W Less than 230 Less than 200
Consumption

Specifications
Central and South Except Central and
Destinations
America South America
Straight Flow
Type
(Full-path Flow)
Ventilation and Heater Core

Size mm 150 x 201.5 x 21

Heater Core
WxHxL (in.) (5.9 x 7.9 x 0.8)
mm
Fin Pitch 1.8 (0.07)
(in.)
Motor Type DPD K62F-13.5T
Fan Type Semi Shroud Fan
Blower
Fan Size
mm (in.) 150 x 70 (5.9 x 2.8) 155 x 65 (6.1 x 2.6)
Dia. x H
Type Multi-flow (Sub-cool)
Air conditioner or Cooler

Size mm 570 x 492.3 x 16 620 x 440.6 x 16

Condenser WxHxL (in.) (22.4 x 18.4 x 0.6) (24.4 x 17.3 x 0.6)
Fin Pitch mm
3.60 (0.14) 3.55 (0.14)
(in.)
Evaporator Type Multi-tank Supper-slim Revolutionary-slim
Structure Structure
 BODY ELECTRICAL AIR CONDITIONER BE-15
Size mm 227.8 x 225 x 58 226.1 x 241 x 38
WxHxL (in.) (9.0 x 8.9 x 2.3) (8.9 x 9.5 x 1.5)
Fin Pitch mm
4.0 (0.16) 3.0 (0.12)
(in.)
Compressor Type 10S15 10S11
BE-16 BODY ELECTRICAL AIR CONDITIONER

2. System Diagram

Manual Control Cooler System

PSW
A/C Pressure
Switch

Engine ECU
ACT
Blower Motor Idle-Up Request Signal
Magnetic Clutch Actuation Signal
AC1

Air Conditioner
Blower Controller Amplifier
Switch

Evaporator TE MGC A/C Magnetic

Temp. Sensor TE-SG Clutch Relay

Temperature TEMP
Control Switch B/V

271BE11

Manual Control Air Conditioner System

A/C Pressure PSW

Switch

Engine ECU
Blower Motor ACT
Idle-Up Request Signal
Magnetic Clutch Actuation Signal
AC1
Blower Controller TE
Air Conditioner A/C Magnetic
Evaporator Amplifier 271BE11
Switch
A/C Switch
Temp. Sensor
A/C SW
TE-SG Clutch Relay
MGC
 BODY ELECTRICAL AIR CONDITIONER BE-17

3. Layout of Main Components

Condenser

Compressor
A/C Magnetic Clutch

Engine ECU

Power Heater Switch*

Heater
Heater Core
Evaporator Expansion Valve Control Panel
Temp. Sensor

Blower Motor

Blower Resistor
Evaporator
A/C Amplifier
271BE12

LHD Model

*: Only for Models with PTC Heater

BE-18 BODY ELECTRICAL AIR CONDITIONER

4. Model Position and Damper Operation

Manual Air Conditioner Model

Front Defroster

PTC Heater*
G H
F
Fresh Air Recirc. Air I
J

K
B A
E Heater Core
D
C
Evaporator
Blower Motor

Side Register Side Register

Center
Foot Well Foot Well
Register
Register Duct Register Duct
271BE13

*: Only for Models with PTC Heater

Function of Main Damper

Control Damper
Control Position Operation
Damper Position
Air Inlet FRESH A Brings in fresh air.
 BODY ELECTRICAL AIR CONDITIONER BE-19
Control
RECIRC B Recirculates internal air.
Damper
Varies the mixture ratio of the fresh air and the
recirculation air in order to regulate the
MAX COLD MAX HOT C~D~E
Air Mix temperature continuously from HOT to
Control
Damper COLD.
Air blows out of the center registers and side
F, K
register.
Air blows out of the center registers, side
F, I
registers, and foot well register ducts.
Air blows out of the foot well register ducts,
H, I and side register. In addition, air blows out
FACE slightly from the Front defroster.
187BE24

BI-LEVEL Defrosts the windshield through the front

187BE25
H, J defroster and side register, while air is also

Mode FOOT blown out from the foot well register ducts.
187BE26
Control Defrosts the windshield through the front
Dampe H, K
FOOT/DEF defroster and side register.
r 187BE27

DEF 187BE28
BE-20 BODY ELECTRICAL AIR CONDITIONER

Manual Cooler Model

Fresh Air Recirc. Air

D
B A C

Evaporator

Side Register Side Register

Front Foot Well Center Front Foot Well

Register Duct Register Register Duct

271BE14

Function of Main Damper

Control Damper
Control Position Operation
Damper Position
Air Inlet FRESH A Brings in fresh air.
Control
RECIRC B Recirculates internal air.
Damper
 BODY ELECTRICAL AIR CONDITIONER BE-21
Air blows out of the center registers and side
Mode FACE 187BE24 C
register.
Control
Air blows out of the center registers, side
Damper BI-LEVEL 187BE25
D
registers, and foot well register ducts.
BE-22 BODY ELECTRICAL AIR CONDITIONER

5. Air Outlets and Air Volume Rations

Manual Air Conditioner Model

D D

B
A
A
B

271BE15

A B C D
Center Side
Air Outlet Mode Foot Defroster
Face Face
FACE 187BE24

BI-LEVEL 187BE25

FOOT 187BE26

FOOT/DEF 187BE27

 BODY ELECTRICAL AIR CONDITIONER BE-23
DEF 187BE28

The size of the circle indicates the proportion of airflow volume.
BE-24 BODY ELECTRICAL AIR CONDITIONER

Manual Cooler Model

B
A
A
B

271BE16

A B C
Center Side
Air Outlet Mode Foot
Face Face
FACE 187BE24

BI-LEVEL 187BE25

The size of the circle indicates the proportion of airflow volume.

 BODY ELECTRICAL AIR CONDITIONER BE-25

CONSTRUCTION AND OPERATION

1. Heater Control Panel

General

The rotary switch type heater control panel is used.

Conventionally, the air outlet mode and the air inlet temperature control switches were operated with
a single cable. Instead, the new model has adopted a method that uses two cables on pulleys that are
always operated in the pulling direction.
Five air outlet modes are provided on the control panel with a heater. To enable finer mode settings, a
positive feel is provided between the positions of these modes, thus enhancing the comfort level.

271BE17
Only for Boost/Vent

271BE18

Only for Boost/Vent with Cooler

Only for Models with Air Conditioner

271BE19

Air Conditioner or Heater Model

BE-26 BODY ELECTRICAL AIR CONDITIONER

Heater Control Cable

Conventionally, the air outlet mode and the air inlet temperature control switches were operated with
a single cable. Instead, the new model has adopted a method that uses two cables on pulleys that are
always operated in the pulling direction.
This cable is circular, and is placed around the cable pulleys that are provided at the heater control
panel and the damper.
The operation of the heater control panel is transmitted to the damper via the control cable, which
always moves in the pulling direction. Due to the consistent action point of the pulleys, the fluctuation
of the operating effort has been minimized through the use of the pulleys. These measures have
improved the ease of use and reduced the operating effort.

Base of Pulley
Pulley
(Heater control panel side)

Pulley
(Damper side)

Cable
Base of Pulley 271BE20

Cable
Pulley
Pulley (Damper side)
(Heater control panel side)
271BE21
 BODY ELECTRICAL AIR CONDITIONER BE-27

2. Air conditioner Unit

General

A semi-center location air conditioner unit, in which the evaporator and heater core are placed in the
vehicles longitudinal direction. As a result, the air conditioner unit has been made compact and
lightweight. Front

Heater Core

Evaporator

271BE22

RHD Model

Evaporator

A revolutionary-slim structure evaporator has been adopted for except Central and South American
model.
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.
BE-28 BODY ELECTRICAL AIR CONDITIONER
c) The evaporator has been made thinner.

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.

Cooling Fin
Tank
Antibacterial Agent

Nylon Layer

Chromate Free
Layer
Micropore Tube Aluminum
Matrix
Tank
271BE66
 BODY ELECTRICAL AIR CONDITIONER BE-29

Heater Core

A compact, lightweight, and highly efficient straight flow (full-path flow) aluminum heater core has
been adopted.

271BE65

PTC Heater

1) General

The PTC (Positive Temperature Coefficient) heater has been adopted as standard equipment on the
double cab model with the 1KD-FTV engine for Australia.
The PTC heater is located above the heater core in the air conditioner unit.
The PTC heater consists of a PTC element, aluminum fin, and brass plate. When current is applied to
the PTC element, it generates heat to warm the air that passes through the unit.

Brass Plate

Aluminum Fin
PTC Element

PTC Heater
BE-30 BODY ELECTRICAL AIR CONDITIONER

Heater Core

271BE23
 BODY ELECTRICAL AIR CONDITIONER BE-31

2) Wiring Diagram

Battery
Power Heater Switch

PTC SW

HOT LP

PTC1

PTC2
MAX Hot Switch
MAX PTC PTC
HOT SW Hater
Hater
Relay Relay
Air Conditioner No.2 No.1
Amplifier
ALT
Alternator

PTC PTC
Heater Heater
HTR No.2 No.1
Engine TW1
ECU
TACH

271BE24

3) PTC Heater Operating Conditions

The ON/OFF function of the PTC heater is controlled by the air conditioner amplifier in accordance
with the water temperature, engine speed, air mix setting, and electrical load (alternator power ratio).
For example, with water temperature, the number of PTC heater operation varies as shown in the
graph below.
BE-32 BODY ELECTRICAL AIR CONDITIONER
Number of PTC
Heater Operation

1 and 2

OFF
65 70 75 80
271BE67
 BODY ELECTRICAL AIR CONDITIONER BE-33

3. Compressor

A compact, lightweight, and low-noise 10-cylinder swash plate type compressor has been adopted.

Swash Plate

Swash Plate Chamber

Shaft

Piston
271BE25

10S11 Type

4. Condenser

General

The new Hilux has adopted a sub-cool condenser. This is a multi-flow condenser consisting of two
cooling portions: a condensing portion and a super-cooling portion, and a gas-liquid separator
(modulator) all integrated together. This condenser has adopted a sub-cool cycle for its cooling cycle
system to improve heat-exchanging efficiency.

Sub-Cool Cycle

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.

Multi-Flow Condenser Condensing Portion

Gaseous Refrigerant

Modulator

Liquid Refrigerant

271BE26
Super-Cooling Portion
BE-34 BODY ELECTRICAL AIR CONDITIONER
 BODY ELECTRICAL AIR CONDITIONER BE-35

NOTE (Except Central and South American Models):

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 thesystem is recharged
with refrigerant based on the point at which the air bubbles disappear, theamount 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 to recharge the system with
refrigerant, see the Hilux Repair Manual.

High
Pressure
Properly Recharged Amount

Point in which Bubbles

Disappear

Amount of
Refrigerant
152BE40

Service Tip

Central and South American Models:

Because the sight glass for checking the condition of the refrigerant has been discontinued, inspect the
refrigerant volume by measuring the refrigerant pressure with a refrigerant charging gauge. For details,
refer to the Hilux Repair Manual.