04 Matrix AC clutch won't engage

mrlullabye · Post by **mrlullabye** » Fri Apr 17, 2009 4:33 am

Air Conditioning problem 2004 Toyota Matrix 4 cyl Front Wheel Drive Manual 110000 miles I changed the clutch in my 2004 Toyota Matrix this weekend, and low and behold the AC clutch will not engage now. I am not a complete noob so here is what all I know. The 10 amp fuse under the dash is not blown.. We actually tested all of the fuses under the dash and under the hood. When you have the AC button pushed with the car running and fan on, the AC light comes on, the engine revs slightly to compensate for the AC clutch engaging, but the AC clutch does not engage. If you jumper the 4 post relay right under the hood the clutch will engage and build pressure until there is about 40 PSI on the low side. Also if you jumper + and - to opposite sides of the small little connectors on the relay you get continuity across the fat post on the relay and that good old relay functioning snap, so it seems ok. (I have ordered another relay however and will put it in just incase later this afternoon)The fans spin when the engine is running. If you jumper the thing that is mounted in the high pressure line I can only assume is a pressure switch the cooling fan under the hood will come on, if you jumper it differently it will come on higher speed. I was not able to jumper the pressure switch in any way that resulted in the AC clutch engaging. It really looks to me like it ought to work, there seems to be enough coolant in the AC system to trigger the low pressure switch. The clutch is connected otherwise jumpering it at the relay would not fire it. The switch in the cabin works otherwise the engine would not rev slightly when it is engaged and rev lower when it is not engaged. I tried unplugging and replugging the TPS thinking it may be stuck in WOT or something but had no effect, other then to make the engine idle rough. Is there possible a dedicated WOT sensor?The fan works. Is there any other sensor I am missing? maybe it is somehow connected to a sensor to tell it when the engine is runnin?

joatmon · Post by **joatmon** » Fri Apr 17, 2009 5:31 am

Quote, originally posted by mrlullabye Â»I changed the clutch in my 2004 Toyota Matrix this weekend, ... I am not a complete noob ...The first implies the second, the clutch is not a token thing to change. I assume that as far as you know, the AC worked before the clutch job, so it seems most likely that something did not get hooked up or perhaps did not get hooked up correctly. I don't really know what to offer, other than this diagram, not sure it will help any, you may already have it. Maybe try to measure voltages at various points to see if they are what they ought to be.

Attached files 049ac.pdf (41 KB)

joatmon · Post by **joatmon** » Fri Apr 17, 2009 5:36 am

Here's another one, seems to indicate that jumpering pins 1 and 4 would simulate correct pressure range to operate, while jumpering pins 2 and 3 would simulate pressure high enough to turn the cooling fan on. Not sure what you'd have to jumper to get the fan to come on at a higher speed, the pressure switch does not appear to be set up to do that normally.I'd still recommend looking over any and all connectors that may have been disconnected for the clutch replacement job, make sure they are all connected welland if you do get it figured out, please post up what fixed it

Attached files onvein40.pdf (10.2 KB)

mrlullabye · Post by **mrlullabye** » Fri Apr 17, 2009 6:14 am

In retrospect the clutch was pretty straight forward. It was the first front wheel drive I had done so removing the drive shafts was a learning experience. For anyone else who does this I wholey recommend removing both drive shafts. Mine were both stubborn as hell and required me to whack them very solidly on the big chunky thing with a ball joint splitting tool and a 4 pound hammer. I tried prying and jerking on both of them for about an hour before I found the magic. The tools I was using were absorbing too much of the impact, and the splitting tool was solid. It knocked them both on with one shot.I printed this wiring diagram out and am looking it over. I was hoping to find some sensor or something I could go check for it to be disconnected. I am not real good at reading these so I don't know how much I will get out of it.I might pull the battery and intake tube back off to look under there for more wires I might have missed.

mrlullabye · Post by **mrlullabye** » Fri Apr 17, 2009 9:02 am

It's fixed. The relay was the problem. Toyota priced the Relay at $72 dollars, went to O'reily's and got one for $22.We had tried to test the relay ourselves and it seemed ok, but apparently something was wrong with our test.

joatmon · Post by **joatmon** » Fri Apr 17, 2009 9:17 am

That's good news. My money was on the disconnected connector somewhere though. Odd the coincidence of the relay going bad the same time as the clutch replacement, but all that matters is that it's fixed and didn't cost you a month's payAnd having a clutch that grabs again is a nice feelingWelcome to Genvibe!

melchloboo · Post by **melchloboo** » Fri May 22, 2009 2:50 am

I am having the exact same problem with an '03 Matrix. 1. Where is the relay located? (...not indicated in my manual.)2. Is the '04 diagram posted here valid for '03 as well?Thanks!

wilthis · Post by **wilthis** » Sun May 24, 2009 8:50 pm

I'm having the same problem also. Which relay is it?Thanks!

joatmon · Post by **joatmon** » Mon Jul 27, 2009 11:22 pm

sorry I didn't notice the questions before, hope you've got it fixed by now. here's a diagram of the underhood fuse block with an arrow pointing to the AC clutch relay (which they call M/G CLT relay)The diagram for 04 should be the same as for 03

Attached files

04 Matrix AC clutch won't engage

04 Matrix AC clutch won't engage

Re: 04 Matrix AC clutch won't engage (mrlullabye)

Re: 04 Matrix AC clutch won't engage (mrlullabye)

Re: 04 Matrix AC clutch won't engage (joatmon)

Re: (mrlullabye)

Re: (mrlullabye)

Re: (wilthis)