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MANUAL AIR CONDITIONER
J AIR CONDITIONER
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SECTION
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MANUAL AIR CONDITIONER
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CONTENTS
PRECAUTIONS ......................................................... 3 . Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 3 . Precautions for Working with HFC-134a (R-134a).... 3 . General Refrigerant Precautions ............................. 3 . Lubricant Precautions ............................................. 4 . Precautions for Refrigerant Connection .................. 4 . FEATURES OF NEW TYPE REFRIGERANT CONNECTION ..................................................... 4 . O-RING AND REFRIGERANT CONNECTION..... 5 Precautions for Servicing Compressor .................... 6 . Precautions for Service Equipment ......................... 6 . RECOVERY/RECYCLING EQUIPMENT ............. 6 . ELECTRONIC LEAK DETECTOR ....................... 6 . VACUUM PUMP .................................................. 7 . MANIFOLD GAUGE SET ..................................... 7 . SERVICE HOSES ................................................ 7 . SERVICE COUPLERS ......................................... 8 . REFRIGERANT WEIGHT SCALE ....................... 8 . CALIBRATING ACR4 WEIGHT SCALE ............... 8 . CHARGING CYLINDER ....................................... 9 . Precautions for Leak Detection Dye ........................ 9 . IDENTIFICATION ................................................. 9 . IDENTIFICATION LABEL FOR VEHICLE ............ 9 . Wiring Diagram and Trouble Diagnosis ................... 9 . PREPARATION ........................................................ 10 . Special Service Tools ............................................ 10 . HFC-134a (R-134a) Service Tools and Equipment.. 10 . REFRIGERATION SYSTEM .................................... 14 . Refrigerant Cycle .................................................. 14 . REFRIGERANT FLOW ...................................... 14 . Refrigerant System Protection .............................. 14 . REFRIGERANT PRESSURE SENSOR ............ 14 . LUBRICANT ............................................................ 15 . Adjustment of Compressor Lubricant Amount ...... 15 . LUBRICANT ....................................................... 15 . PROCEDURES FOR LUBRICANT RETURN OPERATION ...................................................... 15 . LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COMPRESSOR ................................................. 16 . LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR ............................ 16 . TROUBLE DIAGNOSIS ........................................... 17 . CONSULT-II Functions .......................................... 17 . CONSULT-II BASIC OPERATION ...................... 17 . DATA MONITOR ................................................ 18 . Diagnosis Procedure ............................................. 19 . DIAGNOSIS CHART BY SYMPTOM ................. 19 . Component Parts Location .................................... 20 . CR ENGINE MODELS ....................................... 20 . K9K ENGINE MODELS ...................................... 21 . Wiring Diagram --HEATER-- ............................... 22 . Wiring Diagram --PTC/H-- ................................... 23 . Wiring Diagram --A/C-- CR Engine Models ......... 24 . Wiring Diagram --A/C-- K9K Engine Models ....... 26 . Function Inspection ............................................... 28 . Blower Fan Motor System ..................................... 29 . INSPECTION PROCEDURE ............................. 29 . Magnetic Clutch System ........................................ 31 . INSPECTION PROCEDURE ............................. 31 . Insufficient Cooling ................................................ 37 . CHECK FUNCTION (FOR CR ENGINE) ........... 37 . DIAGNOSIS BY PRESSURE GAUGE ............... 39 . DIAGNOSIS OF COMPRESSOR ...................... 41 . Detecting Leaks With Fluorescent Indicator .......... 42 . METHOD FOR DETECTING REFRIGERANT LEAKAGE. .......................................................... 42 . CONTROL UNIT ...................................................... 43 . Removal and Installation ....................................... 43 . REMOVAL .......................................................... 43 . INSTALLATION .................................................. 43 . Disassembly and Assembly ................................... 43 . A/C UNIT ASSEMBLY ............................................. 45 . Removal and Installation ....................................... 45 . REMOVAL .......................................................... 45 . INSTALLATION .................................................. 46 . Disassembly and Assembly ................................... 47 .
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MTC
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MTC-1
HEATER CORE ........................................................ 49 . Removal and Installation ....................................... 49 . REMOVAL .......................................................... 49 . INSTALLATION ................................................... 49 . BLOWER MOTOR ................................................... 50 . Removal and Installation ....................................... 50 . REMOVAL .......................................................... 50 . INSTALLATION ................................................... 50 . BLOWER FAN RESISTOR ...................................... 51 . Removal and Installation ....................................... 51 . REMOVAL .......................................................... 51 . INSTALLATION ................................................... 51 . AIR CONDITIONER FILTER .................................... 52 . Removal, Replacement and Installation ................ 52 . REMOVAL .......................................................... 52 . REPLACEMENT ................................................. 52 . INSTALLATION ................................................... 52 . INTAKE DOOR ......................................................... 53 . Intake Door Cable Adjustment ............................... 53 . MODE DOOR ........................................................... 54 . Mode Door Cable Adjustment ............................... 54 . AIR MIX DOOR ........................................................ 55 . Air Mix Door Cable Adjustment ............................. 55 . THERMO CONTROL AMPLIFIER ........................... 56 . Removal and Installation ....................................... 56 . REMOVAL .......................................................... 56 . INSTALLATION ................................................... 56 . DUCTS AND GRILLES ............................................ 57 . Removal and Installation ....................................... 57 . COMPONENT PARTS LOCATION .................... 57 . CENTRAL VENTILATOR GRILLE ...................... 57 . SIDE VENTILATOR GRILLE .............................. 57 . DEFROSTER NOZZLE AND DUCT ................... 58 . SIDE VENTILATOR DUCT ................................. 59 . CENTER VENTILATOR DUCT ........................... 60 . FOOT DUCT ....................................................... 60 . REFRIGERANT LINES ............................................ 61 . HFC-134a (R-134a) Service Procedure ................ 61 . SETTING OF SERVICE TOOLS AND EQUIPMENT ................................................................. 61 . Component Parts Location .................................... 62 . CR ENGINE MODELS ....................................... 62 . K9K ENGINE MODELS ...................................... 62 . Removal and Installation for Compressor .............. 63 . REMOVAL .......................................................... 63 . INSTALLATION ................................................... 64 . Removal and Installation for Compressor Clutch (CR Engine Models) .............................................. 64 . REMOVAL .......................................................... 64 . INSTALLATION ................................................... 66 . Removal and Installation for Low-Pressure Flexible Hose (CR Engine Models) ..................................... 67 . REMOVAL .......................................................... 67 .
INSTALLATION ...................................................68 . RemovalandInstallationforHigh-PressureFlexible Hose (CR Engine Models) .....................................68 . REMOVAL ...........................................................68 . INSTALLATION ...................................................69 . Removal and Installation for High-Pressure Pipe (CR Engine Models) ...............................................69 . REMOVAL ...........................................................69 . INSTALLATION ...................................................70 . Removal and Installation for Pipe and Hose (K9K Engine Models) ......................................................70 . COMPONENTS ..................................................70 . REMOVAL ...........................................................70 . INSTALLATION ...................................................71 . Removal and Installation for Refrigerant Pressure Sensor ....................................................................71 . REMOVAL AND INSTALLATION ........................71 . RemovalandInstallationforCondenser(CREngine Models) ..................................................................71 . REMOVAL ...........................................................71 . INSTALLATION ...................................................72 . Removal and Installation for Condenser (K9K Engine Models) ......................................................72 . REMOVAL ...........................................................72 . INSTALLATION ...................................................72 . RemovalandInstallationforLiquidTank(CREngine Models) ..................................................................73 . REMOVAL ...........................................................73 . INSTALLATION ...................................................73 . Removal and Installation for Liquid Tank (K9K Engine Models) ......................................................74 . REMOVAL ...........................................................74 . INSTALLATION ...................................................74 . Removal and Installation for Evaporator ................74 . REMOVAL ...........................................................74 . INSTALLATION ...................................................75 . Removal and Installation for Expansion Valve .......75 . REMOVAL ...........................................................75 . INSTALLATION ...................................................75 . Checking for Refrigerant Leaks .............................75 . Checking System for Leaks Using the Fluorescent Leak Detector .........................................................76 . Dye Injection ..........................................................76 . Electronic Refrigerant Leak Detector .....................76 . PRECAUTIONS FOR HANDLING LEAK DETECTOR ........................................................76 . CHECKING PROCEDURE .................................77 . SERVICE DATA AND SPECIFICATIONS (SDS) .....79 . COMPRESSOR .....................................................79 . LUBRICANT ...........................................................79 . REFRIGERANT .....................................................79 . ENGINE IDLING SPEED .......................................79 . BELT TENSION .....................................................79 .
MTC-2
PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
EJS004G7
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The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. q Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. q Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.
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Precautions for Working with HFC-134a (R-134a)
EJS002FU
WARNING: G q Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor failure is likely to occur. q The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol- H lowing handling precautions must be observed: q When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. I q When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. q Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri- MTC cant. Without proper sealing, lubricant will become moisture saturated and should not be used. q Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meet- K ing requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R134a) recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and L lubricant manufacturers. q Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam parts. Damage may result. M
General Refrigerant Precautions
EJS002FV
WARNING: q Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. q Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. q Do not store or heat refrigerant containers above 52°C (125°F). q Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water. q Do not intentionally drop, puncture, or incinerate refrigerant containers. q Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. q Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. q Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a)
MTC-3
PRECAUTIONS
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.
Lubricant Precautions
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EJS002FW
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Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage may result.
EJS002FX
Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location. q Expansion valve to cooling unit q Refrigerant pressure sensor to liquid tank
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
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The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.
SHA815E
MTC-4
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.
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O-Ring Part Numbers and Specifications (CR Engine Models)
Connection type New Former Former New Former New 16 Former
SHA814E
O-ring size 8 10 12
Part number 92471 N8210 92470 N8200 J2476 89956 92472 N8210 92475 71L00 92473 N8210 92475 72L00
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mm (in)
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6.8 (0.268) 6.07 (0.2390) 9.25 (0.3642) 10.9 (0.429) 11.0 (0.433) 13.6 (0.535) 14.3 (0.563) 16.5 (0.650) 17.12 (0.6740)
1.85 (0.0728) 1.78 (0.0701) 1.78 (0.0701) 2.43 (0.0957) 2.4 (0.094) 2.43 (0.0957) 2.3 (0.091) 2.43 (0.0957) 1.78 (0.0701)
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New Former
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92474 N8210 92477 N8200
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O-Ring Part Numbers and Specifications (K9K Engine Models)
Connection type New Piping connection point Low-pressure flexible hose to heater & cooling unit High-pressure pipe to heater & cooling unit Condenser to high-pressure flexible hose Condenser to high-pressure pipe Compressor to low-pressure flexible hose Compressor to high-pressure flexible hose Liquid tank to condenser pipe Former Refrigerant pressure sensor Expansion valve to evaporator Inlet Outlet Part number 77030 65314 77030 65318 77030 65316 77030 65318 77030 65315 77030 65316 -- -- -- -- Qty. 2 2 2 2 2 2 -- -- -- -- Remarks Renault part Renault part Renault part Renault part Renault part Renault part -- -- -- --
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WARNING: Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: When replacing or cleaning refrigerant cycle components, observe the following. q When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low pressure chamber. q When connecting tubes, always use a torque wrench and a back-up wrench. q After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. q When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection. q Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. q Thoroughly remove moisture from the refrigeration system before charging the refrigerant. q Always replace used O-rings. q When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion.
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MTC-5
PRECAUTIONS
KC59G Compressor Nissan A/C System Oil Type R KLH00-PAGR0
Lubricant name: Part number:
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O-ring must be closely attached to dented portion of tube. When replacing the O-ring, be careful not to damage O-ring and tube. Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque.
RHA861F
Precautions for Servicing Compressor
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EJS002FY
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Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow "Maintenance of Lubricant Quantity in Compressor" exactly. Refer to MTC-15, "Adjustment of Compressor Lubricant Amount" . Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner. After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation.
EJS002FZ
Precautions for Service Equipment
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
MTC-6
PRECAUTIONS
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows. q Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. q For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. q If the hose has an automatic shut off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump's ability to pull a deep vacuum and are not recommended.
RHA270DA
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MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a (R-134a) or 134a. Be sure the gauge set has 1/2-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants.
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MTC
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SHA533D
SERVICE HOSES
Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.
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RHA272D
MTC-7
PRECAUTIONS
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur.
Shut-off valve rotation Clockwise Counterclockwise A/C service valve Open Close
RHA273D
REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2-16 ACME.
RHA274D
CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months. To calibrate the weight scale on the ACR4: 1. Press Shift/Reset and Enter at the same time. 2. Press 8787 . "A1 " will be displayed. 3. Remove all weight from the scale. 4. Press 0 , then press Enter . "0.00 " will be displayed and change to "A2 ". 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press Enter -- the display returns to the vacuum mode. 8. Press Shift/Reset and Enter at the same time. 9. Press 6 -- the known weight on the scale is displayed. 10. Remove the known weight from the scale. "0.00 " will be displayed. 11. Press Shift/Reset to return the ACR4 to the program mode.
MTC-8
PRECAUTIONS
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment.
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Precautions for Leak Detection Dye
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The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J41995) pin-point refrigerant leaks. For your safety and your Customer's satisfaction, read and follow all manufacture's operating instructions and precautions prior to performing the work. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 CC) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye in HFC-134a (R-134a) A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs.
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IDENTIFICATION
NOTE: Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label.
MTC
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IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification label on the front side of hood.
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SHA436FA
Wiring Diagram and Trouble Diagnosis
When you read wiring diagrams, refer to the followings: q GI-14, "How to Read Wiring Diagrams". q PG-4, "POWER SUPPLY ROUTING". When you perform trouble diagnosis, refer to the followings: q GI-10, "How to Follow Trouble Diagnoses". q GI-24, "How to Perform Efficient Diagnosis for an Electrical Incident".
EJS002G1
MTC-9
PREPARATION PREPARATION Special Service Tools
Tool number Tool name Description
PFP:00002
EJS002G9
KV99231260 Clutch disc wrench
Removing shaft nut and clutch disc
RJIA0475E
KV992T0001 Clutch disc puller
Removing clutch disc
RJIA0476E
KV992T0002 Pulley installer
Installing pulley
RJIA0477E
KV99233130 Pulley puller
Removing pulley
RJIA0478E
HFC-134a (R-134a) Service Tools and Equipment
EJS002GA
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor malfunction will result.
MTC-10
PREPARATION
Tool number Tool name
Description
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HFC-134a (R-134a) refrigerant
Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size
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S-NT196
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large container 1/2 -16 ACME
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KLH00-PAGR0 Nissan A/C System Oil Type R
S-NT197
Type: Poly alkaline glycol oil (PAG), type R Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Lubricity: 40 m (1.4 Imp fl oz.)
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Recovery/Recycling Recharging equipment (ACR4) Function: Refrigerant Recovery and Recycling and Recharging
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MTC
Electrical leak detector
Power supply:
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DC 12V (Power socket)
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SHA705EB
(J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) HFC-134a (R-134a) Dye injector Use with J-41447, 1/4 ounce bottle (J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) (J-43872) Refrigerant dye cleaner
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Power supply: DC 12V (Battery terminal)
ZHA200H
MTC-11
PREPARATION
Tool number Tool name Description Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety goggles Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)
SHA439F
(J-42220) UV lamp and UV safety goggles
SHA438F
(J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles)
(J-41459) HFC-134a (R-134a) Dye injector Use with J-41447, 1/4 ounce bottle
SHA440F
For injecting 1/4 ounce of fluorescent leak detection dye into A/C system.
(J-43872) Refrigerant dye cleaner
For cleaning dye spills.
SHA441F
Identification:
Manifold gauge set (with hoses and couplers)
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The gauge face indicates HFC-134a (R-134a). Fitting size: Thread size 1/2 -16 ACME
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RJIA0196E
Hose color: Service hoses
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Low hose: Blue with black stripe High hose: Red with black stripe Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 1/2 -16 ACME
High side hose Low side hose Utility hose
S-NT201
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MTC-12
PREPARATION
Tool number Tool name Description
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Service couplers
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Hose fitting to service hose:
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High side coupler Low side coupler
S-NT202
M14 x 1.5 fitting is optional or permanently attached.
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Refrigerant weight scale For measuring of refrigerant Fitting size: Thread size
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1/2 -16 ACME
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S-NT200
Capacity:
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Air displacement:4 CFM Micron rating:20 microns Oil capacity:482 g (17 oz.) Fitting size: Thread size 1/2 -16 ACME
Vacuum pump (Including the isolator valve)
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S-NT203
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MTC
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MTC-13
REFRIGERATION SYSTEM REFRIGERATION SYSTEM Refrigerant Cycle
REFRIGERANT FLOW
Refrigerant basically circulates through compressor, condenser, liquid tank and evaporator and returns to compressor. Vaporization of refrigerant is controlled by expansion valve.
PFP:KA990
EJS002GB
Refrigerant System Protection
REFRIGERANT PRESSURE SENSOR
q
EJS002GC
Refrigerant system is protected from significant high-pressure or low-pressure by refrigerant pressure sensor attached to condenser.
If unexpected pressures are detected in the cooler system (approx. 2.74 MPa (approx. 27.9 kg/cm2 ) or more or 0.14 MPa (approx. 1.4 kg/cm2 ) or less, the compressor is stopped by the refrigerant pressure sensor.) Note: Values in the ( ) indicate gauge pressure.
q
MTC-14
LUBRICANT LUBRICANT Adjustment of Compressor Lubricant Amount
PFP:KLG00
A
EJS002GD
Compressor lubricant circulates through the system with refrigerant. When cooler system component is replaced or after the large refrigerant leak, lubricant needs to be added to compressor. Also it is important to maintain lubricant level properly. If lubricant level is not proper, following might happen. q Insufficient lubricant: Compressor adherence q Lubricant overfill: Insufficient cooling (insufficient heat exchange)
B
C
LUBRICANT
Lubricant name: Part number: KC59G Compressor Nissan A/C System Oil Type R KLH00-PAGR0
D
E
PROCEDURES FOR LUBRICANT RETURN OPERATION
Follow the steps bellow to adjust the lubricant level.
1. CHECK A/C SYSTEM
1. Make sure A/C system operates normally. 2. Make sure a large amount of refrigerant or lubricant does not leak. OK or NG OK >> GO TO 2. NG >> GO TO 3.
F
G
H
2. LUBRICANT RETURN OPERATION
I
1.
2. 3.
Start the engine. Put it in the following state. Engine speed: Idling - 1,200 rpm A/C switch: ON Fan speed: HI Air intake: Recirculation Set temperature: FULL HOT Keep running for approximately 10 minutes. Stop the engine. CAUTION: When a large leak of refrigerant or lubricant is found, do not perform lubricant return operation. >> GO TO 3.
MTC
K
L
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3. CHECK COMPRESSOR
Is compressor replaced? YES >> GO TO MTC-16, "LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR" . NO >> GO TO 4.
4. CHECK OTHER COMPONENTS
Is any other component to be replaced? (evaporator, condenser, liquid tank, large refrigerant or lubricant) YES >> GO TO MTC-16, "LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COMPRESSOR" . NO >> GO TO MTC-37, "CHECK FUNCTION (FOR CR ENGINE)" .
MTC-15
LUBRICANT
LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COMPRESSOR
Add compressor lubricant from the high-pressure port of the compressor according to the table below. indicates lubricant amount that spouts with refrigerant when refrigerant is discharged.
Components to be replaced Evaporator Condenser Liquid tank Lubricant amount to be added 35+ cm3 15+ cm3 5+ cm3
CAUTION: When replacing 2 or more parts, do not sum up . Ex. Lublicant amount to be added to evaporator and liquid tank (cm3 ) = 35 + 5 +
LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR
1. Drain the compressor lubricant from the removed compressor's high and low-pressure ports and measure the amount of lubricant. Drain the compressor lubricant from a new compressor according to the formula below. indicates lubricant amount that spouts with refrigerant when refrigerant is discharged. Lubricant amount drained from new compressor3 ) = Lubricant amount contained in the new compressor (80) Lubricant amount discharged from the removed compressor Lubricant amount that adheres to inside of compressor (20) - = 60 - Lubricant amount discharged from the removed compressor - When adding lubricant, add the appropriate amount of compressor lubricant from the compressor's high-pressure port.
2.
3.
MJIB0049E
MTC-16
TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS CONSULT-II Functions
PFP:00004
A
EJS002FE
CONSULT-II has display functions for work support, self-diagnosis, data monitor, and active tests for each part by combining data reception and command transmission via communication lines from the BCM.
BCM trouble diagnosis item Air conditioner Inspection Item, Diagnosis Mode Data monitor Description Displays BCM input data in real time.
B
C
CONSULT-II BASIC OPERATION
CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. Turn ignition switch OFF. 2. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector. 3. Turn ignition switch ON.
D
E
F
G
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PBIA3525E
4.
Touch "START (NISSAN BASED VHCL)".
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MTC
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BCIA0029E
5.
Touch "BCM" on the "SELECT SYSTEM" screen. q If "BCM" is not displayed, print the "SELECT SYSTEM" screen, and then refer to GI-36, "CONSULT-II Data Link Connector (DLC) Circuit" .
M
BCIA0030E
MTC-17
TROUBLE DIAGNOSIS
6. Touch "AIR CONDITIONER" on the "SELECT TEST ITEM" screen.
RJIA1109E
7.
Touch "DATA MONITOR" on the "SELET DIAG MODE" screen. For details, refer to separate volume "CONSULT-II Operation Manual".
BCIA0031E
DATA MONITOR Operation Procedure
1. 2. Touch "AIR CONDITIONER" on the "SELECT TEST ITEM" screen. Touch "DATA MONITOR" on the "SELET DIAG MODE" screen. For details, refer to separate volume "CONSULT-II Operation Manual". Touch "All SIGNALS" on the "DATA MONITOR" screen. Touch "START". Touch "RECORD" while monitoring to record the status of the item being monitored. To stop recording, touch "STOP".
RJIA1112E
3. 4. 5.
Monitored Item
Monitor item "UNIT" FAN ON SIG AIR COND SW THERMO AMP IGN ON SW [ON/OFF] [ON/OFF] [ON/OFF] [ON/OFF] Contents Displays status "Blower fan on (ON)/blower fan off (OFF)" as judged by the BCM from the input from fan switch. Displays status "Compressor on (ON)/compressor off (OFF)" as judged by the BCM from the input from the controller. Displays status "Thermal control amplifier on (ON)/thermal amplifier off (OFF)" judged by the BCM from the input from thermal control amplifier. Displays status "IGN position (ON)/OFF, ACC position (OFF)" as judged from the key switch signal.
MTC-18
TROUBLE DIAGNOSIS Diagnosis Procedure
DIAGNOSIS CHART BY SYMPTOM
Symptom No air comes out. Airflow volume does not change. Operation inspection Check blower fan motor operation. Suspect systems Blower fan motor harness Possible causes Refer to MTC-29, "Blower Fan Motor System" .
q
EJS002FF
A
B
Improper air mix door lever installation Air mix door system malfunction (damage, locking, etc.) Air mix door cable inoperative Refer to MTC-55, "Air Mix Door Cable Adjustment" .
q
C
Common items (Check these items for either of two malfunctions listed below.) Inaccurate temperature control
Operate temperature control dial. Confirm that air mix door moves through full stroke.
Air mix door harness
q
D
q
E
With the fan setting dial and A/C switch ON, check operation of the magnetic clutch.
Magnetic clutch harness
Refer to MTC-31, "Magnetic Clutch System" .
q
F
No cold air comes out. (Normal airflow amount)
q q
Check refrigerant level. Performance check
Refer to MTC-37, "CHECK FUNCTION (FOR CR ENGINE)" in "Cooling malfunction". Refer to MTC-39, "DIAGNOSIS BY PRESSURE GAUGE" in "Cooling malfunction". Poor engine coolant Blockage of heater hose or heater core Improper installation of mode door lever Mode door system malfunction (damage, locking, etc.) Mode door cable inoperative Refer to MTC-54, "Mode Door Cable Adjustment" . Improper installation of intake door lever Intake door system malfunction (damage, locking, etc.) Intake door cable inoperative Refer to MTC-53, "Intake Door Cable Adjustment" .
G
Cooler system
q
H
I
No warm air comes out. (Airflow volume is normal.)
After warming up engine, heater core inlet and outlet sides of the heater hose do not become warm.
q
Coolant route
q
MTC
q
q
K
Unable to switch air outlets to others.
Operate the mode dial to confirm that the mode door moves through the full stroke.
Mode door harness
q
L
q
M
q
q
Unable to switch intake inlets to others.
Operate the intake switch lever and make sure the intake door moves through a full stroke.
Intake door harness
q
q
MTC-19
TROUBLE DIAGNOSIS Component Parts Location
CR ENGINE MODELS
EJS002FG
MJIA0175E
MTC-20
TROUBLE DIAGNOSIS
K9K ENGINE MODELS
A
B
C
D
E
F
G
H
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MTC
K
L
M
MJIA0198E
MTC-21
TROUBLE DIAGNOSIS Wiring Diagram --HEATER--
SMA for VIN >SJN**AK12U1309269
EJS002FH
MJWA0142E
MTC-22
TROUBLE DIAGNOSIS Wiring Diagram --PTC/H--
SMA for VIN >SJN**AK12U1309269
EJS005KI
A
B
C
D
E
F
G
H
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MTC
K
L
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MJWA0043E
PTC heater function is intended to improve the heating performance with CTP electrical system for air heating system which is broken down into several stages controlled by relays.
MTC-23
TROUBLE DIAGNOSIS Wiring Diagram --A/C-- CR Engine Models
SMA for VIN >SJN**AK12U1309269
EJS002FN
MJWA0143E
MTC-24
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
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MTC
K
L
M
MJWA0019E
MTC-25
TROUBLE DIAGNOSIS Wiring Diagram --A/C-- K9K Engine Models
SMA for VIN >SJN**AK12U1309269
EJS0057F
MJWA0144E
MTC-26
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
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MTC
K
L
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MJWA0042E
MTC-27
TROUBLE DIAGNOSIS Function Inspection
EJS0057G
1. CHECK FAN SPEED
Operate the fan setting dial to make sure the fan speed changes. Confirm operation for all fan speeds. OK or NG OK >> Switch fan speed to "4" and GO TO 2. NG >> Refer to MTC-29, "Blower Fan Motor System" , MTC-31, "Magnetic Clutch System" .
2. CHECK A/C SWITCH
1. Push A/C switch. 2. Check visually that indicator lamp turns on. Check by sound that compressor is operating. OK or NG OK >> GO TO 3. NG >> Magnetic clutch system malfunction: Refer to MTC-31, "Magnetic Clutch System" .
3. CHECK AIR OUTLET
Operate the mode dial to make sure the air outlet changes. OK or NG OK >> GO TO 4. NG >> Mode door system malfunction: Refer to MTC-54, "Mode Door Cable Adjustment" .
4. CHECK AIR INLET
Operate intake air control lever and listen to intake sound to confirm that inlet switches. OK or NG OK >> GO TO 5. NG >> Intake door system malfunction: Refer to MTC-53, "Intake Door Cable Adjustment" .
5. CHECK WITH TEMPERATURE SETTING LOWERED
1. Turn compressor ON. 2. Set temperature control dial to "FULL COLD". 3. Confirm cool air blows from outlets. OK or NG OK >> GO TO 6. NG >> Air mix door system malfunction: Refer to MTC-55, "Air Mix Door Cable Adjustment" .
6. CHECK WITH TEMPERATURE SETTING RAISED
1. Warm up the engine. 2. Set temperature control dial to "FULL HOT". 3. Confirm warm air blows from outlets. OK or NG OK >> If all function checks are normal (no phenomena reoccurrence), refer to MTC-19, "DIAGNOSIS CHART BY SYMPTOM" and perform appropriate diagnosis. NG >> Air mix door system malfunction: Refer to MTC-55, "Air Mix Door Cable Adjustment" .
MTC-28
TROUBLE DIAGNOSIS Blower Fan Motor System
INSPECTION PROCEDURE
Symptom: Blower fan motor does not operate.
SMA for VIN >SJN**AK12U1309269
EJS0057H
A
1. START INSPECTION
Check blower fan motor operation at each fan speed. 1 : Blower fan motor does not operate at all. 2 : Blower fan motor does not operate at one of speeds 1 - 4. Do inspection results indicate 1 or 2 above? 1 >> GO TO 2. 2 >> GO TO 6.
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C
D
2. CHECK POWER SUPPLY CIRCUIT
Disconnect blower fan motor connector, turn ignition switch ON, and check voltage between blower fan motor connector terminal and ground.
Connector terminal Blower fan motor 1 (Without air conditioner) 2 (With air conditioner) Ground Battery voltage Voltage
E
F
G
OK or NG MJIA0199E OK >> GO TO 3. NG >> Check power supply circuit and 15A fuses [Nos. 9 and 10, located in the fuse block (J/B)]. Refer to PG-4, "POWER SUPPLY ROUTING" . q If OK, check for open circuit in wiring harness. Repair or replace as necessary. q If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.
H
I
3. CHECK CIRCUIT CONTINUITY
1. 2. Turn the fan setting dial (fan switch) to any position except OFF. Check continuity between blower fan motor connector terminal and ground.
Connector terminal Blower fan motor 2 (Without air conditioner) 1 (With air conditioner) Ground Yes Continuity
MTC
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L
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Does continuity exist? YES >> GO TO 4. NO >> GO TO 5.
MJIA0200E
MTC-29
TROUBLE DIAGNOSIS
4. CHECK BLOWER FAN MOTOR
Disconnect the blower fan motor connector, and check continuity between blower fan motor terminals 1 and 2.
Connector terminal Blower fan motor 1 2 Yes Continuity
Does continuity exist? YES >> End of trouble diagnosis NO >> Replace the blower fan motor.
MJIA0201E
5. CHECK CIRCUIT CONTINUITY
Check continuity between blower fan motor connector terminal and blower fan resistor terminal 1.
Connector terminal Blower fan motor 2 (Without air conditioner) 1 (With air conditioner) 1 Yes Blower fan Resistor Continuity
Does continuity exist? YES >> GO TO 6. NO >> Repair harness or connector.
MJIB0058E
6. CHECK BLOWER FAN RESISTOR
Disconnect blower fan resistor connector, and check continuity between blower fan resistor terminals 1 and 2, 3, 4.
Connector terminal Blower fan resistor 2 1 3 4 Approx. 0.32 Approx. 1.4 Approx. 2.7 Continuity
Does continuity exist? YES >> GO TO 7. NO >> Replace blower fan resistor.
MJIA0180E
MTC-30
TROUBLE DIAGNOSIS
7. CHECK FAN SWITCH
Disconnect controller connector, and check continuity between controller terminals 1 and 2, 3, 4, 5, 6.
Connector terminal Controller 1 5 6 4 3 2 Fan: OFF Fan: Speed 4 Fan: Speed 3 Fan: Speed 2 Fan: Speed 1
MJIA0181E
A
B
Condition Continuity
C
Yes
D
OK or NG OK >> GO TO 8. NG >> Replace controller.
E
8. CHECK CIRCUIT CONTINUITY
Check continuity between the controller and the blower fan resistor terminals.
Connector terminal Controller 5 4 3 2 Blower fan Resistor 1 2 3 4 Yes
MJIA0182E
F
G
Continuity
H
I
Does continuity exist? YES >> GO TO 9. NO >> Repair harness or connector.
MTC
9. CHECK FAN SWITCH GROUND CIRCUIT
Check continuity between controller terminal 6 and ground.
Connector terminal Controller 6 Ground Continuity Yes
K
L
M
Does continuity exist? YES >> End of trouble diagnosis NO >> Repair harness or connector.
MJIA0183E
Magnetic Clutch System
INSPECTION PROCEDURE
Symptom: When A/C switch and fan switch are turned ON, magnetic clutch does not operate.
EJS0057I
1. CHECK WITH AUTO ACTIVE TEST MODE
Perform auto active test to make sure magnetic clutch operates. Refer to PG-42, "Auto Active Test" . OK or NG OK >> GO TO 7. NG >> GO TO 2.
MTC-31
TROUBLE DIAGNOSIS
2. CHECK MAGNETIC CLUTCH VOLTAGE
Disconnect compressor connector, turn ignition switch ON, and check voltage between compressor terminal 1 and ground.
Connector terminal Compressor 1 Ground Voltage Battery voltage
OK or NG OK >> q GO TO 4. (CR engine models) q GO TO 5. (K9K engine models) NG >> After Checking the Fuse (#41), GO TO 3. For the Fuse Block Layout, Refer to PG-4, "POWER SUPPLY ROUTING" . q If fuse is OK, check for open circuit in harness. q If a fuse is NG, determine the possible cause, repair circuit and replace blown fuse.
MJIB0050E
3. CHECK CIRCUIT CONTINUITY
Disconnect the IPDM E/R connector, and check continuity between compressor terminal 1 and IPDM E/R terminal 41.
Connector terminal Compressor 1 IPDM E/R 41 Yes Continuity
Does continuity exist? YES >> q GO TO 4. (CR engine models) q GO TO 6. (K9K engine models) NO >> Repair harness or connector.
MJIB0051E
4. CHECK MAGNETIC CLUTCH
Check continuity between compressor terminal 1 and ground.
Connector terminal Compressor 1 Ground Continuity Yes
Does continuity exist? YES >> Apply battery voltage to magnetic clutch directly and check operation sound. 1. If inspection results are NG, replace magnetic clutch. 2. If magnetic clutch is normal, replace IPDM E/R. NO >> Replace magnetic clutch.
RJIA1019E
MTC-32
TROUBLE DIAGNOSIS
5. CHECK GROUND CIRCUIT
Check continuity between compressor terminal 2 and ground.
Connector terminal Compressor 2 Ground Continuity Yes
A
B
Does continuity exist? YES >> GO TO 6. NO >> Repair harness or connector.
MJIA0205E
C
D
6. CHECK MAGNETIC CLUTCH
Check continuity between compressor terminals 1 and 2.
Connector terminal Compressor 1 2 Continuity Yes
E
F
Does continuity exist? YES >> Apply battery voltage to magnetic clutch directly and check operation sound. 1. If inspection results are NG, replace magnetic clutch. 2. If magnetic clutch is normal, replace IPDM E/R. NO >> Replace magnetic clutch.
G
H
MJIA0206E
I
7. CHECK REFRIGERANT PRESSURE SENSOR
Check refrigerant pressure sensor. Refer to MTC-14, "REFRIGERANT PRESSURE SENSOR" . OK or NG OK >> Connect compressor and IPDM E/R connectors, then GO TO 8. NG >> Repair or replace parts according to the inspection results.
MTC
K
8. CHECK BCM INPUT SIGNAL
L
q
With CONSULT-II Check if the compressor ON-OFF, fan ON-OFF and thermal amplifier ON-OFF using the BCM can "air conditioner" data monitor Refer to MTC-17, "CONSULT-II Functions" .
M
q
Without CONSULT-II GO TO 9. OK or NG OK >> GO TO 21. NG >> q Blower fan switch malfunction: GO TO 9. q A/C switch malfunction: GO TO 13. q Thermal amplifier malfunction: GO TO 17.
RJIA1112E
MTC-33
TROUBLE DIAGNOSIS
9. CHECK FAN ON SIGNAL
Check voltage between controller terminal 1 and ground.
Connector terminal Controller 1 Ground Condition Fan: ON Fan: OFF Voltage Approx. 12V Approx. 1V
OK or NG OK >> GO TO 13. NG >> GO TO 10.
MJIA0185E
10. CHECK CIRCUIT CONTINUITY
Disconnect controller and BCM connectors, and check continuity between BCM terminal 50 and controller terminal 1.
Connector terminal BCM 50 Controller 1 Yes Continuity
Does continuity exist? YES >> GO TO 11. NO >> Repair harness or connector.
MJIA0186E
11. CHECK FAN SWITCH
Check continuity between controller terminals 1 and 6.
Connector terminal Controller 1 6 Fan: OFF Yes Condition Continuity
Does continuity exist? YES >> GO TO 12. NO >> Replace controller.
MJIA0187E
12. CHECK GROUND CIRCUIT
Check continuity between controller terminal 6 and ground.
Connector terminal Controller 6 Ground Continuity Yes
Does continuity exist? YES >> Connect controller connector, and GO TO 13. NO >> Repair harness or connector.
MJIA0188E
MTC-34
TROUBLE DIAGNOSIS
13. CHECK AIR CONDITIONER SIGNAL
Check voltage between controller terminal 12 and ground.
Connector terminal Controller 12 Ground Voltage Battery voltage
A
B
OK or NG OK >> GO TO 14. NG >> GO TO 16.
MJIA0189E
C
D
14. CHECK A/C SWITCH
Check continuity between controller terminals 10 and 12.
Connector terminal Controller 10 12 A/C switch: Only during operation Yes Condition Continuity
E
F
G
OK or NG OK >> GO TO 15. NG >> Replace controller.
MJIA0190E
H
15. CHECK GROUND CIRCUIT
Check continuity between controller terminal 10 and ground.
Connector terminal Controller 10 Ground Continuity Yes
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MTC
K
Does continuity exist? YES >> GO TO 17. NO >> Repair harness or connector.
MJIA0191E
L
16. CHECK CIRCUIT CONTINUITY
Disconnect BCM connector and check continuity between controller terminal 12 and BCM terminal 61.
Connector terminal Controller 12 BCM 61 Continuity Yes
M
Does continuity exist? YES >> Replace BCM. NO >> Repair harness or connector.
MJIA0192E
MTC-35
TROUBLE DIAGNOSIS
17. CHECK 1: THERMAL CONTROL AMPLIFIER POWER SUPPLY CIRCUIT
Disconnect thermal control amplifier connector, turn ignition switch ON, and check voltage between thermal control amplifier terminal 3 and ground.
Connector terminal Thermal control amplifier 3 Ground Voltage Approx. 12V
OK or NG OK >> GO TO 18. NG >> GO TO 20.
MJIA0194E
18. CHECK 2: THERMAL CONTROL AMPLIFIER POWER SUPPLY CIRCUIT
Check voltage between thermal control amplifier terminal 1 and ground.
Connector terminal Thermal control amplifier 1 Ground Voltage Battery voltage
OK or NG OK >> GO TO 19. NG >> Check fuse (#16). For the Fuse Block Layout, Refer to PG-4, "POWER SUPPLY ROUTING" . q If fuse is OK, check for open circuit in harness. q If a fuse is NG, determine the possible cause, repair circuit and replace blown fuse.
MJIA0195E
19. CHECK GROUND CIRCUIT
Check continuity between thermal control amplifier terminal 2 and ground.
Connector terminal Thermal control amplifier 2 Ground Continuity Yes
Does continuity exist? YES >> Replace thermal control amplifier. NO >> Repair harness or connector.
MJIA0196E
20. CHECK CIRCUIT CONTINUITY
Disconnect BCM connector, and check continuity between thermal control amplifier terminal 3 and BCM terminal 49.
Connector terminal Thermal control amplifier 3 BCM 49 Continuity Yes
Does continuity exist? YES >> Replace BCM. NO >> Repair harness or connector.
MJIA0193E
MTC-36
TROUBLE DIAGNOSIS
21. CHECK CAN COMMUNICATION CIRCUIT
Check the CAN communication between the BCM and ECM control unit, and the ECM control unit and IPDM E/R. Refer to BCS-31, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" and LAN-6, "CAN Communication Unit" . OK or NG OK >> End of trouble diagnosis NG >> Repair or replace parts based on the diagnosis results.
A
B
C
Insufficient Cooling
CHECK FUNCTION (FOR CR ENGINE) Inspection Procedure
1. 2. 3. 4. 5.
EJS0057J
D
Connect manifold gauge to vehicle cooler system (service valve). Attach a psychrometer to blower unit air inlet (under glove box). Attach a dry-bulb thermometer to rightcenter of ventilator grille. Start and warm up the engine. After warming-up engine, make sure engine speed is the specified idle speed. Operate compressor. Adjust controller to match conditions below. Fan speed Inlet Outlet Predetermined temperature : HI : Recirculation (REC) : Ventilation (VENT) : FULL COLD
E
F
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6. 7. 8. 9.
H Fully open the hood and door windows, and close all the doors. Keep this state until the cooler system becomes stable (after approximately 10 minutes). I Keep the engine speed at idle. Measure the temperature and humidity at the air inlets, temperature at the air outlets, and the high-pressure and low-pressure of the cooler cycle, and compare them to "Ambient temperature - pressure characteristic", "Intake air temperature - outlet air temperature characteristic" for estimating. MTC
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MTC-37
TROUBLE DIAGNOSIS
Performance Curve
Ambient Temperature - Pressure Characteristics
RJIA1024E
Intake Air Temperature - Pressure Characteristics
RJIA1025E
MTC-38
TROUBLE DIAGNOSIS
DIAGNOSIS BY PRESSURE GAUGE
Connect a manifold gauge to the cooler cycle (service valve), and determine faulty parts and possible causes by pressure in the cooler cycle, then troubleshoot.
Symptom Cycle status Possible causes Insufficient cooling of condenser
q
A
Action
B
Operation malfunction of radiator and condenser fan Improper installation of air guide Clogged condenser or dirty fins
q
Repair or replace as necessary Clean and repair condenser fins.
C
They return to normal when condenser is cooled with water.
q
q
D
q
High-pressure and low-pressure are both high.
Excessively charged refrigerant When the compressor has been stopped, pressure drops quickly by approximately 2 kg/cm2 , and then decreases gradually. Temperature at low-pressure pipe is lower than that at evaporator outlet, or low-pressure pipe becomes frosted. Temperature differences occur at points where high-pressure pipe is crushed or clogged.
Discharge refrigerant completely, evacuate again, and recharge with proper amount of refrigerant. Discharge refrigerant completely, evacuate again, and recharge with proper amount of refrigerant.
E
F
Mixed air in the cooler system
G
Expansion valve opened too far (excessive refrigerant flow). Crushed points or clogs in high-pressure pipe between compressor and condenser Expansion valve is blocked.
Replace expansion valve.
H
High-pressure is extremely high.
Repair or replace as necessary
I
MTC
Remove foreign materials from expansion valve or replace expansion valve.
Evaporator outlet is not cold. Frost forms on evaporator inlet.
q
Gas leakage around sensor unit. Clogged by foreign material
q
K
High-pressure and low-pressure are both low (low-pressure occasionally becomes minus).
Temperature differences occur at the outlet and inlet pipe of the liquid tank or the liquid tank becomes frosted.
Liquid tank malfunction (strainer clogged) Evaporator fins are clogged or crushed. Insufficient airflow
Replace liquid tank
L
Repair or replace. Refer to MTC-29, "Blower Fan Motor System" .
q
M
Evaporator becomes frosted.
Some temperature difference occurs between high-pressure and low-pressure pipes of the compressor.
Check for refrigerant leaks. Discharge refrigerant completely, evacuate again, and recharge with proper amount of refrigerant.
Insufficient refrigerant amount
q
MTC-39
TROUBLE DIAGNOSIS
Symptom Cycle status Possible causes Water mixed in cooler system. (Blockage caused by moisture freezing at the expansion valve.) Compressor malfunction (improper compression)
q
Action Discharge refrigerant completely, evacuate again to remove all moisture, and recharge with proper amount of refrigerant. Be certain to replace liquid tank.
Occasionally high-pressure becomes low, and low-pressure becomes minus.
Sometimes evaporator outlet is not cold and sometimes frost forms on evaporator inlet.
High-pressure is low, and lowpressure is high.
When compressor is stopped, pressure equalizes quickly and there is no temperature difference between compressor highpressure pipes and low-pressure pipes.
Damage or breakage of valve Gasket worn or damaged
Replace compressor.
q
MTC-40
TROUBLE DIAGNOSIS
DIAGNOSIS OF COMPRESSOR
If there is a compressor unit malfunction (internal noise, insufficient cooling), follow table below and perform trouble diagnosis.
Symptom Checklist Cooler system internal pressure Check compressor oil condition. Compressor body Insufficient cooling (Note 1) Cooler system internal pressure Inspection Method Result Both high- and lowpressure sides are high. (Note 2) High/low-pressures hunt. (Note 2) Sample compressor oil and judge. Check rotation of compressor. If seized or stuck, sample compressor oil and judge. Check with a manifold gauge. If the difference between high-pressure and low-pressure is small or almost the same, sample compressor oil and judge. Action
A
B
Recharge with proper amount of refrigerant. Replace compressor only.
Noise (rattling or rolling sound) from compressor unit when A/C is ON.
Check with a manifold gauge.
C
D
Refer to the criteria shown in compressor lubricant.
Diagnostic Result 1: Replace compressor only. Diagnostic result 2: Replace compressor and liquid tank.
E
F
G
Outlet air temperature rises temporarily while driving. (Note 2)
H
-- -- -- Replace compressor only.
Note 1: First conduct inspection according to trouble diagnosis for each malfunction. Note 2: Applicable only to variable-capacity compressor
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MTC
K
L
SJIA0232E
M
MTC-41
TROUBLE DIAGNOSIS Detecting Leaks With Fluorescent Indicator
METHOD FOR DETECTING REFRIGERANT LEAKAGE.
EJS0057K
SJIA0233E
1. 2.
Wear goggles provided with the fluorescent detector. Connect the UV lamp power cable to the negative battery terminal. 3. Press UV lamp switch. Check for cooler system leaks. (Light green fluorescent will appear at the leak.) 4. Repair or replace parts with refrigerant leaks and wipe off the fluorescent indicator. CAUTION: Completely wipe off all fluorescent indicators. Use a cotton swab or something similar to remove indicator from gaps SJIA0234E between parts, screw threads, and similar places. 5. After finishing work, use a UV lamp to make sure no fluorescent indicator remains. CAUTION: q Do not look directly into the UV lamp light source. q For continuous operating time of UV lamp and other details, follow the Owner's Manual when performing the operation. q Dust, dirt, and adhesive of packing materials used in condenser, evaporator, and other locations may fluoresce. Be careful to avoid misidentifying leaks.
Inspection Procedure
q
q
q
Shine UV lamp on pipe joints from different angles to make sure there are no leaks. Use a cotton swab or something similar to wipe water off of drain hoses. By shining UV lamp, a check can also be made to detect leaks from evaporator. Use a mirror to check for refrigerant leaks in difficult to see areas.
SJIA0235E
MTC-42
CONTROL UNIT CONTROL UNIT Removal and Installation
REMOVAL
1. 2. 3. Remove cluster lid "C". Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove the air intake lever. Remove the screws and clips, and then remove the air conditioner finisher.
B
PFP:27500
A
EJS002GE
C
D
MJIA0036E
E
Remove the air mix door cable, mode door cable, and intake door cable from the air conditioner unit. 5. Remove screws, and pull out controller. 6. Disconnect connector and remove controller. CAUTION: Adjust the door cables during installation. Refer to MTC-53, "Intake Door Cable Adjustment" , MTC-54, "Mode Door Cable Adjustment" and MTC-55, "Air Mix Door Cable Adjustment" .
MJIA0037E
4.
F
G
H
INSTALLATION
Install in the reverse order of removal.
I
Disassembly and Assembly
EJS002GF
MTC
K
L
M
RJIA1073J
1. 4. 7.
Rear window defogger switch Fan control dial Controller
2. 5. 8.
Air conditioner switch Temperature control dial Illumination bulb
3. 6. 9.
Mode dial Air intake lever Mode door cable
10. Intake door cable
11. Air mix door cable
MTC-43
CONTROL UNIT
NOTE: Install the inner cable of each door cable to the corresponding lever, as shown in the figure. Press the outer cable until it hooks on the tabs and becomes fixed.
MJIA0038E
MTC-44
A/C UNIT ASSEMBLY A/C UNIT ASSEMBLY Removal and Installation
REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R134a)] to discharge refrigerant. 2. Drain engine coolant. 3. Disconnect the low-pressure flexible hose and high-pressure pipe from the evaporator. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere.
MJIA0039E
PFP:27210
A
EJS002GG
B
C
D
E
4. Pull out the heater hoses from the heater core. CAUTION: q Some coolant may spill when heater hoses are disconnected. q Close off the coolant inlet and outlet on the heater core (2 locations) with waste.
F
G
H
MJIA0040E
I
5. 6.
Remove instrument panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove the vehicle harness clips and then remove the instrument panel stay.
MTC
K
L
MJIA0041E
M
MTC-45
A/C UNIT ASSEMBLY
NOTE: This illustration is for RHD model. The layout for LHD model is symmetrically opposite.
MJIA0042E
Remove the ventilator duct mounting screws and clips. Remove the air conditioner mounting bolts, steering member mounting bolts, column shaft mounting bolts, and the harness clips. 9. Remove the BCM. Refer to BCS-31, "Removal and Installation of BCM" . 10. Remove the steering member, and then remove the air conditioner unit.
7. 8.
INSTALLATION
CAUTION: q Replace all O-rings on the pipes with new ones. Apply a coat of compressor lubricant prior to installation. q After charging with refrigerant, check for refrigerant leaks. 1. Install the air conditioner unit. CAUTION: Confirm that the air conditioner drain and drain hose positions match up. Air conditioner unit mounting bolt. Tightening : 5.98 - 7.65 N·m (0.61 - 0.78 kg-m, torque 53 - 67 in-lb) 2. Perform removal steps 3-10 in reverse order. Steering member mounting nut and bolt Tightening :11 - 13 N·m (1.1 - 1.4 kg-m, 8.2 torque 9.5 ft-lb) Mounting bolts for the low-pressure flexible hoses and high-pressure pipes. Tightening :2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26 torque - 52 in-lb) 3. 4. Fill engine coolant. Charge refrigerant using refrigerant recovery unit [for HFC-134a(R-134a)].
MJIA0043E
MTC-46
A/C UNIT ASSEMBLY Disassembly and Assembly
EJS002GH
A
B
C
D
E
F
G
H
I
MTC
K
L
M
RJIA1075J
1. 4. 7.
Blower fan motor case (RH) Foot duct (RH) Air mix door
2. 5. 8. 11.
Cover (RH) Cooling hose Foot duct (LH) Screw
3. 6. 9. 12. 15. 18. 21. 24. 27. 30. 33. 36.
Screw Blower fan motor Screw Cover (LH) Defroster rod Heater core Thermal control amplifier Screw Screw Attachment case Screw Bolt
10. Clips 13. Blower fan motor case (LH) 16. Deflator door 19. Heater pipe cover 22. Heater pipe packing 25. Bracket 28. Blower fan resistor 31. Air mix door lever 34. Heater pipe clip
14. Ventilation door 17. Foot door 20. Screw 23. Lower blo