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HA
When you read wiring diagrams: Read GI section, HOW TO READ WIRING DIAGRAMS. See EL section, POWER SUPPLY ROUTING for power distribution circuit. When you perform trouble diagnoses, read GI section, HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT.
HA-2
HA-3
SHA815E
HA-4
MANUAL AND AUTO PRECAUTIONS AND PREPARATION Precautions for Refrigerant Connection (Contd)
SHA876E
CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.
O-ring size
Part number 92472 N8200 92471 N8210 92470 N8200 92472 N8210 92471 N8200 92473 N8210 92475 72L00 92474 N8210 92477 N8200
mm (in) W 4.5 (0.177) 6.8 (0.268) 6.07 (0.2390) 10.9 (0.429) 10.8 (0.425) 13.6 (0.535) 14.3 (0.563) 16.5 (0.650)
mm (in)
6 8 12 16 19
1.40 (0.0551) 1.85 (0.0728) 1.78 (0.0701) 2.43 (0.0957) 1.78 (0.0701) 2.43 (0.0957) 2.3 (0.091) 2.43 (0.0957) 1.78 (0.0701)
17.12 (0.6740)
In accordance with the adoption of the new type refrigerant connection, the following components are not interchangeable between the former year model (1996 year model) and the current year model (1998 year model). Compressor Condenser Cooling unit Liquid tank Tubes and flexible hoses
HA-5
MANUAL AND AUTO PRECAUTIONS AND PREPARATION Precautions for Refrigerant Connection (Contd)
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. When the compressor is removed, store it in the same position as it is when mounted on the car. Failure to do so will cause lubricant to enter the low pressure chamber. When connecting tubes, always use a torque wrench and a back-up wrench. After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. 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. 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. Thoroughly remove moisture from the refrigeration system before charging the refrigerant. Always replace used O-rings. When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0 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
HA-6
NT232
NT378
NT376
Installing pulley
NT235
HA-7
NT196
Type: Poly alkylene glycol oil (PAG), type S Application: HFC-134a (R-134a) swash plate (piston) compressors (Nissan only) Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz)
NT197
NT195
NT198
Identification: The gauge face indicates R-134a. Fitting size: Thread size 1/2-16 ACME
NT199
HA-8
MANUAL AND AUTO PRECAUTIONS AND PREPARATION HFC-134a (R-134a) Service Tools and Equipment (Contd)
Tool number (Kent-Moore No.) Tool name Service hoses High side hose (J-39501-72) Low side hose (J-39502-72) Utility hose (J-39476-72) Service couplers High side coupler (J-39500-20) Low side coupler (J-39500-24)
NT202
Description
Note Hose color: 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 Hose fitting to service hose: M14 x 1.5 fitting is optional or permanently attached.
NT201
NT200
Capacity: Air displacement: 4 CFM Micron rating: 20 microns Oil capacity: 482 g (17 oz) Fitting size: Thread size 1/2-16 ACME
NT203
HA-9
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 situated near the hose-to-pump connection, as follows. Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. 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. 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 pumps ability to pull a deep vacuum and are not recommended.
RHA270D
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.
RHA272D
HA-10
MANUAL AND AUTO PRECAUTIONS AND PREPARATION Precautions for Service Equipment (Contd)
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
RHA273D
RHA274D
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinders 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.
HA-11
The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank, evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case.
FREEZE PROTECTION
Under normal operating conditions, when the AUTO is switched on, the compressor runs continuously, and the evaporator pressure, and therefore temperature, is controlled by the V-6 variable displacement compressor to prevent freeze up.
RHA036D
HA-12
DESCRIPTION
HA-13
DESCRIPTION General
The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the swash plate allows the pistons stroke to change so that refrigerant discharge can be continuously changed from 10.5 to 184 cm3 (0.641 to 11.228 cu in).
RHA037DA
HA-14
Operation
1. Operation control valve Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure. Operation of the valve controls the internal pressure of the crankcase. The angle of the swash plate is controlled between the crankcases internal pressure and the piston cylinder pressure. 2. Maximum cooling Refrigerant pressure on the low-pressure side increases with an increase in heat loads. When this occurs, the control valves bellows compress to open the low-pressure side valve and close the high-pressure side valve. This causes the following pressure changes: the crankcases internal pressure to equal the pressure on the low-pressure side; the cylinders internal pressure to be greater than the crankcases internal pressure. Under this condition, the swash plate is set to the maximum stroke position.
RHA473C
HA-15
RHA474C
HA-16
RHA424E
HA-17
SHA847E
HA-18
MANUAL
RHA426EA
MODE SWITCHES
These switches allow control of the air discharge outlets. When the MODE switch is moved to DEF or F/D, the push control amplifier sets the intake door to FRESH. The compressor turns on when the MODE switch is moved to DEF.
HA-19
DESCRIPTION
NOTE
MANUAL
HA-20
TROUBLE DIAGNOSES
MANUAL
Reference item
Operational check (Refer to HA-22.) Symptom Chart (Refer to HA-24.) Symptom Chart (Refer to HA-24.)
Preliminary Check (Refer to HA-26.) Main Power Supply and Ground Circuit Check (Refer to HA-44.) Harness layout (Refer to HA-37.)
Malfunctioning part(s)
REPAIR.
REPAIR/REPLACE.
NG
FINAL CHECK OK
CHECK OUT
HA-21
MANUAL
The purpose of the operational check is to confirm that the system is as it should be. The systems which will be checked are the blower, mode (discharge air), intake air, temperature decrease, temperature increase and A/C switch.
CONDITIONS:
Engine running and at normal operating temperature.
RHA427E
RHA428E
Confirm that discharge air comes out according to the air distribution table at left. Refer to Discharge Air Flow, DESCRIPTION (HA-18). NOTE: Confirm that the compressor clutch is engaged (visual inspection) and intake door position is at FRESH when the DEF button is pressed. Confirm that the intake door position is at FRESH when the F/D button is pressed. Intake door position is checked in the next step.
2)
RHA429E
HA-22
MANUAL
Press REC switch. Recirculation indicator should illuminate. Listen for intake door position change (air flow sound from intake unit).
RHA430E
RHA431E
RHA432E
RHA433E
HA-23
MANUAL
HA-26
HA-27
HA-28
HA-28
HA-29
HA-30
HA-45
HA-47
HA-49
HA-50
HA-52
HA-44
HA-44
REFERENCE PAGE
Diagnostic procedure 1
Diagnostic procedure 2
Diagnostic procedure 3
Diagnostic procedure 4
Diagnostic procedure 5
Preliminary check 1
Preliminary check 2
Preliminary check 3
Preliminary check 4
Preliminary check 5
Preliminary check 6
SYMPTOM A/C does not blow cold air. Insufficient heating. Blower motor does not rotate. Air outlet does not change. Intake door does not change in VENT, B/L or FOOT mode. Intake door is not set at FRESH in DEF or F/D mode. Air mix door does not change. Magnet clutch does not engage when A/C switch and fan switch are ON. Magnet clutch does not engage in DEF mode. Noise ,
k k
k k
k k
k k
k k
: The number means checking order. k : Checking order depends on malfunction in each flow chart.
HA-24
HA-44
k k
k k
k k k k k k k
VENT switch B/L switch FOOT switch F/D switch DEF switch k k Fan switch Mode door motor Intake door motor k k Air mix door motor A/C relay Triple-pressure switch Compressor (Magnet clutch) ECM (ECCS control module) Harness Compressor
Electrical Components Inspection HA-55 HA-56 HA-57 HA-57 HA-56 HA-56 HA-129
HA-25
k k k k k k k k k k k k k k k k k k k
k k k k k k k k k k
MANUAL
Refer to EC section.
MANUAL
Does intake door change from Fresh position to REC position when REC switch is turned ON? (Make sure the intake door has moved by listening for air flow sound from the intake unit.) Yes
No
Does intake door change from REC position to Fresh position when F/D switch or DEF switch is pushed? Yes
No
INSPECTION END
HA-26
MANUAL
NG
No
CHECK BLOWER MOTOR OPERATION. Perform Diagnostic Procedure 1. Refer to HA-45. CHECK FOR EVAPORATOR COIL FREEZE UP. Remove intake unit. Check if evaporator freezes. NG (Freezes up.) OK (Does not freeze up.)
CHECK COMPRESSOR BELT TENSION. Refer to MA section (Checking Drive Belts, ENGINE MAINTENANCE). NG
OK
CHECK REFRIGERATION CYCLE PRESSURE WITH MANIFOLD GAUGE CONNECTED. Refer to HA-33. NG OK
NG
OK
HA-27
MANUAL
No
Push A/C switch and turn A/C system OFF. Make sure that magnet clutch is disengaged.
With engine running, does magnet clutch engage normally when DEF switch and fan switch are ON? Yes
No
INSPECTION END
PRELIMINARY CHECK 4
Air outlet does not change.
TURN IGNITION SWITCH ON. DOES AIR COME OUT NORMALLY FROM EACH DUCT WHEN EACH MODE SWITCH IS SELECTED? No
INSPECTION END
HA-28
MANUAL
Blower motor
Compressor
Expansion valve
Refrigerant line
Belt
Check for noise in all modes and temperature settings. Noise is constant.
NG
Check air discharge ducts for obstructions, foreign materials or air leakage.
Readjust belt tension. Refer to MA section (Checking Drive Belts, ENGINE MAINTENANCE).
The pulley center does not match. Readjust the pulley center.
HA-29
MANUAL
NG
Check the following: Engine coolant level (Refer to MA section.) Hoses for leaks or kinks Radiator cap (Refer to LC section.) Air in cooling system. OK
NG
Repair/replace as necessary.
Check by feel the heater inlet and outlet hoses. Hot inlet Warm outlet
Back flush heater core, drain and refill coolant. Retest. Hot inlet Warm outlet
System OK
HA-30
NG
OK
OK
NG
OK
CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHART. (Refer to HA33.)
NG
RECOVER REFRIGERANT USING RECOVERY RECYCLING EQUIPMENT AND CHARGE SPECIFIED AMOUNT OF REFRIGERANT.
Note NG
CHECK HIGH AND LOW SIDE PRESSURE. USE PERFORMANCE CHART. (Refer to HA33.)
BOTH HIGH AND LOW PRESSURE SIDES ARE TOO HIGH HIGH PRESSURE SIDE IS TOO HIGH AND LOW PRESSURE SIDE IS TOO LOW HIGH PRESSURE SIDE IS TOO LOW AND LOW PRESSURE SIDE IS TOO HIGH BOTH HIGH AND LOW PRESSURE SIDES ARE TOO LOW LOW PRESSURE SIDE SOMETIMES BECOMES NEGATIVE LOW PRESSURE SIDE BECOMES NEGATIVE
OK
OK
END
Malfunctioning temperature control operation (air mix door position improperly adjusted)/ Malfunctioning water cock operation (incorrect valve closure)
Note:
HA-31
Discontinued wiring or component circuits or poor connection/ Malfunctioning resistor, amplifier, etc./Burned out fuse or low battery voltage
k B
Belt slipping
HA-32
Testing must be performed as follows: Vehicle location: Indoors or in the shade (in a well ventilated place) Doors: Closed Door window: Open Hood: Open TEMP. setting: Max. COLD Discharge Air: Face Vent RECIRC switch: (Recirculation) ON FAN speed: 4-speed A/C switch: ON Engine speed: 1,500 rpm Operate the air conditioning system for 10 minutes before taking measurements.
TEST READING
Recirculating-to-discharge air temperature table
Inside air (Recirculating air) at blower assembly inlet Relative humidity % Air temperature C (F) 20 (68) 25 (77) 50 - 60 30 (86) 35 (95) 20 (68) 25 (77) 60 - 70 30 (86) 35 (95) 10.0 - 12.4 (50 - 54) 15.2 - 18.0 (59 - 64) 7.6 - 10.0 (46 - 50) 12.4 - 15.2 (54 - 59) 2.6 - 3.6 (37 - 38) 5.7 - 7.6 (42 - 46) Discharge air temperature at center ventilator C (F) 1.5 - 2.6 (35 - 37) 3.7 - 5.7 (39 - 42)
If pressure is not within range, refer to HA-34, Trouble Diagnoses for Abnormal Pressure.
HA-33
TROUBLE DIAGNOSES
Insufficient condenser cooling performance " k 1 Condenser fins are clogged. k 2 Improper fan rotation of cooling fan Low-pressure pipe is not Poor heat exchange in concold. denser When compressor is stopped (After compressor operation high-pressure value quickly stops, high pressure decreases drops by approximately 196 too slowly.) kPa (2 kg/cm2, 28 psi). It " AC359A Air in refrigeration cycle then decreases gradually thereafter. Engine tends to overheat. Engine cooling systems malfunction. Excessive liquid refrigerant An area of the low-pressure on low-pressure side pipe is colder than areas Excessive refrigerant disnear the evaporator outlet. charge flow Plates are sometimes cov Expansion valve is open a ered with frost. little compared with the specification. " k 1 Improper thermal valve installation k 2 Improper expansion valve adjustment High-pressure tube or parts Upper side of condenser and High-pressure side is too high located between compressor high-pressure side are hot, and low-pressure side is too and condenser are clogged or however, liquid tank is not so low. crushed. hot.
Check and repair each engine cooling system. Replace expansion valve.
Check and repair or replace malfunctioning parts. Check lubricant for contamination.
AC360A
HA-34
MANUAL AND AUTO TROUBLE DIAGNOSES Trouble Diagnoses for Abnormal Pressure (Contd)
Gauge indication High-pressure side is too low and low-pressure side is too high. Refrigerant cycle High and low-pressure sides become equal soon after compressor operation stops. Probable cause Corrective action Compressor pressure operation Replace compressor. is improper. " Damaged inside compressor packings
Compressor discharge capacity Replace compressor. No temperature difference between high and low-pressure does not change. (Compressor stroke is set at maximum.) sides
AC356A
There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. Liquid tank inlet and expansion valve are frosted. Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. Expansion valve inlet may be frosted. Temperature difference occurs somewhere in highpressure side AC353A Expansion valve and liquid tank are warm or only cool to the touch. There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted.
Check and repair malfuncHigh-pressure pipe located tioning parts. between liquid tank and expan Check lubricant for contamision valve is clogged. nation.
An area of the low-pressure pipe is colder than areas near the evaporator outlet. Air flow volume is not enough or is too low.
Low refrigerant charge. " Leaking fittings or components. Expansion valve closes a little compared with the specification. " k 1 Improper expansion valve adjustment k 2 Malfunctioning thermal valve k 3 Outlet and inlet may be clogged. Low-pressure pipe is clogged or crushed.
Check for refrigerant leaks. Refer to Checking Refrigerant Leaks, HA-126. Remove foreign particles by using compressed air. Check lubricant for contamination.
Evaporator is frozen. " Compressor discharge capacity does not change. (Compressor stroke is set at maximum length.)
Check and repair malfunctioning parts. Check lubricant for contamination. Replace compressor.
HA-35
MANUAL AND AUTO TROUBLE DIAGNOSES Trouble Diagnoses for Abnormal Pressure (Contd)
Gauge indication Low-pressure side sometimes becomes negative. Refrigerant cycle Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted. Probable cause Corrective action Refrigerant does not discharge Drain water from refrigerant or replace refrigerant. cyclically. Replace liquid tank. " Moisture is frozen at expansion valve outlet and inlet. " Water is mixed with refrigerant.
AC354A
High-pressure side is closed and refrigerant does not flow. " Expansion valve or liquid tank is frosted.
AC362A
Leave the system at rest until no frost is present. Start it again to check whether or not the problem is caused by water or foreign particles. If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. If due to foreign particles, remove expansion valve and remove particles with dry and compressed air (not shop air). If either of the above methods cannot correct the problem, replace expansion valve. Replace liquid tank. Check lubricant for contamination.
HA-36
MANUAL
RHA111F
HA-37
MANUAL
RHA132G
HA-38
MANUAL
MHA704A
HA-39
MANUAL
MHA705A
HA-40
MANUAL
MHA706A
HA-41
MANUAL
MHA707A
HA-42
MANUAL
MHA708A
HA-43
TROUBLE DIAGNOSES
MANUAL
k 14
RHA464EB
Body ground
Check body ground circuit for push control unit. 1. Disconnect push control unit harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal k 17 and body ground.
Ohmmeter terminal
k 17
Body ground
Continuity Yes
RHA465EB
HA-44
TROUBLE DIAGNOSES
INCIDENT 1 2 3 4 5 Fan fails to rotate. Fan does not rotate at 1-speed. Fan does not rotate at 2-speed. Fan does not rotate at 3-speed. Fan does not rotate at 4-speed. Flow chart No.
MANUAL
Diagnostic Procedure 1
SYMPTOM: Blower motor does not rotate. Perform PRELIMINARY CHECK 2 before referring to the following flow chart.
Check if blower motor rotates properly at each fan speed. Conduct check as per flow chart at left. (Go to next page.)
k B
CHECK POWER SUPPLY FOR BLOWER MOTOR. Disconnect blower motor harness connector. Do approx. 12 volts exist between blower motor harness terminal k 1 and body ground? Yes
RHA466E
No
Check power supply circuit and 15A fuses (No. and , located in the fuse block). Refer to EL section (Wiring Diagram, POWER SUPPLY ROUTING).
Check circuit continuity between blower motor harness terminal k 2 and body ground.
NG
OK
NG
RHA467E
No CHECK BLOWER MOTOR CIRCUIT BETWEEN BLOWER MOTOR AND RESISTOR. Do approx. 12 volts exist Note between resistor harness Check circuit continuity between blower terminal k 1 and body motor harness terminal k 2 and resistor ground? harness terminal k 1 . Continuity should exist. Yes If OK, check harness for short.
RHA468E
k A (Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
RHA469E
HA-45
MANUAL
k B
NG
Replace resistor.
RHA470E
CHECK FAN SWITCH CIRCUIT. Do approx. 12 volts exist between each fan switch harness terminal and body ground?
Flow chart No. Terminal No. Voltage
k 4 k 3
RHA471E
k 2 k 1
Body ground
Approx. 12V
Yes
RHA477E
k 2 k 3 k 4
NG
Note
Check circuit continuity between fan switch harness terminal k 6 and body ground.
OK
Replace blower motor. Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-46
MANUAL
SYMPTOM: Air outlet does not change. Perform PRELIMINARY CHECK 4, Main Power Supply and Ground Circuit Check before referring to the flow chart below.
CHECK MODE DOOR MOTOR POSITION SWITCH. 1. Turn VENT switch ON with ignition switch at ON position. 2. Turn ignition switch OFF. Disconnect push control unit connector. 3. Turn ignition switch ON. Check continuity between terminal k 1 or k 2 of push control unit harness connector and body ground. 4. Using above procedures, check for continuity in any other mode, as indicated in chart.
Mode switch
RHA478E
NG
SHA454EB
Note
CHECK BODY GROUND CIRCUIT FOR MODE DOOR MOTOR. Does continuity exist between mode door motor harness terminal k 1 and body ground? Yes
Terminal No.
k 1 or k 2 k 2 or k 3 k 3 or k 4 k 4 or k 5 k 5 or k 6
Continuity
Note
Body ground
Yes
Check circuit continuity between each terminal on push control unit and on mode door motor.
Terminal No. Continuity
OK
Yes
OK
k A (Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-47
MANUAL
Reconnect push control unit and mode door motor harness connectors.
CHECK FOR OUTPUT OF PUSH CONTROL UNIT. Change the mode from VENT to DEF, and from DEF to VENT. Do approx. 12 volts exist between push control unit harness terminals k 7 and k 8 in both cases?
Terminal No. k 7 k 8 Mode door operation Stop VENT , DEF 12V
SHA455EB
No
Voltage 0V
Each side
DEF , VENT
Yes
HA-48
MANUAL
SYMPTOM: Intake door does not change in VENT, B/L or FOOT mode. Perform PRELIMINARY CHECK 1, Main Power Supply and Ground Circuit Check before referring to the following flow chart below.
CHECK INTAKE DOOR MOTOR POSITION SWITCH. 1. Turn REC switch ON with ignition switch at ON position. 2. Turn ignition switch OFF. Disconnect push control unit connector. 3. Check if continuity exists between terminal k 21 of push control unit harness connector and body ground. 4. Using above procedures, check for REC switch OFF position as indicated in chart.
REC switch ON OFF Terminal No. k 21 or k 9 Body ground k 24 or k 10 Continuity Yes
NG
SHA689E
CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR. Does continuity exist between intake door motor harness terminal k 5 and body ground? Yes
Note
Check circuit continuity between each terminal on push control unit and on intake door motor.
Terminal No.
RHA112F
OK
Continuity
Yes
OK
Reconnect push control unit and intake door motor harness connector. Note
NG Check continuity between push 20 (k 11 ) control unit harness terminal k and intake door motor harness terminal k 7 (k 6 ). Continuity should exist. If OK, check harness for short. OK
CHECK FOR OUTPUT OF PUSH CONTROL UNIT. Check voltage between intake door motor harness terminals k 6 and k 7 , for conditions below.
REC switch ON OFF Terminal No.
k 7 k 6
RHA114F
k 6 k 7
Voltage 12V
OK
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
RHA115F
HA-49
MANUAL
SYMPTOM: Air mix door does not change. Perform PRELIMINARY CHECK 2, Main Power Supply and Ground Circuit Check before referring to the following chart.
CHECK POWER SUPPLY FOR AIR MIX DOOR MOTOR. Disconnect air mix door motor harness connector. Do approx. 12V exist between air mix door motor harness terminal k 3 and body ground? Yes
No
RHA116F
Check power supply circuit and 7.5A fuse (No. 16 , located in the fuse block). Refer to EL section (Wiring Diagram, POWER SUPPLY ROUTING).
Note
Check circuit continuity between air mix door motor harness terminal No. k 1 and body ground.
RHA117F
OK
Note
Check circuit continuity between each terminal on push control unit and air mix door motor.
Terminal No. Push control unit k 22 k 23 k 26 Air mix door motor k 4 k 5 k 2 Yes Continuity
OK
Reconnect push control unit and air mix door motor harness connector.
RHA118F
k A (Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-50
MANUAL
No CHECK FOR PUSH CONTROL UNIT Replace push control unit. OUTPUT. Slide the temperature control lever from Hot to Cold and Cold to Hot. Do approx. 12 volts exist between push control unit harness terminals k 22 and k 23 in both cases?
Terminal No. k 22 k 23 Temp. control lever operation HOT , COLD Approx. 12V COLD , HOT STOP Approx. 0V Voltage
Each side
Yes
RHA487EB
CHECK FOR PBR RESISTANCE IN AIR MIX DOOR MOTOR. (Refer to HA-57.) No
Yes
HA-51
MANUAL
SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON. Perform PRELIMINARY CHECK 2 before referring to the following chart.
CHECK POWER SUPPLY FOR COMPRESSOR. Disconnect compressor harness connector. Do approx. 12 volts exist between compressor harness terminal k 1 and body ground?
No
RHA129GA
Yes
Note
Check circuit continuity between A/C relay harness terminal k 3 and compressor harness terminal k 1 . Continuity should exist. If OK, check harness for short. OK
RHA130GA
CHECK POWER SUPPLY FOR A/C RELAY. Do approx. 12 volts exist between A/C relay harness terminals k 1 ,k 5 and body ground? Yes No
NG
Check power supply circuit and 7.5A fuses (No. 16 and 61 , located in the fuse block). Refer to EL section (Wiring Diagram, POWER SUPPLY ROUTING).
RHA493E
CHECK COIL SIDE CIRCUIT OF A/C RELAY. Do approx. 12 volts exist between ECM (ECCS control module) harness terminal k 12 and body ground? [For terminal arrangement, refer to last page (Foldout page).] Yes
Check circuit continuity between A/C relay harness terminal k 2 and ECM (ECCS control module) harness terminal k 12 . [For terminal arrangement, refer to last page (Foldout page).] Continuity should exist. If OK, check harness for short.
k A (Go to next page.) Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
RHA494EA
HA-52
MANUAL
CHECK COIL SIDE CIRCUIT OF A/C RELAY CONTROLLED BY ECM (ECCS control module). Do approx. 8 to 9 volts exist between ECM (ECCS control module) harness terminal No. k 21 and body ground? [For terminal arrangement, refer to last page (Foldout page).]
RHA129FA
Yes
No
CHECK ECM (ECCS control module). Refer to EC section (ECM Terminals and Reference Value, TROUBLE DIAGNOSES General Description).
CHECK TRIPLE-PRESSURE SWITCH CIRCUIT BETWEEN TRIPLEPRESSURE SWITCH AND ECM (ECCS control module). Disconnect triple-pressure switch harness connector. Do approx. 8 to 9 volts exist between triple-pressure switch harness terminal k 1 and body ground? Yes No
NG
Note
Check circuit continuity between ECM (ECCS control module) harness terminal k 21 and triple-pressure switch harness terminal k 1 . [For terminal arrangement, refer to last page (Foldout page).] Continuity should exist. If OK, check harness for short. Note
RHA131G
Check circuit continuity between triplepressure switch harness terminal k 4 and push control unit harness terminal k 13 . Continuity should exist. If OK, check harness for short.
OK
RHA015G
HA-53
MANUAL
OK NG
OK
Note
Check circuit continuity between push control unit harness terminal k 12 and fan switch harness terminal k 5 . Continuity should exist. If OK, check harness for short. OK
Note
RHA503E
CHECK BODY GROUND CIRCUIT FOR FAN SWITCH. Does continuity exist between fan switch harness terminal k 6 and body ground?
Yes NG
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-54
MANUAL
k k k k
k k k k
k k k k
3 4
BLOWER MOTOR
Check blower motor for smooth rotation. Ensure that there are no foreign particles inside the intake unit.
RHA244D
BLOWER RESISTOR
Check continuity between terminals.
AHA230
RHA504EB
HA-55
TRIPLE-PRESSURE SWITCH
Terminals High-pressure side line pressure kPa (kg/cm2, psi) Increasing to 157 - 226 (1.6 - 2.3, 23 - 33) Decreasing to 152.0 - 201.0 (1.55 - 2.05, 22.0 - 29.2) Increasing to 1,422 - 1,618 (14.5 - 16.5, 206 - 235) Decreasing to 1,128 - 1,422 (11.5 - 14.5, 164 - 206) Decreasing to 1,667 - 2,059 (17 - 21, 242 - 299) Increasing to 2,452 - 2,844 (25 - 29, 356 - 412) Operation Continuity
ON
Exists.
Low-pressure side
SHA691E
k 1 -k 4
OFF
ON
Exists.
Mediumpressure side*
k 2 -k 3
OFF
ON
Exists.
High-pressure side
k 1 -k 4
OFF
A/C RELAY
Check circuit continuity between terminals by supplying 12 volts to coil side terminals of the relay.
AHA233
2. 3. 4.
RHA439E
HA-56
MANUAL
2. 3. 4. 5.
SHA848E
Install air mix door motor on heater unit and connect sub-harness. Make sure lever of air mix door is fitted into the slit of air mix door link. Turn ignition switch to ON. Slide temperature control lever to full cold. Check that air mix door operates properly when temperature control lever is slid to full hot and full cold. Check PBR characteristics. Measure resistance between air mix door motor terminals k 1 and k 2 .
RHA564EA
INTAKE DOOR
1. Install intake door motor on intake unit and connect it to main harness. Make sure lever of intake door motor is fitted into the slit of intake door link. Turn ignition switch to ON. Turn REC switch ON. Check that intake door operates properly when REC switch is turned ON and OFF.
2. 3. 4.
RHA442EA
HA-57
DESCRIPTION Introduction
AIR CONDITIONER LAN SYSTEM OVERVIEW CONTROL SYSTEM
The LAN system consists of auto amp., air mix door motor and mode door motor. A configuration of these components is shown in the diagram below.
AUTO
RHA439G
Features
SYSTEM CONSTRUCTION (LAN)
A small network is constructed between the auto amplifier, air mix door motor and mode door motor. The auto amplifier and motors are connected by data transmission lines and motor power supply lines. The LAN network is built through the ground circuits of the two motors. Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted through the data transmission lines connecting the auto amplifier and two motors. The following functions are contained in LCUs built into the air mix door motor and the mode door motor. Address Motor opening angle signals Data transmission Motor stop and drive decision Opening angle sensor (PBR function) Comparison Decision (Auto amplifier indicated value and motor opening angle comparison)
RHA440G
Operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door and mode door opening angle data to the air mix door motor LCU and mode door motor LCU. The air mix door motor and mode door motor read their respective signals according to the address signal. Opening angle indication signals received from the auto amplifier and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/ COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier.
HA-58
AUTO
RHA441G
RHA442G
HA-59
AUTO
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position. With FAN switch set to AUTO, the blower motor starts to gradually increase air flow volume. When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.
Self-diagnostic system
The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of problems.
HA-60
AUTO
RHA380G
AUTO SWITCH
The compressor, air intake doors, air mix door, mode doors, and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator. The air conditioning cooling function operates only when the engine is running.
ECON SWITCH
Fully automatic control with the compressor off. With the compressor off, the system will not remove heat (cool) or de-humidify. The system will maintain the in-vehicle temperature at the set temperature when the set temperature is above the ambient (outside) temperature.
OFF SWITCH
The compressor and blower are off, the air intake doors are set to the outside air position. Then, the mode doors are set to the foot (78% foot and 22% defrost) position. In the off position the ATC system uses the vehicles flow through ventilation. It tries to maintain the interior temperature based on the last set temperature of the system.
FAN SWITCH
Manual control of the blower speed. Four speeds are available for manual control (as shown on the display screen): low , medium low , medium high , high
MODE SWITCH
Manual control of the air discharge outlets. Four selections are available (as shown on the display screen): , bi-level , foot , defrost/foot face
AMBIENT SWITCH
Shows the ambient (outside) air temperature on display screen for 5 seconds.
HA-61
AUTO
ON position: Interior air is recirculated inside the vehicle. OFF position: Automatic control resumes. Recirculation is canceled when AUTO, DEF or ECON is selected. Recirculation resumes when another mode is chosen.
HA-62
DESCRIPTION
NOTE
AUTO
HA-63
TROUBLE DIAGNOSES
AUTO
Reference item
No
Yes
ELIMINATE GOOD PART(S)/HARNESS(ES)/ CONNECTOR(S) ELECTRICALLY. Malfunctioning harness(es)/ connector(s) Malfunctioning part(s)
REPAIR.
REPAIR/REPLACE.
NG
FINAL CHECK
OK
CHECK OUT
HA-64
AUTO
The purpose of the operational check is to confirm that the system is as it should be. The systems which will be checked are the blower, mode (discharge air), intake air, temperature decrease, temperature increase, A/C switch and the memory function.
CONDITIONS:
Engine running and at normal operating temperature.
Press fan switch (up side) one time. Blower should operate on low speed. The fan symbol should have one blade lit . Press fan switch (up side) one more time. Continue checking blower speed and fan symbol until all speeds are checked. Leave blower on MAX speed .
RHA382G
2)
Confirm that discharge air comes out according to the air distribution table at left. Refer to Discharge Air Flow, DESCRIPTION (HA-18). NOTE: Confirm that the compressor clutch is engaged (visual inspection) and intake door position is at FRESH when the DEF button is pressed. Intake door position is checked in the next step.
RHA429E
HA-65
AUTO
Press REC switch. Recirculation indicator should illuminate. Listen for intake door position change (you should hear blower sound change slightly).
RHA383G
RHA384G
RHA385G
3)
RHA386G
RHA387G
HA-66
AUTO
Press OFF switch. Turn the ignition off. Turn the ignition on. Press the AUTO switch. Confirm that the set temperature remains at previous temperature.
RHA388G
RHA389G
HA-67
AUTO
Diagnostic Procedure Diagnostic Procedure 1 (HA-95) Diagnostic Procedure 2 (HA-96) Diagnostic Procedure 3 (HA-97) Diagnostic Procedure 4 (HA-98) k k k k k k k k k k k k k k Diagnostic Procedure 5 (HA-99) k k k k k k k
SYMPTOM
Air outlet does not change. Intake door does not change. Insufficient cooling Insufficient heating Blower motor operation is malfunctioning. Magnet clutch does not engage. Discharged air temperature does not change. Noise Ambient sensor circuit is open. In-vehicle sensor circuit is open. Result of self-diagnosis STEP 2 Intake sensor circuit is open. Sunload sensor circuit is open. PBR signal is open. Ambient sensor circuit is shorted. In-vehicle sensor circuit is shorted. Intake sensor circuit is shorted. Sunload sensor circuit is shorted. PBR signal is shorted. k k k k
k k k
k k k k k k k
k k k k k k k k k k k k k k k k k k
k k k k k k k
k k k k k k k
Mode door motor and/or air mix door motor do not operate normally. Intake door motor does not operate normally. Blower motor operation is malfunctioning under out of Starting Fan Speed Control. Magnet clutch does not operate after performing Preliminary Check 6. Self-diagnosis cannot be performed. k k
k k k k
k k k k
k k k
: The numbers refer to the probability of the cause, being the most likely. k: As for checking order, refer to each flow chart. (It depends on malfunctioning portion.)
HA-68
k Diagnostic Procedure 6 (HA-100) Diagnostic Procedure 7 (HA-102) Diagnostic Procedure 8 (HA-104) k k Auto amp. (LCU) (HA-94) 15A Fuses #2 and #3 (HA-94) 7.5A Fuses #16 and #40 (HA-94) 7.5A Fuse #61 (HA-94) k k Ambient sensor (HA-111) In-vehicle sensor (HA-110) k Intake sensor (HA-112) Thermal transmitter (EL) k k k k Sunload sensor (HA-111) k k Air mix door motor (HA-114) k k k Mode door motor (HA-116) k k k Intake door motor (HA-118) k k k Blower motor (HA-107) k k k Fan control amp. (HA-119) k k A/C relay (HA-107) k k Triple-pressure switch (HA-107) k k Magnet clutch (Compressor) (HA-129) k k k k k k A/C control unit (HA-110) k k k k ECM (ECCS control module) (EC) k Cooling fan motor (EC) k Cooling fan relay (EC) k k k k k k k k k k k k k k k Harness
k k k k
Diagnostic Proce- Main Power Supply and dure Ground Circuit Check
k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k k
HA-69
k k k k k k k k k k k k k k k k k k
AUTO
AUTO
Within 5 seconds after starting engine (ignition switch is turned ON), press at least 5 seconds. switch for
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from normal control to the self-diagnostic system is done as follows. Start the engine (turn the ignition switch from OFF to ON). And press switch for at least 5 seconds. The switch must be pressed within 5 seconds after starting the engine (ignition switch is turned ON). This system will be canceled by either pressing switch or turning the ignition switch OFF. Shifting from one step to another is accomplished by means of pushing (HOT) or (COLD) switch, as required. Additionally shifting from STEP 5 to AUXILIARY MECHANISM is accomplished by means of pushing (fan up) switch.
Ignition switch: OFF switch: ON
switch: ON
STEP 5 Temperature detected by each sensor is checked. Multiplex communication errors are detected.
Note: For STEP 4 and 5, engine must be running for compressor to operate.
HA-70
AUTO
Set in self-diagnostic mode. [Within 5 seconds after starting engine (ignition switch is turned ON), press switch ON for 5 seconds.]
STEP 1
No
Yes
Press
(HOT) switch.
No
Malfunctioning
(HOT) switch
Yes
Press
(COLD) switch.
No
Malfunctioning
(COLD) switch
Yes
Press
*1: Conduct self-diagnosis STEP 2 under sunshine. When conducting indoors, direct light (more than 60W) at sunload sensor or Code No. will indicate despite the fact that sunload sensor is functioning properly.
Display
Code No.
Press
(HOT) switch.
k A Note: At any time, you can return to a previous step in the self-diagnosis by pressing the (COLD) switch.
HA-71
AUTO
STEP 3 All mode door and intake door motor position switches are in good order.
Display
Code No.
Malfunctioning part or circuit Position switch VENT B/L FOOT Mode door motor
Mode door and intake door motor position switch(es) is(are) malfunctioning.
Display
Code No. of malfunctioning mode door and intake door motor position switch(es) is(are) indicated on display.
Press
(HOT) switch.
STEP 4
Display
REC
Code No.
Air mix door Full Cold Full Cold Full Hot Full Hot Full Hot Full Hot
Blower motor 4 - 5V
Compressor ON
Press
(DEF) switch.
B/L REC
9 - 11V
ON
Press
(HOT) switch.
B/L
20% FRE
7 - 9V
OFF
k B
FOOT
FRE
7 - 9V
OFF
F/D
FRE
7 - 9V
ON
DEF
FRE
10 - 12V
ON
HA-72
AUTO
Display
STEP 5
Display
Display
[Multiplex communication error between control unit and auto amplifier is detected]
(AUTO)
END
HA-73
AUTO
When switchs LED and segments are in functioning properly in STEP 1, LED and display will come on.
RHA390G
If LEDs or segments malfunction, LED will not come on or display will show incomplete segment.
RHA391G
RHA499AB
If a sensor is malfunctioning, the corresponding code No. blinks on display. A short circuit is identified by a blinking mark preceding mode number.
RHA392G
HA-74
AUTO
If two or more sensors malfunction, corresponding code Nos. respectively blink two times.
RHA501A
Sensors and abnormalities If a circuit is opened or shorted, display shows its code No. when input corresponds with any of following conditions.
Code No. Sensor Ambient sensor Open circuit Less than 41.9C (43F) Short circuit Greater than 100C (212F)
In-vehicle sensor
Intake sensor
Sunload sensor*2
PBR*1
Less than 5%
*1: 95% and 5% refer to percentage with respect to stroke of air mix door. (Full cold: 0%, Full hot: 100%) *2: Conduct self-diagnosis STEP 2 under sunshine. When conducting indoors, direct light (more than 60W) at sunload sensor.
RHA383DB
HA-75
AUTO
When abnormalities are detected, display shows a code No. corresponding with malfunctioning part.
Code No.
Malfunctioning part
RHA394G
VENT
B/L
FOOT
FOOT/ DEF
DEF
FRE
20% FRE
REC
If two or more mode or intake doors are out of order, corresponding code numbers respectively blink two times. If mode door motor harness connector is disconnected, the following display pattern will appear. , , , ,
!
If intake mode door harness connector is disconnected, the following display pattern will appear. , ,
!
RHA498A
If any mode door motor position switch is malfunctioning, mode door motor will also malfunction.
RHA495A
During inspection in STEP 4, the auto amp. will forcefully transmit an output to the affected actuators. The corresponding code Nos. are shown on display as indicated in the table below. Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation.
Code No. Actuator Mode door Intake door Air mix door Blower motor Compressor VENT REC Full Cold 4-5 V ON B/L REC Full Cold 9 - 11 V ON B/L 20% FRE Full Hot 7-9 V OFF FOOT FRE Full Hot 7-9 V OFF F/D FRE Full Hot 7-9 V ON DEF FRE Full Hot 10 - 12 V ON
RHA429E
HA-76
AUTO
STEP 5: Checks temperature detected by sensors, and detects multiplex communication error
Checks temperature detected by sensors Display shows in STEP 5 mode. When FRONT DEF switch is pressed one time, display shows temperature detected by ambient sensor. When FRONT DEF switch is pressed second time, display shows temperature detected by in-vehicle sensor. When FRONT DEF switch is pressed third time, display shows temperature detected by intake sensor. When FRONT DEF switch is pressed fourth time, display returns to original presentation .
RHA054D
RHA426G
RHA395G
If temperature shown on display greatly differs from actual temperature, check sensor circuit at first. Then inspect sensor itself according to the procedures described in Control System Input Component. Refer to HA-110.
HA-77
AUTO
Display shows in STEP 5 mode. [Multiplex communication error between push control unit and auto amplifier is detected]
Display Signal direction In good order A/C control unit , auto amp.
RHA056D
CAUTION: The auto amp. memorizes any communication error in the system in a normal control with battery connected. When there is an error, display will be as shown above. When plural errors occur, the display of each error will blink two times for 0.5 second intervals. If a communication error is displayed, follow the flow chart below. Determine if the error occurred in the past or is currently happening.
HA-78
AUTO
SHA197E
When battery cable is disconnected, trimmer operation is canceled and temperature set becomes that of initial condition, i.e. 0C (0F).
HA-79
AUTO
CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTIC PROCEDURE BELOW CORRESPONDING TO EACH CODE NO. Code No. How to repair Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Reference page HA-95 HA-96 HA-97 HA-98 HA-99 HA-95 HA-96 HA-97 HA-98 HA-99
Are sensor circuits for ambient sensor, in-vehicle sensor and intake sensor operating normally? If malfunction is suspected, check temperature detected by each sensor using Self-diagnosis STEP 5. Confirm the temperature is within normal range before performing Diagnostic Procedures.
CHECK MODE DOOR MOTOR. Set up Self-diagnosis STEP 3. Is mode door motor operating normally? Code No. 30 should be indicated on the display after approx. 3 seconds. Yes
No
CHECK MODE DOOR OPERATION. Set up Self-diagnosis STEP 4. Does air outlet change according to each code No.?
No
NG
Repair or adjust.
VENT
B/L
B/L
FOOT
F/D2
DEF
Air outlet control system is normal. Refer to Mode door control specification. (HA-116)
HA-80
AUTO
CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTIC PROCEDURE BELOW CORRESPONDED TO EACH CODE NO. Code No. How to repair Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Reference page HA-95 HA-96 HA-97 HA-98 HA-99 HA-95 HA-96 HA-97 HA-98 HA-99
Are sensor circuits for ambient sensor, in-vehicle sensor and intake sensor operating normally? If malfunction is suspected, check temperature detected by each sensor using Self-diagnosis STEP 5. Confirm the temperature is within normal range before performing Diagnostic Procedures.
CHECK INTAKE DOOR MOTOR OPERATION. Set up Self-diagnosis STEP 4. Does intake air change according to each code No.?
No
CHECK INTAKE DOOR ROD or LEVER MECHANISM. Refer to CONTROL LINKAGE ADJUSTMENT. (HA-108) OK
NG
Repair or adjust.
REC
REC
20% FRE
FRE
FRE
FRE
Intake door control system is normal. Refer to Intake door control specification. (HA117)
HA-81
AUTO
NG
OK NG
OK NG
OK NG
OK NG
OK NG
OK NG
Go to EC section.
OK NG
CHECK REFRIGERATION CYCLE PRESSURE WITH MANIFOLD GAUGE CONNECTED. Refer to Performance Chart. (HA33)
OK NG
CHECK FOR EVAPORATOR COIL FREEZE UP. 1. Confirm center vent air is discharged sufficiently. OK (Does not freeze up.)
(Freezes up.)
NG
OK
PERFORM TEMPERATURE SETTING TRIMMING. 1. Set up AUXILIARY MECHANISM mode in self-diagnosis. 2. Press (COLD) switch at desirable times.
HA-82
AUTO
NG
NG
CHECK THE FOLLOWING: Engine coolant level (Refer to MA section.) Hoses for leaks or kinks Radiator cap (Refer to LC section.) Air in cooling system. OK
NG
Repair/replace as necessary.
NG
NG
Repair leaks.
CHECK BY FEEL THE HEATER INLET AND OUTLET HOSES. Hot inlet Warm outlet
Note
Note
Back flush heater core, drain and refill coolant. Retest. Hot inlet Warm outlet
SYSTEM OK
Note: To avoid unnecessary service of heating system, first perform TEMPERATURE SETTING TRIMMING. Refer to AUXILIARY MECHANISM, Self-diagnosis. (HA-79)
HA-83
AUTO
CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTIC PROCEDURE BELOW CORRESPONDING TO EACH CODE NO. Code No. How to repair Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Reference page HA-95 HA-96 HA-97 HA-98 HA-99 HA-95 HA-96 HA-97 HA-98 HA-99
Are sensor circuits for ambient sensor, in-vehicle sensor and intake sensor operating normally? If malfunction is suspected, check temperature detected by each sensor using Self-diagnosis STEP 5. Confirm the temperature is within normal range before performing Diagnostic Procedures.
CHECK BLOWER MOTOR OPERATION. Set up Self-diagnosis STEP 4. Does blower speed change according to each code No.?
Code No. Blower motor speed
No
Low
Middle high
Middle low
High
Yes
Is engine coolant temperature below 50C (122F) and ambient temperature below 15C (59F)? Yes
No
Blower motor operation is normal. Refer to Fan speed control specification. (HA-119)
IS BLOWER MOTOR CONTROLLED UNDER STARTING FAN SPEED CONTROL? Refer to Starting fan speed control. (HA-119) Yes
No
HA-84
AUTO
CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTIC PROCEDURE BELOW CORRESPONDED TO EACH CODE NO. Code No. How to repair Reference page HA-95 HA-96 HA-97 HA-98 HA-99 HA-95 HA-96 HA-97 HA-98 HA-99
Are sensor circuits for ambient sensor, in-vehicle sensor and intake sensor operating normally? If malfunction is suspected, check temperature detected by each sensor using Self-diagnosis STEP 5. Confirm the temperature is within normal range before performing Diagnostic Procedures.
CHECK MAGNET CLUTCH OPERATION. Set up Self-diagnosis STEP 4. Does magnet clutch operate according to each code No.?
Code No. Actuator Compressor
No
NG
ON
ON
OFF
OFF
ON
ON
Magnet clutch control system is normal. Refer to MAGNET CLUTCH CONTROL. (HA120)
HA-85
AUTO
No
CHECK SENSOR CIRCUIT IN DETAIL ACCORDING TO THE DIAGNOSTIC PROCEDURE BELOW CORRESPONDING TO EACH CODE NO. Code No. How to repair Reference page HA-95 HA-96 HA-97 HA-98 HA-99 HA-95 HA-96 HA-97 HA-98 HA-99
Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5. Go to Diagnostic Procedure 1. Go to Diagnostic Procedure 2. Go to Diagnostic Procedure 3. Go to Diagnostic Procedure 4. Go to Diagnostic Procedure 5.
CHECK AIR MIX DOOR OPERATION. Set up Self-diagnosis STEP 4. Does discharged air temperature change according to each code No.?
Full hot No
Air mix door control system is normal. Refer to Air mix door control specification. (HA-132)
Are sensor circuits for ambient sensor, in-vehicle sensor and intake sensor operating normally? If malfunction is suspected, check temperature detected by each sensor using Self-diagnosis STEP 5. Confirm the temperature is within normal range before performing Diagnostic Procedures.
CHECK AIR MIX DOOR MECHANISM. Refer to CONTROL LINKAGE ADJUSTMENT. (HA-108) OK
NG
Repair or adjust.
HA-86
AUTO
Blower motor
Compressor
Expansion valve
Refrigerant line
Belt
Check for noise in all modes and temperature settings. Noise is constant.
NG
Check air discharge ducts for obstructions, foreign materials or air leakage.
Readjust belt tension. Refer to MA section (Checking Drive Belts, ENGINE MAINTENANCE).
The pulley center does not match. Readjust the pulley center.
HA-87
AUTO
RHA098FE
HA-88
AUTO
SHA969E
HA-89
AUTO
MHA709A
HA-90
AUTO
MHA710A
HA-91
AUTO
MHA711A
HA-92
AUTO
MHA712A
HA-93
TROUBLE DIAGNOSES
AUTO
Body ground
Check body ground circuit for push control unit. 1. Disconnect push control unit harness connector. 2. Connect ohmmeter from harness side. 3. Check for continuity between terminal k 32 and body ground.
Ohmmeter terminal
k 32
Body ground
Continuity Yes
RHA430GC
HA-94
AUTO
SYMPTOM: Ambient sensor circuit is open or shorted. ( or is indicated on display as a result of conducting Self-diagnosis STEP 2.)
CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU). Disconnect ambient sensor harness connector. Do approx. 5 volts exist between ambient sensor harness terminal k 2 and body ground? Yes No
RHA030G
Note
Check circuit continuity between ambient sensor harness terminal k 1 and auto amp. (LCU) harness terminal k 33 . Continuity should exist. If OK, check harness for short. OK
RHA399GB
Note
RHA400GB
Check circuit continuity between ambient sensor harness terminal k 2 and auto amp. (LCU) harness terminal k 11 . Continuity should exist. If OK, check harness for short. OK
NG
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-95
AUTO
SYMPTOM: In-vehicle sensor circuit is open or shorted. ( or is indicated on display as a result of conducting Self-diagnosis STEP 2.)
CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. (LCU). Disconnect in-vehicle sensor harness connector. Do approx. 5 volts exist between in-vehicle sensor harness terminal k 2 and body ground? Yes No
RHA033G
Note
Check circuit continuity between in-vehicle sensor harness terminal k 1 and auto amp. (LCU) harness terminal k 3 . Continuity should exist. If OK, check harness for short. OK
RHA401GB
Note
RHA402GB
Check circuit continuity between in-vehicle sensor harness terminal k 2 and auto amp. (LCU) harness terminal k 11 . Continuity should exist. If OK, check harness for short. OK
NG
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-96
AUTO
SYMPTOM: Intake sensor circuit is open or shorted. ( or is indicated on auto amp. as a result of conducting Selfdiagnosis STEP 2.)
RHA431G
CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND AUTO AMP. (LCU). Disconnect intake sensor harness connector. Do approx. 5 volts exist between intake sensor harness terminal No.k 1 and body ground? Yes
No
Note
Check circuit continuity between intake sensor harness terminal No.k 1 and auto amp. (LCU) harness terminal No.k 1 . Continuity should exist. If OK, check harness for short. OK
RHA432GB
Note
Check circuit continuity between intake sensor harness terminal No.k 2 and auto amp. (LCU) harness terminal No.k 11 . Continuity should exist. If OK, check harness for short. OK
RHA433GB
NG
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-97
AUTO
SYMPTOM: Sunload sensor circuit is open or shorted. ( or is indicated on display as a result of conducting Self-diagnosis STEP 2.)
CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. (LCU). Disconnect sunload sensor harness connector. Do approx. 5 volts exist between sunload sensor harness terminal k 2 and body ground? Yes No
RHA034G
Note
Check circuit continuity between sunload sensor harness terminal k 1 and auto amp. (LCU) harness terminal k 12 . Continuity should exist. If OK, check harness for short. OK
RHA403GB
Note
RHA404GB
Check circuit continuity between sunload sensor harness terminal k 2 and auto amp. (LCU) harness terminal k 11 . Continuity should exist. If OK, check harness for short. OK
NG
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-98
AUTO
SYMPTOM: Mode door motor and/or air mix door motor do not operate normally. ( or is indicated on auto amp. as a result of conducting Self-diagnosis STEP 2.)
CHECK POWER SUPPLY FOR AUTO AMP. (LCU) SIDE. Do approx. 12 volts exist between auto amp. (LCU) terminal k 21 and body ground?
SHA957EA
No
Yes CHECK SIGNAL AUTO AMP. (LCU) SIDE. Do approx. 5.5 volts exist between auto amp. (LCU) terminal k 16 and body ground? Yes
No
Note
CHECK POWER SUPPLY FOR MOTOR SIDE. Do approx. 12 volts exist between door motor (LCU) harness terminal k 1 and body ground?
SHA958EA
Yes Note CHECK SIGNAL MOTOR SIDE. Do approx. 5.5 volts exist between door motor (LCU) terminal k 3 and body ground? Yes
Note
CHECK MOTOR GROUND CIRCUIT. Check harness continuity between door motor (LCU) harness terminal k 2 and body ground.
SHA959EA
OK
Disconnect the mode door motor and air mix door motor connector.
CHECK THE MODE DOOR MOTOR OPERATION. Reconnect the mode door motor and confirm the motor operation.
NG
CHECK THE AIR MIX DOOR MOTOR OPERATION. Reconnect the air mix door motor and confirm the motor operation.
NG
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
SHA961EA
HA-99
AUTO
SYMPTOM: Intake door motor does not operate normally. Perform Self-diagnosis STEPS 1, 2 and 4 before referring to the flow chart.
Note CHECK BODY GROUND CIRCUIT FOR INTAKE DOOR MOTOR. Disconnect intake door motor harness connector. Does continuity exist between intake door motor harness terminal k 5 and body ground? Yes
SHA971E
RHA413GB
Note NG
CHECK FOR AUTO AMP. (LCU) OUTPUT. Set up Self-diagnosis STEP 4. Measure voltage across auto amp. (LCU) harness terminals and body ground.
Code No. Terminal No. Condition REC 0 Body ground 20% REC 5 0 5 FRE 0 Voltage V 5
Check circuit continuity between each terminal on auto amp. (LCU) and on intake door motor.
Terminal No. Auto amp. (LCU) k 8 k 19 k 18 k 19 k 28 k 36 Intake door motor k 2 k 1 k 3 k 4 k 7 k 6 Yes Continuity
k 19 k 8 ,k 18 k 8 k 19 , k 18 k 18 k 19 , k 8
5V: Approx. 5V
INSPECTION END
SHA972E
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-100
AUTO
CHECK FOR AUTO AMP. (LCU) OUTPUT. Set up Self-diagnosis STEP 4. Measure voltage across auto amp. (LCU) harness terminals and body ground.
Code No. Terminal No. Condition REC Body ground FRE 12 0 0 Voltage V 12
NG
k 28 k 36 k 28 k 36
OK
RHA415GB
HA-101
AUTO
SYMPTOM: Blower motor operation is malfunctioning under out of Starting Fan Speed Control. Perform Preliminary Check 5 before referring to the following flow chart.
CHECK POWER SUPPLY FOR AUTO AMP. Disconnect auto amp. harness connector. Do approx. 12 volts exist between auto amp. harness terminal k 33 and body ground? Yes
No
RHA416GB
Check power supply circuit and 15A fuses (No. and , located in the fuse block). Refer to EL section (Wiring Diagram, POWER SUPPLY ROUTING.)
CHECK POWER SUPPLY FOR FAN CONTROL AMP. Disconnect fan control amp. harness connector. Do approx. 12 volts exist between fan 1 and control amp. harness terminal k body ground?
RHA536E
No
Yes Note
CHECK POWER SUPPLY FOR BLOWER MOTOR. Disconnect blower motor harness connector. Do approx. 12 volts exist between blower motor harness terminal k 1 and body ground? Yes
No
CHECK BODY GROUND CIRCUIT FOR FAN CONTROL AMP. Check harness continuity between fan control amp. harness terminal k 3 and body ground. Continuity should exist. If OK, check harness for short.
OK
Check power supply circuit and 15A and fuses (No. , located in the fuse block). Refer to EL section (Wiring Diagram, POWER SUPPLY ROUTING). Note
RHA537E
Reconnect fan control amp. harness connector and auto amp. harnesses connector.
Check circuit continuity between blower motor harness terminal k 1 and fan control amp. harness terminal k 1 . Continuity should exist. If OK, check harness for short. OK
CHECK FOR OUTPUT OF AUTO AMP. Set up Self-diagnosis STEP 4. Measure voltage across fan control amp. harness terminal k 2 and body ground.
RHA110F
Code No. ,
OK
RHA539E
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-102
AUTO
Disconnect auto amp. (LCU) and fan control amp. harness connector.
Note
RHA540E
Check harness continuity between auto amp. (LCU) harness terminal k 35 and fan control amp. harness terminal k 2 . Continuity should exist. If OK, check harness for short. OK
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
RHA417GB
HA-103
AUTO
SYMPTOM: Magnet clutch does not engage after performing Preliminary Check 6. Perform Preliminary Check 6 before referring to the flow chart.
No Disconnect A/C relay harCHECK POWER SUPPLY FOR COM ness connector. PRESSOR. 1. Disconnect compressor harness connector. 2. Set up code No. in Self-diagnosis Note STEP 4. Check circuit continuity 3. Do approx. 12 volts exist between combetween A/C relay harness pressor harness terminal k 1 and body 3 and compressor terminal k ground? harness terminal k 1 . Yes Continuity should exist. If OK, check harness for short.
RHA824FC
OK
RHA419GB
CHECK POWER SUPPLY FOR A/C RELAY. Disconnect A/C relay. Do approx. 12 volts exist between A/C relay harness terminal k 1 ,k 5 and body ground? Yes
No
Check power supply circuit and 7.5A fuses (No. 16 , located in the fuse block and No. 61 , located in the fuse and fusible link box). Refer to EL section (Wiring Diagram, POWER SUPPLY ROUTING). Replace A/C relay.
CHECK A/C RELAY AFTER DISCONNECTING IT. (Refer to Electrical Components Inspection.) (HA-107)
NG
OK
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-104
AUTO
Note No
CHECK COIL SIDE CIRCUIT OF A/C RELAY. Do approx. 12 volts exist between ECM (ECCS control module) harness terminal k 12 and body ground? Yes
RHA546E
Check circuit continuity between A/C relay harness terminal k 2 and ECM (ECCS control module) harness terminal k 12 . Continuity should exist. If OK, check harness for short. Replace triple-pressure switch.
NG
RHA547EA
CHECK TRIPLE-PRESSURE SWITCH CIRCUIT BETWEEN TRIPLE-PRESSURE SWITCH AND ECM (ECCS CONTROL MODULE). Disconnect triple-pressure switch harness connector. Do approx. 12 volts exist between triplepressure switch harness terminal k 1 and body ground? Yes
No
Note
RHA014G
Check circuit continuity between ECM (ECCS control module) harness terminal k 21 and triple-pressure switch harness terminal k 1 . Continuity should exist. If OK, check harness for short. OK
RHA015G
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
HA-105
AUTO
RHA420GB
CHECK AUTO AMP. (LCU) CIRCUIT BETWEEN AUTO AMP. (LCU) AND TRIPLE-PRESSURE SWITCH. Do approx. 12 volts exist between auto amp. (LCU) harness terminal k 22 and body ground? Yes
Check circuit continuity between auto amp. (LCU) harness terminal k 22 and triple-pressure switch harness terminal k 4 . Continuity should exist. If OK, check harness for short.
Note: If the result is NG or No after checking circuit continuity, repair harness or connector.
RHA421GA
HA-106
AUTO
Check blower motor for smooth rotation. Ensure that there are no foreign particles inside the intake unit.
RHA244D
TRIPLE-PRESSURE SWITCH
Terminals High-pressure side line pressure kPa (kg/cm2, psi) Increasing to 157 - 226 (1.6 - 2.3, 23 - 33) Decreasing to 152.0 - 201.0 (1.55 - 2.05, 22.0 29.2) Increasing to 1,422 - 1,618 (14.5 - 16.5, 206 - 235) Decreasing to 1,128 - 1,422 (11.5 - 14.5, 164 - 206) Decreasing to 1,667 - 2,059 (17 - 21, 242 - 299) Increasing to 2,452 - 2,844 (25 - 29, 356 - 412) Operation Continuity
ON
Exists.
Low-pressure side
k 1 -k 4
OFF
SHA691E
Mediumpressure side*
ON
k 2 -k 3
OFF
ON
High-pressure side
k 1 -k 4
OFF
A/C RELAY
Check circuit continuity between terminals by supplying 12 volts to coil side terminals of the relay.
AHA233
HA-107
AUTO
2. 3.
RHA439E
Install mode door motor on heater unit and connect it to main harness. Make sure lever of mode door motor is fitted into the slit of mode door link. Set up code No. in Self-diagnosis STEP 4. Make sure mode door operates properly when changing from code No. to by pushing DEF switch.
VENT
B/L
B/L
FOOT
F/D
DEF
2. 3.
RHA438G
Full cold
Full hot
INTAKE DOOR
1. Install intake door motor on intake unit and connect it to main harness. Make sure lever of intake door motor is fitted in the slit of intake door link. Set up code No. in Self-diagnosis STEP 4. Make sure intake door operates properly when changing from code No. to by pushing DEF switch.
2. 3.
RHA442EA
REC
20% FRE
FRE
HA-108
AUTO
The control system consists of a) input sensors and switches, b) the auto amp. (microcomputer), and c) outputs. The relationship of these components is shown in the diagram below:
SHA973E
HA-109
AUTO
The PTC is built into the A/C control unit. It can be set at an interval of 1C (2F) through both (HOT) and (COLD) control switches. Setting temperature is digitally displayed.
IN-VEHICLE SENSOR
The in-vehicle sensor is attached to A/C control finisher. It converts variations in temperature of compartment air drawn from an aspirator into a resistance value. It is then input into the auto amp. After disconnecting in-vehicle sensor harness connector, measure resistance between terminals k 1 and k 2 at sensor harness side, using the table below.
Temperature C (F) 15 (5) 10 (14) 5 (23) 0 (32) 5 (41) 10 (50) 15 (59) 20 (68) 25 (77) 30 (86) 35 (95) 40 (104) 45 (113) Resistance k 12.73 9.92 7.80 6.19 4.95 3.99 3.24 2.65 2.19 1.81 1.51 1.27 1.07
RHA423G
ASPIRATOR
The aspirator is located on heater unit. It produces vacuum pressure due to air discharged from the heater unit, continuously taking compartment air in the aspirator.
RHA458E
RHA482A
HA-110
AMBIENT SENSOR
The ambient sensor is attached to the radiator core support. It detects ambient temperature and converts it into a resistance value which is then input to the auto amp. After disconnecting ambient sensor harness connector, measure resistance between terminals k 1 and k 2 at sensor harness side, using the table below.
Temperature C (F) 15 (5)
RHA459E
Resistance k 12.73 9.92 7.80 6.19 4.95 3.99 3.24 2.65 2.19 1.81 1.51 1.27 1.07
10 (14) 5 (23) 0 (32) 5 (41) 10 (50) 15 (59) 20 (68) 25 (77) 30 (86) 35 (95) 40 (104) 45 (113)
SUNLOAD SENSOR
The sunload sensor is located on the right defroster grille. It detects sunload entering through windshield by means of a photo diode and converts it into a current value which is then input to the auto amp. Measure voltage between terminals k 1 and k 2 at vehicle harness side, using the table below.
Input current mA
RHA460E
When checking sunload sensor, select a place where sun shines directly on it.
HA-111
INTAKE SENSOR
After disconnecting intake sensor harness connector, measure 1 and k 2 at sensor harness side, resistance between terminals k using the table below.
Temperature C (F) 20 (4) 10 (14)
RHA434G
HA-112
SYSTEM DESCRIPTION
AUTO
RHA423G
HA-113
SHA974E
RHA568E
RHA437G
HA-114
System operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door and mode door opening angle data to the air mix door motor LCU and mode door motor LCU. The air mix door motor and mode door motor read their respective signals according to the address signal. Opening angle indication signals received from the auto amplifier and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/COLD or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier.
SHA975E
HA-115
RHA573E
RHA439E
HA-116
System operation
The intake door control determines intake door position based on the ambient temperature and the invehicle temperature. When the ECON, DEF, or OFF buttons are pushed, the auto amp. sets the intake door at the Fresh position.
SHA976E
RHA576EB
HA-117
RHA442EA
RHA502G
4) 5) 6) 7)
System operation
SHA970E
HA-118
AUTOMATIC MODE
In the automatic mode, the blower motor speed is calculated by the auto amp. based on inputs from the PBR, in-vehicle sensor, sunload sensor, and ambient sensor. The blower motor applied voltage ranges from approximately 4.5 volts (lowest speed) to 12 volts (highest speed). To control blower speed, the auto amp. supplies a signal (in the range of 2.5V to 9V), to the fan control amplifier. Based on this signal, the fan control amplifier controls the current flow from the blower motor to ground.
delay, the blower will operate at low speed until the engine coolant temperature rises above 50C (122F). Then the blower speed will increase to the objective speed.
STARTING FAN SPEED CONTROL Start up from COLD SOAK condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 50C (122F), the blower will not operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and engine coolant temperature. In the most extreme case (very low ambient) the blower starting delay will be 150 seconds. After this
RHA579EB
AHA191
HA-119
HA-120
SERVICE PROCEDURES
RHA275DF
RHA276DG
HA-121
MANUAL AND AUTO SERVICE PROCEDURES HFC-134a (R-134a) Service Procedure (Contd)
Set the recovery/recycling equipment.
NG *1
Repair.
*1
Complete charging (specified amount less partial charge amount) (Refer to SDS).
*2
Check for A/C operation and A/C cool- .................. ing performance
Note: *1 Before charging refrigerant, ensure engine is off. *2 Before checking for leaks, start engine to activate air conditioning system then turn engine off. Service valve caps must be installed to prevent leakage.
HA-122
SERVICE PROCEDURES
LUBRICANT
Name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0
Can lubricant return operation be performed? A/C system works properly. There is no evidence of a large amount of lubricant leakage. No
Yes
Perform lubricant return operation, proceeding as follows: -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------1. Start engine, and set the following conditions: Test condition Engine speed: Idling to 1,200 rpm A/C or AUTO switch: ON Blower speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30C (77 to 86F).] 2. Next item is for V-5 or V-6 compressor. Connect the manifold gauge, and check that the high pressure side pressure is 588 kPa (6 kg/cm2, 85 psi) or higher. If less than the reference level, attach a cover to the front face of the condenser to raise the pressure. 3. Perform lubricant return operation for about 10 minutes. 4. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation.
Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.) No
After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added
Lubricant to be added to system Amount of lubricant m (US fl oz, Imp fl oz) 75 (2.5, 2.6) 75 (2.5, 2.6) 5 (0.2, 0.2) 30 (1.0, 1.1)
*1: If compressor is replaced, addition of lubricant is included in the flow chart. *2: If refrigerant leak is small, no addition of lubricant is needed.
HA-123
MANUAL AND AUTO SERVICE PROCEDURES Maintenance of Lubricant Quantity in Compressor (Contd)
k A
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/ recycling equipment. 2. Remove the drain plug of the old (removed) compressor (applicable only to V-5, V-6 or DKS-16H compressor). Drain the lubricant into a graduated container and record the amount of drained lubricant. 3. Remove the drain plug and drain the lubricant from the new compressor into a separate, clean container. 4. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening. 5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor through the suction port opening. 6. Torque the drain plug. V-5 or V-6 compressor: 18 - 19 Nm (1.8 - 1.9 kg-m, 13 - 14 ft-lb) DKS-16H compressor: 14 - 16 Nm (1.4 - 1.6 kg-m, 10 - 12 ft-lb) 7. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time. Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.
RHA065DD
HA-124
SHA875E
HA-125
Perform a visual inspection of all refrigeration parts, fittings, hoses, and components for signs of A/C lubricant leakage, damage and corrosion.
SHA705E
1.
SHA707EA
2.
SHA706E
HA-126
SHA708EA
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor or tobacco smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement so that the leaking refrigerant is not dispersed. 1. Charge the system with the specified amount of refrigerant. 2. Run the engine with the A/C compressor ON for at least 2 minutes. 3. Stop engine.
Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector on the high pressure line. The pressure in the high pressure line will gradually drop after refrigerant circulation stops and pressure in the low pressure line will gradually rise, as shown in the graph. Leaks are more easily detected when pressure is high.
SHA839E
4.
Conduct the leak test from the high side to the low side at a through k m . Refer to HA-125. points k Perform a leak check for the following areas carefully. Clean the component to be checked and move the leak detector probe completely around the connection/component. Compressor Check the fitting of high and low pressure hoses, relief valve and shaft seal. Liquid tank Check the pressure switch, tube fitting and the fusible plug mounts. Service valves Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). Cooling unit Turn blower fan on High for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Insert the leak detector probe into the drain hose immediately after stopping the engine. (Keep the probe inserted for at least ten seconds.)
HA-127
RHA463E
Belt Tension
Refer to MA section (Checking Drive Belts, ENGINE MAINTENANCE).
HA-128
RHA122F
Compressor Clutch
REMOVAL
When removing center bolt, hold clutch disc with clutch disc wrench.
RHA136EB
RHA123F
HA-129
RHA124F
RHA138E
Pulley removal Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned onto the edge of the pulley assembly.
RHA139E
RHA125F
RHA145E
HA-130
Pulley
Check the appearance of the pulley assembly. If the contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.
RHA126F
Coil
Check lubricant for loose connection or cracked insulation.
INSTALLATION
Install the field coil. Be sure to align the coils pin with the hole in the compressors front head. Install the field coil harness clip using a screwdriver.
RHA142E
Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers.
RHA143EA
Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand.
RHA127F
Using the holder to prevent clutch disc rotation, tighten the bolt to 14 Nm (1.4 kg-m, 10 ft-lb) torque. After tightening the bolt, check that the pulley rotates smoothly.
RHA086E
HA-131
BREAK-IN OPERATION
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
RHA087E
HA-132
LUBRICANT
Model Name CALSONIC make V-6 Nissan A/C System Oil Type S KLH00-PAGS0
REFRIGERANT
Type Capacity kg (lb) HFC-134a (R-134a) 0.650.05 (1.430.11)
BELT TENSION
Refer to Checking Drive Belts (MA section).
HA-133
HA
CONTENTS
PRECAUTIONS AND PREPARATION............................2 Supplemental Restraint System (SRS) AIR BAG ............................................................................2 Precautions for Working with HFC-134a (R-134a) .....3 General Refrigerant Precautions .................................3 Precautions for Refrigerant Connection ......................4 Precautions for Servicing Compressor........................7 Special Service Tools ..................................................7 HFC-134a (R-134a) Service Tools and Equipment....................................................................8 Precautions for Service Equipment ...........................10 DESCRIPTION ...............................................................12 Refrigeration Cycle ....................................................12 V-6 Variable Displacement Compressor....................13 Component Layout ....................................................17 Discharge Air Flow.....................................................18 DESCRIPTION ...............................................................19 Control Operation ......................................................19 TROUBLE DIAGNOSES ...............................................21 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................21 Operational Check .....................................................22 Symptom Chart..........................................................24 Preliminary Check......................................................26 TROUBLE DIAGNOSES ...............................................31 Performance Test Diagnoses ....................................31 Performance Chart ....................................................33 Trouble Diagnoses for Abnormal Pressure ...............34 TROUBLE DIAGNOSES ...............................................37 Harness Layout..........................................................37 Circuit Diagram ..........................................................39 Wiring Diagram A/C, M ....................................40 Main Power Supply and Ground Circuit Check ........44 Diagnostic Procedure 1 .............................................45 Diagnostic Procedure 2 .............................................47 Diagnostic Procedure 3 .............................................49 Diagnostic Procedure 4 .............................................50 Diagnostic Procedure 5 .............................................52 Electrical Components Inspection .............................55 Control Linkage Adjustment.......................................56 DESCRIPTION ...............................................................58 Introduction ................................................................58 Features.....................................................................58 Control Operation ......................................................61 TROUBLE DIAGNOSES ...............................................64 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................64 Operational Check .....................................................65 Symptom Chart..........................................................68 Self-diagnosis ............................................................70 Preliminary Check......................................................80 Harness Layout..........................................................88 Circuit Diagram ..........................................................90 Wiring Diagram A/C, A .....................................91 Main Power Supply and Ground Circuit Check ........94 Diagnostic Procedure 1 .............................................95 Diagnostic Procedure 2 .............................................96 Diagnostic Procedure 3 .............................................97 Diagnostic Procedure 4 .............................................98 Diagnostic Procedure 5 .............................................99 Diagnostic Procedure 6 ...........................................100 Diagnostic Procedure 7 ...........................................102 Diagnostic Procedure 8 ...........................................104 Electrical Components Inspection ...........................107 Control Linkage Adjustment.....................................108 SYSTEM DESCRIPTION .............................................109 Overview of Control System....................................109 Control System Input Components .........................110 Control System Automatic Amplifier (Auto amp.) ....113 Control System Output Components.......................113 SERVICE PROCEDURES ...........................................121 HFC-134a (R-134a) Service Procedure ..................121 Maintenance of Lubricant Quantity in Compressor .............................................................123 Refrigerant Lines .....................................................125 Checking Refrigerant Leaks ....................................126 Compressor Mounting .............................................128 Belt Tension .............................................................128
CONTENTS
Fast Idle Control Device (FICD) ..............................128 Compressor .............................................................129 Compressor Clutch ..................................................129
(Contd)
SERVICE DATA AND SPECIFICATIONS (SDS) ........133 General Specifications.............................................133 Inspection and Adjustment ......................................133
98.10.1/A32d98