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AIR CONDITIONER

SECTION
MANUAL AIR CONDITIONER
MTC B

E
CONTENTS
SERVICE INFORMATION ............................ 2 Air Mix Door Motor Circuit ....................................... 30 F
Intake Door Motor Circuit ......................................... 30
PRECAUTIONS .................................................. 2 Blower Motor Circuit ................................................ 31
Precaution for Supplemental Restraint System Magnet Clutch Circuit .............................................. 32 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Intake Sensor Circuit ............................................... 33
SIONER" ................................................................... 2 Insufficient Cooling (With Heater) ............................ 33
Precaution for Procedure without Cowl Top Cover .. 2 Insufficient Cooling (Without Heater) ....................... 40
H
Precaution for Working with HFC-134a (R-134a) ..... 2 Insufficient Heating .................................................. 46
General Refrigerant Precaution ................................ 2
Precaution for Refrigerant Connection ..................... 3 A/C UNIT ASSEMBLY ...................................... 48
Disassembly and Assembly..................................... 48 I
PREPARATION .................................................. 7
Special Service Tool ................................................. 7 COOLING UNIT ASSEMBLY ............................ 50
HFC-134a (R-134a) Service Tool and Equipment.... 7 Disassembly and Assembly..................................... 50
MTC
Commercial Service Tool........................................ 10
DUCTS AND GRILLES ..................................... 52
LUBRICANT ..................................................... 11 Disassembly and Assembly..................................... 52
Maintenance of Lubricant Quantity in Compressor 11 K
REFRIGERANT LINES ..................................... 53
AIR CONDITIONER CONTROL ....................... 13 Component .............................................................. 53
Description of Control System ................................ 13 Removal and Installation for Compressor ............... 54
Removal and Installation for Compressor Clutch .... 55 L
Control Operation ................................................... 13
Discharge Air Flow .................................................. 15 Check Disc to Pulley Clearance .............................. 57
Air Distribution ........................................................ 16 Checking of Refrigerant Leaks ................................ 57
System Description ................................................. 16 Checking System for Leaks Using the Fluorescent M
Leak Detector .......................................................... 57
TROUBLE DIAGNOSIS .................................... 19 Dye Injection ............................................................ 58
CONSULT-III Function ............................................ 19 Electrical Leak Detector ........................................... 58 N
How to Perform Trouble Diagnosis for Quick and
Accurate Repair ...................................................... 19 SERVICE DATA AND SPECIFICATIONS
Component Parts and Harness Connector Loca- (SDS) ................................................................ 63
tion .......................................................................... 20 Compressor ............................................................. 63 O
Schematic ............................................................... 23 Lubricant .................................................................. 63
Wiring Diagram - A/C -............................................ 24 Refrigerant ............................................................... 63
Air Control Terminal and Reference Value ............. 29 ENGINE IDLING SPEED......................................... 64 P
Mode Door Motor Circuit......................................... 30 BELT TENSION ....................................................... 64

Revision: 2007 September MTC-1 D40


PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003291987

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 “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING:
• 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.
• 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 “SUPPLEMENTAL RESTRAINT SYSTEM”.
• 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 har-
ness connectors.
Precaution for Procedure without Cowl Top Cover INFOID:0000000003291988

When performing the procedure after removing cowl top cover,


cover the lower end of windshield with urethane, etc.

PIIB3706J

Precaution for Working with HFC-134a (R-134a) INFOID:0000000002978913

CAUTION:
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed and compressor
malfunction is likely occur.
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. 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 fol-
lowing 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, never remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possible
to min-imize 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.
- Never allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrene foam parts.
Damage may result.
General Refrigerant Precaution INFOID:0000000002978914

WARNING:
• Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant.

Revision: 2007 September MTC-2 D40


PRECAUTIONS
< SERVICE INFORMATION >
If accidental system discharge occurs, ventilate work area before resuming service. Additional
health and safety information may be obtained from refrigerant and lubricant manufacturers. A
• Never release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
• Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air
B
conditioning system.
• Never store or heat refrigerant containers above 52C (126F).
• Never 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. C
• Never intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
• Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suf- D
focation.
• Never 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) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may E
cause injury or prop-erty damage. Additional health and safety information may be obtained from
refrigerant manufactur-ers.
Precaution for Refrigerant Connection INFOID:0000000002978915
F

A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.
• Expansion valve to cooling unit G
• Refrigerant pressure sensor
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
• The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi- H
nates the possibility 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. I
• The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facili-
tating piping connections.
MTC

SHA815E
O
O-RING AND REFRIGERANT CONNECTION

Revision: 2007 September MTC-3 D40


PRECAUTIONS
< SERVICE INFORMATION >
LHD models

JPIIA0428GB

Revision: 2007 September MTC-4 D40


PRECAUTIONS
< SERVICE INFORMATION >
RHD models
A

MTC

JPIIA0429GB
K
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Never confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant may leak at the L
con-nection.
O-Ring Part Numbers and Specifications
M
Connection type Piping connection point Part number QTY O-ring size
Condenser to condenser adapter 92472 N8210 2 12
N
Condenser adapter to high-pressure flexible hose 92472 N8210 1 12
Condenser to adapter high-pressure pipe 92471 N8210 1 8
Low-pressure flexible hose to low-pressure pipe 92474 N8210 1 19 O
Low-pressure pipe to expansion valve 92473 N8210 1 16
New
High-pressure pipe to expansion valve 92471 N8210 1 8
P
Compressor to low-pressure flexible hose 92474 N8210 1 19
Compressor to high-pressure flexible hose 92472 N8210 1 12
Inlet 1
Liquid tank to condenser pipe 92471 N8210 8
Outlet 1

Revision: 2007 September MTC-5 D40


PRECAUTIONS
< SERVICE INFORMATION >
Connection type Piping connection point Part number QTY O-ring size
Refrigerant pressure sensor to condenser J2476 89956 1 10
Former High-pressure side 92471 EB70A 1 12
Expansion valve to evaporator
Low-pressure side 92473 EB70A 1 19
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 way at 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 dust and moisture.
• When installing an air conditioner in the vehicle, connect the pipes at the final stage of the operation.
Never 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 tubes, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.

Name : Nissan A/C System Oil Type R


• O-ring must be closely attached to the groove of tube.
• When replacing the O-ring, be careful not to damage O-ring and tube.
• Connect tube until a click can be heard, then tighten the nut or bolt by hand. Make sure that the O-
ring is installed to tube correctly.
• After connecting line, perform leak test and make sure that there is no leakage from connections.
When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then
tighten connections of seal seat to the specified torque.

RHA861F

Revision: 2007 September MTC-6 D40


PREPARATION
< SERVICE INFORMATION >
PREPARATION
A
Special Service Tool INFOID:0000000002978916

B
Tool number
Tool name Description

KV99106200
Installing pulley
Pulley installer D

S-NT235
E

KV99233130 F
Removing pulley
Pulley puller

G
LHA172

HFC-134a (R-134a) Service Tool and Equipment INFOID:0000000002978917


H
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 I
refrigerant/lubri-cant.
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 MTC
mixed use of the refrigerants/lubricant.
Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.
K
Tool number
(SPX-North America No.) Description
Tool name
L

Container color: Light blue


Container marking: HFC-134a (R- M
HFC-134a (R-134a) refrigerant 134a)
Fitting size: Thread size
• Large container 1/2″-16 ACME
N
S-NT196

Type: Polyalkylene glycol oil (PAG), O


type R (DH-PR)
Nissan A/C System Oil Type R Application:
(DH-PR) HFC-134a (R-134a) vane rotary com-
pressors (Nissan only) P
Capacity: 40 m (1.4 Imp fl oz.)
S-NT197

Revision: 2007 September MTC-7 D40


PREPARATION
< SERVICE INFORMATION >
Tool number
(SPX-North America No.) Description
Tool name

Recovery/Recycling/ Function: Refrigerant recovery, recy-


Recharging equipment (ACR4) cling and recharging

RJIA0195E

Power supply:
Electrical A/C leak detector
DC 12 V (Cigarette lighter)

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 Power supply:
Use with J-41447, 1/4 ounce bottle DC 12 V (Battery terminal)
(J-41447)
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872) ZHA200H
Refrigerant dye cleaner

Power supply:
DC 12 V (Battery terminal)
(J-42220) For checking refrigerant leak when flu-
UV lamp and UV safety goggles orescent dye is installed in A/C system
Includes:
UV lamp and UV safety goggles
SHA438F

Application:
For HFC-134a (R-134a) PAG oil
(J-41447)
Container:
HFC-134a (R-134a) fluorescent
1/4 ounce (7.4 cc) bottle
leak detection dye
(Includes self-adhesive dye identifica-
(Box of 24, 1/4 ounce bottles)
tion labels for affixing to vehicle after
charging system with dye.)
SHA439F

Revision: 2007 September MTC-8 D40


PREPARATION
< SERVICE INFORMATION >
Tool number
(SPX-North America No.) Description A
Tool name

B
(J-41459)
For injecting 1/4 ounce of fluorescent
HFC-134a (R-134a) dye injector
leak detection dye into A/C system.
Use with J-41447, 1/4 ounce bottle C

SHA440F

(J-43872) E
For cleaning dye spills.
Refrigerant dye cleaner

SHA441F F

G
Identification:
• The gauge face indicates HFC-134a
Manifold gauge set (with hoses
and couplers)
(R-134a). H
Fitting size: Thread size
• 1/2″-16 ACME

RJIA0196E

Hose color:
MTC
• Low hose: Blue with black stripe
Service hoses
• High hose: Red with black stripe
• High-pressure side hose
• Utility hose: Yellow with black stripe K
• Low-pressure side hose
or green with black stripe
• Utility hose
Hose fitting to gauge:
• 1/2″-16 ACME
S-NT201
L

Service couplers Hose fitting to service hose: M


• High-pressure side coupler M14 x 1.5 fitting is optional or perma-
• Low-pressure side coupler nently attached.

N
S-NT202

Revision: 2007 September MTC-9 D40


PREPARATION
< SERVICE INFORMATION >
Tool number
(SPX-North America No.) Description Tool name

For measuring of refrigerant


Refrigerant weight scale Fitting size: Thread size
1/2″-16 ACME

S-NT200

Capacity:
• Air displacement: 4 CFM
Vacuum pump • Micron rating: 20 microns
(Including the isolator valve) • Oil capacity: 482 g (17 oz.)
Fitting size: Thread size
• 1/2″-16 ACME
S-NT203

Commercial Service Tool INFOID:0000000002978918

Tool number
Description
Tool name

Clutch disk holding tool Clutch disk holding tool

WHA230

Revision: 2007 September MTC-10 D40


LUBRICANT
< SERVICE INFORMATION >
LUBRICANT
A
Maintenance of Lubricant Quantity in Compressor INFOID:0000000002978919

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres- B
sor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain
the specified amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
• Lack of lubricant: May lead to a seized compressor C
• Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
D
Name : Nissan A/C System Oil Type R

LUBRICANT RETURN OPERATION E


Adjust the lubricant quantity according to the test group shown below.
1.CHECK LUBRICANT RETURN OPERATION
F
Can lubricant return operation be performed?
• A/C system works properly.
• There is no evidence of a large amount of lubricant leakage.
CAUTION: G
If excessive lubricant leakage is noted, never perform the lubricant return operation.
OK or NG
OK >> GO TO 2. H
NG >> GO TO 3.
2.PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS I
1. Start the engine, and set to the following
conditions: - Engine speed: Idling to 1,200 rpm
- A/C switch: ON
- Blower speed: Max. position MTC
- Temp. control: Optional [Set so that intake air temperature is 25 to 30C (77 to 86F).]
- Intake position: Recirculation ( )
2. Perform lubricant return operation for about 10 minutes. K
3. Stop the engine.

>> GO TO 3. L
3.CHECK REPLACEMENT PART
M
Should the compressor be replaced?
YES >> Go to "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" .
NO >> Go to "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT N
EXCEPT COMPRESSOR" .
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-
PRESSOR O
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added:
P
Lubricant to be added to system
Part replaced Amount of lubricant Remarks
m (Imp fl oz.)
Evaporator 75 (2.6) —
Condenser 35 (1.2) —
Liquid tank 5 (0.2) —

Revision: 2007 September MTC-11 D40


LUBRICANT
< SERVICE INFORMATION >
Lubricant to be added to system
Part replaced Amount of lubricant Remarks
m (Imp fl oz.)
30 (1.1) Large leak
In case of refrigerant leak
*1
— Small leak
*1: If the refrigerant leak is small, no addition of lubricant is needed.

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT


1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from the equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged
into the recovery/recycling equipment.
3. Drain the lubricant from the old (removed) compressor into a graduated container and recover the
amount of lubricant drained.
4. Drain the lubricant from the new compressor into a separate, clean container.
5. 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.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this
lubricant to new compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add another 5 m (0.2 Imp fl oz.) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz.) of lubricant when replaces the compressor only.

SJIA0596E

Revision: 2007 September MTC-12 D40


AIR CONDITIONER CONTROL
< SERVICE INFORMATION >
AIR CONDITIONER CONTROL
A
Description of Control System INFOID:0000000002978920

The control system consists of input sensors, switches, the air control (microcomputer) and outputs. B
The relationship of these components is shown in the figure below:
WITH HEATER
C

JSIIA0929GB H
WITHOUT HEATER

MTC

JSIIA0930GB

N
Control Operation INFOID:0000000002978921

WITH HEATER O

Revision: 2007 September MTC-13 D40


AIR CONDITIONER CONTROL
< SERVICE INFORMATION >

JPIIA0430ZZ

1. Fan control dial 2. Temperature control dial 3. Mode control dial


4. A/C switch 5. Rear window defogger switch 6. Recirculation (REC) switch

FAN CONTROL DIAL


This dial turns the fan ON and OFF, and controls fan speed.
TEMPERATURE CONTROL DIAL
This dial is adjust the temperature of the discharge air.
MODE CONTROL DIAL
This dial controls the air flow outlet. When blower motor operates, this dial turns MAX A/C position, air inlet is
set to REC and compressor is ON.
A/C SWITCH
Compressor is ON or OFF with this switch.
REAR WINDOW DEFOGGER SWITCH
When switch is ON, rear window is defogged.
RECIRCULATION (REC) SWITCH
• When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
• When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automati-
cally turned OFF. REC mode can be re-entered by pressing REC switch again.
WITHOUT HEATER

Revision: 2007 September MTC-14 D40


AIR CONDITIONER CONTROL
< SERVICE INFORMATION >

JPIIA0431ZZ F

1. Fan control dial 2. Temperature control dial 3. Mode control dial


4. A/C switch 5. Rear window defogger switch 6. Recirculation (REC) switch G
FAN CONTROL DIAL
This dial turns the fan ON and OFF, and controls fan speed.
H
TEMPERATURE CONTROL DIAL
This dial is to adjust a value of evaporator freeze protection control.
MODE CONTROL DIAL
I
This dial controls the air flow outlet. When blower motor operates, this dial turns MAX A/C position, air inlet is
set to REC and compressor is ON.
A/C SWITCH MTC
Compressor is ON or OFF with this switch.
REAR WINDOW DEFOGGER SWITCH
When switch is ON, rear window is defogged. K
RECIRCULATION (REC) SWITCH
• When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
• When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automati- L
cally turned OFF. REC mode can be re-entered by pressing REC switch again.
Discharge Air Flow INFOID:0000000002978922
M

JPIIA0442ZZ
P
NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

Revision: 2007 September MTC-15 D40


AIR CONDITIONER CONTROL
< SERVICE INFORMATION >
Air Distribution INFOID:0000000003292160

WITH HEATER

JPIIA0443GB

WITHOUT HEATER

JSIIA0506GB

System Description INFOID:0000000002978923

SWITCHES AND THEIR CONTROL FUNCTION


WITH HEATER

JPIIA0440GB

Revision: 2007 September MTC-16 D40


AIR CONDITIONER CONTROL
< SERVICE INFORMATION >

JPIIA0441GB H
WITHOUT HEATER

MTC

SJIA1874E

Revision: 2007 September MTC-17 D40


AIR CONDITIONER CONTROL
< SERVICE INFORMATION >

JSIIA0934GB

Revision: 2007 September MTC-18 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
TROUBLE DIAGNOSIS
A
CONSULT-III Function INFOID:0000000002978924

CONSULT-III can display each diagnosis item using the diagnosis test modes shown following. B

System part Check item, diagnosis mode Description


BCM Data monitor Displays BCM input data in real time. C
DATA MONITOR
Display Item List D

Monitor item name


Contents
“operation or unit”
E
Displays “IGN position (On)/OFF, ACC position (Off)” status as judged from ignition switch signal
IGN ON SW “On/Off”
through the CAN communication.
Displays “COMP (On)/COMP (Off)” status as judged from air conditioner switch signal through the
COMP ON SIG “On/Off” F
CAN communication.
Displays “FAN (On)/FAN (Off)” status as judged from blower fan motor switch signal through the CAN
FAN ON SIG “On/Off”
communication.
G
How to Perform Trouble Diagnosis for Quick and Accurate Repair INFOID:0000000002978925

WORK FLOW H

MTC

SJIA1078E K
SYMPTOM TABLE
L
Symptom Reference Page
Air outlet does not change. MTC-30, "Mode
Go to Trouble Diagnosis Procedure for Mode Door Motor. Door Motor Cir-
Mode door motor is malfunctioning. cuit" M
Intake door does not change. MTC-30, "Intake
Go to Trouble Diagnosis Procedure for Intake Door Motor. Door Motor Cir-
Intake door motor is malfunctioning. cuit" N
MTC-31, "Blower
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor. Motor Circuit"
MTC-32, "Magnet O
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. Clutch Circuit"
MTC-40, "Insuffi-
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling. cient Cooling P
(Without Heater)"

Revision: 2007 September MTC-19 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Component Parts and Harness Connector Location INFOID:0000000002978926

ENGINE COMPARTMENT

SJIA1904E

PASSENGER COMPARTMENT

Revision: 2007 September MTC-20 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
LHD models
A

MTC

JPIIA0447ZZ

P
1. Air control 2. Intake door motor 3. Blower motor resistor
4. Intake sensor 5. Air mix door motor 6. Mode door motor

Revision: 2007 September MTC-21 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
RHD models

JPIIA0446ZZ

1. Air control 2. Mode door motor 3. Air mix door motor


4. Intake sensor 5. Intake door motor 6. Blower motor resistor

Revision: 2007 September MTC-22 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Schematic INFOID:0000000002978927

MTC

PJWA0207E
P

Revision: 2007 September MTC-23 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Wiring Diagram - A/C - INFOID:0000000002978928

PJWA0208E

Revision: 2007 September MTC-24 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

MTC

PJWA0209E

Revision: 2007 September MTC-25 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

TJWB0279E

Revision: 2007 September MTC-26 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

MTC

PJWA0210E

Revision: 2007 September MTC-27 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

PJWA0211E

Revision: 2007 September MTC-28 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Air Control Terminal and Reference Value INFOID:0000000002978929
A
Measure voltage between each terminal and ground by referring ter-
minal and reference value for air control.
B

D
SJIA1896E

PIN CONNECTOR TERMINAL LAYOUT


E

SJIA1960E
H
Terminals and Reference Value for Air Control

Terminal Wire Ignition Voltage (V)


Item Condition I
No. color switch (Approx.)
1 BR Mode door motor CW ON Clockwise rotation Battery voltage

2 W Air mix door motor CW ON Clockwise rotation Battery voltage MTC


3 G Air mix door motor CCW ON Counterclockwise rotation Battery voltage
4 Y Intake door motor CW ON Clockwise rotation Battery voltage
5 O Intake door motor CCW ON Counterclockwise rotation Battery voltage K
6 P Power supply from IGN ON — Battery voltage
ON A/C switch: OFF 5V L
10 W Compressor ON signal A/C switch: ON (Blower
ON 0V
motor operates.)

12 L Intake sensor ON — 0-5V M


13 V Intake sensor ground ON — 0V
14 R Mode door motor CCW ON Counterclockwise rotation Battery voltage
Blower motor: OFF Battery voltage N
18 GR Blower monitor ON
Blower motor: ON 0V
19 GR Power supply from BAT — — Battery voltage
O
20 B Ground — — 0V
21 V Mode door motor feedback ON — 0-5V
22 SB Air mix door motor feedback ON — 0-5V P
Power supply for mode door motor
23 G ON — 5V
PBR
26 P Ground for mode door motor PBR ON — 0V

Revision: 2007 September MTC-29 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Mode Door Motor Circuit INFOID:0000000002978930

SYMPTOM
• Air outlet does not change.
• Mode door motor does not operate normally.
SYSTEM DESCRIPTION
Component Parts

Mode door control system components are:


• Air control
• Mode door motor
• PBR (built into mode door motor)
System Operation
The mode door position (VENT and B/L) is set by the air control by means of the mode door motor. When a
mode door position is selected on the air control, voltage is applied to the mode door motor while ground is
applied to the other circuit, causing the mode door motor to rotate. The direction of rotation is determined by
which circuit has voltage applied to it, and which one has ground applied to it. The front air control monitors
the mode door position by measuring the voltage signal on the PBR circuit.

Air Mix Door Motor Circuit INFOID:0000000003292816

SYMPTOM:
• Discharge air temperature does not change.
• Air mix door motor does not operate.
SYSTEM DESCRIPTION
Component Parts

Air mix door control system components are:


• Air control
• Air mix door motor
• PBR (built-into air mix motor)
System Operation
The air control receives data from the temperature selected by the driver and rear passenger. The air control
then applies a voltage to one circuit of the appropriate air mix door motor, while ground is applied to the other
circuit, causing the appropriate air mix door motor to rotate. The direction of rotation is determined by which
circuit has voltage applied to it, and which one has ground applied to it. The air control monitors the air mix
door positions by measuring the voltage signal on the PBR circuits of each door.

Air Mix Door Control Specification

WJIA0435E

Intake Door Motor Circuit INFOID:0000000002978931

SYMPTOM
• Intake door does not change.

Revision: 2007 September MTC-30 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
• Intake door motor does not operate normally.
A
SYSTEM DESCRIPTION
Component Parts
B
Intake door control system components are:
• Air control
• Intake door motor
System Operation C
The intake door control determines the intake door position based on the position of the recirculation switch.
When the recirculation switch is depressed the intake door motor rotate closing off the fresh air inlet and
recir-culating the cabin air. If the recirculation switch is depressed again, the intake door motor rotate in the D
oppo-site direction, again allowing fresh air into the cabin.
When blower motor operates, mode control dial turns MAX A/C position, intake door is fixed to REC position.
E
Blower Motor Circuit INFOID:0000000002978932

SYMPTOM: Blower motor operation is malfunctioning. F


SYSTEM DESCRIPTION
Component Parts
• Air control G
• Blower switch
• Blower motor resistor
• Blower motor H
• Blower motor relay
COMPONENT INSPECTION
I
Blower Motor Relay
Check continuity between terminals by supplying battery voltage
and ground to coil side terminals of relay.
MTC

LJIA0068E P
Blower Motor
Confirm smooth rotation of the blower motor.
• Ensure that there are no foreign particles inside the cooling unit assembly.

Revision: 2007 September MTC-31 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
• Apply battery voltage to terminal + and ground to terminal - and
verify that the motor operates freely and quietly.

SJIA1900E

Blower Switch
Check continuity between terminals at each switch position.

SJIA1901E

Blower Motor Resistor


Check continuity between terminals. There will be resistance, but
there should not be an open or short between any two terminals.

SJIA1902E

Magnet Clutch Circuit INFOID:0000000002978933

SYMPTOM: Magnet clutch does not engage.


SYSTEM DESCRIPTION
The air control controls compressor operation based on intake temperature and a signal from ECM.
Evaporator Freeze Protection Control
When intake air temperature is higher than 5C (41F), the
compres-sor turns ON. The compressor turns OFF when intake air
tempera-ture is lower than 3.5C (38F).

JSIIA0935GB

COMPONENT INSPECTION
Refrigerant Pressure Sensor

Revision: 2007 September MTC-32 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
The refrigerant pressure sensor is attached to the condenser.
A

SJIA1905E

D
Intake Sensor Circuit INFOID:0000000002978935

COMPONENT INSPECTION E
Intake Sensor
After disconnecting intake sensor connector, measure resistance between terminals 1 and 2 at sensor side.
Refer to the table below. F

Temperature °C (°F) Resistance kΩ


−15 (5) 12.07 G
−10 (14) 9.49
−5 (23) 7.52
H
0 (32) 6.00
5 (41) 4.82
10 (50) 3.90 I
15 (59) 3.17
20 (68) 2.59
MTC
25 (77) 2.14
30 (86) 1.77
35 (95) 1.47 K
40 (104) 1.23
45 (113) 1.04
L
If NG, replace intake sensor.
Insufficient Cooling (With Heater) INFOID:0000000003292817

M
SYMPTOM: Insufficient cooling
INSPECTION FLOW
N

Revision: 2007 September MTC-33 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

JSIIA0931GB

*1 .MA-15, "Checking Drive Belts" *2 MTC-30, "Air Mix Door Motor Circuit" *3 "Test Reading"
(QR25DE) or MA-24, "Checking
Drive Belts" (YD25DDTi)
*4 EC-116, "System Description" (QR), *5 ."PERFORMANCE TEST DIAG-
EC-249, "Description" (YD TYPE 1*) NOSES"
or EC-412, "Description" (YD TYPE
2*)

*For further information refer to EC-172, "How to Check Vehicle Type".


PERFORMANCE TEST DIAGNOSES

Revision: 2007 September MTC-34 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

MTC

N
RJIA1601E

*1 "PERFORMANCE CHART" *2 "PERFORMANCE CHART" *3 "Trouble Diagnoses for Unusual O


Pressure"
*4 MTC-30, "Air Mix Door Motor Circuit"

Revision: 2007 September MTC-35 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

WJIA0361E

*1 MTC-57, "Check Disc to Pulley *2 MTC-31, "Blower Motor Circuit". *3 MA-15, "Checking Drive Belts"
Clearance". (QR25DE) or MA-24, "Checking
Drive Belts" (YD25DDTi)

PERFORMANCE CHART
Test Condition
Testing must be performed as follows:

Revision: 2007 September MTC-36 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Vehicle condition Indoors or in the shade (in a well-ventilated place) A


Doors Closed
Door windows Open
B
Hood Open
TEMP. Max. COLD

Mode control dial (Ventilation) set C


Recirculation (REC) switch (Recirculation) set

Blower speed Max. speed set


D
Engine speed Idle speed
Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading E

Recirculating-to-discharge Air Temperature Table


Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator F
Relative humidity Air temperature C (F)
% C (F)
15 (59) 3.8 - 5.4 (39 - 42)
G
50 - 60 20 (68) 6.9 - 8.9 (44 - 48)
25 (77) 11.0 - 13.5 (52 - 56)
15 (59) 5.4 - 6.9 (42 - 44) H
60 - 70 20 (68) 8.9 - 11.0 (48 - 52)
25 (77) 13.5 - 16.0 (56 - 61)
I
Ambient Air Temperature-to-operating Pressure Table
Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
2 2
Relative humidity Air temperature kPa (bar, kg/cm , psi) kPa (bar, kg/cm , psi) MTC
% C (F)
870 - 1070 140 - 172
25 (77)
(8.70 - 10.70, 8.87 - 10.91, 126.2 - 155.2) (1.40 - 1.72, 1.43 - 1.75, 20.3 - 24.9)
K
1,025 - 1,255 168 - 207
30 (86)
(10.25 - 12.55, 10.46 - 12.80, 148.6 - 182.0) (1.68 - 2.07, 1.71 - 2.11, 24.4- 30.0)
50 - 70
1,205 - 1,475 205 - 250 L
35 (95)
(12.05 - 14.75, 12.29 - 15.05, 174.7 - 213.9) (2.05 - 2.50, 2.09 - 2.55, 29.7 - 36.3)
1,490 - 1,820 265 - 325
40 (104)
(14.90 - 18.20, 15.20 - 18.56, 216.1 - 263.9) (2.65 - 3.25, 2.70 - 3.32, 38.4 - 47.1)
M
TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE
Whenever system's high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since N
the standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air
tempera-ture-to-operating pressure table).
Both High- and Low-pressure Sides are Too High O

Revision: 2007 September MTC-37 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Gauge indication Refrigerant cycle Probable cause Corrective action

The pressure returns to nor- Excessive refrigerant charge in refrig- Reduce refrigerant until
mal soon after water is eration cycle. specified pressure is ob-
splashed on the condenser. tained.
Insufficient condenser cooling perfor-
mance.
• Clean condenser.
Air suction by cooling fan is in- ↓
• Check and repair cooling
sufficient. 1. Condenser fins are clogged.
fan if necessary.
2. Improper fan rotation of cooling
fan.
Both high- and low-pressure • Low-pressure pipe is not
sides are too high. cold.
• When compressor is Poor heat exchange in condenser
stopped high-pressure val- (After compressor operation stops,
ue quickly drops by approx- high-pressure decreases too slowly.). Evacuate repeatedly and
imately 196 kPa (1.96 bar, 2 ↓ recharge system.
2
kg/cm , 28 psi). It then de- Air in refrigeration cycle.
creases gradually thereaf-
AC359A
ter.
Check and repair each en-
Engine tends to overheat. Engine cooling systems malfunction.
gine cooling system.
• Excessive liquid refrigerant on low-
pressure side.
• An area of the low-pressure • Excessive refrigerant discharge
pipe is colder than areas flow.
near the evaporator outlet. • Expansion valve is open a little Replace expansion valve.
• Low-pressure pipe is some- compared with the specification.
times covered with frost. ↓
Improper expansion valve adjust-
ment.

High-pressure Side is Too High and Low-pressure Side is Too Low

Gauge indication Refrigerant cycle Probable cause Corrective action


High-pressure side is too high and
low-pressure side is too low.

Upper side of condenser and High-pressure tube or parts lo- • Check and repair or replace
high-pressure side are hot, cated between compressor malfunctioning parts.
however, liquid tank is not so and condenser are clogged or • Check lubricant for contami-
hot. crushed. nation.

AC360A

High-pressure Side is Too Low and Low-pressure Side is Too High

Gauge indication Refrigerant cycle Probable cause Corrective action


Compressor pressure opera-
High-pressure side is too low and
High- and low-pressure sides tion is improper.
low-pressure side is too high.
become equal soon after com- ↓ Replace compressor.
pressor operation stops. Damaged inside compressor
packings.
Compressor pressure opera-
No temperature difference be- tion is improper.
tween high- and low-pressure ↓ Replace compressor.
sides. Damaged inside compressor
AC356A
packings.

Both High- and Low-pressure Sides are Too Low

Revision: 2007 September MTC-38 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Gauge indication Refrigerant cycle Probable cause Corrective action A


• There is a big temperature
difference between liquid
tank outlet and inlet. Outlet • Replace liquid tank.
Liquid tank inside is slightly B
temperature is extremely • Check lubricant for contami-
clogged.
low. nation.
• Liquid tank inlet and expan-
sion valve are frosted. C
• Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank. High-pressure pipe located be- • Check and repair malfunc- D
• Expansion valve inlet is tween liquid tank and expan- tioning parts.
• Check lubricant for contami-
frosted. sion valve is clogged.
nation.
• Temperature difference oc- E
curs somewhere in high-
pressure side.
Low refrigerant charge.
Expansion valve and liquid Check refrigerant for leaks. F
Both high- and low-pressure sides tank are warm or slightly cool ↓ Refer to MTC-57, "Checking of
are too low. when touched. Leaking fittings or compo- Refrigerant Leaks".
nents.
Expansion valve closes a little G
compared with the specifica-
tion.
There is a big temperature dif- ↓ • Remove foreign particles by
ference between expansion 1. Improper expansion using compressed air. H
AC353A valve inlet and outlet while the valve adjustment. • Check lubricant for contami-
valve itself is frosted. 2. Malfunctioning expansion nation.
valve.
3. Outlet and inlet may be
I
clogged.
• Check and repair malfunc-
An area of the low-pressure MTC
Low-pressure pipe is clogged tioning parts.
pipe is colder than areas near
or crushed. • Check lubricant for contami-
the evaporator outlet.
nation.
• Check intake sensor circuit. K
Refer to MTC-33, "Intake
Sensor Circuit".
• Replace compressor.
Air flow volume is not enough
Evaporator is frozen. • Repair evaporator fins. L
or is too low.
• Replace evaporator.
• Check blower motor circuit.
Refer to MTC-31, "Blower
Motor Circuit". M

Low-pressure Side Sometimes Becomes Negative


N
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side sometimes be-
comes negative. • Air conditioning system does
not function and does not cy- Refrigerant does not discharge O
cyclically.
clically cool the compart-
↓ • Drain water from refrigerant
ment air.
Moisture is frozen at expan- or replace refrigerant.
• The system constantly func-
sion valve outlet and inlet. • Replace liquid tank. P
tions for a certain period of

time after compressor is
Water is mixed with refrigerant.
stopped and restarted.
AC354A

Low-pressure Side Becomes Negative

Revision: 2007 September MTC-39 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Gauge indication Refrigerant cycle Probable cause Corrective action


Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
• If water is the cause, initially
cooling is okay. Then the wa-
Low-pressure side becomes nega- ter freezes causing a block-
tive. age. Drain water from
High-pressure side is closed refrigerant or replace refrig-
Liquid tank or front/rear side of and refrigerant does not flow. erant.
expansion valve’s pipe is frost- ↓ • If due to foreign particles, re-
ed or wet with dew. Expansion valve or liquid tank move expansion valve and
is frosted. remove the particles with dry
and compressed air (not
AC362A
shop air).
• If either of the above meth-
ods cannot correct the mal-
function, replace expansion
valve.
• Replace liquid tank.
• Check lubricant for contami-
nation.

Insufficient Cooling (Without Heater) INFOID:0000000002978934

SYMPTOM: Insufficient cooling


INSPECTION FLOW

JSIIA0932GB

Revision: 2007 September MTC-40 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

*1 MA-15, "Checking Drive Belts" *2 "Test Reading" *3 MTC-19, "How to Perform Trouble A
(QR25DE) or MA-24, "Checking Diagnosis for Quick and Accurate
Drive Belts" (YD25DDTi) Repair"
*4 EC-116, "System Description" (QR), *5 "PERFORMANCE TEST DIAGNO-
EC-249, "Description" (YD TYPE 1*) SIS" B
or EC-412, "Description" (YD TYPE
2*)

*For further information refer to EC-172, "How to Check Vehicle Type". C

PERFORMANCE TEST DIAGNOSIS


D

MTC

SJIA1889E

Revision: 2007 September MTC-41 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

*1 "PERFORMANCE CHART" *2 "TROUBLE DIAGNOSIS FOR UN-


USUAL PRESSURE"

SJIA1642E

*1 MTC-57, "Check Disc to Pulley *2 MTC-31, "Blower Motor Circuit" *3 MA-24, "Checking Drive Belts"
Clearance"

PERFORMANCE CHART

Revision: 2007 September MTC-42 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >
Test Condition
Testing must be performed as follows: A

Vehicle condition Indoors or in the shade (in a well-ventilated place)


Doors Closed B
Door windows Open
Hood Open
C
TEMP. Max. COLD

Mode control dial (Ventilation) set

Recirculation (REC) switch (Recirculation) set D


Blower speed Max. speed set
Engine speed Idle speed
E
Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading
F
Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature C (F)
G
% C (F)
15 (59) 3.8 - 5.4 (39 - 42)
50 - 60 20 (68) 6.9 - 8.9 (44 - 48) H
25 (77) 11.0 - 13.5 (52 - 56)
15 (59) 5.4 - 6.9 (42 - 44)
60 - 70 20 (68) 8.9 - 11.0 (48 - 52) I
25 (77) 13.5 - 16.0 (56 - 61)

Ambient Air Temperature-to-operating Pressure Table MTC


Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
2 2
Relative humidity Air temperature kPa (bar, kg/cm , psi) kPa (bar, kg/cm , psi)
% C (F) K
870 - 1070 140 - 172
25 (77)
(8.70 - 10.70, 8.87 - 10.91, 126.2 - 155.2) (1.40 - 1.72, 1.43 - 1.75, 20.3 - 24.9)
1,025 - 1,255 168 - 207 L
30 (86)
(10.25 - 12.55, 10.46 - 12.80, 148.6 - 182.0) (1.68 - 2.07, 1.71 - 2.11, 24.4- 30.0)
50 - 70
1,205 - 1,475 205 - 250
35 (95)
(12.05 - 14.75, 12.29 - 15.05, 174.7 - 213.9) (2.05 - 2.50, 2.09 - 2.55, 29.7 - 36.3)
M
1,490 - 1,820 265 - 325
40 (104)
(14.90 - 18.20, 15.20 - 18.56, 216.1 - 263.9) (2.65 - 3.25, 2.70 - 3.32, 38.4 - 47.1)

TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE N


Whenever system's high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since
the standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air
O
tempera-ture-to-operating pressure table).
Both High- and Low-pressure Sides are Too High
P

Revision: 2007 September MTC-43 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Gauge indication Refrigerant cycle Probable cause Corrective action

The pressure returns to nor- Excessive refrigerant charge in refrig- Reduce refrigerant until
mal soon after water is eration cycle. specified pressure is ob-
splashed on the condenser. tained.
Insufficient condenser cooling perfor-
mance.
• Clean condenser.
Air suction by cooling fan is in- ↓
• Check and repair cooling
sufficient. 1. Condenser fins are clogged.
fan if necessary.
2. Improper fan rotation of cooling
fan.
Both high- and low-pressure • Low-pressure pipe is not
sides are too high. cold.
• When compressor is Poor heat exchange in condenser
stopped high-pressure val- (After compressor operation stops,
ue quickly drops by approx- high-pressure decreases too slowly.). Evacuate repeatedly and
imately 196 kPa (1.96 bar, 2 ↓ recharge system.
2
kg/cm , 28 psi). It then de- Air in refrigeration cycle.
creases gradually thereaf-
AC359A
ter.
Check and repair each en-
Engine tends to overheat. Engine cooling systems malfunction.
gine cooling system.
• Excessive liquid refrigerant on low-
pressure side.
• An area of the low-pressure • Excessive refrigerant discharge
pipe is colder than areas flow.
near the evaporator outlet. • Expansion valve is open a little Replace expansion valve.
• Low-pressure pipe is some- compared with the specification.
times covered with frost. ↓
Improper expansion valve adjust-
ment.

High-pressure Side is Too High and Low-pressure Side is Too Low

Gauge indication Refrigerant cycle Probable cause Corrective action


High-pressure side is too high and
low-pressure side is too low.

Upper side of condenser and High-pressure tube or parts lo- • Check and repair or replace
high-pressure side are hot, cated between compressor malfunctioning parts.
however, liquid tank is not so and condenser are clogged or • Check lubricant for contami-
hot. crushed. nation.

AC360A

High-pressure Side is Too Low and Low-pressure Side is Too High

Gauge indication Refrigerant cycle Probable cause Corrective action


Compressor pressure opera-
High-pressure side is too low and
High- and low-pressure sides tion is improper.
low-pressure side is too high.
become equal soon after com- ↓ Replace compressor.
pressor operation stops. Damaged inside compressor
packings.
Compressor pressure opera-
No temperature difference be- tion is improper.
tween high- and low-pressure ↓ Replace compressor.
sides. Damaged inside compressor
AC356A
packings.

Both High- and Low-pressure Sides are Too Low

Revision: 2007 September MTC-44 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Gauge indication Refrigerant cycle Probable cause Corrective action A


• There is a big temperature
difference between liquid
tank outlet and inlet. Outlet • Replace liquid tank.
Liquid tank inside is slightly B
temperature is extremely • Check lubricant for contami-
clogged.
low. nation.
• Liquid tank inlet and expan-
sion valve are frosted. C
• Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank. High-pressure pipe located be- • Check and repair malfunc- D
• Expansion valve inlet is tween liquid tank and expan- tioning parts.
• Check lubricant for contami-
frosted. sion valve is clogged.
nation.
• Temperature difference oc- E
curs somewhere in high-
pressure side.
Low refrigerant charge.
Expansion valve and liquid Check refrigerant for leaks. F
Both high- and low-pressure sides tank are warm or slightly cool ↓ Refer to MTC-57, "Checking of
are too low. when touched. Leaking fittings or compo- Refrigerant Leaks".
nents.
Expansion valve closes a little G
compared with the specifica-
tion.
There is a big temperature dif- ↓ • Remove foreign particles by
ference between expansion 1. Improper expansion using compressed air. H
AC353A valve inlet and outlet while the valve adjustment. • Check lubricant for contami-
valve itself is frosted. 2. Malfunctioning expansion nation.
valve.
3. Outlet and inlet may be
I
clogged.
• Check and repair malfunc-
An area of the low-pressure MTC
Low-pressure pipe is clogged tioning parts.
pipe is colder than areas near
or crushed. • Check lubricant for contami-
the evaporator outlet.
nation.
• Check intake sensor circuit. K
Refer to MTC-33, "Intake
Sensor Circuit".
• Replace compressor.
Air flow volume is not enough
Evaporator is frozen. • Repair evaporator fins. L
or is too low.
• Replace evaporator.
• Check blower motor circuit.
Refer to MTC-31, "Blower
Motor Circuit". M

Low-pressure Side Sometimes Becomes Negative


N
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side sometimes be-
comes negative. • Air conditioning system does
not function and does not cy- Refrigerant does not discharge O
cyclically.
clically cool the compart-
↓ • Drain water from refrigerant
ment air.
Moisture is frozen at expan- or replace refrigerant.
• The system constantly func-
sion valve outlet and inlet. • Replace liquid tank. P
tions for a certain period of

time after compressor is
Water is mixed with refrigerant.
stopped and restarted.
AC354A

Low-pressure Side Becomes Negative

Revision: 2007 September MTC-45 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

Gauge indication Refrigerant cycle Probable cause Corrective action


Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
• If water is the cause, initially
cooling is okay. Then the wa-
Low-pressure side becomes nega- ter freezes causing a block-
tive. age. Drain water from
High-pressure side is closed refrigerant or replace refrig-
Liquid tank or front/rear side of and refrigerant does not flow. erant.
expansion valve’s pipe is frost- ↓ • If due to foreign particles, re-
ed or wet with dew. Expansion valve or liquid tank move expansion valve and
is frosted. remove the particles with dry
and compressed air (not
AC362A
shop air).
• If either of the above meth-
ods cannot correct the mal-
function, replace expansion
valve.
• Replace liquid tank.
• Check lubricant for contami-
nation.

Insufficient Heating INFOID:0000000003292818

SYMPTOM: Insufficient heating


INSPECTION FLOW

Revision: 2007 September MTC-46 D40


TROUBLE DIAGNOSIS
< SERVICE INFORMATION >

MTC

L
JSIIA0933GB

*1 CO-9, "Changing Engine Coolant" *2 CO-12, "Removal and Installation" *3 EC-82, "Component Description" M
(QR) or CO-33, "Changing Engine (QR), EC-238, "Description" (YD
Coolant" (YD) TYPE 1*) or EC-401, "Description"
(YD TYPE 2*)
N
*4 MTC-30, "Air Mix Door Motor Circuit"

*For further information refer to EC-172, "How to Check Vehicle Type".


O

Revision: 2007 September MTC-47 D40


A/C UNIT ASSEMBLY
< SERVICE INFORMATION >
A/C UNIT ASSEMBLY
Disassembly and Assembly INFOID:0000000003292850

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

JPIIA0436GB

1. Center ventilator door 2. Side ventilator door 3. Defroster door


4. Seal 5. Distributor module case 6. Seal
7. Intake case RH 8. Intake case LH 9. Intake door
10. Blower motor 11. Evaporator 12. Seal
13. Seal 14. Expansion valve packing 15. O-ring
16. Expansion valve 17. Packing 18. Seal
19. Lower A/C unit case 20. Insulator 21. Intake sensor
22. Blower fan resisitor 23. Heater core bracket 24. Air mix door
25. Heater core 26. Heater core support 27. Foot duct 1
28. Foot door 29. Foot duct 2 30. Upper A/C unit case
31. Mode door motor 32. Mode door motor bracket 33. Main link

Revision: 2007 September MTC-48 D40


A/C UNIT ASSEMBLY
< SERVICE INFORMATION >
34. Center ventilator door lever 35. Side ventilator door lever 36. Defroster door lever
37. Foot door lever 1 38. Foot door link 39. Foot door lever 2 A
40. Air mix door motor 41. Intake door motor

B
: N·m (kg-m, in-lb)

CAUTION:
• Use care not to damage the seats and interior trim panels when removing the cooling unit C
assembly with it attached to the steering member.

MTC

Revision: 2007 September MTC-49 D40


COOLING UNIT ASSEMBLY
< SERVICE INFORMATION >
COOLING UNIT ASSEMBLY
Disassembly and Assembly INFOID:0000000002978936

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

JPIIA0437GB

1. Center ventilator door 2. Side ventilator door 3. Seal


4. Distributor module case 5. Seal 6. Intake case RH
7. Intake case LH 8. Intake door 9. Blower motor
10. Evaporator 11. Seal 12. Seal
13. Expansion valve packing 14. O-ring 15. Expansion valve
16. Packing 17. Seal 18. Lower cooling unit case
19. Insulator 20. Intake sensor 21. Blower fan resisitor
22. Foot duct 1 23. Foot door 24. Foot duct 2
25. Upper cooling unit case 26. Mode door motor 27. Mode door motor bracket
28. Main link 29. Center ventilator door lever 30. Side ventilator door lever

Revision: 2007 September MTC-50 D40


COOLING UNIT ASSEMBLY
< SERVICE INFORMATION >
31. Foot door lever 1 32. Foot door link 33. Foot door lever 2
34. Intake door motor A

: N·m (kg-m, in-lb)


B
CAUTION:
• Use care not to damage the seats and interior trim panels when removing the cooling unit
assembly with it attached to the steering member. C

MTC

Revision: 2007 September MTC-51 D40


DUCTS AND GRILLES
< SERVICE INFORMATION >
DUCTS AND GRILLES
Disassembly and Assembly INFOID:0000000002978937

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

JPIIA0439ZZ

1. Ventilator duct RH 2. Side defroster duct RH (with heat- 3. Center ventilator duct
er)
4. Center defroster nozzle (with heater) 5. Side defroster duct LH (with heat- 6. Ventilator duct LH
er)
7. Foot duct 8. Instrument panel 9. Side ventilator grille LH
10. Cluster lid C 11. Center ventilator grille LH 12. Center ventilator grille RH
13. Side ventilator grille RH

Revision: 2007 September MTC-52 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
REFRIGERANT LINES
A
Component INFOID:0000000002978938

Refer to MTC-3, "Precaution for Refrigerant Connection".


B
LHD models

MTC

M
JPIIA0434GB

1. A/C unit assembly (with heater) or cool- 2. O-ring 3. Low-pressure pipe


ing unit assembly (without heater) N
4. High-pressure pipe 5. Condenser 6. Liquid tank
7. Compressor 8. High-pressure flexible hose 9. Low-pressure flexible hose
10. Expansion valve 11. Evaporator 12. Refrigerant pressure sensor O

: N·m (kg-m, ft-lb)


P
: N·m (kg-m, in-lb)

RHD models

Revision: 2007 September MTC-53 D40


REFRIGERANT LINES
< SERVICE INFORMATION >

JPIIA0435GB

1. A/C unit assembly (with heater) or cool- 2. O-ring 3. High-pressure pipe


ing unit assembly (without heater)
4. Condenser 5. Liquid tank 6. Compressor
7. High-pressure flexible hose 8. Low-pressure flexible hose 9. Low-pressure pipe
10. Evaporator 11. Expansion valve 12. Refrigerant pressure sensor

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

Removal and Installation for Compressor INFOID:0000000002978939

QR25DE

Revision: 2007 September MTC-54 D40


REFRIGERANT LINES
< SERVICE INFORMATION >

JPIIA0450GB F

1. Compressor

G
YD25DDTi

MTC

SJIA1907E

M
1. Timing chain case 2. Alternator and compressor bracket 3. Compressor
4. Cylinder block
N
Removal and Installation for Compressor Clutch INFOID:0000000002978940

QR25DE
O

Revision: 2007 September MTC-55 D40


REFRIGERANT LINES
< SERVICE INFORMATION >

JPIIA0451GB

1. Magnet clutch assembly 2. Magnet coil 3. Pulley


4. Clutch disc 5. Snap ring 6. Thermal protector (built in)
7. Compressor

YD25DDTi

SJIA1908E

1. Magnet clutch assembly 2. Magnet coil 3. Pulley


4. Clutch disc 5. Snap ring 6. Thermal protector (built in)
7. Compressor

Revision: 2007 September MTC-56 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
Check Disc to Pulley Clearance INFOID:0000000002978941

A
Check clearance around entire periphery of clutch disc.

Disc-to-pulley clearance : 0.3 - 0.6 mm B


(0.012 - 0.024 in)
If specified clearance is not obtained, replace adjusting shim
(spacer) and readjust. C

WHA194
H
Checking of Refrigerant Leaks INFOID:0000000002978943

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
I
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electrical leak detector or fluorescent dye leak
detector (SST: J-42220).
If dye is observed, confirm the leak with an electrical leak detector. It is possible a prior leak was repaired MTC
and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections. K
When searching for refrigerant leaks using an electrical leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electrical leak detector probe slower and closer to the suspected leak area will improve L
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak Detector INFOID:0000000002978944
M
1. Check A/C system for leaks using the UV lamp and safety goggles (SST: J-42220) in a low sunlight area
(area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a
bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain open- N
ing indicates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue. O
3. After the leak is repaired, remove any residual dye using dye cleaner (SST: J-43872) to prevent future
misdiagnosis.
4. Perform a system performance check and verify the leak repair with an approved electrical leak detector. P
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.

Revision: 2007 September MTC-57 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
Dye Injection INFOID:0000000002978945

(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
2
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm ,
50 psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (SST: J-41459).
3. Connect the injector tool to the A/C low-pressure side service valve.
4. Start the engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool (SST: J-41459) (refer to the manufacture’s
operating instructions).
6. With the engine still running, disconnect the injector tool from the service valve.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system
connection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on
the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye
to penetrate a leak and become visible.
8. Attach blue label as necessary.
Electrical Leak Detector INFOID:0000000002978946

PRECAUTIONS FOR HANDLING LEAK DETECTOR


When performing a refrigerant leak check, use an A/C electrical
leak detector (SST) or equivalent. Ensure that the instrument is
calibrated and set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak
detec-tor properly, read the operating instructions and perform any
speci-fied maintenance.

SHA705EB

1. Position probe approximately 5 mm (3/16 in) away from point to


be checked.

SHA707EA

Revision: 2007 September MTC-58 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
2. When testing, circle each fitting completely with probe.
A

SHA706E

D
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
E

G
SHA708EA

CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette H
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. Stop the engine. I
2. Connect a suitable A/C manifold gauge set (SST) to the A/C service valves.
2
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm , 50 psi) above 16C
MTC
(61F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16C (61F), leaks may not be detected since the system may not reach 345 kPa K
2
(3.45 bar, 3.52 kg/cm , 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet i) to the
low-pressure side (evaporator drain hose j to shaft seal o). Perform a leak check for the following areas L
carefully. Clean the component to be checked and move the leak detected probe completely around the
connection/component.
M

Revision: 2007 September MTC-59 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
LHD models

JPIIA0448GB

: N·m (kg-m, in-lb)

Revision: 2007 September MTC-60 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
RHD models
A

MTC

JPIIA0449GB
K

: N·m (kg-m, in-lb)


L
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor. M
Liquid tank
Check the fitting of refrigerant connection.
Service valves N
Check all around the service valves. Ensure service valve caps are secured on the service valves (to
pre-vent leaks).
NOTE:
O
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the P
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer's recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.

Revision: 2007 September MTC-61 D40


REFRIGERANT LINES
< SERVICE INFORMATION >
If no leaks are found, perform steps 7 - 10.
7. Start the engine.
8. Set the A/C control as follows;
a. A/C switch: ON
b. Air flow: VENT (Ventilation)
c. Intake door position: Recirculation
d. Temperature setting: Max. cold
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Stop the engine and perform leak check again following steps 4
through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.

SHA839E

11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
pressure is displayed, recover refrigerant from equipment lines.
12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent as necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Perform A/C performance test to ensure system works properly.

Revision: 2007 September MTC-62 D40


SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Compressor INFOID:0000000002978947

QR25DE B

Model Calsonic Kansei make CR-14


C
Type Vanes rotary
Displacement
144 (8.79)
3
cm (cu in)/rev D
Cylinder bore × stroke
64.2 (2.53) x 9.9 (0.39)
mm (in)
Direction of rotation Clockwise (viewed from drive end) E
Drive belt Poly V

YD25DDTi
F

Model Calsonic Kansei make CR-12


Type Vanes rotary G
Displacement
110 (6.71)
3
cm (cu in)/rev
Cylinder bore × stroke H
50.2 (1.98) x 8.5 (0.33)
mm (in)
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V I

Lubricant INFOID:0000000002978948

MTC
QR25DE

Model Calsonic Kansei make CR-14 K


Name Nissan A/C System Oil Type R (DH-PR)
Total in system 180 (6.34)
Capacity L
Compressor (Service part) charging
m (lmp fl oz) 180 (6.34)
amount

YD25DDTi M

Model Calsonic Kansei make CR-12


N
Name Nissan A/C System Oil Type R (DH-PR)
Total in system 150 (5.28)
Capacity
Compressor (Service part) charging O
m (lmp fl oz) 150 (5.28)
amount

Refrigerant INFOID:0000000002978949
P

Type HFC-134a (R-134a)


Capacity
kg (lb) 0.70 (1.54)

Revision: 2007 September MTC-63 D40


SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION >
ENGINE IDLING SPEED INFOID:0000000002978950

Refer to EC-170, "Idle Speed and Ignition Timing" (QR), EC-326, "General Specification" (YD TYPE 1*) or
EC-503, "General Specification" (YD TYPE 2*).
*For further information refer to EC-172, "How to Check Vehicle Type".
BELT TENSION INFOID:0000000002978951

Refer to MA-15, "Checking Drive Belts" (QR25DE) or MA-24, "Checking Drive Belts" (YD25DDTi).

Revision: 2007 September MTC-64 D40