Text preview for : Aria Condizionata.pdf part of NISSAN Almera Tino Automatic Air Conditioner (pag. 68)
Back to : Almera Tino_04_.part1.rar | Home
AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
SECTION
AUTOMATIC AIR CONDITIONER
ATC
A
B
C
D
CONTENTS
PRECAUTIONS ......................................................... 4 . Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER" ................................................................. 4 . Precautions for Working with HFC-134a (R-134a).... 4 . General Refrigerant Precautions ............................. 4 . Lubricant Precautions ............................................. 5 . Precautions for Refrigerant Connection .................. 5 . FEATURES OF NEW TYPE REFRIGERANT CONNECTION ..................................................... 5 . O-RING AND REFRIGERANT CONNECTION..... 6 Precautions for Servicing Compressor .................... 7 . Precautions for Service Equipment ......................... 8 . RECOVERY/RECYCLING EQUIPMENT ............. 8 . ELECTRONIC LEAK DETECTOR ....................... 8 . VACUUM PUMP .................................................. 8 . MANIFOLD GAUGE SET ..................................... 8 . SERVICE HOSES ................................................ 8 . SERVICE COUPLERS ......................................... 9 . REFRIGERANT WEIGHT SCALE ....................... 9 . CALIBRATING ACR4 WEIGHT SCALE ............... 9 . CHARGING CYLINDER ....................................... 9 . Precautions for Leak Detection Dye ........................ 9 . IDENTIFICATION ............................................... 10 . IDENTIFICATION LABEL FOR VEHICLE .......... 10 . Wiring Diagrams and Trouble Diagnosis ............... 10 . PREPARATION .........................................................11 . Special Service Tools .............................................11 . HFC-134a (R-134a) Service Tools and Equipment...11 . REFRIGERATION SYSTEM .................................... 15 . Refrigerant Cycle .................................................. 15 . REFRIGERANT FLOW ...................................... 15 . FREEZE PROTECTION .................................... 15 . Refrigerant System Protection .............................. 15 . REFRIGERANT PRESSURE SENSOR (WITH QG ENGINE) ...................................................... 15 . DUAL-PRESSURE SWITCH (WITH YD ENGINE) ............................................................ 15 . PRESSURE RELIEF VALVE .............................. 15 . CSV613 Variable Displacement Compressor ........ 16 . GENERAL INFORMATION ................................ 16 . DESCRIPTION ................................................... 16 . Component Layout ................................................ 19 . LUBRICANT ............................................................. 20 . Maintenance of Lubricant Quantity in Compressor.. 20 . LUBRICANT ....................................................... 20 . LUBRICANT RETURN OPERATION ................. 20 . LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR ................................................. 21 . LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT ...................... 21 . AIR CONDITIONER CONTROL .............................. 22 . Overview Air Conditioner LAN Control System ..... 22 . System Construction ............................................. 22 . OPERATION ....................................................... 22 . TRANSMISSION DATA AND TRANSMISSION ORDER .............................................................. 23 . AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) .................................... 23 . FAN SPEED CONTROL ..................................... 24 . INTAKE DOOR CONTROL ................................ 24 . OUTLET DOOR CONTROL ............................... 24 . MAGNET CLUTCH CONTROL .......................... 24 . SELF-DIAGNOSTIC SYSTEM ........................... 24 . Overview of Control system ................................... 24 . Control Operation .................................................. 25 . DISPLAY SCREEN ............................................. 25 . AUTO SWITCH .................................................. 25 . TEMPERATURE DIAL (POTENTIO TEMPERATURE CONTROL) .............................................. 25 . A/C SWITCH ...................................................... 25 . DEFROSTER (DEF) SWITCH ............................ 25 . MODE SWITCH ................................................. 25 . FAN SWITCH ..................................................... 25 . OFF SWITCH ..................................................... 25 . FRESH (FRE) SWITCH ..................................... 25 . RECIRCULATION (REC) SWITCH .................... 26 . REAR WINDOW DEFOGGER SWITCH ............ 26 . Fail-safe Function .................................................. 26 .
E
F
G
H
I
ATC
K
L
M
ATC-1
Discharge Air Flow ................................................ 27 . System Description ................................................ 28 . SWITCHES AND THEIR CONTROL FUNCTION 28 ... TROUBLE DIAGNOSIS ........................................... 29 . How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................... 29 . WORK FLOW ..................................................... 29 . SYMPTOM TABLE ............................................. 29 . ComponentParts and Harness Connector Location 30 ... ENGINE COMPARTMENT ................................. 30 . PASSENGER COMPARTMENT ......................... 31 . Circuit Diagram ...................................................... 32 . Wiring Diagram ...................................................... 33 . Auto Amp. Terminals and Reference Value ........... 39 . PIN CONNECTOR TERMINAL LAYOUT ........... 39 . AUTO AMP. INSPECTION TABLE ..................... 39 . Self-diagnosis Function ....................................... .. 41 . DESCRIPTION ................................................... 41 . FUNCTION CONFIRMATION PROCEDURE ..... 42 . AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER .......................................... 49 . Operational Check ................................................. 50 . CHECKING MEMORY FUNCTION .................... 50 . CHECKING BLOWER ........................................ 50 . CHECKING DISCHARGE AIR ........................... 51 . CHECKING RECIRCULATION ........................... 52 . CHECKING FRESH SWITCH ............................ 52 . CHECKING TEMPERATURE DECREASE ........ 52 . CHECKING TEMPERATURE INCREASE ......... 52 . CHECKING AUTO MODE .................................. 53 . Power Supply and Ground Circuit for Auto Amp. ... 54 INSPECTION FLOW .......................................... 54 . COMPONENT DESCRIPTION ........................... 54 . DIAGNOSTIC PROCEDURE FORA/C SYSTEM 55 ... LAN System Circuit ............................................... 56 . DIAGNOSTIC PROCEDURE FOR LAN SYSTEM CIRCUIT .................................................... 56 . Mode Door Motor Circuit ....................................... 59 . INSPECTION FLOW .......................................... 59 . SYSTEM DESCRIPTION ................................... 60 . COMPONENT DESCRIPTION ........................... 61 . DIAGNOSTIC PROCEDURE FOR MODE DOOR ................................................................. 61 . Air Mix Door Motor Circuit ..................................... 62 . INSPECTION FLOW .......................................... 62 . SYSTEM DESCRIPTION ................................... 63 . COMPONENT DESCRIPTION ........................... 64 . DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR .................................................. 64 . Intake Door Motor Circuit ....................................... 65 . INSPECTION FLOW .......................................... 65 . SYSTEM DESCRIPTION ................................... 66 . COMPONENT DESCRIPTION ........................... 66 . DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR .................................................. 67 . Blower Motor Circuit .............................................. 68 . INSPECTION FLOW .......................................... 68 . SYSTEM DESCRIPTION ................................... 69 .
COMPONENT DESCRIPTION ...........................70 . DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR ...............................................................70 . COMPONENT INSPECTION ..............................73 . Magnet Clutch Circuit .............................................74 . INSPECTION FLOW ...........................................74 . SYSTEM DESCRIPTION ....................................75 . DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH .............................................................75 . COMPONENT INSPECTION ..............................80 . Insufficient Cooling .................................................82 . INSPECTION FLOW ...........................................82 . PERFORMANCE TEST DIAGNOSES ...............84 . PERFORMANCE CHART ...................................86 . TROUBLE DIAGNOSES FORUNUSUAL PRESSURE ..................................................................87 . Insufficient Heating ................................................90 . INSPECTION FLOW ...........................................90 . Noise ......................................................................92 . INSPECTION FLOW ...........................................92 . Self-diagnosis ........................................................93 . INSPECTION FLOW ...........................................93 . Memory Function ...................................................94 . INSPECTION FLOW ...........................................94 . Ambient Sensor Circuit ..........................................95 . COMPONENT DESCRIPTION ...........................95 . AMBIENT TEMPERATURE INPUT PROCESS...95 DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR .............................................................95 . COMPONENT INSPECTION ..............................97 . In-vehicle Sensor Circuit ........................................97 . COMPONENT DESCRIPTION ...........................97 . DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR .............................................................98 . COMPONENT INSPECTION ..............................99 . Sunload Sensor Circuit ........................................ 100 . COMPONENT DESCRIPTION ......................... 100 . SUNLOAD INPUT PROCESS .......................... 100 . DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR ........................................................... 100 . COMPONENT INSPECTION ............................ 102 . Intake Sensor Circuit ............................................ 103 . COMPONENT DESCRIPTION ......................... 103 . DIAGNOSTICPROCEDUREFORINTAKESENSOR .................................................................. 103 . Multiplex Communication Circuit .......................... 104 . DIAGNOSTIC PROCEDURE FOR MULTIPLEX COMMUNICATION CIRCUIT ........................... 104 . CONTROLLER ....................................................... 108 . Removal and Installation ...................................... 108 . AUTO AMP ............................................................. 109 . REMOVAL AND INSTALLATION ......................... 109 . AMBIENT SENSOR ............................................... 110 . Removal and Installation ...................................... 110 . IN-VEHICLE SENSOR ........................................... 111 . Removal and Installation ...................................... 111 . SUNLOAD SENSOR .............................................. 112 . Removal and Installation ...................................... 112 .
ATC-2
INTAKE SENSOR CIRCUIT ...................................113 . Removal and Installation ......................................113 . REMOVAL .........................................................113 . INSTALLATION .................................................113 . BLOWER UNIT .......................................................115 . Removal and Installation ......................................115 . REMOVAL .........................................................115 . INSTALLATION .................................................115 . Disassembly and Assembly .................................115 . BLOWER MOTOR ..................................................116 . Removal and Installation ......................................116 . INTAKE DOOR MOTOR .........................................117 . Removal and Installation ......................................117 . HEATER & COOLING UNIT ASSEMBLY ..............118 . Removal and Installation ......................................118 . REMOVAL .........................................................118 . INSTALLATION .................................................119 . Disassembly and Assembly ................................ 120 . MODE DOOR MOTOR .......................................... 121 . Removal and Installation ..................................... 121 . AIR MIX DOOR MOTOR ........................................ 122 . Removal and Installation ..................................... 122 . FAN CONTROL AMPLIFIER ................................. 123 . Removal and Installation ..................................... 123 . VENTILATION AIR FILTER ................................... 124 . Removal and Installation ..................................... 124 . FUNCTION ....................................................... 124 . REPLACEMENT TIMING ................................. 124 . REPLACEMENT AND PROCEDURES ........... 124 . HEATER CORE ..................................................... 125 . Removal and Installation ..................................... 125 . DUCTS AND GRILLES ......................................... 126 . Removal and Installation ..................................... 126 . VENTILATOR DUCT, DEFROSTER NOZZLE AND DEFROSTER DUCTS ............................. 126 . CENTER VENTILATOR GRILLE ..................... 126 . SIDE VENTILATOR GRILLE ............................ 127 . FOOT DUCT .................................................... 127 . FLOOR DUCT .................................................. 127 . REFRIGERANT LINES .......................................... 128 . HFC-134a (R-134a) Service Procedure .............. 128 . SETTING OF SERVICE TOOLS AND EQUIPMENT ............................................................... 128 . Components ........................................................ 130 . QG ENGINE MODELS ..................................... 130 .
YD22DDT ENGINE MODELS .......................... 131 . YD22DDTI ENGINE MODELS ......................... 132 . Compressor ......................................................... 133 . REMOVAL ........................................................ 133 . INSTALLATION ................................................ 134 . Compressor Clutch .............................................. 135 . REMOVAL ........................................................ 135 . INSTALLATION ................................................ 136 . Low-pressure Flexible Hose ................................ 138 . REMOVAL ........................................................ 138 . INSTALLATION ................................................ 138 . High-pressure Flexible Hose ............................... 138 . REMOVAL ........................................................ 138 . INSTALLATION ................................................ 139 . High-pressure Pipe .............................................. 139 . REMOVAL ........................................................ 139 . INSTALLATION ................................................ 139 . Refrigerant Pressure Sensor ............................... 140 . REMOVAL AND INSTALLATION ..................... 140 . Dual-pressure Switch .......................................... 140 . REMOVAL AND INSTALLATION ..................... 140 . Condenser Assembly .......................................... 141 . REMOVAL ........................................................ 141 . INSTALLATION ................................................ 141 . Evaporator ........................................................... 141 . REMOVAL ........................................................ 141 . INSTALLATION ................................................ 142 . Expansion Valve .................................................. 142 . REMOVAL ........................................................ 142 . INSTALLATION ................................................ 142 . Checking for Refrigerant Leaks ........................... 143 . Checking System for Leaks Using the Fluorescent Leak Detector ...................................................... 143 . Dye Injection ........................................................ 143 . Electronic Refrigerant Leak Detector ................... 144 . PRECAUTIONS FOR HANDLING LEAK DETECTOR ...................................................... 144 . CHECKING PROCEDURE .............................. 145 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 147 . Compressor ......................................................... 147 . Lubricant .............................................................. 147 . Refrigerant ........................................................... 147 . Engine Idling Speed ............................................ 147 . Belt Tension ......................................................... 147 .
A
B
C
D
E
F
G
H
I
ATC
K
L
M
ATC-3
PRECAUTIONS
PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
EJS002ZH
The Supplemental Restraint System such as "AIR BAG" and "SEAT BELT PRE-TENSIONER", used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: q To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. q Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. q Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors.
Precautions for Working with HFC-134a (R-134a)
EJS002ZI
WARNING: q Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. q The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result.
General Refrigerant Precautions
EJS002ZJ
WARNING: q Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. q Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. q Do not store or heat refrigerant containers above 52°C (125°F). q Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water. q Do not intentionally drop, puncture, or incinerate refrigerant containers. q Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. q Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. q Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
ATC-4
PRECAUTIONS
injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.
A
Lubricant Precautions
q
EJS002ZK
q
q
q
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result.
EJS002ZL
B
C
D
E
F
G
Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location. q Expansion valve to evaporator q Dual-pressure switch (or refrigerant pressure sensor) to liquid tank
H
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
q
I
q
The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing ATC characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. K
L
M
SHA815E
ATC-5
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
RHA246I
CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.
O-Ring Part Numbers and Specifications
Connection type Piping connection point Low-pressure flexible hose to heater & cooling unit High-pressure pipe to heater & cooling unit Condenser to high-pressure flexible hose New Condenser to high-pressure pipe Compressor to low-pressure flexible hose Compressor to high-pressure pipe Liquid tank to condenser pipe Inlet Outlet Dual-pressure switch (or refrigerant pressure sensor) Former Expansion valve to evaporator Inlet Outlet J2476 89956 92475 71L00 92475 72L00 Part number 92473 N8210 92471 N8210 92472 N8210 92471 N8210 92474 N8210 92472 N8210 92471 N8210 Qty. 1 1 1 1 1 1 1 1 1 1 1 O-ring size: 10mm O-ring size: 12mm O-ring size: 16mm Remarks O-ring size: 16mm O-ring size: 8mm O-ring size: 12mm O-ring size: 8mm O-ring size: 19mm O-ring size: 12mm O-ring size: 8mm
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.
ATC-6
PRECAUTIONS
q
q q q
q
q q q
When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low pressure chamber. 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: Part number: Nissan A/C System Oil Type S KLH00-PAGS0
A
B
C
D
E
q q q
q
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.
F
G
H
I
ATC
K
L
M
RHA861F
Precautions for Servicing Compressor
q q q
EJS002ZM
q
q
q
Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow "Maintenance of Lubricant Quantity in Compressor" exactly. Refer to ATC-20, "Maintenance of Lubricant Quantity in Compressor" . Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner. After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for usual operation.
ATC-7
PRECAUTIONS Precautions for Service Equipment
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.
EJS002ZN
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturers instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows. q Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. q For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. q If the hose has an automatic shut off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pumps ability to pull a deep vacuum and are not recommended.
RHA270DA
MANIFOLD GAUGE SET
Be certain that the gauge face indicates HFC-134a (R-134a) or 134a. Be sure the gauge set has 1/2-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants.
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
ATC-8
PRECAUTIONS
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur.
Shut-off valve rotation Clockwise Counterclockwise A/C service valve Open Close
RHA273D
A
B
C
D
REFRIGERANT WEIGHT SCALE
Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2-16 ACME.
E
F
G
RHA274D
H
CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months. I To calibrate the weight scale on the ACR4: 1. Press Shift/Reset and Enter at the same time. 2. Press 8787 . "A1 " will be displayed. ATC 3. Remove all weight from the scale. 4. Press 0 , then press Enter . "0.00 " will be displayed and change to "A2 ". 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of K the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press Enter -- the display returns to the vacuum mode. L 8. Press Shift/Reset and Enter at the same time. 9. Press 6 -- the known weight on the scale is displayed. 10. Remove the known weight from the scale. "0.00 " will be displayed. M 11. Press Shift/Reset to return the ACR4 to the program mode.
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.
Precautions for Leak Detection Dye
q
EJS002ZO
q
q
q
The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J41995) pin-point refrigerant leaks. For your safety and your Customers satisfaction, read and follow all manufactures operating instructions and precautions prior to performing the work.
ATC-9
PRECAUTIONS
q
q
q
q q q
q
A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye in HFC-134a (R-134a) A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs.
IDENTIFICATION
NOTE: Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label.
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification label on the front side of hood.
MJIA0001E
Wiring Diagrams and Trouble Diagnosis
When you read wiring diagrams, refer to the followings: q GI-11, "How to Read Wiring Diagram" in GI section. q EL-11, "Power Supply Routing" in EL section. When you perform trouble diagnosis, refer to the followings: q GI-21, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section. q GI-31, "How to Follow Trouble Diagnosis" in GI section.
EJS002ZP
ATC-10
PREPARATION PREPARATION Special Service Tools
Tool number Tool name Description
PFP:00002
A
EJS002ZQ
B
C
D
KV99106100 Clutch disc wrench
S-NT232
Removing shaft nut and clutch disc
E
F
RJIA0194E
G
KV99232340 or KV992T0001 Clutch disc puller
S-NT376
Removing clutch disc
H
I
KV99106200 Pulley installer
ATC
Installing pulley
K
S-NT235
HFC-134a (R-134a) Service Tools and Equipment
EJS002ZR
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor malfunction will result.
L
M
ATC-11
PREPARATION
Tool number Tool name
Description
HFC-134a (R-134a) refrigerant
Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size
q
S-NT196
Large container 1/2 -16 ACME
KLH00-PAGS0 Nissan A/C System Oil Type S
Type: Poly alkylene glycol oil (PAG), type S Application: HFC-134a (R-134a) swash plate compressors (Nissan only) Lubricity: 40 m (1.4 Imp fl oz.)
S-NT197
Recovery/Recycling/ Recharging equipment (ACR4)
Function: Refrigerant Recovery and Recycling and Recharging
RJIA0195E
Electrical leak detector
Power supply: DC 12V (Cigarette lighter)
SHA705EB
(J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) Fluorescent dye leak detector (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box, of 24, 1/4 ounce bottles) (J-43872) Dye cleaner
Power supply: DC 12V (Battery terminal)
ZHA200H
ATC-12
PREPARATION
Tool number Tool name Description Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety goggles Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)
SHA439F
A
B
(J-42220) Fluorescent dye leak detector
C
SHA438F
D
(J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles)
E
F
(J-41459) HFC-134a (R-134a) Dye injector Use with J-41447, 1/4 ounce bottle
SHA440F
For injecting 1/4 ounce of fluorescent leak detection dye into A/C system.
G
H
(J-43872) Dye cleaner
I
For cleaning dye spills.
ATC
SHA441F
K
Identification: Manifold gauge set (with hoses and couplers)
q
The gauge face indicates HFC-134a (R-134a). Fitting size: Thread size 1/2 -16 ACME
L
q
M
RJIA0196E
Hose color: Service hoses
q q q q q q
Low hose: Blue with black stripe High hose: Red with black stripe Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 1/2 -16 ACME
High side hose Low side hose Utility hose
S-NT201
q
Service couplers
q q
Hose fitting to service hose:
q
High side coupler Low side coupler
S-NT202
M14 x 1.5 fitting is optional or permanently attached.
ATC-13
PREPARATION
Tool number Tool name Description
Refrigerant weight scale
For measuring of refrigerant Fitting size: Thread size
q
1/2 -16 ACME
S-NT200
Capacity:
q
Air displacement: 4 CFM Micron rating: 20 microns Oil capacity: 482 g (17 oz.) Fitting size: Thread size 1/2 -16 ACME
Vacuum pump (Including the isolator valve)
q q
S-NT203
q
ATC-14
REFRIGERATION SYSTEM REFRIGERATION SYSTEM Refrigerant Cycle
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, through the 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.
B
PFP:KA990
A
EJS002ZS
FREEZE PROTECTION
Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore, temperature is controlled by the CSV613 displacement compressor to prevent freeze up.
C
D
Refrigerant System Protection
REFRIGERANT PRESSURE SENSOR (WITH QG ENGINE)
EJS002ZT
The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (27.5 bar, 28 kg/cm2 , 398 psi), or below about 134 kPa (1.37 bar, 1.4 kg/cm2 , 20 psi).
E
F
DUAL-PRESSURE SWITCH (WITH YD ENGINE)
The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch, located on the liquid tank (condenser). If the system pressure rises above or falls below the specifications, the dual-pressure switch opens to interrupt the compressor operation.
G
H
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (37.3 bar, 38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.
I
ATC
K
L
M
RJIA2321E
ATC-15
REFRIGERATION SYSTEM CSV613 Variable Displacement Compressor
GENERAL INFORMATION
1. The CSV613 compressor differs from previous units. The vent temperatures of the CSV613 compressor do not drop too far below 5°C (41°F) when: Evaporator intake air temperature is less than 20°C (68°F). Engine is running at speeds less than 1,500 rpm. This is because the CSV613 compressor provides a means of "capacity" control. The CSV613 compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems. A "clanking" sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the swash plate has changed and is not a problem. For air conditioning systems with the CSV613 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It normally ranges from 147 to 177 kPa (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm2 , 21 to 26 psi) under varying conditions. In previous compressors, however, suction pressure was reduced with increases in engine speed.
EJS002ZU
2.
3. 4.
5.
DESCRIPTION General
The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity.
ATC-16
REFRIGERATION SYSTEM
The tilt of the swash plate allows the pistons stroke to change so that refrigerant discharge can be continuously changed from 6.0 to 125 cm3 (0.366 to 7.628 cu. in).
A
B
C
D
E
F
G
H
I
ATC
K
L
M
RHA854HA
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. Maximum Cooling Refrigerant pressure on the lowpressure 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: q The crankcases internal pressure to equal the pressure on the low-pressure side;
2.
ATC-17
REFRIGERATION SYSTEM
q 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
3.
Capacity Control q Refrigerant pressure on suction side is low during high speed driving or when ambient or interior temperature is low. q The bellows expands when refrigerant pressure on the suction pressure side drops below approximately 177 kPa (1.77 bar, 1.8 kg/cm2 , 26 psi). Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high pressure enters the crankcase. q The force acts around the journal pin near the swash plate, and is generated by the pressure difference before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the swash plate.
RHA474C
ATC-18
REFRIGERATION SYSTEM Component Layout
EJS002ZV
A
B
C
D
E
F
G
H
I
ATC
K
L
M
NHA367
ATC-19
LUBRICANT LUBRICANT Maintenance of Lubricant Quantity in Compressor
PFP:KLG00
EJS002ZW
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: q Lack of lubricant: May lead to a seized compressor q Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
Name: Part number: Nissan A/C System Oil Type S KLH00-PAGS0
LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed? q A/C system works properly. q There is no evidence of a large amount of lubricant leakage. Yes or No Yes >> GO TO 2. No >> GO TO 3.
2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:
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 30°C (77 to 86°F).] Intake position: Recirculation (REC) 2. Perform lubricant return operation for about 10 minutes. 3. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation.
1.
>> GO TO 3.
3. CHECK COMPRESSOR
Should the compressor be replaced? Yes or No Yes >> Go to ATC-21, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" . No >> GO TO 4.
ATC-20
LUBRICANT
4. CHECK ANY PART
Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.) Yes or No Yes >> Go to ATC-21, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR" . No >> Carry out the A/C performance test.
A
B
C
LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR
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 Part replaced Amount of lubricant m (Imp fl oz.) 75 (2.6) 35 (1.2) 10 (0.4) 30 (1.1) *1:If refrigerant leak is small, no addition of lubricant is needed. Remarks
D
E
Evaporator Condenser Liquid tank In case of refrigerant leak
Large leak Small leak *1
F
G
H
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT
1. 2. 3. 4. 5. 6. 7. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines. I Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling equipment. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount ATC of lubricant drained. Drain the lubricant from the new compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this K lubricant to new compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor through the suction port opening. L If the liquid tank also needs to be replaced, add an additional 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 if only replacing the compressor.
M
ATC-21
AIR CONDITIONER CONTROL AIR CONDITIONER CONTROL Overview Air Conditioner LAN Control System
The LAN system consists of auto amp., mode door motor, air mix door motor and intake door motor. A configuration of these components is shown in the diagram below.
PFP:27500
EJS002ZX
RJIA0480E
System Construction
EJS002ZY
A small network is constructed between the auto amplifier, air mix door motor, mode door motor and intake 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 three 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 three motors. The following functions are contained in LCUs built into the air mix door motor, mode door motor and intake door motor. q Address q Motor opening angle signals q Data transmission q Motor stop and drive decision q Opening angle sensor (PBR function) q Comparison q Decision (Auto amplifier indicated value and motor opening angle comparison)
RHA350H
OPERATION
The auto amplifier receives data from each of the sensors. The amplifier sends mode door, air mix door and intake door opening angle data to the mode door motor LCU, air mix door motor LCU and intake door motor LCU. The mode door motor, air mix door motor and intake 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, DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection data is returned to the auto amplifier.
ATC-22
AIR CONDITIONER CONTROL
A
B
C
RHA351H
TRANSMISSION DATA AND TRANSMISSION ORDER
D
Amplifier data is transmitted consecutively to each of the door motors following the form shown in figure below. Start: Initial compulsory signal sent to each of the door motors. E Address: Data sent from the auto amplifier is selected according to data-based decisions made by the air mix door motor, mode door motor and intake door motor. If the addresses are identical, the opening angle data and error check signals are received by the door motor LCUs. The LCUs then make the appropriate error decision. If the opening angle data is usual, door control F begins. If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon the corrected opening angle data. G Opening angle: Data that shows the indicated door opening angle of each door motor. Error check: Procedure by which sent and received data is checked for errors. Error data is then compiled. The error check H prevents corrupted data from being used by the air mix door motor, mode door motor and intake door motor. Error data can be related to the following problems. q Unusual electrical frequency I q Poor electrical connections q Signal leakage from transmission lines ATC q Signal level fluctuation Stop signal: At the end of each transmission, a stop operation, in-operation, or internal problem message is delivered to K the auto amplifier. This completes one data transmission and control cycle.
L
M
RHA352H
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.
ATC-23
AIR CONDITIONER CONTROL
FAN SPEED CONTROL
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.
INTAKE DOOR CONTROL
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor.
OUTLET DOOR CONTROL
The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload.
MAGNET CLUTCH CONTROL
The ECM controls compressor operation using input signals from the refrigerant pressure sensor (with QG engine), throttle position sensor and auto amplifier.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of malfunctions.
Overview of Control system
EJS002ZZ
The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs. The relationship of these components is shown in the diagram below:
RJIA0687E
ATC-24
AIR CONDITIONER CONTROL Control Operation
EJS00300
A
B
C
D
E
F
G
H
RJIA1675E
I
DISPLAY SCREEN
Displays the operational status of the system.
ATC
AUTO SWITCH
The compressor, intake doors, air mix doors, outlet 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.
K
TEMPERATURE DIAL (POTENTIO TEMPERATURE CONTROL)
Increase or decrease the set temperature.
L
A/C SWITCH
The compressor is ON or OFF. (Pressing the A/C switch when the AUTO switch is ON will turn off the A/C switch and compressor.)
M
DEFROSTER (DEF) SWITCH
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.
MODE SWITCH
Control the air discharge outlets.
FAN SWITCH
Manually controls the blower speed. Five speeds are available for manual control (as shown on the display screen).
OFF SWITCH
The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot position.
FRESH (FRE) SWITCH
OFF position: Interior air is recirculated inside the vehicle. ON position: Outside air is drawn into the passenger compartment. (When RECIRCULATION switch is ON, the FRESH switch turns OFF automatically.)
ATC-25
AIR CONDITIONER CONTROL
RECIRCULATION (REC) SWITCH
OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is drawn into the passenger compartment. (When the FRESH switch is ON or the compressor is turned from ON to OFF, the RECIRCULATION switch turns OFF automatically.)
REAR WINDOW DEFOGGER SWITCH
When illumination is ON, rear window is defogged.
Fail-safe Function
EJS00301
If fail-safe request signal is sent from AV control unit, or if communication error exists between auto amplifier and AV control unit for at least 30 seconds, air conditioner is controlled under following conditions.
Compressor Air inlet Air outlet Blower fan speed Set temperature : ON : Fresh : AUTO : AUTO : Setting before communication error occurs
ATC-26
AIR CONDITIONER CONTROL Discharge Air Flow
EJS00302
A
B
C
D
E
F
G
H
I
ATC
K
L
M
NHA371
ATC-27
AIR CONDITIONER CONTROL System Description
SWITCHES AND THEIR CONTROL FUNCTION
EJS00303
RHA592H
RJIA1677E
ATC-28
TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS How to Perform Trouble Diagnoses for Quick and Accurate Repair
WORK FLOW
B
PFP:00004
A
EJS00304
C
D
SHA900E
E
*1
ATC-50, "Operational Check"
SYMPTOM TABLE
Symptom Reference Page ATC-54, "Power Supply and Ground Circuit for Auto Amp." ATC-59, "Mode Door Motor Circuit" ATC-62, "Air Mix Door Motor Circuit" ATC-65, "Intake Door Motor Circuit" ATC-68, "Blower Motor Circuit" ATC-74, "Magnet Clutch Circuit" ATC-82, "Insufficient Cooling" ATC-90, "Insufficient Heating" ATC-92, "Noise" ATC-93, "Selfdiagnosis" ATC-94, "Memory Function" ATC-104, "Multiplex Communication Circuit"
F
A/C system does not come on.
Go to Trouble Diagnosis Procedure for A/C System.
G
Air outlet does not change. Mode door motor does not operate normally. Discharge air temperature does not change. Air mix door motor does not operate normally. Intake door does not change. Intake door motor does not operate normally. Blower motor operation is malfunctioning. Blower motor operation is malfunctioning under out of starting fan speed control. Magnet clutch does not engage. Insufficient cooling Insufficient heating Noise Self-diagnosis cannot be performed. Memory function does not operate. Go to Trouble Diagnosis Procedure for Blower Motor. Go to Trouble Diagnosis Procedure for Intake Door Motor.(LAN) Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN) Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN)
H
I
ATC
K
Go to Trouble Diagnosis Procedure for Magnet Clutch. Go to Trouble Diagnosis Procedure for Insufficient Cooling. Go to Trouble Diagnosis Procedure for Insufficient Heating. Go to Trouble Diagnosis Procedure for Noise. Go to Trouble Diagnosis Procedure for Self-diagnosis. Go to Trouble Diagnosis Procedure for Memory Function. Go to Trouble Diagnosis Procedure for Multiplex Communication Circuit.
L
M
A/C system cannot be controlled.
ATC-29
TROUBLE DIAGNOSIS Component Parts and Harness Connector Location
ENGINE COMPARTMENT
EJS00305
RJIA2322E
ATC-30
TROUBLE DIAGNOSIS
PASSENGER COMPARTMENT
A
B
C
D
E
F
G
H
I
ATC
K
L
M
RJIA2323E
ATC-31
TROUBLE DIAGNOSIS Circuit Diagram
EJS00306
YHA493A
ATC-32
TROUBLE DIAGNOSIS Wiring Diagram
EJS00307
A
B
C
D
E
F
G
H
I
ATC
K
L
M
YHA494A
ATC-33
TROUBLE DIAGNOSIS
YHA495A
ATC-34
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
YHA496A
ATC-35
TROUBLE DIAGNOSIS
YHA497A
ATC-36
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
YHA498A
ATC-37
TROUBLE DIAGNOSIS
YHA499A
ATC-38
TROUBLE DIAGNOSIS Auto Amp. Terminals and Reference Value
Measure voltage between each terminal and body ground by following AUTO AMP. INSPECTION TABLE.
EJS00308
A
B
C
D
RJIA0750E
PIN CONNECTOR TERMINAL LAYOUT
E
F
G
RJIA1680E
H
AUTO AMP. INSPECTION TABLE
TERMINAL NO. 1 2 3 WIRE COLOR OR/B W/G OR/L ITEM Intake sensor Ambient sensor In-vehicle sensor CONDITION Voltage (V) -
I
ATC
K
4 L/B Speed sensor signal IGN ON Speedometer: Approx. 40 km/h (25 MPH)
L
ELF1080D
M
5 R/Y LAN signal IGN ON -
HAK0652D
9
L/W
Multiplex communication (Tx) signal A/C amp. AV
IGN ON
-
RJIA0212E
ATC-39
TROUBLE DIAGNOSIS
TERMINAL NO. WIRE COLOR ITEM CONDITION Voltage (V)
10
L/R
Multiplex communication (Rx) signal AV A/C amp.
IGN ON
-
RJIA0213E
11 12
B/Y OR
Sensor ground Sunload sensor
IGN ON IGN ON
-
Approx. 0 -
17
PU/W
Water temperature sensor signal
IGN ON
Engine coolant temperature: Approx. 60°C
SKIA0056J
18 BR/W Compressor feed back signal IGN ON A/C ON When refrigerant pressure sensor connector is disconnected.
Approx. 0 Approx. 5
20
L
Multiplex communication (CLK) signal
IGN ON
-
HAK0363D
21
G/Y
Power supply for mode door, air mix door and intake door motor Compressor ON signal Ground Power supply for BATT Power supply for IGN Fan ON signal Power supply for ACC Blower fan motor feed back signal Fan control amp. control signal
IGN ON IGN ON IGN ON IGN OFF IGN ON IGN ON IGN ON IGN ON IGN ON Blower fan: ON Blower fan: OFF Compressor: ON Compressor: OFF
-
Approx. 12 Approx. 0 Approx. 5
22 24 26 27 29 33 34 35
L/R B R/B Y/G LG/B L/W L/B L/Y
-
Approx. 0 Approx. 12 Approx. 12 Approx. 0 Approx. 5
Fan speed: Manual 1st Manual 1st - 4th speed Fan speed: Manual 5th speed
Approx. 12 Approx. 8 Approx. 2.5 - 3.5 Approx. 9.0
ATC-40
TROUBLE DIAGNOSIS Self-diagnosis Function
DESCRIPTION
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch from OFF to ON) and pressing OFF switch for at least 5 seconds. The "OFF" switch must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be canceled by either pressing A/C switch or turning the ignition switch OFF. Shifting from one step to another is accomplished by means of turning temperature dial, as required. Additionally shifting from STEP 6 to AUXILIARY MECHANISM is accomplished by means of pushing (fan) UP switch.
EJS00309
A
B
C
D
E
F
G
H
I
ATC
K
L
M
RJIA1681E
ATC-41
TROUBLE DIAGNOSIS
FUNCTION CONFIRMATION PROCEDURE
1. SET IN SELF-DIAGNOSTIC MODE
Method 1 (Without navigation system, or with navigation system) 1. Turn ignition switch to ON. 2. Within 10 seconds after starting engine (ignition switch is turned ON.), press and hold OFF switch for at least 5 seconds. 3. The self-diagnosis (step 1) should start. Method 2 (Only with navigation system) 1. Turn OFF the audio system. 2. While pressing "Vehicle Information" switch, turn audio switch (volume adjustment dial) by at least 30 notches. 3. Trouble diagnosis initial screen appears. Using joystick, select "Confirmation and Adjustment". And press "Confirm". 4. Confirmation and adjustment initial screen appears. Using joystick, select "Air-conditioner trouble diagnosis", and press "Confirm" to start self-diagnosis (step 1). CAUTION: If battery voltage drops below 12V during step diagnosis 3, actuator speed becomes slower and as a result, the system may generate an error even when operation is normal. To avoid this, start engine before performing this diagnosis. >> GO TO 2.
ATC-42
TROUBLE DIAGNOSIS
2. STEP 1 - LEDS AND DISPLAY ARE CHECKED
Check LEDs illuminate and display screen.
A
B
C
D
E
F
G
H
I
RJIA2324E
OK or NG OK >> GO TO 3. NG >> Malfunctioning OFF switch or LEDs. >> Check multi-function switch.
ATC
K
3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP 2
1. Turn the temperature dial clockwise. 2. Advance to self-diagnosis STEP 2? Yes or No Yes >> GO TO 4. No >> Malfunctioning temperature dial. >> Check multi-function switch.
L M
4. CHECK TO RETURN SELF-DIAGNOSIS STEP 1
1. Turn the temperature dial counterclockwise. 2. Return to self-diagnosis STEP 1? Yes or No Yes >> GO TO 5. No >> Malfunctioning temperature dial. >> Check multi-function switch.
ATC-43
TROUBLE DIAGNOSIS
5. STEP 2 - SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT
1. Turn the temperature dial clockwise. 2. Does code No.20 appear on the display? Yes or No Yes >> GO TO 6. No >> GO TO 14.
RJIA0219E
6. STEP 3 - MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED
1. Turn the temperature dial clockwise. 2. Does code No.30 appear on the display? Yes or No Yes >> GO TO 7. No >> GO TO 15.
RJIA0220E
7. STEP 4 - OPERATION OF EACH ACTUATOR IS CHECKED
1. 2. Turn the temperature dial clockwise. Press DEF switch, code No. of each actuator test is indicated on the display. >> GO TO 8.
RJIA1114E
ATC-44
TROUBLE DIAGNOSIS
8. CHECK ACTUATORS
Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage and compressor operation.
A
B
C
D
E
F
G
RHA280I
H
41 Mode door position Intake door position Air mix door position Blower fan Compressor VENT REC FULL COLD Approx. 4.5V ON
42 B/L REC FULL COLD Approx. 10.5V ON
43 B/L 20% FRE FULL HOT Approx. 8.5V OFF
44 FOOT FRE FULL HOT Approx. 8.5V OFF
45 D/F FRE FULL HOT Approx. 8.5V ON
46 DEF FRE FULL HOT Approx. 12V ON
I
ATC
Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation. OK or NG OK >> GO TO 9. NG >> q Air outlet does not change. Go to ATC-59, "Mode Door Motor Circuit" . q Intake door does not change. Go to ATC-65, "Intake Door Motor Circuit" . q Blower motor operation is malfunctioning. Go to ATC-68, "Blower Motor Circuit" . q Magnet clutch does not engage. Go to ATC-74, "Magnet Clutch Circuit" . q Discharge air temperature does not change. Go to ATC-62, "Air Mix Door Motor Circuit"
K
L
M
9. STEP 5 - TEMPERATURE OF EACH SENSOR IS CHECKED
1. 2. Turn the temperature dial clockwise. Code No.51 appears on the display. >> GO TO 10.
ATC-45
TROUBLE DIAGNOSIS
10. CHECK AMBIENT SENSOR
Press DEF switch one time, temperature detected by ambient sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 11. NG >> Go to ATC-95, "Ambient Sensor Circuit" .
RJIA0755E
11. CHECK IN-VEHICLE SENSOR
Press DEF switch the second time, temperature detected by in-vehicle sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 12. NG >> Go to ATC-97, "In-vehicle Sensor Circuit" .
RJIA0758E
12. CHECK INTAKE SENSOR
Press DEF switch the third time, temperature detected by intake sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 13. NG >> Go to ATC-103, "Intake Sensor Circuit" .
RJIA0760E
13. CHECK MULTIPLEX COMMUNICATION ERROR
Press REC (Recirculation) switch. Multiplex communication error between AV AND NAVI CONTROL UNIT (or DISPLAY UNIT) and auto amp. is detected. (If plural errors occur, the display of each error will blink two times for 0.5 second int