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AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
SECTION
AUTOMATIC AIR CONDITIONER
ATC
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CONTENTS
APPLICATION NOTICE ............................................. 3 . How to Check Vehicle Type .................................... 3 . 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 ................................................ 9 . SERVICE COUPLERS ......................................... 9 . REFRIGERANT WEIGHT SCALE ....................... 9 . CALIBRATING ACR4 WEIGHT SCALE ............... 9 . CHARGING CYLINDER ..................................... 10 . Precautions for Leak Detection Dye ...................... 10 . IDENTIFICATION ............................................... 10 . IDENTIFICATION LABEL FOR VEHICLE .......... 10 . PREPARATION .........................................................11 . HFC-134a (R-134a) Service Tools and Equipment...11 . REFRIGERATION SYSTEM .................................... 14 . Refrigerant Cycle .................................................. 14 . REFRIGERANT FLOW ...................................... 14 . FREEZE PROTECTION .................................... 14 . Refrigerant System Protection .............................. 14 . REFRIGERANT PRESSURE SENSOR ............ 14 . PRESSURE RELIEF VALVE .............................. 14 . LUBRICANT ............................................................ 15 . Adjustment of Compressor Lubricant Amount ...... 15 . LUBRICANT ....................................................... 15 . PROCEDURES FOR LUBRICANT RETURN OPERATION ....................................................... 15 . LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COMPRESSOR ................................................. 16 . LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR ............................ 16 . AUTO AIR CONDITIONER SYSTEM ...................... 17 . Description ............................................................. 17 . TROUBLE DIAGNOSIS ........................................... 18 . CONSULT-II Functions .......................................... 18 . CONSULT-II BASIC OPERATION ...................... 18 . DATA MONITOR ................................................ 19 . Diagnosis Procedure ............................................. 20 . DIAGNOSIS CHART BY SYMPTOM ................. 20 . Component Parts Location .................................... 22 . CR ENGINE MODELS ....................................... 22 . HR ENGINE MODELS ....................................... 23 . K9K ENGINE MODELS ...................................... 24 . Circuit Diagram ...................................................... 25 . Wiring Diagram --A/C-- CR Engine Models ......... 26 . Wiring Diagram --A/C-- HR Engine Models ......... 30 . Wiring Diagram --A/C-- K9K Engine Models ....... 34 . Wiring Diagram --PTC/H-- K9K Engine LHD Models .......................................................................... 38 . A/C Auto Amp. Input/Output Signal Standard ........ 39 . Self-Diagnosis Function ......................................... 40 . DESCRIPTION ................................................... 40 . OPERATION PROCEDURE ............................... 41 . Difference Between Set Temperature and Control Temperature .......................................................... 45 . DESCRIPTION ................................................... 45 . HOW TO SET ..................................................... 45 . Function Inspection ............................................... 45 . Air Conditioning System ........................................ 47 . Ambient Sensor System ........................................ 47 . In-Vehicle Sensor System ..................................... 49 . Sunload Sensor System ........................................ 50 . Intake Sensor System ........................................... 51 . Coolant Temperature Signal System ..................... 53 . Blower Motor System ............................................ 54 .
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ATC-1
Intake Door Motor System ..................................... 58 . Mode Door Motor System ...................................... 58 . Air Mix Door Motor System .................................... 60 . Magnetic Clutch System ........................................ 61 . Check Fan ON Signal ............................................ 64 . Component Inspection ........................................... 65 . REFRIGERANT PRESSURE SENSOR ............. 65 . Insufficient Cooling ................................................ 65 . CHECK FUNCTION (FOR GASOLINE ENGINE).. 65 . DIAGNOSIS BY PRESSURE GAUGE ............... 67 . DIAGNOSIS OF COMPRESSOR ....................... 69 . Detecting Leaks With Fluorescent Indicator .......... 70 . METHOD FOR DETECTING REFRIGERANT LEAKAGE ........................................................... 70 . CONTROL UNIT ....................................................... 71 . Removal and Installation ....................................... 71 . REMOVAL .......................................................... 71 . INSTALLATION ................................................... 71 . Disassembly and Assembly ................................... 71 . AMBIENT SENSOR ................................................. 73 . Removal and Installation ....................................... 73 . IN-VEHICLE SENSOR ............................................. 74 . Removal and Installation ....................................... 74 . SUNLOAD SENSOR ................................................ 75 . Removal and Installation ....................................... 75 . INTAKE SENSOR .................................................... 76 . Removal ................................................................ 76 . Installation .............................................................. 76 . A/C UNIT ASSEMBLY ............................................. 77 . Removal and Installation ....................................... 77 . REMOVAL .......................................................... 77 . INSTALLATION ................................................... 78 . Disassembly and Assembly ................................... 79 . HEATER CORE ........................................................ 81 . Removal and Installation ....................................... 81 . REMOVAL .......................................................... 81 . INSTALLATION ................................................... 81 . BLOWER MOTOR ................................................... 82 . Removal and Installation ....................................... 82 . REMOVAL .......................................................... 82 . INSTALLATION ................................................... 82 . AIR CONDITIONER FILTER .................................... 83 . Removal, Replacement and Installation ................ 83 . REMOVAL .......................................................... 83 . REPLACEMENT ................................................. 83 . INSTALLATION ................................................... 83 . INTAKE DOOR MOTOR .......................................... 84 . Removal and Installation ....................................... 84 . MODE DOOR MOTOR ............................................. 85 . Removal and Installation ....................................... 85 . AIR MIX DOOR MOTOR .......................................... 86 . Removal and Installation ....................................... 86 .
FAN CONTROL AMPLIFIER ....................................87 . Removal and Installation ...................................... ..87 . DUCTS AND GRILLES ............................................88 . Removal and Installation ...................................... ..88 . COMPONENT PARTS LOCATION .....................88 . CENTRAL VENTILATOR GRILLE ......................88 . SIDE VENTILATOR GRILLE ..............................88 . DEFROSTER NOZZLE AND DUCT ...................89 . SIDE VENTILATOR DUCT .................................90 . FOOT DUCT .......................................................91 . REFRIGERANT LINES ............................................92 . Component Parts Location ....................................92 . CR ENGINE MODELS ........................................92 . HR ENGINE MODELS ........................................93 . K9K ENGINE MODELS ......................................94 . Removal and Installation for Compressor ..............95 . REMOVAL ...........................................................95 . INSTALLATION ...................................................95 . Removal and Installation for Pipe and Hose ..........96 . REMOVAL ...........................................................96 . INSTALLATION ...................................................96 . Removal and Installation for Refrigerant Pressure Sensor ....................................................................97 . REMOVAL AND INSTALLATION ........................97 . Removal and Installation for Condenser (Models without Integrated Condenser) ...............................97 . REMOVAL ...........................................................97 . INSTALLATION ...................................................98 . Removal and Installation for Condenser (Models with Integrated Condenser) ....................................98 . REMOVAL ...........................................................98 . INSTALLATION ...................................................98 . RemovalandInstallationforLiquidTank(CREngine with A/T Models) ....................................................98 . REMOVAL ...........................................................98 . INSTALLATION ...................................................99 . RemovalandInstallationforLiquidTank(ExceptCR Engine with A/T Models) ........................................99 . REMOVAL ...........................................................99 . INSTALLATION ...................................................99 . Removal and Installation for Evaporator ................99 . REMOVAL ...........................................................99 . INSTALLATION ................................................. 100 . Removal and Installation for Expansion Valve ..... 100 . REMOVAL ......................................................... 100 . INSTALLATION ................................................. 100 . SERVICE DATA AND SPECIFICATIONS (SDS) ... 102 . COMPRESSOR ................................................... 102 . LUBRICANT ......................................................... 102 . REFRIGERANT ................................................... 102 . ENGINE IDLING SPEED ..................................... 102 . BELT TENSION ................................................... 102 .
ATC-2
APPLICATION NOTICE APPLICATION NOTICE How to Check Vehicle Type
PFP:00000
A
EJS006AJ
Confirm K9K engine type with Model written on identification plate (refer to GI-44, "IDENTIFICATION INFORMATION" ), then refer to service information in ATC section.
Vehicle type xTKxxxxK12Vxx xTKxxxxK12Yxx xTKxxxxK12Txx xTKxxxxK12Uxx Engine type Euro3 48kW Euro3 60kW Euro4 50kW Euro4 63kW
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ATC
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ATC-3
PRECAUTIONS
PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT PRE-TENSIONER"
EJS004HI
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)
EJS004HJ
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 failure 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: q When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. q When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. q Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. q Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R134a) recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. q Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam parts. Damage may result.
General Refrigerant Precautions
EJS004HK
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)
ATC-4
PRECAUTIONS
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.
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Lubricant Precautions
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EJS004HL
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Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-134a) recovery equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage may result.
EJS004HM
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Precautions for Refrigerant Connection
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A new type refrigerant connection has been introduced to all refrigerant lines except the following location. q Expansion valve to cooling unit q Refrigerant pressure sensor to liquid tank
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FEATURES OF NEW TYPE REFRIGERANT CONNECTION
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The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi- ATC nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. K The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.
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SHA815E
ATC-5
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.
O-Ring Part Numbers and Specifications (CR Engine Models)
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 flexible hose Liquid tank to condenser pipe Refrigerant pressure sensor Former Expansion valve to evaporator Inlet Outlet Part number 92473 BC700 92471 BC700 92472 BC700 92471 BC700 92474 BC700 92472 BC700 92471 N8210 -- 92477 AX000 92477 AX005 Qty. 1 1 1 1 1 1 1 1 1 Remarks
O-Ring Part Numbers and Specifications (HR Engine Models)
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 flexible hose Liquid tank to condenser pipe Refrigerant pressure sensor Former Expansion valve to evaporator Inlet Outlet Part number 92473 BC700 92471 BC700 92472 BC700 92471 BC700 92474 N8210 92472 N8210 92471 N8210 -- 92477 AX000 92477 AX005 Qty. 1 1 1 1 1 1 1 1 1 Remarks
O-Ring Part Numbers and Specifications (K9K Engine Models)
Connection type Piping connection point Low-pressure flexible hose to heater & cooling unit Low-pressure flexible hose to Low-pressure pipe High-pressure pipe to heater & cooling unit New Condenser to high-pressure flexible hose Condenser to high-pressure pipe Compressor to low-pressure flexible hose Compressor to high-pressure flexible hose Liquid tank to condenser pipe Refrigerant pressure sensor Former Expansion valve to evaporator Inlet Outlet Part number 92473 BC700 92473 BC700 92471 BC700 92472 BC700 92471 BC700 92474 BC700 92472 BC700 92471 N8210 -- 92477 AX000 92477 AX005 Qty. 1 1 1 1 1 1 1 1 1 1 Remarks
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.
ATC-6
PRECAUTIONS
CAUTION: When replacing or cleaning refrigerant cycle components, observe the following. q When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low pressure chamber. q When connecting tubes, always use a torque wrench and a back-up wrench. q After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. q When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection. q Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. q Thoroughly remove moisture from the refrigeration system before charging the refrigerant. q Always replace used O-rings. q When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Part number:
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KC59G Compressor Nissan A/C System Oil Type R KLH00-PAGR0
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O-ring must be closely attached to dented portion of tube. When replacing the O-ring, be careful not to damage O-ring and tube. Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. After connecting line, conduct leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque.
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RHA861F
Precautions for Servicing Compressor
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Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow "Maintenance of Lubricant Quantity in Compressor" exactly. Refer to ATC-15, "Adjustment of Compressor Lubricant Amount" . Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner.
ATC-7
PRECAUTIONS
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After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation.
EJS004HO
Precautions for Service Equipment
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows. q Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. q For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. q If the hose has an automatic shut off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump's ability to pull a deep vacuum and are not recommended.
RHA270DA
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
ATC-8
PRECAUTIONS
SERVICE HOSES
Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.
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RHA272D
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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
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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.
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ATC
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RHA274D
CALIBRATING ACR4 WEIGHT SCALE
Calibrate the scale every three months. To calibrate the weight scale on the ACR4: 1. Press Shift/Reset and Enter at the same time. 2. Press 8787 . "A1 " will be displayed. 3. Remove all weight from the scale. 4. Press 0 , then press Enter . "0.00 " will be displayed and change to "A2 ". 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press Enter -- the display returns to the vacuum mode. 8. Press Shift/Reset and Enter at the same time. 9. Press 6 -- the known weight on the scale is displayed. 10. Remove the known weight from the scale. "0.00 " will be displayed. 11. Press Shift/Reset to return the ACR4 to the program mode.
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ATC-9
PRECAUTIONS
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment.
Precautions for Leak Detection Dye
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The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J41995) pin-point refrigerant leaks. For your safety and your Customer's satisfaction, read and follow all manufacture's operating instructions and precautions prior to performing the work. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 CC) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye in HFC-134a (R-134a) A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs.
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.
SHA436FA
ATC-10
PREPARATION PREPARATION HFC-134a (R-134a) Service Tools and Equipment
PFP:00002
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EJS004HR
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.
Tool number Tool name Description
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Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size
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HFC-134a (R-134a) refrigerant
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large container 1/2 -16 ACME
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Type: Poly alkaline glycol oil (PAG), type R Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Lubricity: 40 m (1.4 Imp fl oz.)
KLH00-PAGR0 Nissan A/C System Oil Type R
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S-NT197
ATC
Recovery/Recycling Recharging equipment (ACR4)
Function: Refrigerant Recovery and Recycling and Recharging
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Electrical leak detector
Power supply:
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DC 12V (Power socket)
SHA705EB
ATC-11
PREPARATION
Tool number Tool name (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) HFC-134a (R-134a) Dye injector Use with J-41447, 1/4 ounce bottle (J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) (J-43872) Refrigerant dye cleaner Description
Power supply: DC 12V (Battery terminal)
ZHA200H
(J-42220) UV lamp and UV safety goggles
SHA438F
Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety goggles Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)
(J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles)
SHA439F
(J-41459) HFC-134a (R-134a) Dye injector Use with J-41447, 1/4 ounce bottle
SHA440F
For injecting 1/4 ounce of fluorescent leak detection dye into A/C system.
(J-43872) Refrigerant dye cleaner
For cleaning dye spills.
SHA441F
Identification:
Manifold gauge set (with hoses and couplers)
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The gauge face indicates HFC-134a (R-134a). Fitting size: Thread size 1/2 -16 ACME
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RJIA0196E
ATC-12
PREPARATION
Tool number Tool name Description
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Hose color: Service hoses
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Low hose: Blue with black stripe High hose: Red with black stripe Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: 1/2 -16 ACME
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High side hose Low side hose Utility hose
S-NT201
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Service couplers
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Hose fitting to service hose:
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High side coupler Low side coupler
S-NT202
M14 x 1.5 fitting is optional or permanently attached.
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For measuring of refrigerant Fitting size: Thread size
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Refrigerant weight scale
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-16 ACME
S-NT200
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Capacity:
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Air displacement:4 CFM Micron rating:20 microns Oil capacity:482 g (17 oz.) Fitting size: Thread size 1/2 -16 ACME
Vacuum pump (Including the isolator valve)
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S-NT203
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ATC
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ATC-13
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 at dash panel.
PFP:KA990
EJS006G2
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 SD6V12 displacement compressor to prevent freeze up.
Refrigerant System Protection
REFRIGERANT PRESSURE SENSOR
EJS006G3
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).
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.
MJIB0355E
ATC-14
LUBRICANT LUBRICANT Adjustment of Compressor Lubricant Amount
PFP:KLG00
A
EJS004HU
Compressor lubricant circulates through the system with refrigerant. When air conditioner system component is replaced or after the large refrigerant leak, lubricant needs to be added to compressor. Also it is important to maintain lubricant level properly. If lubricant level is not proper, following might happen. q Insufficient lubricant: Compressor adherence q Lubricant overfill: Insufficient cooling (insufficient heat exchange)
B
C
LUBRICANT
Lubricant name Part number : Nissan A/C System Oil Type R : KLH00-PAGR0
D
PROCEDURES FOR LUBRICANT RETURN OPERATION
Follow the steps bellow to adjust the lubricant level.
E
1. CHECK A/C SYSTEM
1. Make sure A/C system operates normally. 2. Make sure a large amount of refrigerant or lubricant does not leak. OK or NG OK >> GO TO 2. NG >> GO TO 3.
F
G
2. LUBRICANT RETURN OPERATION
1.
H
2. 3.
Start the engine. Put it in the following state. Engine speed: Idling - 1,200 rpm A/C or AUTO switch: ON Fan speed: HI Air inlet: Recirculation Set temperature: FULL HOT Keep running for approximately 10 minutes. Stop the engine. CAUTION: When a large leak of refrigerant or lubricant is found, do not perform lubricant return operation. >> GO TO 3.
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ATC
K
L
3. CHECK COMPRESSOR
Is compressor replaced? YES >> GO TO ATC-16, "LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR" . NO >> GO TO 4.
M
4. CHECK OTHER COMPONENTS
Is any other component to be replaced? (evaporator, condenser, liquid tank, large leak of refrigerant or lubricant) YES >> GO TO ATC-16, "LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COMPRESSOR" . NO >> GO TO ATC-65, "Insufficient Cooling" .
ATC-15
LUBRICANT
LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COMPRESSOR
Add compressor lubricant from the high-pressure port of the compressor according to the table below. indicates lubricant amount that spouts with refrigerant when refrigerant is discharged.
Components to be replaced Evaporator Condenser Liquid tank Lubricant amount to be added 35+ cm3 15+ cm3 5+ cm3
CAUTION: When replacing 2 or more parts, do not sum up . Ex. Lublicant amount to be added to evaporator and liquid tank (cm3 ) = 35 + 5 +
LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR
1. Drain the compressor lubricant from the removed compressor's high and low-pressure ports and measure the amount of lubricant.
MJIB0133E
2.
3.
Drain the compressor lubricant from a new compressor according to the formula below. indicates lubricant amount that spouts with refrigerant when refrigerant is discharged. Lubricant amount drained from new compressor (cm3 ) = Lubricant amount contained in the new compressor (80) - Lubricant amount discharged from the removed compressor - Lubricant amount that adheres to inside of compressor (20) - = 60 - Lubricant amount discharged from the removed compressor - When adding lubricant, add the appropriate amount of compressor lubricant from the compressor's highpressure port.
ATC-16
AUTO AIR CONDITIONER SYSTEM AUTO AIR CONDITIONER SYSTEM Description
q
PFP:27500
A
EJS004HV
The auto air conditioner detects the vehicle cabin temperature, outside air temperature, intake air temperature, and amount of malfunction sunlight using an interior air sensor, ambient air sensor, intake temperature sensor, and sunload sensor. A comparison of the detected values and temperature set by the temperature setting switch is made by the A/C auto amp (internal controller) and then the blown air temperature, vent blown air volume, vents, and air intake are adjusted to maintain the temperature set for the cabin.
B
C
D
E
F
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ATC
K
L
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ATC-17
TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS CONSULT-II Functions
PFP:00004
EJS004HW
The CONSULT-II has display functions for work support, self-diagnosis, data monitor, and active tests for each part by combining data reception and command transmission via communication lines from the BCM.
BCM trouble diagnosis item Air conditioner system Inspection Item, Diagnosis Mode Data monitor Description Displays BCM input data in real time.
CONSULT-II BASIC OPERATION
1. 2. Turn ignition switch OFF. Connect the CONSULT-II to data link connector via the CONSULT-II CONVERTER. For details, refer to the supplied CONSULT-II Operation Manual (Supplement-III) and CONSULT-II CONVERTER Operation Manual. CAUTION: If the CONSULT-II is connected without the CONSULT-II, CONVERTER, malfunction may be detected by self-diagnosis in control modules that use CAN communication. Turn ignition switch ON. Touch "START (NISSAN BASED VHCL)".
3. 4.
MJIA0065E
BCIA0029E
5.
Touch "BCM" on the "SELECT SYSTEM" screen. q If "BCM" is not displayed, print the "SELECT SYSTEM" screen, and then refer to LAN-5, "PRECAUTIONS" .
BCIA0030E
6.
Touch "AIR CONDITIONER" on the "SELECT TEST ITEM" screen".
MJIA0067E
ATC-18
TROUBLE DIAGNOSIS
7. Touch "DATA MONITOR" on the "SELET DIAG MODE" screen. For details, refer to separate volume "CONSULT-II Operation Manual".
A
B
C
BCIA0031E
DATA MONITOR Operation Procedure
1. 2. Touch "AIR CONDITIONER" on the "SELECT TEST ITEM" screen". Touch "DATA MONITOR" on the "SELET DIAG MODE" screen. For details, refer to separate volume "CONSULT-II Operation Manual". Touch "ALL SIGNALS" on the "DATA MONITOR" screen. Touch "START". Touch "RECORD" while monitoring to record the status of the item being monitored. To stop recording, touch "STOP".
MJIA0068E
D
E
F
3. 4. 5.
G
H
Monitored Item
Monitor item [UNIT] FAN ON SIG AIR COND SW IGN ON SW [ON/OFF] [ON/OFF] [ON/OFF] Contents Displays status "Blower fan on (ON)/blower fan off (OFF)" as judged by the BCM from the input from the A/C auto amp. Displays status "Compressor on (ON)/compressor off (OFF)" as judged by the BCM from the input from the A/C auto amp. Displays the "ON/OFF, ACC (OFF)" status determined from the ignition switch signal.
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ATC
K
L
M
ATC-19
TROUBLE DIAGNOSIS Diagnosis Procedure
DIAGNOSIS CHART BY SYMPTOM
Symptom No air comes out. Airflow volume does not change. Operation inspection Check blower motor operation. The circuit above is normal. Check installation condition of air mix door motor. Set temperature to 18°C and 32°C. Make sure air mix door operates for its full stroke. Common items (Check these items for any of the three malfunctions listed below.) Suspect systems Blower motor circuit A/C auto amp. circuit Possible causes Refer to ATC-54, "Blower Motor System" and ATC-53, "Coolant Temperature Signal System" . A/C auto amp. malfunction
q
EJS004HX
Air mix door circuit
q
Improper installation of air mix door rod or air mix door lever. Malfunction of air mix door system (damage, locking, etc.)
Air mix door motor circuit
Refer to ATC-60, "Air Mix Door Motor System" .
q
Malfunction indicated in Self-Diagnosis Step 2.
Sensor circuit
Sensor Malfunction; Refer to ATC-51, "Intake Sensor System" , ATC-50, "Sunload Sensor System" , ATC-49, "In-Vehicle Sensor System" , ATC-47, "Ambient Sensor System" . Sensor harness malfunction
q
Inaccurate temperature control
After normal indication in SelfDiagnosis Step 3, reset the actuator to zero position. Malfunction indicated in Self-Diagnosis Step 3. With A/C switch ON, check operation of magnetic clutch.
q q
Air mix door circuit
Misreading of the door position of the A/C auto amp. ATC-40, "SelfDiagnosis Function" Refer to ATC-60, "Air Mix Door Motor System" . Refer to ATC-61, "Magnetic Clutch System" , ATC-64, "Check Fan ON Signal" . Refer to ATC-65, "Insufficient Cooling" in "Cooling Malfunction". A/C auto amp. malfunction
q
Air mix door motor circuit
No cold air comes out. (Normal airflow amount)
Magnetic clutch circuit
Check refrigerant level. Performance check
Air conditioner system A/C auto amp. circuit Coolant circuit A/C auto amp. circuit Blower motor circuit
The circuit above is normal. No warm air comes out. (Airflow volume is normal.) After warming up engine, heater core inlet and outlet sides of the heater hose do not become warm. The circuit above is normal. Blower motor speed does not change when switching fan switch. Large difference between set temperature and interior air temperature The inlet of the interior sensor does not draw in smoke when the fan switch is set to speed 4. Check the difference between set temperature and control temperature. The circuit above is normal.
Poor engine coolant Blockage of heater hose or heater core
q
A/C auto amp. malfunction Refer to ATC-54, "Blower Motor System" .
q
Aspirator malfunction Aspirator duct is loose or crushed.
Aspirator circuit
q
--
Improperly set temperature difference ATC-45, "Difference Between Set Temperature and Control Temperature" A/C auto amp. malfunction
A/C auto amp. circuit
ATC-20
TROUBLE DIAGNOSIS
Symptom Operation inspection Suspect systems
q
Possible causes Improper installation of mode door rod, mode door link and mode door lever Mode door system malfunction (damage, locking, etc.)
A
Mode door operation check (manual operation) Unable to switch air outlets to others.
Mode door circuit
q
B
After normal indication in SelfDiagnosis Step 3, reset the actuator to zero position. Malfunction indicated in Self-Diagnosis Step 3. The circuit above is normal. Intake door operation check (manual operation)
Mode door circuit
Misreading of the door position of the A/C auto amp. ATC-40, "SelfDiagnosis Function" Refer to ATC-58, "Mode Door Motor System" . A/C auto amp. malfunction
q
C
Mode door motor circuit A/C auto amp. circuit
D
Intake door circuit
q
Improper installation of intake door lever Intake door system malfunction (damage, locking, etc.)
E
Unable to switch intake inlets to others.
Malfunction indicated in Self-Diagnosis Step 3. The circuit above is normal.
Intake door motor circuit A/C auto amp. circuit
Refer to ATC-58, "Intake Door Motor System" . A/C auto amp. malfunction
F
G
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ATC
K
L
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ATC-21
TROUBLE DIAGNOSIS Component Parts Location
CR ENGINE MODELS
EJS004HY
MJIA0069E
ATC-22
TROUBLE DIAGNOSIS
HR ENGINE MODELS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
MJIB0272E
ATC-23
TROUBLE DIAGNOSIS
K9K ENGINE MODELS
MJIA0217E
ATC-24
TROUBLE DIAGNOSIS Circuit Diagram
EJS004HZ
A
B
C
D
E
F
G
H
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ATC
K
L
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MJWA0251E
ATC-25
TROUBLE DIAGNOSIS Wiring Diagram --A/C-- CR Engine Models
EJS004I0
MJWA0252E
ATC-26
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
MJWA0253E
ATC-27
TROUBLE DIAGNOSIS
MJWA0170E
ATC-28
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
MJWA0254E
ATC-29
TROUBLE DIAGNOSIS Wiring Diagram --A/C-- HR Engine Models
EJS006AF
MJWA0255E
ATC-30
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
MJWA0169E
ATC-31
TROUBLE DIAGNOSIS
MJWA0225E
ATC-32
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
M
MJWA0256E
ATC-33
TROUBLE DIAGNOSIS Wiring Diagram --A/C-- K9K Engine Models
EJS0057O
MJWA0257E
ATC-34
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
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ATC
K
L
M
MJWA0173E
ATC-35
TROUBLE DIAGNOSIS
MJWA0174E
ATC-36
TROUBLE DIAGNOSIS
A
B
C
D
E
F
G
H
I
ATC
K
L
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MJWA0175E
ATC-37
TROUBLE DIAGNOSIS Wiring Diagram --PTC/H-- K9K Engine LHD Models
EJS006AG
MJWA0262E
PTC heater function is intended to improve the heating performance with CTP electrical system for air heating system which is broken down into several stages controlled by relays.
ATC-38
TROUBLE DIAGNOSIS A/C Auto Amp. Input/Output Signal Standard
Terminal No. 1 2 3 4 5 6 7 8 9 10 11 12 Measuring condition Wire color GY Y LG LG P R OR R W GY PU B Signal Designation Battery power supply Ignition power supply Sunload sensor signal Ambient sensor signal In-vehicle sensor signal Sensor ground Intake sensor signal Ignition power supply Blower fan feedback signal Fan ON signal Illumination power supply Illumination ground Ignition switch OFF ON -- -- -- ON -- ON ON ON ON ON Operation (status) -- -- -- -- -- -- -- -- Fan speed: Manual speed 1 Blower fan: ON Blower fan: OFF Lighting switch: 1st -- At idle (after warming up, approx. 80°C) 13 BR Engine coolant temperature signal ON CAUTION: The waveforms vary depending on the coolant temperature.
SKIA2224J
EJS004I1
A
Voltage (V) (Approx.)
B
Battery voltage Battery voltage Note 4 Note 3 Note 1 0 Note 2 Battery voltage 8 Battery voltage 1 Battery voltage 0
C
D
E
F
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0 Battery voltage 1 5 1 Battery voltage Battery voltage 0 Battery voltage 0 0 Battery voltage
14 15 16
B OR Y
Ground Ignition feedback (blower motor) signal Compressor ON signal Rear window defogger switch signal Rear window defogger feedback signal Intake door motor drive signal
ON ON ON
-- -- Compressor ON Compressor OFF Rear window defogger: ON
ATC
K
17
W
ON
Rear window defogger: OFF Rear window defogger: ON
L
18
L
ON
Rear window defogger: OFF RECFRE
19
G
ON
M
FREREC REC or FRE switch RECFRE FREREC
20 25 26 27
R LG L BR
Intake door motor drive signal
ON
Air mix door motor drive signal
ON
Immediately after temperature adjustment switch operation
29
P
HAK0627D
ATC-39
TROUBLE DIAGNOSIS
Terminal No. 30 31 32 34 Measuring condition Wire color W PU GY Y
HAK0627D
Signal Designation
Ignition switch
Operation (status)
Voltage (V) (Approx.)
Mode door motor drive signal
ON
Immediately after mode switch operation
Note 1: Refer to ATC-49, "In-Vehicle Sensor System" . Note 2: Refer to ATC-51, "Intake Sensor System" . Note 3: Refer to ATC-47, "Ambient Sensor System" . Note 4: Refer to ATC-50, "Sunload Sensor System" .
Self-Diagnosis Function
DESCRIPTION
q
EJS004I2
The self-diagnosis system consists of steps 1 to 5, and diagnosis sensor operations by checking for failures of each sensor and outputting control signals predetermined for each output device.
Step 1 Description Check the display and LEDs Step 2 Check sensors Step 3 Check positions of doors in the A/C unit Step 4 Individual output device inspection
q q
Step 5
q
Check detected temperatures of sensors
q q
Ambient sensor In-vehicle sensor Intake sensor Sun-load sensor Mode door motor Air mix door motor
Mode door motor Intake door motor Air mix door motor Blower motor Compressor Fan ON signal
q
q q q q q
The following sensor Ambient sensor In-vehicle sensor Intake sensor
Part to be diagnosed
q q
Display LED
q q
q
ATC-40
TROUBLE DIAGNOSIS
OPERATION PROCEDURE Description
A
B
C
D
E
F
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MJIA0070E
Switching to Self-Diagnosis Mode
q
Turn ignition switch OFF, then turn it to start engine. Within 10 seconds after starting the engine, press and hold the OFF switch for at least 5 seconds. Self-diagnosis (step1) should start. CAUTION: Diagnosis should be carried out with the engine running. If the battery voltage drops below 12V during step 3 trouble diagnosis, the actuator speeds become slower and NO results may be returned even for normal operation. Turn ignition switch OFF or press AUTO switch.
ATC
K
Finishing Self-Diagnosis Mode
q
L
Shifting the Steps
q
M
Use the temperature adjustment switch to switch between steps 1 through 5.
Procedure
1. START SELF-DIAGNOSIS
1. Turn ignition switch from OFF position to engine start. Within 10 seconds of engine start, press and hold OFF switch for approximately 5 seconds or longer. Is self-diagnosis mode activated? YES >> GO TO 2. NO >> Replace A/C auto amp.
ATC-41
TROUBLE DIAGNOSIS
2. STEP 1 - CHECK DISPLAY AND LEDS
Check LEDs of all controller switches. Check all liquid crystal display segments. Normal: All segments and LEDs are illuminated. Error: LEDs and sections of malfunctioning locations are not illuminated. Are LEDs and display normal? YES >> GO TO 3. NO >> Replace A/C auto amp.
MJIA0071E
3. STEP 2 - CHECK ALL SENSORS
Press temperature adjustment switch (Up: ) to change to step 2. 2. A "2" is displayed, followed by display of check results. Normal: "20" is displayed. Error: The first position of the display number corresponding to malfunctioning sensor will flash. "AUTO" is shown on the display when there is a short-circuit. OK or NG OK >> GO TO 5. NG >> GO TO 4.
MJIA0072E
1.
4. CHECK SENSOR MALFUNCTION
When an error occurs, the first position of the display number corresponding to this sensor will flash. If it is determined at this time that there is a short in the sensor circuit, "AUTO" will flash. Further, if there is an error in multiple sensors, the first positions of the corresponding display numbers will flash twice.
Displayed No. 21 22 24 25 Corresponding sensor Ambient sensor In-vehicle sensor Intake sensor Sunload sensor Error return condition OPEN Approx. -42°C or less Approx. -42°C or less Approx. -42°C or less 33 W/m2 (28.4 Kcal/m2 ·h) or less SHORT Approx. 100°C or more Approx. 100°C or more Approx. 100°C or more 1677 W/m2 (1422 Kcal/m2 ·h) or more Reference page ATC-47, "Ambient Sensor System" ATC-49, "In-Vehicle Sensor System" ATC-51, "Intake Sensor System" ATC-50, "Sunload Sensor System"
Example: If there is an open circuit in the ambient sensor, the A/C auto amp. registers extreme cold (-42°C or less) and adjusts the temperature control warmer. CAUTION: Sun-load sensor may register malfunction when indoors, at dusk, or at other times when light is insufficient.
OK or NG OK >> End of self-diagnosis NG >> Malfunction in corresponding sensor system
ATC-42
TROUBLE DIAGNOSIS
5. STEP 3 - CHECK AIR MIX DOOR AND MODE DOOR MOTOR
1. 2. Press temperature adjustment switch (Up: ) to change to step 3. A "3" is displayed, followed by a display of check results. Send output signals to the air mix door motor and mode door motor and inspect both motors. Normal: "30" is displayed. Error: The indicator lamp for the door position where the error occurred flashes. At this time, if it is judged that there is a short in the door motor circuit, "AUTO" will be displayed. If there is an error in multiple door motors, the corresponding display numbers will flash in ascending order. door motors corresponding to the DTC
Displayed No. Corresponding door motor 31, 32, 33, 34 Air mix door 35, 36, 37, 38 Mode door
A
B
C
D
MJIA0073E
E
F
DTC for an inoperative harness
Corresponding door motor Corresponding terminal (Door motor side) Corresponding terminal (A/C auto amp. side) Displayed number for short circuit Displayed number for open circuit 5 27
AUTO
Air mix door motor 2 26 31
AUTO
Mode door motor 6 25 5 32 34
AUTO
G
6 30
AUTO
1 29 32
AUTO
2 31 35
AUTO
1 34
AUTO
H
33
AUTO
36
37
38
I
31
32
33
34
35
36
37
38
NOTE: q If all four terminals of each door motor show a DTC for an open circuit, there is probably a disconnected connector or an open circuit in the door motor drive power supply harness. q If a short circuit occurs in the harness between terminals for each door motor and drive signal, although it cannot be detected by self-diagnosis, the door motor will vibrate when it operates.
ATC
K
L
M
MJIA0074E
Door Motor Zero Position Reset q Pressing the DEF switch during step 3 will send a reset signal to air mix door and mode door motor to reset them to the zero position. During reset: The 30 and DEF switch indicator lamps will flash. (For approx. 9 seconds)
MJIA0075E
ATC-43
TROUBLE DIAGNOSIS
OK or NG OK >> GO TO 6. NG >> Refer to ATC-58, "Mode Door Motor System" or ATC-60, "Air Mix Door Motor System" .
6. STEP 4 - CHECK EACH OUTPUT DEVICE
1. 2. 3. Press temperature adjustment switch (Up: ) to change to step 4. Each time the DEF switch is pressed, the display will change to 4142 43 44 45 46 41. Follow table below and check outlet, inlet, airflow temperature, blower motor applied voltage, magnetic clutch operation, and air mix ratio. Each operating condition should be checked visually, by listening for noise, by touching air outlets with your hand, and so on.
Displayed No. Mode door Intake door Air mix door position Blower motor Applied voltage Magnetic clutch Fan ON signal 41 VENT Recirculation Full Cold 5V ON 12V 42 B/L Recirculation Full Cold 10.5V ON 12V 43 B/L Fresh air Halfway (50%) 8.5V ON 12V 44 FOOT Fresh air Halfway (50%) 8.5V OFF 1V 45 D/F Fresh air Full Hot 8.5V OFF 1V 46 DEF Fresh air Full Hot Battery voltage ON 12V
OK or NG OK >> GO TO 7. NG >> q Outlet does not change: Refer to ATC-58, "Mode Door Motor System" . q Inlet does not change: Refer to ATC-51, "Intake Sensor System" . q Airflow temperature does not change: Refer to ATC-60, "Air Mix Door Motor System" . q Blower motor malfunction: Refer to ATC-54, "Blower Motor System" . q Magnetic clutch does not engage or operate: Refer to ATC-61, "Magnetic Clutch System" .
7. STEP 5 - DISPLAY OF TEMPERATURE DETECTED AT EACH SENSOR
1. 2. Press temperature adjustment switch (Up: ) to change to step 5. Pressing DEF switch once cycles from 5detected temperature at ambient sensor detected temperature at in-vehicle sensor detected temperature at intake sensor 5.
MJIA0076E
OK or NG OK >> End of self-diagnosis NG >> q Ambient sensor malfunction: Refer to ATC-47, "Ambient Sensor System" . q Inside air temperature malfunction: Refer to ATC-49, "In-Vehicle Sensor System" . q Intake sensor malfunction: Refer to ATC-51, "Intake Sensor System" .
ATC-44
TROUBLE DIAGNOSIS Difference Between Set Temperature and Control Temperature
DESCRIPTION
q
EJS004I3
A
If the temperature felt by the customer is different than the airflow temperature controlled by the set temperature, A/C auto amp. control temperature can be adjusted to compensate for the set temperature (displayed temperature). Change to self-diagnosis mode. Refer to ATC-41, "Switching to Self-Diagnosis Mode" .
B
HOW TO SET
1. 2. 3. 4. In self-diagnosis step 5, press the fan switch (Up: ). A "0" is shown in the display. Pressing the temperature adjustment switch increases or decreases the display temperature throughout a range of +3°C through -3°C (in increments of 1°C).At this time, if the setting difference is negative, AUTO is displayed. NOTE: When the set temperature (display temperature) is set to 25°C and -3°C, the temperature controlled by A/C auto amp. is 25°C - 3°C = 22°C and the temperature becomes lower than set temperature. CAUTION: When the battery is disconnected or the battery voltage becomes 9V or less, the difference between the set temperature (display) and control temperature is cancelled.
EJS004I4
C
D
E
F
Function Inspection
1. CHECK FAN SPEED
Operate fan switch to make sure fan speed changes. Confirm operation for all fan speeds. OK or NG OK >> Switch fan speed to "4" and GO TO 2. NG >> Blower motor system malfunction: Refer to ATC-54, "Blower Motor System" .
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2. CHECK AIR OUTLET
1. Operate mode switch and DEF switch. 2. Confirm air outlets change according to each indicated air outlet. OK or NG OK >> GO TO 3. NG >> Mode door system malfunction: Refer to ATC-58, "Mode Door Motor System" .
ATC
K
3. CHECK AIR INLET
1. Press REC switch to change recirculation. 2. Listen to intake sound and confirm air inlets change. 3. Press FRE switch to change to fresh air intake. 4. Listen to intake sound and confirm air inlets change. OK or NG OK >> GO TO 4. NG >> Intake door system malfunction: Refer to ATC-58, "Intake Door Motor System" .
L
M
4. CHECK WITH TEMPERATURE SETTING LOWERED
1. Turn compressor ON. 2. Press temperature adjustment switch (Down: ) and lower temperature setting to 18°C. 3. Confirm cool air blows from outlets. OK or NG OK >> GO TO 5. NG >> Air mix door system malfunction: Refer to ATC-60, "Air Mix Door Motor System" .
ATC-45
TROUBLE DIAGNOSIS
5. CHECK WITH TEMPERATURE SETTING RAISED
1. Warm up the engine. 2. Press temperature adjustment switch (Up: ) and raise temperature setting to 32°C. 3. Confirm warm air blows from outlets. OK or NG OK >> GO TO 6. NG >> Air mix door system malfunction: Refer to ATC-60, "Air Mix Door Motor System" .
6. CHECK AUTO MODE
Press AUTO switch and confirm that AUTO is displayed. Make sure display and indicator lamp turns on by pressing A/C switch. Listen to make sure compressor is operating. (Temperature of air blowing from outlets and fan speed vary depending on ambient temperature.) OK or NG OK >> GO TO 7. NG >> Refer to ATC-20, "DIAGNOSIS CHART BY SYMPTOM" . 1. 2.
7. CHECK A/C SWITCH
1. Press A/C switch and make sure compressor turns off. 2. Press A/C switch again and make sure compressor turns on. OK or NG OK >> If all function checks are normal (no phenomena reoccurrence), refer to ATC-20, "DIAGNOSIS CHART BY SYMPTOM" . NG >> Refer to ATC-20, "DIAGNOSIS CHART BY SYMPTOM" .
ATC-46
TROUBLE DIAGNOSIS Air Conditioning System
Symptom: Air conditioner does not operate.
EJS004I5
A
1. CHECK POWER SUPPLY CIRCUIT OF A/C AUTO AMP.
1. 2. 3. 4. Turn ignition switch OFF. Disconnect the A/C auto amp. connector. Turn ignition switch ON. Check voltage between A/C auto amp. connector M63 terminal 1, 2, 8 and ground. 1 (GY) - Ground 2 (Y) - Ground 8 (R) - Ground : Battery voltage : Battery voltage : Battery voltage
B
C
D
E
OK or NG OK >> GO TO 2. NG >> Check power supply circuit, 10A fuses [No. 4 and 8, located in the fuse block (J/B)] and 15A fuses [No. 9 and MJIA0218E 10, located in the fuse block (J/B)]. Refer to PG-5, "POWER SUPPLY ROUTING" . q If fuse is OK, check for open circuit in wiring harness. Repair or replace as necessary. q If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.
F
G
2. CHECK GROUND CIRCUIT OF A/C AUTO AMP.
Check continuity between A/C auto amp. connector M63 terminal 14 and ground. 14 (B) - Ground : Continuity should exist. OK or NG OK >> Replace A/C auto amp. NG >> Repair harness or connector.
H
I
ATC
K
MJIA0219E
Ambient Sensor System
EJS004I6
L
1. CHECK POWER SUPPLY CIRCUIT
1. 2. 3. 4. Turn ignition switch OFF. Disconnect ambient sensor connector. Turn ignition switch ON. Check voltage between ambient sensor connector E52 terminal 1 and ground. 1 (LG) - Ground OK or NG OK >> GO TO 2. NG >> GO TO 4. : Approx. 5V
M
MJIB0116E
ATC-47
TROUBLE DIAGNOSIS
2. CHECK CIRCUIT CONTINUITY
1. 2. 3. Turn ignition switch OFF. Disconnect the A/C auto amp. connector. Check continuity between ambient sensor connector E52 terminal 2 and A/C auto amp. connector M64 terminal 6. 2 (OR) - 6 (OR) : Continuity should exist.
OK or NG OK >> GO TO 3. NG >> Repair harness or connector.
MJIB0117E
3. CHECK AMBIENT SENSOR
Check resistance between terminals 1 and 2 on ambient sensor. OK or NG OK >> 1. Replace A/C auto amp. 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" . NG >> 1. Replace ambient sensor. 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" .
MJIB0118E
4. CHECK CIRCUIT CONTINUITY
1. 2. Disconnect the A/C auto amp. connector. Check continuity between ambient sensor connector E52 terminal 1 and A/C auto amp. connector M64 terminal 4. 1 (LG) - 4 (LG) 3. : Continuity should exist.
Check continuity between ambient sensor connector E52 terminal 1 and ground. 1 (LG) - Ground : Continuity should not exist.
OK or NG OK >> 1. Replace A/C auto amp. 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" . NG >> Repair harness or connector.
MJIB0119E
ATC-48
TROUBLE DIAGNOSIS In-Vehicle Sensor System
EJS004I7
1. CHECK POWER SUPPLY CIRCUIT
1. 2. 3. 4. Turn ignition switch OFF. Disconnect in-vehicle sensor connector. Turn ignition switch ON. Check voltage between in-vehicle sensor connector M39 terminal 1 and ground. 1 (LG) - Ground OK or NG OK >> GO TO 2. NG >> GO TO 4. : Approx. 5V
A
B
C
D
E
MJIA0083E
2. CHECK CIRCUIT CONTINUITY
1. 2. 3. Turn ignition switch OFF. Disconnect the A/C auto amp. connector. Check continuity between in-vehicle sensor connector M39 terminal 2 and A/C auto amp. connector M64 terminal 6. 2 (R) - 6 (R) : Continuity should exist.
F
G
H
OK or NG OK >> GO TO 3. NG >> Repair harness or connector.
I
ATC
MJIA0222E
3. CHECK IN-VEHICLE SENSOR
Check the resistance between in-vehicle sensor terminals 1 and 2. OK or NG OK >> 1. Replace A/C auto amp. 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" . NG >> 1. Replace in-vehicle sensor. 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" .
MJIA0085E
K
L
M
ATC-49
TROUBLE DIAGNOSIS
4. CHECK CIRCUIT CONTINUITY
1. 2. Disconnect the A/C auto amp. connector. Check continuity between in-vehicle sensor connector M18 terminal 1 and A/C auto amp. connector m64 terminal 5. 1 (P) - 5 (P) 3. : Continuity should exist.
Check continuity between in-vehicle sensor connector M18 terminal 1 and ground. 1 (P) - Ground : Continuity should not exist.
OK or NG OK >> 1. Replace A/C auto amp. 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" . NG >> Repair harness or connector.
MJIA0223E
Sunload Sensor System
EJS004I8
1. CHECK POWER SUPPLY CIRCUIT
1. 2. 3. 4. Turn ignition switch OFF. Disconnect sunload sensor connector. Turn ignition switch ON. Check voltage between sunload sensor connector M18 terminal 1 and ground 1 (LG) - Ground OK or NG OK >> GO TO 2. NG >> GO TO 4. : Approx. 5V
MJIB0135E
2. CHECK CIRCUIT CONTINUITY
1. 2. 3. Turn ignition switch OFF. Disconnect the A/C auto amp. connector. Check continuity between sunload sensor connector M18 terminal 2 and A/C auto amp. connector M64 terminal 6. 2 (R) - 6 (R) : Continuity should exist.
OK or NG OK >> GO TO 3. NG >> Repair harness or connector.
MJIB0136E
ATC-50
TROUBLE DIAGNOSIS
3. CHECK SUNLOAD SENSOR
1. Connect the sunload sensor and A/C auto amp. connectors. 2. Check voltage between sunload sensor terminal 1 and ground. NOTE: q When checking indoors, use a lamp of approximately 60W. Move the lamp towards and away from the sensor to check. q Sunload amount produced by direct sunshine in fair weather is equivalent to approximately 0.77 W/m2 (660 kcal/m2 ·h). OK or NG OK >> 1. Replace A/C auto amp. MJIA0089E 2. Perform self-diagnosis step 2. Make sure result is normal. Refer to ATC-40, "Self-Diagnosis Function" . NG >> 1. Replace sunload sensor. 2. Perform self-diagnosis st