Urvan.pdf

MTC-1

MANUAL AIR CONDITIONER

J AIR CONDITIONER

CONTENTS

C

D

E

F

G

H

I

K

L

M

SECTION

A

B

MTC

MANUAL AIR CONDITIONER

PRECAUTIONS .......................................................... 4Precautions for Supplemental Restraint System(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-SIONER” .................................................................. 4Precautions for Working with HFC-134a (R-134a)..... 4General Refrigerant Precautions .............................. 4Lubricant Precautions .............................................. 5Precautions for Leak Detection Dye ......................... 5

IDENTIFICATION .................................................. 5IDENTIFICATION LABEL FOR VEHICLE ............. 6

Precautions for Refrigerant Connection ................... 6FEATURES OF NEW TYPE REFRIGERANTCONNECTION ...................................................... 6O-RING AND REFRIGERANT CONNECTION..... 7

Precautions for Servicing Compressor ................... 10Precautions for Service Equipment ........................ 10

RECOVERY/RECYCLING EQUIPMENT ............ 10ELECTRONIC LEAK DETECTOR ...................... 10VACUUM PUMP ..................................................11MANIFOLD GAUGE SET .....................................11SERVICE HOSES ................................................11SERVICE COUPLERS ........................................ 12REFRIGERANT WEIGHT SCALE ...................... 12CALIBRATING ACR4 WEIGHT SCALE .............. 12CHARGING CYLINDER ...................................... 12

Wiring Diagrams and Trouble Diagnosis ................ 12PREPARATION ......................................................... 14

Special Service Tools ............................................. 14HFC-134a (R-134a) Service Tools and Equipment... 14Commercial Service Tool ....................................... 17

REFRIGERATION SYSTEM ..................................... 18Refrigerant Cycle ................................................... 18

REFRIGERANT FIOW ........................................ 18Refrigerant System Protection ............................... 18

DUAL PRESSURE SWITCH ............................... 18PRESSURE RELIEF VALVE ............................... 18

LUBRICANT .............................................................. 19Maintenance of Lubricant Quantity in Compressor... 19

LUBRICANT ........................................................ 19LUBRICANT RETURN OPERATION .................. 19LUBRICANT AJUSTING PROCEDURE FORCOMPONENTS REPLACEMENT EXCEPTCOMPRESSOR .................................................. 20LUBRICANT ADJUSTING PROCEDURE FORCOMPRESSOR REPLACEMENT ....................... 20

AIR CONDITIONER CONTROL ............................... 22Control Operation ................................................... 22

FAN CONTROL KNOB ........................................ 22MODE CONTROL KNOB .................................... 22TEMPERATURE CONTROL KNOB .................... 22RECIRCULATION (REC) SWITCH ..................... 22AIR CONDITIONER SWITCH ............................. 22REAR COOLER FAN CONTROLKNOB(FRONT) ................................................... 23REAR COOLER FAN SWITCH ........................... 23

Discharge Air Flow ................................................. 24Component Layout ................................................. 25Component Location .............................................. 26System Description ................................................. 27

SWITCHESAND THEIR CONTROL FUNCTION... 27TROUBLE DIAGNOSIS ............................................ 28

How to Perform Trouble Diagnoses for Quick andAccurate Repair ...................................................... 28

WORK FLOW ...................................................... 28SYMPTOM TABLE .............................................. 28

ComponentPartsandHarnessConnectorLocation... 29............................................................................ 29

Wiring Diagram —HEATER— ................................ 30Schematic —A/C— ................................................. 31Wiring Diagram —A/C— ......................................... 32Wiring Diagram —R/COOL— ................................. 36Operational Check .................................................. 38

CONDITIONS: ..................................................... 38PROCEDURE: .................................................... 38

Blower Motor Circuit ............................................... 40Rear Cooler Fan Motor Circuit ................................ 44

MTC-2

Magnet Clutch Circuit ............................................. 50Intake Door Circuit .................................................. 55Insufficient Cooling ................................................. 55

INSPECTION FLOW ........................................... 56PERFORMANCE TEST DIAGNOSES ................ 57PERFORMANCE CHART ................................... 59TROUBLE DIAGNOSES FOR ABNORMALPRESSURE ......................................................... 60

Insufficient Heating ................................................. 63INSPECTION FLOW ........................................... 64

Noise ...................................................................... 65INSPECTION FLOW ........................................... 65

CONTROLLER .......................................................... 66Removal and Installation ........................................ 66Disassembly and Assembly .................................... 67

BLOWER AND COOLING UNIT ASSEMBLY ....... ... 68Removal and Installation ........................................ 68

REMOVAL ........................................................... 68INSTALLATION .................................................... 69

Disassembly and Assembly .................................... 70BLOWER FAN MOTOR ............................................ 71

Removal and Installation ........................................ 71BLOWER FAN RESISTOR ....................................... 72

Removal and Installation ........................................ 72INTAKE DOOR ACTUATOR ..................................... 73

Removal and Installation ........................................ 73HEATER UNIT ASSEMBLY ...................................... 74

Removal and Installation ........................................ 74REMOVAL ........................................................... 74INSTALLATION .................................................... 75

Disassembly and Assembly .................................... 76HEATER CORE ......................................................... 77

Removal and Installation ........................................ 77REAR A/C UNIT ASSEMBLY ................................... 78

Removal and Installation ........................................ 78INSTALLATION .................................................... 78INSTALLATION .................................................... 78

Disassembly and Assembly .................................... 79REAR BLOWER FAN MOTOR ................................. 80

Removal and Installation ........................................ 80REMOVAL ........................................................... 80INSTALLATION .................................................... 80

REAR BLOWER FAN RESISTOR ............................ 81Removal and Installation ........................................ 81

DRAIN HOSE ............................................................ 82Removal and Installation ........................................ 82

DRAIN HOSE (RH) .............................................. 82DRAIN HOSE (LH) .............................................. 82

REAR A/C CONTROLLER ....................................... 83Removal and Installation ........................................ 83Disassembly and Assembly .................................... 83

REAR HEATER UNIT ASSEMBLY ........................... 84Removal and Installation ........................................ 84

BUILT-IN TYPE REAR HEATER (4 DOOR AND5 DOOR) .............................................................. 84FOOR-TYPE REAR HEATER (MICROBUS) ....... 84

Disassembly and Assembly .................................... 85BUILT-IN TYPE REAR HEATER (4 DOOR AND

5 DOOR) ..............................................................85FOOR-TYPE REAR HEATER (MICROBUS) .......86

Rear Blower Fan Motor ...........................................86REMOVAL AND INSTALLATION .........................86

Rear Blower Fan Resistor .......................................87REMOVAL AND INSTALLATION .........................87

Rear Heater Duct (4 Door) ......................................87Rear Heater Control ................................................87

REMOVAL AND INSTALLATION .........................87DISASSEMBLY AND ASSEMBLY .......................88

Rear Heater Hose ...................................................88REMOVAL AND INSTALLATION .........................88

MODE DOOR ............................................................90Adjustment of Cable ................................................90

AIR MIX DOOR ..........................................................91Adjustment of Cable ................................................91

DUCT AND GRILLE ..................................................92Removal and Installation .........................................92

VENTILATOR DUCT, DEFROSTER NOZZLE,AND DUCT ..........................................................92CENTRAL VENTILATOR GRILLE .......................92SIDE VENTILATOR GRILLE ...............................93FOOT DUCT ........................................................93REAR VENTILATOR GRILLE ..............................93REAR INTAKE GRILLE .......................................93

A/C CYCLE ................................................................94Component Parts Drawing ......................................94

WITHOUT REAR A/C ..........................................95WITH REAR A/C ..................................................96

Compressor ............................................................97REMOVAL ............................................................97INSTALLATION ....................................................98

Overhaul .................................................................99Removal ..................................................................99Inspection ..............................................................100

CLUTCH DISC ...................................................100PULLEY .............................................................100COIL ...................................................................100

Installation .............................................................100BREAK-IN OPERATION ....................................101

High-Pressure Flexible Hose 1 and Low-PressureFlexible Hose 1 .....................................................102

REMOVAL ..........................................................102INSTALLATION ..................................................103

Low-Pressure Pipe 1 .............................................103REMOVAL ..........................................................103INSTALLATION ..................................................104

Low-Pressure Pipe 2 .............................................104REMOVAL ..........................................................104INSTALLATION ..................................................104

High-Pressure Pipe 1 ............................................105REMOVAL ..........................................................105INSTALLATION ..................................................105

High-Pressure Pipe 2 ............................................106REMOVAL ..........................................................106INSTALLATION ..................................................106

High-Pressure Pipe 3 ............................................107REMOVAL ..........................................................107

MTC-3

C

D

E

F

G

H

I

K

L

M

A

B

MTC

INSTALLATION ................................................. 107High-Pressure Flexible Hose 2 and Low-PressureFlexible Hose 2 (Rear A/C Side) .......................... 107

REMOVAL ......................................................... 107INSTALLATION ................................................. 108

High-Pressure Pipe 4 ........................................... 108REMOVAL ......................................................... 108INSTALLATION ................................................. 109

Pressure Switch ................................................... 109REMOVAL AND INSTALLATION ...................... 109

Condenser Assembly ........................................... 109

REMOVAL AND INSTALLATION ...................... 109DISASSEMBLY AND ASSEMBLY ......................111

Rear Evaporator ....................................................111REMOVAL AND INSTALLATION .......................111

Front Expansion Valve .......................................... 112REMOVAL AND INSTALLATION ...................... 112

Rear Expansion Valve .......................................... 112REMOVAL AND INSTALLATION ...................... 112

Liquid Tank ........................................................... 113REMOVAL AND INSTALLATION ...................... 113

MTC-4

PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEATBELT PRE-TENSIONER” EJS0011K

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used alongwith a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certaintypes of collision. Information necessary to service the system safely is included in the SRS and SB section ofthis Service Manual.WARNING:● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance must be per-formed by an authorized NISSAN/INFINITI dealer.

● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and AirBag Module, see the SRS section.

● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. SRS wiring harnesses can be identified by yellow harness connectors.

Precautions for Working with HFC-134a (R-134a) EJS0011L

WARNING:● CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants

are mixed and compressor failure is likely to occur, refer to “CONTAMINATED REFRIGERANT”below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refriger-ant Recovery/Recycling Recharging equipment (ACR4) (J-39500-INF) and Refrigerant Identifier.

● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-nents. If lubricant other than that specified is used, compressor failure is likely to occur.

● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-lowing handling precautions must be observed:

– When removing refrigerant components from a vehicle, immediately cap (seal) the component tominimize the entry of moisture from the atmosphere.

– When installing refrigerant components to a vehicle, do not remove the caps (unseal) until justbefore connecting the components. Connect all refrigerant loop components as quickly as possi-ble to minimize the entry of moisture into system.

– Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-cant. 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 andthroat. Remove R-134a from the A/C system, using certified service equipment meeting require-ments of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If acci-dental system discharge occurs, ventilate work area before resuming service. Additional healthand 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 EJS0011M

WARNING:● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the

refrigerant every time an air conditioning system is discharged.● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or

air conditioning system.● Do not store or heat refrigerant containers above 52 °C (125°F).● 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.● Do not intentionally drop, puncture, or incinerate refrigerant containers.● Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.

PRECAUTIONS

MTC-5

C

D

E

F

G

H

I

K

L

M

A

B

MTC

● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to preventsuffocation.

● Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-tioning systems with compressed air during repair. Some mixtures of air and R-134a have beenshown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury orproperty damage. Additional health and safety information may be obtained from refrigerant man-ufacturers.

Lubricant Precautions EJS0011N

● 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.

● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The followinghandling precautions must be observed:

– When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimizethe entry of moisture from the atmosphere.

– When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before con-necting the components. Connect all refrigerant loop components as quickly as possible to minimize theentry of moisture into system.

– Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. With-out 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 R-134a from the A/C system, using certified service equipment meeting requirements of SAEJ2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system dis-charge occurs, ventilate work area before resuming service. Additional health and safety information maybe obtained from refrigerant and lubricant manufacturers.

● Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damagemay result.

Precautions for Leak Detection Dye EJS001FO

● 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 glasses to protect your eyes and enhance the visibility ofthe fluorescent dye.

● The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo-rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J-41995) pin-point refrigerant leaks.

● For your safety and your Customer's satisfaction, read and follow all manufacture's operating instructionsand precautions prior to performing the work.

● A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft sealshould 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 misdiagnosisduring 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 periodof 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 R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye

in R-12 A/C system or R-12 leak detector dye in 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 failure

occurs.

IDENTIFICATIONNOTE:Vehicles with factory installed fluorescent dye have a green label.Vehicles without factory installed fluorescent dye have a blue label.

MTC-6

PRECAUTIONS

IDENTIFICATION LABEL FOR VEHICLEVehicles with factory installed fluorescent dye have this identificationlabel on the front side of hood.

Precautions for Refrigerant Connection EJS0011O

A new type refrigerant connection has been introduced to all refrigerant lines except the following location.● Expansion valve to cooling unit● Dual pressure switch to liquid tank

FEATURES OF NEW TYPE REFRIGERANT CONNECTION● The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-

nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction ofthe O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealingcharacteristics.

● The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil-itating piping connections.

SHA436FA

SHA815E

PRECAUTIONS

MTC-7

C

D

E

F

G

H

I

K

L

M

A

B

MTC

O-RING AND REFRIGERANT CONNECTION

SJIA0001E

MTC-8

PRECAUTIONS

SJIA0002E

PRECAUTIONS

MTC-9

C

D

E

F

G

H

I

K

L

M

A

B

MTC

CAUTION:The new and former refrigerant connections use different O-ring configurations. Do not confuse O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, oraround, the connection.

O-Ring Part Numbers and Specifications

WARNING:Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system isless than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.CAUTION:When replacing or cleaning refrigerant cycle components, observe the following.● When the compressor is removed, store it in the same position as it is when mounted on the car.

Failure to do so will cause lubricant to enter the low pressure chamber.● When connecting tubes, always use a torque wrench and a back-up wrench.● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-

tion. Do not remove the seal caps of pipes and other components until just before required forconnection.

● Allow components stored in cool areas to warm to working area temperature before removing sealcaps. This prevents condensation from forming inside A/C components.

● Thoroughly remove moisture from the refrigeration system before charging the refrigerant.● Always replace used O-rings.● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not

to apply lubricant to threaded portion.Lubricant name: Nissan A/C System Oil Type SPart number: KLH00-PAGS0

● O-ring must be closely attached to dented portion of tube.● When replacing the O-ring, be careful not to damage O-ring and tube.● Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that

the O-ring is installed to tube correctly.

Connec-tion type

O-ringsize

Part number D mm (in) W mm (in)

New8

92471 N8210 6.8 (0.268) 1.85 (0.0728)

Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)

Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)

New12

92472 N8210 10.9 (0.429) 2.43 (0.0957)

Former 92475 71L00 11.0 (0.433) 2.4 (0.094)

New16

92473 N8210 13.6 (0.535) 2.43 (0.0957)

Former 92475 72L00 14.3 (0.563) 2.3 (0.091)

New19

92474 N8210 16.5 (0.650) 2.43 (0.0957)

Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)

New 24 92195 AH300 21.8 (0.858) 2.4 (0.094)

SHA814E

MTC-10

PRECAUTIONS

● 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 con-nections of seal seat to the specified torque.

Precautions for Servicing Compressor EJS0011P

● 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 Compres-

sor” exactly. Refer to MTC-19, " Maintenance of Lubricant Quantity in Compressor " .● Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-

cant, 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 compressoris 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 normaloperation.

Precautions for Service Equipment EJS0011Q

RECOVERY/RECYCLING EQUIPMENTBe certain to follow the manufacturers instructions for machine operation and machine maintenance. Neverintroduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTORBe certain to follow the manufacturer's instructions for tester operation and tester maintenance.

RHA861F

PRECAUTIONS

MTC-11

C

D

E

F

G

H

I

K

L

M

A

B

MTC

VACUUM PUMPThe lubricant contained inside the vacuum pump is not compatiblewith the specified lubricant for HFC-134a (R-134a) A/C systems.The vent side of the vacuum pump is exposed to atmospheric pres-sure. So the vacuum pump lubricant may migrate out of the pumpinto the service hose. This is possible when the pump is switched offafter evacuation (vacuuming) and hose is connected to it.To prevent this migration, use a manual valve placed near the hose-to-pump connection, as follows.● Usually vacuum pumps have a manual isolator valve as part of

the pump. Close this valve to isolate the service hose from thepump.

● For pumps without an isolator, use a hose equipped with a man-ual shut-off valve near the pump end. Close the valve to isolatethe hose from the pump.

● If the hose has an automatic shut off valve, disconnect the hosefrom the pump. As long as the hose is connected, the valve isopen and lubricating oil may migrate.

Some one-way valves open when vacuum is applied and closeunder a no vacuum condition. Such valves may restrict the pump'sability to pull a deep vacuum and are not recommended.

MANIFOLD GAUGE SETBe certain that the gauge face indicates R-134a or 134a. Be sure thegauge set has 1/2″-16 ACME threaded connections for servicehoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants.

SERVICE HOSESBe certain that the service hoses display the markings described(colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hosesopposite the manifold gauge.

RHA270DA

SHA533D

RHA272D

MTC-12

PRECAUTIONS

SERVICE COUPLERSNever attempt to connect HFC-134a (R-134a) service couplers to anCFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers willnot properly connect to the CFC-12 (R-12) system. However, if animproper connection is attempted, discharging and contaminationmay occur.

REFRIGERANT WEIGHT SCALEVerify that no refrigerant other than HFC-134a (R-134a) and speci-fied lubricants have been used with the scale. If the scale controlsrefrigerant flow electronically, the hose fitting must be 1/2″-16ACME.

CALIBRATING ACR4 WEIGHT SCALECalibrate the scale every three months.To calibrate the weight scale on the ACR4 (J-39500-INF):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.

CHARGING CYLINDERUsing a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valvewhen filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of anelectronic scale or of quality recycle/recharge equipment.

Wiring Diagrams and Trouble Diagnosis EJS0011T

When you read wiring diagrams, refer to the followings:● GI-13, "How to Read Wiring Diagrams" in GI section.● PG-3, "Wiring Diagram — POWER —"in PG section.When you perform trouble diagnosis, refer to the followings:● GI-9, "How to Follow Trouble Diagnoses" in GI section.

Shut-off valve rotation A/C service valve

Clockwise Open

Counterclockwise Close

RHA273D

RHA274D

PRECAUTIONS

MTC-13

C

D

E

F

G

H

I

K

L

M

A

B

MTC

● GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

MTC-14

PREPARATION

PREPARATION PFP:00002

Special Service Tools EJS0011U

HFC-134a (R-134a) Service Tools and Equipment EJS0011V

Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubri-cant.Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-cant.Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handlesrefrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoidmixed use of the refrigerants/lubricant.Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination willoccur and compressor failure will result.

Tool numberTool name

Description

KV99231260Clutch disc wrench

Removing shaft nut and clutch disc

KV992T0001Clutch disc puller

Removing clutch disc

KV992T0002Pulley installer

Installing pulley

NT204

RJIA0194E

NT206

NT207

PREPARATION

MTC-15

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Tool number(Kent-Moore No.)Tool name

Description

HFC-134a (R-134a) refrigerant

Container color:Light blueContainer marking:HFC-134a (R-134a)Fitting size:Thread size

● large container 1/22 -16 ACME

KLH00-PAGS0( - )Nissan A/C System Oil Type S

Type:Poly alkylene glycol oil (PAG),type SApplication:HFC-134a (R-134a)Swash plate compressors (Nissanonly)Lubricity:40 ml [Litre] (1.4 US fl oz,1.4 Imp fl oz)

(J-39500-INF)Recovery/RecyclingRecharging equipment (ACR4)

Function:Refrigerant Recovery andRecycling and Recharging

(J-41995)Electrical leak detector

Power supply:

● DC 12V (Cigarette lighter)

(J-43926)Refrigerant dye leak detection kitKit includes:(J-42220) UV lamp and UV safetyglasses(J-41459) Refrigerant dye injector(J-41447) qty. 24HFC-134a (R-134a) refrigerantdye(J-43872) Refrigerant dye cleaner

Power supply:DC 12V (Battery terminal)

S-NT196

S-NT197

RJIA0195E

AHA281A

SHA437F

MTC-16

PREPARATION

(J-42220)Fluorescent dye leak detector

Power supply: DC 12V (Batteryterminal)For checking refrigerant leak whenfluorescent dye is installed in A/Csystem.Includes: UV lamp and UV safetyglasses

(J-41447)HFC-134a (R-134a) Fluorescentleak detection dye(Box of 24, 1/4 ounce bottles)

Application: For HFC-134a (R-134a)PAG oilContainer: 1/4 ounce (7.4cc) bottle(Includes self-adhesive dyeidentification labels for affixing tovehicle after charging system withdye.)

(J-41459)HFC-134a (R-134a) Dye injectorUse with J-41447, 1/4 ouncebottle

For injecting 1/4 ounce of fluorescentleak detection dye into A/C system.

(J-43872)Dye cleaner

For cleaning dye spills.

(J-39183)Manifold gauge set (with hosesand couplers)

Identification:

● The gauge face indicates R-134a.Fitting size:Thread size

● 1/22 -16 ACME

Service hoses

● High side hose(J-39501-72)

● Low side hose(J-39502-72)

● Utility hose(J-39476-72)

Hose color:

● Low hose:Blue with black stripe

● High hose:Red with black stripe

● Utility hose:Yellow with black stripeor green with black stripeHose fitting to gauge:

● 1/22 -16 ACME


Description

SHA438F

SHA439F

SHA440F

SHA441F

RJIA0196E

S-NT201

PREPARATION

MTC-17

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Commercial Service Tool EJS0011W

Service couplers

● High side coupler(J-39500-20)

● Low side coupler(J-39500-24)

Hose fitting to service hose:

● M14 x 1.5 fitting is optional orpermanently attached.

(J-39650)Refrigerant weight scale

For measuring of refrigerantFitting size:Thread size

● 1/22 -16 ACME

(J-39649)Vacuum pump(Including the isolator valve)

Capacity:

● Air displacement:4 CFM

● Micron rating:20 microns

● Oil capacity:482 g (17 oz)Fitting size:Thread size

● 1/22 -16 ACME


Description

S-NT202

S-NT200

S-NT203

Tool name Description

Refrigerant identifier equipmentFor checks refrigerant purity and forsystem contamination

RJIA0197E

MTC-18

REFRIGERATION SYSTEM

REFRIGERATION SYSTEM PFP:KA990

Refrigerant Cycle EJS0011X

REFRIGERANT FIOWThe 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 iscontrolled by an externally equalized expansion valve, located inside the evaporator case.

Refrigerant System Protection EJS0011Y

DUAL PRESSURE SWITCHThe refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,located on the liquid tank. If the system pressure rises above or falls below the specifications, the dual-pres-sure switch, located on the liquid tank.If the system pressure rises above or falls below the specifications,thedual-pressure switch opens to interrupt the compressor operation.

PRESSURE RELIEF VALVEThe 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 abnormal level [more than 3,727 kPa (38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant intothe atmosphere.

SJIA0003E

LUBRICANT

MTC-19

C

D

E

F

G

H

I

K

L

M

A

B

MTC

LUBRICANT PFP:KLG00

Maintenance of Lubricant Quantity in Compressor EJS0011Z

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-sor when replacing any component or after a large gas leakage occurred. It is important to maintain the speci-fied amount.If lubricant quantity is not maintained properly, the following malfunctions may result:● Lack of lubricant: May lead to a seized compressor● Excessive lubricant: Inadequate cooling (thermal exchange interference)

LUBRICANT

LUBRICANT RETURN OPERATIONAdjust the lubricant quantity according to the test group shown below.

1. CHECK LUBRICANT RETURN OPERATION

Can lubricant return operation be performed?● A/C system works properly.● 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:

1. Start engine, and set the following conditions:– Test condition

Engine speed: Idling to 1,200 rpmA/C switch:ONBlower speed:Max. positionTemp. 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.

>> GO TO 3.

3. CHECK COMPRESSOR

Should the compressor be replaced?Yes or No

Yes >> Go to MTC-20, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-MENT" .

No >> GO TO 4.

Name :Nissan A/C System Oil Type S

Part number :KLH00-PAGS0

MTC-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 largeamount of lubricant leakage.)Yes or No

Yes >> Go to MTC-20, "LUBRICANT AJUSTING PROCEDURE FOR COMPONENTS REPLACEMENTEXCEPT COMPRESSOR" .

No >> Carry out the A/C performance test.

LUBRICANT AJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-PRESSORAfter replacing any of the following major components, add the correct amount of lubricant to the system.Amount of lubricant to be added

*1:If refrigerant leak is small, no addition of lubricant is needed.

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If

NG, recover refrigerant from equipment lines.2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into

the recovery/recycling equipment.3. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount

of lubricant drained.4. Drain the lubricant from the new compressor into a separate, clean container.5. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this

lubricant to new compressor through the suction port opening.6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant

to new compressor through the suction port opening.7. If the liquid tank also needs to be replaced, add an additional 5 ml [Litre] (0.2 US fl oz, 0.2 Imp fl oz) of

lubricant at this time.Do not add this 5 ml(0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.

Part replaced

Lubricant to be added to system

RemarksAmount of lubricantml [Litre] (US fl oz, Imp fl oz)

Evaporator 75 (2.5, 2.6) -

Rear evaporator 20 (0.6, 0.7) -

Condenser 35 (1.2, 1.2) -

Liquid tank 10 (0.3, 0.4) -

In case of refrigerant leak30 (1.0, 1.1) Large leak

- Small leak *1

LUBRICANT

MTC-21

C

D

E

F

G

H

I

K

L

M

A

B

MTCRHA065DD

MTC-22

AIR CONDITIONER CONTROL

AIR CONDITIONER CONTROL PFP:27500

Control Operation EJS001ED

FAN CONTROL KNOBThis knob turns the fan ON and OFF, and controls fan speed.

MODE CONTROL KNOBThis knob controls the direction of air flow through the front discharge outlets.

TEMPERATURE CONTROL KNOBThis knob allows adjustment of the outlet air temperature.

RECIRCULATION (REC) SWITCHOFF position: Outside air is drawn into the passenger compartment.ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.

AIR CONDITIONER SWITCHThe air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the com-pressor will turn ON. The indicator lamp will also light.The air conditioner cooling function operates only when the engine is running.

SJIA0004E


MTC-23

C

D

E

F

G

H

I

K

L

M

A

B

MTC

REAR COOLER FAN CONTROL KNOB(FRONT)The control of the rear blower speed can be obtained by rotating the rear cooler fan control knob.

REAR COOLER FAN SWITCHThe rear cooler fan switch controls the rear blower speed regardless of the rear cooler fan control knob(front)position. In any other position(1-4), it allows the rear cooler fan switch to control the rear blower speed,

MTC-24


Discharge Air Flow EJS001EE

SJIA0005E


MTC-25

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Component Layout EJS001EF

SJIA0006E

MTC-26


Component Location EJS001ES

ZJIA0003E


MTC-27

C

D

E

F

G

H

I

K

L

M

A

B

MTC

System Description EJS001ET

SWITCHES AND THEIR CONTROL FUNCTION

SJIA0103E

SJIA0104E

MTC-28

TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS PFP:00004

How to Perform Trouble Diagnoses for Quick and Accurate Repair EJS001FP

WORK FLOW*1:Operational Check MTC-38

SYMPTOM TABLE

SHA900E

Symptom Reference Page

Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor. MTC-40

Rear cooler fan motor operation is malfunc-tioning.

Go to Trouble Diagnosis Procedure for Rear cooler fan Motor. MTC-44

Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. MTC-50

Insufficient cooling. Go to Trouble Diagnosis Procedure for Insufficient Cooling. MTC-55

Intake door does not change.Go to Trouble Diagnosis Procedure for Intake Door Motor. MTC-55

Intake door motor does not operate normally.

Insufficient heating. Go to Trouble Diagnosis Procedure for Insufficient Heating. MTC-63

Noise. Go to Trouble Diagnosis Procedure for Noise. MTC-65

TROUBLE DIAGNOSIS

MTC-29

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Component Parts and Harness Connector Location EJS00121

ZJIA0003E

MTC-30

TROUBLE DIAGNOSIS

Wiring Diagram —HEATER— EJS00122

TJWH0001E

TROUBLE DIAGNOSIS

MTC-31

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Schematic —A/C— EJS001GQ

TJWH0002E

MTC-32

TROUBLE DIAGNOSIS

Wiring Diagram —A/C— EJS001GR

TJWH0003E

TROUBLE DIAGNOSIS

MTC-33

C

D

E

F

G

H

I

K

L

M

A

B

MTC

TJWH0004E

MTC-34

TROUBLE DIAGNOSIS

TJWH0005E

TROUBLE DIAGNOSIS

MTC-35

C

D

E

F

G

H

I

K

L

M

A

B

MTC

TJWH0006E

MTC-36

TROUBLE DIAGNOSIS

Wiring Diagram —R/COOL— EJS00123

TJWH0007E

TROUBLE DIAGNOSIS

MTC-37

C

D

E

F

G

H

I

K

L

M

A

B

MTC

TJWH0008E

MTC-38

TROUBLE DIAGNOSIS

Operational Check EJS00124

The purpose of the operational check is to confirm that the system operates as it should. The systems whichare checked are the blower, mode (discharge air), intake air (recirculation), temperature decrease, tempera-ture increase, and A/C compressor.

CONDITIONS:Engine running at normal operating temperature.

PROCEDURE:1. Check Blower Motor1. Turn fan control knob to 1-speed.

Blower should operate on 1-speed.2. Then turn fan control knob to 2-speed, and continue checking

blower speed until all four speeds are checked.3. Leave blower on 4-speed.If NG, go to MTC-40, "Blower Motor Circuit"If OK, continue with the check.

2. Check A/C Switch1. Turn fan control knob to the desired (1 to 4 speed) position.2. Push the A/C switch to turn ON the air conditioner.

The indicator lamp should come on when air conditioner is ON.3. Confirm that the compressor clutch engages (audio or visual

inspection).4. Check for cold air at the appropriate discharge air outlets.If NG, go to MTC-50, "Magnet Clutch Circuit" .If OK, continue with next check.If all operational checks are OK (symptom cannot be duplicated), goto Incident Simulation Tests in MTC-28, "How to Perform TroubleDiagnoses for Quick and Accurate Repair" , and perform tests asoutlined to simulate driving conditions environment. If symptom appears, refer to MTC-28, "SYMPTOMTABLE" and perform applicable trouble diagnoses procedures.

3. Check Discharge Air1. Turn mode control knob to each mode position.

SJIA0043E

SJIA0044E

SJIA0045E

TROUBLE DIAGNOSIS

MTC-39

C

D

E

F

G

H

I

K

L

M

A

B

MTC

2. Confirm that discharge air comes out according to the air distri-bution table at left.Refer to MTC-24, "Discharge Air Flow" .

If NG, go toMTC-90, "Adjustment of Cable" .If OK, continue with next check.

4. Check Recirculation1. Press recirculation switch.

Recirculation indicator should light.2. Listen for intake door position to change (you should hear

blower sound change slightly).If NG, go to MTC-55, "Intake Door Circuit" .If OK, continue with next check.

5. Check Temperature Decrease1. Turn temperature control knob to full cold.2. Check for cold air at discharge air outlets.If NG, go toMTC-55, "Insufficient Cooling" .If OK, continue with next check.

SJIA0046E

SJIA0047E

SJIA0048E

MTC-40

TROUBLE DIAGNOSIS

6. Check Temperature Increase1. Turn temperature control knob to full hot.2. Check for hot air at discharge air outlets.If NG, go to MTC-63, "Insufficient Heating" .If OK, continue with next check.

7. Check rear cooler1. Turn fan control knob (front) to the desired (1 to 4 speed) posi-

tion.2. Push A/C switch to turn ON the air conditioner is ON.3. Push rear cooler switch.

Blower should operate on 1-speed.4. Then turn fan control knob to 2-speed, and continue checking

blower speed until all four speeds are checked.5. Leave blower on 3-speed.If NG, go to MTC-44, "Rear Cooler Fan Motor Circuit" .If OK, continue with the check.

Blower Motor Circuit EJS00125

SYMPTOM:● Blower motor does not rotate.

1. DIAGNOSTIC PROCEDURE

Check if blower motor rotates properly at each fan speed.

Does not rotate at any speed>>GO TO 2Does not rotate at 1-4 speed>>GO TO 8

2. CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

Disconnect blower motor harness connector.

OK or NGOK >> GO TO 3NG >> GO TO 13

SJIA0049E

SJIA0050E

Terminals

Voltage(+)(-)

Connector Wire color

M223-1 L/R Ground Approx. 12V

SJIA0051E

TROUBLE DIAGNOSIS

MTC-41

C

D

E

F

G

H

I

K

L

M

A

B

MTC

3. CHECK BLOWER MOTOR GROUND CIRCUIT

1. Disconnect blower motor connector.2. Turn fan control knob to 4-speed.

Yes or NoYes >> GO TO 4No >> GO TO 5

4. CHECK BLOWER MOTOR

Apply 12 volt to blower motor terminal 1 and ground to blower motorterminal 2.Dose blower motor rotate?

Yes >> INSPECTION ENDNo >> Replace blower motor.

5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT

1. Connect blower motor connector.2. Disconnect resistor connector.


TerminalsContinuity

Blower motor

GroundConnector Wire colorYes

M223-2 L/B

Continuity should exist.SJIA0052E

SJIA0053E

TerminalsVoltage

(+) (-)

Connector Wire colorGround Approx. 12 V

M222 -2 L/B

SJIA0054E

MTC-42

TROUBLE DIAGNOSIS

6. CHECK CIRCUIT CONTINUITY

Disconnect blower motor connector.

Yes or NoYes >> Check the following.

● If NG, repair harness or connectors.– Harness connectors M13, M222 and M223.– Harness for open or short between blower motor and fan switch, resistor.

No >> Repair harness or connector.

7. CHECK FAN SWITCH GROUND

Disconnect fan switch harness connector.

Yes or NoYes >> GO TO 8No >> Repair harness or connector.

8. CHECK FAN RESISTOR CONTINUITY

Yes or NoYes >> GO TO 9No >> Replace resistor.

9. CHECK FAN RESISTOR

1. Reconnect fan resistor and resistor.2. Check if blower motor rotates properly at each fan speed.


TerminalsContinuity

Blower motor Resistor

Connector Wire color Connector Wire colorYes

M223-2 L/B M222-2 R

Continuity should exist.

SJIA0055E

TerminalsContinuity

Fan switch


M13-6 B


SJIA0056E

TerminalsContinuity

Resistor

M222-2

M222-1

YesM222-3

M222-4

M222-6

Continuity should exist. SJIA0057E

TROUBLE DIAGNOSIS

MTC-43

C

D

E

F

G

H

I

K

L

M

A

B

MTC

10. FAN SWITCH POWER SUPPLY CIRCUIT

Turn fan control knob to off position.




● If NG, repair harness or connectors.– Harness for open or short between blower motor and fan switch, fan resistor


12. CHECK FAN SWITCH

Disconnect fan switch harness connector M13 and check continuitybetween terminals at each fan switch position.

Yes or NoYes >> INSPECTION ENDNo >> Replace fan switch

Terminals

Voltage(+) (-)

Fan switch

Ground

Connectors Wire color

Approx. 12 V

M13-2 L/B

M13-3 L/W

M13-4 L/Y

M13-5 L/GSJIA0058E

TerminalsContinuity


Connectors Wire color Connectors Wire color

Yes

M13-2 L/B M222-3 L/B

M13-3 L/W M222-6 L/W

M13-4 L/Y M222-4 L/Y

M13-5 L/G M222-1 L/G


SJIA0059E

TerminalsContinuity

Fan switch position Fan switch

1

M13-6

M13-2

Yes2 M13-4

3 M13-3

4 M13-2


MTC-44

TROUBLE DIAGNOSIS

13. CHECK BLOWER MOTOR RELAY

1. Disconnect blower motor relay.2. Apply 12 volt to blower motor relay terminal 3 and ground to

blower relay terminal 5.


● If NG, repair harness or connectors.– Harness for open or short between blower motor relay and fuse block (J/B)

No >> Replace blower motor relay.

Rear Cooler Fan Motor Circuit EJS00126

SYMPTOM:● Rear cooler fan motor does not rotate.

1. DIAGNOSTIC PROCEDURE

1. Engine running and A/C ON.2. Turn fan control knob (front) to the desired (1 to 4 speed) position.3. Check if rear cooler fan motor rotate properly at each fan speed.

Does not rotate at any speed>>GO TO 2Does not rotate at 1-3 speed>>GO TO 8Magnet clutch does not engage>> MTC-50, "Magnet Clutch Circuit" .

2. CHECK REAR COOLER FAN MOTOR POWER SUPPLY CIRCUIT

Disconnect rear cooler fan motor connector.


TerminalsContinuity

Blower motor relay

M39 (J/B) -1 M39 (J/B) -2 Yes


SJIA0061E

Terminals

Voltage(+)(-)


R107-1 L/R Ground Approx. 12V

SJIA0062E

TROUBLE DIAGNOSIS

MTC-45

C

D

E

F

G

H

I

K

L

M

A

B

MTC

3. CHECK REAR COOLER FAN MOTOR GROUND CIRCUIT

Push rear cooler fan switch.

Yes or NoYes >> GO TO 4No >> GO TO 5

4. CHECK REAR COOLER FAN MOTOR

Apply 12 volts to rear cooler fan motor terminal 1 and ground to rearcooler fan motor terminal 2.Does rear cooler fan motor rotate?

Yes >> INSPECTION ENDNo >> Replace rear blower fan motor.

5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT

1. Connect rear cooler fan motor connector.2. Disconnect resistor.


Terminals

Continuity(+) (-)

Blower motor


R107-2 L/B


SJIA0063E

SJIA0064E

Terminals

Voltage(+)(-)


R104-1 L/R Ground Approx. 12V

SJIA0065E

MTC-46

TROUBLE DIAGNOSIS


Disconnect rear cooler fan motor connector.

OK or NGOK >> Check the following.

● If NG, repair harness or connectors.– Harness connectors R102,R104 and R107.– Harness for open or short between rear cooler fan motor and fan switch, fan resistor.

NG >> Repair harness or connector.

7. CHECK REAR COOLER FAN SWITCH GROUND

1. Disconnect rear cooler fan switch connector.2. Check continuity between rear cooler fan switch connector ter-

minal 6 and ground.


8. CHECK FAN RESISTOR CONTINUITY

1. Disconnect fan resistor connector.2. Check continuity between fan resistor terminals.

Yes or NoYes >> GO TO 9No >> Replace resistor.

TerminalsContinuity



R107-2 L/B R104-2 R


SJIA0066E

TerminalsContinuity

Fan switch

GroundConnectors Wire color

YesR102-1 B

R102-6 B


TerminalsContinuity

Resistor

R104-2

R104-1

YesR104-4

R104-6


SJIA0068E

TROUBLE DIAGNOSIS

MTC-47

C

D

E

F

G

H

I

K

L

M

A

B

MTC

9. CHECK FAN RESISTOR

1. Reconnect rear cooler fan resistor.2. Check if rear cooler fan motor rotates properly at each fan speed.


10. REAR COOLER FAN SWITCH POWER SUPPLY CIRCUIT

Push rear cooler switch to off.



Check continuity between rear cooler fan switch and rear coolerresister.


● If NG, repair harness or connectors.– Harness connectors R102, R104 and R107– Harness for open or short between blower motor and fan switch, fan resistor


TerminalsVoltage

Fan switch

Ground


Approx. 12 VR102-2 L/B

R102-3 L/W

R102-4 L/Y

SJIA0069E

TerminalsContinuity

Fan switch Resistor


YesR102-2 L/B R104-1 L/B

R102-3 L/W R104-4 L/W

R102-4 L/Y R104-6 L/Y


MTC-48

TROUBLE DIAGNOSIS

12. CHECK REAR COOLER FAN SWITCH

Disconnect rear cooler fan switch connector and check continuitybetween terminals at each fan switch position.

Yes or NoYes >> INSPECTION ENDNo >> Replace rear cooler fan switch

13. CHECK REAR COOLER RELAY

1. Disconnect rear cooler relay.2. Apply 12 volt to rear cooler relay terminal 1 and ground to rear

cooler relay terminal 2.


● If NG, repair harness or connectors.– Harness for open or short between blower relay and fuse block (J/B).● If OK, GO TO 14

No >> Replace rear cooler relay.

14. CHECK REAR COOLER SWITCH (REAR)

Disconnect rear cooler switch (rear) connector.

Yes or NoYes >> GO TO 15No >> Replace rear cooler fan switch (rear)

TerminalsContinuity

Fan switch position Fan switch

1

R102-1

R102-2

Yes2 R102-3

3 R102-4


TerminalsContinuity

Rear cooler relay

R106-3 R106-5 Yes


SJIA0095E

TerminalsContinuity

Switch position Fan switch

ON-1R103-2

R103-5Yes

ON-2 R103-4


SJIA0072E

TROUBLE DIAGNOSIS

MTC-49

C

D

E

F

G

H

I

K

L

M

A

B

MTC


Disconnect rear cooler relay.


16. CHECK REAR COOLER SWITCH (FRONT)

1. Connect rear cooler relay and rear cooler switch.2. Engine running and A/C ON.3. Turn fan control knob (front) to the desired (1 to 4 speed) posi-

tion.

OK or NGOK >> GO TO 17NG >> Repair harness or connector.


Disconnect rear cooler switch and thermo control amp.


TerminalsContinuity

Rear cooler switch Rear cooler relay


R103-3 R106-2


SJIA0073E

TerminalsVoltage

Rear cooler switch

GroundConnector Wire colorApprox. 12 V

M16-2 R


TerminalsContinuity

Rear cooler switch Thermo control amp.


M16-2 R M6-2 R


SJIA0075E

MTC-50

TROUBLE DIAGNOSIS

18. CHECK REAR COOLER SWITCH (FRONT) CONTINUITY

Yes or NoYes >> GO TO 19No >> Replace rear cooler fan switch (front)


Description


● If NG, repair harness or connectors.– Harness for open or short between blower relay and fuse block (J/B).


Magnet Clutch Circuit EJS00127

SYMPTOM:● Magnet clutch does not engage when A/C switch and fan switch are ON.

1. CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT

1. Disconnect A/C compressor harness connector.2. Press the A/C switch ON.

OK or NGOK >> 1. If NG, replace magnet clutch.

2. Check magnet clutch operation.NG >> GO TO 2

TerminalsContinuity

Switch position Fan switch

ON-1M16-2

M16-3Yes

ON-2 M16-1


SJIA0076E

TerminalsContinuity

Rear cooler switch (front) Rear cooler switch (rear)


YesM16-1 L/B R103-4 L/B

M16-3 L/W R103-5 L/W


Terminals

Voltage(+)(-)


F9-1 (Gasolineengine)

R/WGround Approx. 12V

A10-1 (Diesel engine) R/Y

SJIA0078E

TROUBLE DIAGNOSIS

MTC-51

C

D

E

F

G

H

I

K

L

M

A

B

MTC


1. Disconnect A/C relay.2. Check circuit continuity between A/C relay connector and A/C

compressor connector.3.


3. CHECK A/C RELAY POWER SUPPLY

OK or NGOK >> GO TO 4.NG >> Check power supply circuit and 10A(No.13), 15A(No.15,

16) fuse at fuse block. Refer to PG-78, "FUSE BLOCK-JUNCTION BOX(J/B)" .

4. CHECK CIRCUIT CONTINUITY BETWEEN TERMINAL ON A/C RELAY

1. Disconnect A/C relay.2. When apply 12 volts between connector No.1 and 2, Check cir-

cuit continuity.

Yes or NoYes >> GO TO 5No >> Replace A/C relay.

terminalsContinuity

Compressor connectors A/C relay connector

F9-1 (Gasoline engine) R/W M128-5 R/WYes

A10-1 (Diesel engine) R/Y M128-5 R/Y


TerminalsVoltage

(+) (-)

Connector Wire colorGround Approx. 12 V

M128 -1, 3 and 6 L

SJIA0080E

TerminalsContinuity

Connectors Wire color Connectors Wire colors

M128-3L

M128-5(Gasoline engine)

R/W

YesM128-5(Diesel engine)

R/Y

M128-6 M128-7 R/W


SJIA0081E

MTC-52

TROUBLE DIAGNOSIS


1. Reconnect A/C relay.2. Engine running and A/C ON.


6. CHECK A/C ON SIGNAL IN ECM

Engine running and A/C ON.

OK or NGOK >> INSPECTION END. Refer to MTC-28, "How to Perform

Trouble Diagnoses for Quick and Accurate Repair" .>> ● When compressor ON, do not approx. 0 V. GO TO 7

● When compressor OFF, do not approx. 12 V. Refer to KA Engine (Gasoline) EC-61, "ECMINSPECTION TABLE" ,ZD Engine (Diesel)EC-222, "ECM INSPECTION TABLE" .

7. CHECK DUAL PRESSURE SWITCH

Disconnect dual pressure switch connector.

Yes or NoYes >> GO TO 8No >> Replace dual pressure switch.

Terminals

ContinuityA/C relay ECM

Connector Wire color Connectors Wire color

M128-2 B/WF106-23 (Gasoline)

B/W YesF111-15 (Diesel)


Terminals

Condition Voltage(+)(-)


M106-23(Gasoline)B/W Ground

COMP:ON Approx. 0V

M111-15(Diesel) COMP:OFF Approx. 12V

SJIA0083E

TerminalsContinuity

Dual pressure switch


H15-2 B/R H15-1 BR/Y


SJIA0084E

TROUBLE DIAGNOSIS

MTC-53

C

D

E

F

G

H

I

K

L

M

A

B

MTC

8. CHECK COMPRESSOR ON SIGNAL IN ECM

Engine running and A/C ON.

OK or NGOK >> GO TO 12

>> ● When compressor ON, do not approx. 0V. GO TO 9● When compressor OFF, do not approx. 12 V. Refer to

KA Engine (Gasoline) EC-61, "ECM INSPECTION TABLE" , ZD Engine (Diesel) EC-222, "ECMINSPECTION TABLE" .

9. CHECK POWER SUPPLY FOR THERMO CONTROL AMP.

Disconnect thermo control amp.


10. CHECK CIRCUIT CONTINUITY FOR THERMO CONTROL AMP.

Disconnect thermo control amp. connector and A/C switch connec-tor.


Terminals

Condition Voltage(+)(-)


F106-46(Gassoline)BR/Y Ground

COMP:ON Approx. 0V

F111-21(Diesel) COMP:OFF Approx. 12V

SJIA0085E

TerminalsVoltage

(+) (-)

Connector Wire colorGround Approx. 12V

M6- 1 and (3) L and (B/R)

SJIA0086E

TerminalsContinuity

Thermo control amp. A/C switch


M6-2 R M10-1 R


SJIA0087E

MTC-54

TROUBLE DIAGNOSIS

11. CHECK THERMO CONTROL AMP.

1. Connect thermo control amp. and A/C switch connector.2. Engine running and A/C ON.

OK or NGOK >> GO TO 12NG >> Replacer thermo control amp.

12. CHECK POWER SUPPLY FOR A/C SWITCH

Disconnect A/C switch connector.



Disconnect fan switch.


14. CHECK FAN SWITCH GROUND


TerminalsVoltage

(+) (-)


M6- 2 R

SJIA0088E

TerminalsVoltage

(+) (-)


M10- 1 R

SJIA0089E

TerminalsContinuity

A/C switch Fan switch


M10-2 G/Y M13-1 G/Y


SJIA0090E

TerminalsContinuity

Fan switch


M13-6 B


SJIA0091E

TROUBLE DIAGNOSIS

MTC-55

C

D

E

F

G

H

I

K

L

M

A

B

MTC

15. CHECK FAN SWITCH

Turn fan control knob to ON (any speed position except OFF).

Yes or NoYes >> Replace A/C switch.No >> Replace fan switch.

Intake Door Circuit EJS00128

SYMPTOM:● Intake door does not operate.

1. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR

Observe intake door operation when the REC switch is pushed ONand OFF.

OK or NGOK >> GO TO 3NG >> ● Check power supply circuit and 10A(No.13), 15A(No.15, 16) fuse at fuse block. Refer to PG-78,

"FUSE BLOCK-JUNCTION BOX(J/B)" .● If OK, replace intake door motor.


Disconnect intake door connector and REC switch.

Yes or NoYes >> Replace REC switch.No >> Repair harness or connector.

Insufficient Cooling EJS00129

SYMPTOM: Insufficient cooling

TerminalsContinuity

Fan switch


M13-1 G/Y M13-6 B


SJIA0092E

REC switchcondition

Terminals

Voltage(+)(-)


ONM5-2 BR

Ground

Approx. 12V

OFF Approx. 0V

ONM5-4 L/W

Approx. 0V

OFF Approx. 12VSJIA0093E

TerminalsContinuity

Fan switch


M13-1 G/Y M13-6 B


SJIA0094E

MTC-56

TROUBLE DIAGNOSIS

INSPECTION FLOW

*1 MTC-90 *2 MTC-60 *3 MTC-57

*4 MTC-38 *5 MTC-28 *6 MTC-97

*7 KA24DE;EM-14 ,ZD30DD;EM-107 *8 KA24DE;CO-20 ,ZD30DD;CO-42

WHA292

TROUBLE DIAGNOSIS

MTC-57

C

D

E

F

G

H

I

K

L

M

A

B

MTC

PERFORMANCE TEST DIAGNOSES

*1 MTC-59 *2 MTC-59 *3 MTC-60

MHA649A

MTC-58

TROUBLE DIAGNOSIS

*1 MTC-50 *2 KA24DE;EM-14 ,ZD30DD;EM-107

LHA260

TROUBLE DIAGNOSIS

MTC-59

C

D

E

F

G

H

I

K

L

M

A

B

MTC

PERFORMANCE CHARTTest ConditionTesting must be performed as follows:

Test Reading (Single A/C equipped model)Recirculating-to-discharge Air Temperature Table

Ambient Air Temperature-to-operating Pressure Table

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

Doors Closed

Door windows Open

Hood Open

TEMP. Max. COLD

Mode door (Ventilation) set

Intake door (Recirculation) set

(blower) speed Max. speed set

Engine speed Idle speed

Operate the air conditioning system for 10 minutes before taking measurements.

Rear cooler ON (For rear cooler equipped model only)

Inside air (Recirculating air) at blower assembly inletDischarge air temperature at center ventilator

°C (°F)Relative humidity%

Air temperature°C (°F)

50 - 60

25 (77) 6.5 - 9.0 (44 - 48)

30 (86) 11.3 - 14.0 (52 - 57)

35 (95) 16.4 - 20.0 (62 - 68)

40 (104) 21.7 - 26.0 (71 - 79)

60 - 70

25 (77) 9.0 - 11.5 (48 - 53)

30 (86) 14.0 - 17.3 (57 - 63)

35 (95) 20.0 - 23.4 (68 - 74)

40 (104) 26.0 - 29.7 (79 - 85)

Ambient airHigh-pressure (Discharge side)

kPa (bar,kg/cm2, psi)Low-pressure (Suction side)

kPa (bar,kg/cm2, psi)Relative humidity%


50 - 70

25 (77)950 - 1160

(9.5 - 11.6, 9.69 - 11.83, 137.8 -168.2)

130 - 160(1.3 - 1.6, 1.33 - 1.63, 18.9 - 23.2)

30 (86)1300 - 1390

(13.0 - 13.9, 13.26 - 14.18, 188.5 -201.6)

170 - 210(1.7 - 2.1, 1.73 - 2.14, 24.7 - 30.5)

35 (95)1320 - 1620

(13.2 - 16.2, 13.46 - 16.52, 191.4 -234.9)

210 - 260(2.1 - 2.6, 2.14 - 2.65, 30.5 - 37.7)

40 (104)1510- 1850

(15.1 - 18.5, 15.40 - 18.87, 219.0 -268.3)

250 - 300(2.5 - 3.0, 2.55 - 3.06, 36.3 - 43.5)

MTC-60

TROUBLE DIAGNOSIS

Test Reading (Dual A/C equipped model)Recirculating-to-discharge Air Temperature TableFront

Rear

Ambient Air Temperature-to-operating Pressure Table

TROUBLE DIAGNOSES FOR ABNORMAL PRESSUREWhenever system's high and/or low side pressure is abnormal, diagnose using a manifold gauge. The markerabove the gauge scale in the following tables indicates the standard (normal) pressure range. Since the stan-dard (normal) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-to-operating pressure table).




50 - 60

25 (77) 12.4 - 14.9 (54- 59)

30 (86) 16.7 - 19.7 (62 - 67)

35 (95) 21.0 - 24.5 (70 - 76)

40 (104) 25.57 - 29.5 (78 - 85)

60 - 70

25 (77) 14.9 - 17.5 (59 - 64)

30 (86) 19.7 - 22.5 (67 - 73)

35 (95) 24.5 - 27.5 (76 - 82)

40 (104) 29.5 - 34.0 (85 - 93)




50 - 60

25 (77) 10.5 - 13.0 (51 - 55)

30 (86) 15.5 - 18.5 (60 - 65)

35 (95) 20.5 - 24.0 (69 - 75)

40 (104) 25.5 - 29.5 (78 - 85)

60 - 70

25 (77) 13.0 - 15.5 (55 - 60)

30 (86) 18.5 - 21.5 (65 - 71)

35 (95) 24.0 - 27.4 (75 - 81)

40 (104) 29.5 - 34.0 (85 - 93)

Ambient airHigh-pressure (Discharge side)

kPa (bar,kg/cm2, psi)Low-pressure (Suction side)

kPa (bar,kg/cm2, psi)Relative humidity%


50 - 70

25 (77)910 - 1010

(9.1 - 10.1, 9.28 - 10.30, 132.0 -146.5)

240 - 270(2.40 - 2.75, 2.45 - 2.75, 34.8 - 39.2)

30 (86)1050 - 1170

(10.5 - 11.7, 10.71 - 11.93, 152.3 -169.7)

.270 - 310(2.7 - 3.1, 2.75 - 3.16, 39.2 - 45.0)

35 (95)1240 - 1380

(12.4 - 13.8, 12.65 - 14.08,179.8 -200.1)

330 - 360(3.3 - 3.6, 3.37 - 3.67, 47.9 - 52.2)

40 (104)1430- 1590

(14.3 - 15.9, 14.59 - 16.22, 207.4 -230.6)

360 - 400(3.6 - 4.0, 3.67 - 4.08, 52.2 - 58.0)

TROUBLE DIAGNOSIS

MTC-61

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Both High and Low-pressure Sides are Too High.

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

Gauge indication Refrigerant cycle Probable cause Corrective action

Both high and low-pressuresides are too high.

Pressure is reduced soon afterwater is splashed on con-denser.

Excessive refrigerant charge inrefrigeration cycle

Reduce refrigerant until speci-fied pressure is obtained.

Air suction by cooling fan isinsufficient.

Insufficient condenser coolingperformance↓1. Condenser fins are clogged.

2. Improper fan rotation of cool-ing fan

● Clean condenser.

● Check and repair cooling fanas necessary.

● Low-pressure pipe is notcold.

● When compressor is stoppedhigh-pressure value quicklydrops by approximately 196kPa (2 kg/cm2, 28 psi). Itthen decreases graduallythereafter.

Poor heat exchange in con-denser(After compressor operationstops, high pressure decreasestoo slowly.)↓Air in refrigeration cycle

Evacuate repeatedly andrecharge system.

Engine tends to overheat.Engine cooling systems mal-function.

Check and repair each enginecooling system.

● An area of the low-pressurepipe is colder than areasnear the evaporator outlet.

● Plates are sometimes cov-ered with frost.

● Excessive liquid refrigeranton low-pressure side

● Excessive refrigerant dis-charge flow

● Expansion valve is open a lit-tle compared with the specifi-cation.

↓1. Improper thermal valve

installation

2. Improper expansion valveadjustment

Replace expansion valve.

AC359A


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

Upper side of condenser andhigh-pressure side are hot,however, liquid tank is not sohot.

High-pressure tube or partslocated between compressorand condenser are clogged orcrushed.

● Check and repair or replacemalfunctioning parts.

● Check lubricant for contami-nation.

AC360A

MTC-62

TROUBLE DIAGNOSIS

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

Both High- and Low-pressure Sides are Too Low.


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

become equal soon after com-pressor operation stops.

Compressor pressure opera-tion is improper.↓Damaged inside compressorpackings

Replace compressor.

No temperature differencebetween high and low-pres-sure sides

Compressor pressure opera-tion is improper.↓Damaged inside compressorpackings.

Replace compressor.

AC356A


Both high- and low-pressure sidesare too low.

● There is a big temperaturedifference between receiverdrier outlet and inlet. Outlettemperature is extremelylow.

● Liquid tank inlet and expan-sion valve are frosted.

Liquid tank inside is slightlyclogged.

● Replace desiccant assy.


● Temperature of expansionvalve inlet is extremely lowas compared with areasnear liquid tank.

● Expansion valve inlet maybe frosted.

● Temperature differenceoccurs somewhere in high-pressure side

High-pressure pipe locatedbetween receiver drier andexpansion valve is clogged.

● Check and repair malfunc-tioning parts.


Expansion valve and liquidtank are warm or only coolwhen touched.

Low refrigerant charge↓Leaking fittings or components

Check refrigerant for leaks.

There is a big temperature dif-ference between expansionvalve inlet and outlet while thevalve itself is frosted.

Expansion valve closes a littlecompared with the specifica-tion.↓1. Improper expansion valve

adjustment

2. Malfunctioning thermalvalve

3. Outlet and inlet may beclogged.

● Remove foreign particles byusing compressed air.


An area of the low-pressurepipe is colder than areas nearthe evaporator outlet.

Low-pressure pipe is cloggedor crushed.

● Check and repair malfunc-tioning parts.


Air flow volume is not enoughor is too low.

Evaporator is frozen.

● Check thermo control amp.operation.

● Replace compressor.

AC353A

TROUBLE DIAGNOSIS

MTC-63

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Low-pressure Side Sometimes Becomes Negative.

Low-pressure Side Becomes Negative.

Insufficient Heating EJS0012A

SYMPTOM: Insufficient heating


Low-pressure side sometimesbecomes negative.

● Air conditioning systemdoes not function and doesnot cyclically cool the com-partment air.

● The system constantly func-tions for a certain period oftime after compressor isstopped and restarted.

Refrigerant does not dis-charge cyclically.↓Moisture is frozen at expan-sion valve outlet and inlet.↓Water is mixed with refriger-ant.

● Drain water from refrigerantor replace refrigerant.


AC354A


Low-pressure side becomes nega-tive.

Liquid tank or front/rear side ofexpansion valve's pipe isfrosted or dewed.

High-pressure side is closedand refrigerant does not flow.↓Expansion valve or liquid tankis frosted.

Leave the system at rest untilno frost is present. Start itagain to check whether or notthe problem is caused bywater or foreign particles.

● If water is the cause, initiallycooling is okay. Then thewater freezes causing ablockage. Drain water fromrefrigerant or replace refrig-erant.

● If due to foreign particles,remove expansion valveand remove the particleswith dry and compressed air(not shop air).

● If either of the above meth-ods cannot correct the prob-lem, replace expansionvalve.



AC362A

MTC-64

TROUBLE DIAGNOSIS

INSPECTION FLOW

*1 MTC-91 *2 MTC-38 *3 MTC-28

*4 KA24DE:CO-22, "WATER INLETAND THERMOSTAT ASSY" ,ZD30DD:CO-45, "THERMOSTATAND WATER PIPING"

*5 KA24DE:CO-9, "Changing EngineCoolant" , ZD30DD: CO-32, "Chang-ing Engine Coolant"

*6 MTC-77, "HEATER CORE"

*7 KA24DE:CO-14, "CHECKING RADI-ATOR CAP" ,ZD30DD:CO-37,"CHECKING RADIATOR CAP"

LHA261

TROUBLE DIAGNOSIS

MTC-65

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Noise EJS0012B

SYMPTOM: Noise

INSPECTION FLOW

*1 MTC-100 *2 MTC-100 *3 MTC-19

*4 KA24DE;EM-14 ,ZD30DD;EM-107

SHA336FA

MTC-66

CONTROLLER

CONTROLLER PFP:27500

Removal and Installation EJS0017X

1. Remove cluster lid finisher “C”.2. Remove air mix door, and mode door cable.3. Remove air mix door, and mode door cable fixing clips.

4. Remove screws (4), and pull out controller.5. Disconnect the connector, and remove controller.

ZJIA0008E

ZJIA0007E

ZJIA0009E

CONTROLLER

MTC-67

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Disassembly and Assembly EJS0017Y

ZJIA0010J

1 Finisher 2 Mode control dial 3 Temperature control dial

4 Fan control dial 5 E-ring 6 A/C panel

7 Mode door cable 8 Air mix door cable 9 Clips

10 REC switch knob 11 REC switch 12 Valve

13 A/C switch knob 14 A/C switch 15 Controller

16 Fan switch 17 Valve 18 Harness

MTC-68

BLOWER AND COOLING UNIT ASSEMBLY

BLOWER AND COOLING UNIT ASSEMBLY PFP:27210

Removal and Installation EJS0017Z

REMOVAL1. Remove front grille.2. Use refrigerant collecting equipment (for HFC134a) to discharge

refrigerant.3. Remove instrument lower assistance panel.4. Remove headlight (LH).

5. Disconnect high-pressure pipe 2 and low-pressure pipe 1 fromevaporator.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

6. Remove fixing nuts of blower and cooling unit.

7. Remove connectors and clips.8. Separate instrument panel at points shown in the figure at left.9. Remove bolts and screws, and displace cover and lower duct.

10. Remove air mix door cable fixing clip.

ZJIA0012E

ZJIA0013E

ZJIA0015E

ZJIA0008E


MTC-69

C

D

E

F

G

H

I

K

L

M

A

B

MTC

11. Remove door lock relay, SRS air bag connector, air bag harnessclip, and keyless entry control connector.

12. Remove instrument panel stay (LH).13. Displace cover, and remove blower and cooling unit.

INSTALLATION1. Install blower and cooling unit.

2. Perform removal steps of 3 - 12 in reverse order.CAUTION:● Replace O-rings on high-pressure and low-pressure pipes with new ones. Install new O-rings with

compressor oil applied.● After filling refrigerant, check system for refrigerant leak.

3. Charge refrigerant using refrigerant recovery unit (for HFC134a).

ZJIA0014E

Blower & cooling unit assembly mounting bolts and nuts

Tightening torque : 4.31 - 5.78 N·m (0.44 - 0.59 kg·m, 39 - 51 in-lb)

Blower & cooling unit assembly mounting screws


Instrument panel stay mounting nuts

Tightening torque : 11 - 13 N·m (1.1 - 1.4 kg·m, 98 - 115 in-lb)

High-pressure pipe 2 mounting bolts


Low-pressure pipe 1 mounting bolts


MTC-70


Disassembly and Assembly EJS00180

ZJIA0016J

1 Support bracket (RH) 2 Support bracket (LH) 3 Screw

4 Evaporator lower case 5 Intake case 6 Intake door

7 Blower case 1 8 Blower case 2 9 Intake door lever

10 Intake door rod 11 Screw 12 Intake door actuator

13 Sub-harness 14 Seal 15 Bolt

16 Insulator 17 Piping block 18 Expansion valve

19 Evaporator 20 Thermal amplifier 21 Blower fan motor

22 Blower fan resistor 23 Screw 24 Blower fan harness

25 Coolant hose 26 Evaporator upper case 27 Drain hose

28 Clips

BLOWER FAN MOTOR

MTC-71

C

D

E

F

G

H

I

K

L

M

A

B

MTC

BLOWER FAN MOTOR PFP:27226

Removal and Installation EJS00181

1. Remove instrument lower assistance panel.2. Remove connectors and clips.3. Separate instrument panel at points shown in the figure at left.

4. Disconnect coolant hose, and remove blower fan motor.

ZJIA0015E

ZJIA0017E

MTC-72

BLOWER FAN RESISTOR

BLOWER FAN RESISTOR PFP:27150


1. Remove instrument lower assistance panel.2. Remove blower fan resistor.

CAUTION:When thermal fuse of blower fan resistor is blown, inspectblower fan motor and harness, and then replace blower fanresistor with new one. Never repair thermal fuse.

ZJIA0018E

INTAKE DOOR ACTUATOR

MTC-73

C

D

E

F

G

H

I

K

L

M

A

B

MTC

INTAKE DOOR ACTUATOR PFP:27730


1. Remove instrument lower assistance panel.2. Remove intake door actuator.

ZJIA0019E

MTC-74

HEATER UNIT ASSEMBLY

HEATER UNIT ASSEMBLY PFP:27100


REMOVAL1. Drain engine coolant.2. Loosen clamps as shown in the figure, and disconnect heater

hoses from heater & cooling unit assembly. Close coolant inlet/outlet on heater core (2 locations) with shop cloths.

3. Remove instrument panel assembly.4. Remove instrument panel stay (LH).

5. Remove instrument panel stay (RH).

6. Dislocate lower duct, and displace cover.

ZJIA0023E

ZJIA0020E

ZJIA0021E

ZJIA0022E


MTC-75

C

D

E

F

G

H

I

K

L

M

A

B

MTC

7. Remove heater unit assembly mounting nuts.8. Remove heater unit assembly.

INSTALLATION1. Install heater unit assembly.

2. Perform removal steps of 2 to 6 in reverse order.

3. Fill engine coolant.

SJIA0099E

Heater unit assembly mounting nuts


Instrument panel stay mounting nuts


MTC-76



ZJIA0024E

HEATER CORE

MTC-77

C

D

E

F

G

H

I

K

L

M

A

B

MTC

HEATER CORE PFP:27140


1. Remove heater unit assembly.2. Remove heater core support.3. Pull out heater core from heater case.

ZJIA0026E

MTC-78

REAR A/C UNIT ASSEMBLY

REAR A/C UNIT ASSEMBLY PFP:27400


INSTALLATION1. Use refrigerant collecting equipment (for HFC134a) to discharge

refrigerant.2. Remove roof headlining.3. Disconnect drain hose (RH), and connector.

4. Remove insulator, and disconnect high-pressure flexible hose 2and low-pressure flexible hose 2 from rear A/C unit assembly.

CAUTION:Seal connecting points of pipes with caps or vinyl tape, etc. toprevent them from being exposed to atmosphere.5. Disconnect drain hose (LH)

6. Remove mounting bolts, and remove rear A/C unit assembly.

INSTALLATION1. Install rear A/C unit assembly.

2. Perform removal steps from 2 to 5 in reverse order.CAUTION:● Replace O-rings on high-pressure and low-pressure flexible

hoses with new ones. Install new O-rings with compressoroil applied.

● After filling refrigerant, check system for refrigerant leak.● Replace insulator on connections of rear A/C unit assembly and low-pressure flexible hose 2 with

new ones.

ZJIA0028E

ZJIA0029E

ZJIA0030E

Rear A/C unit assembly mounting bolts

Tighteningtorque

: 4.31 - 5.78 N·m (0.44 - 0.59 kg·m,39 - 51 in-lb)

High-pressure flexible hose 2 union nut

Tighteningtorque

: 9.8 - 19.6 N·m (1.0 - 2.0 kg·m, 87 -173 in-lb)

ZJIA0031E

REAR A/C UNIT ASSEMBLY

MTC-79

C

D

E

F

G

H

I

K

L

M

A

B

MTC

3. Charge refrigerant using refrigerant recovery unit (for HFC134a).


Low-pressure flexible hose 2 union nut

Tighteningtorque

: 19.6 - 29.4 N·m (2.0 - 3.0 kg·m, 15 -21 ft-lb)

1 Cover 2 Bolt 3 Screw

4 Rear blower fan motor 5 Rear A/C harness 6 Lower case

7 Seal 8 Bracket 1 9 Evaporator

10 Bracket 2 11 Screw 12 Rear blower fan resistor

13 Relay 14 Upper case 15 Air duct (LH)

16 Air duct (RH) 17 Bracket 3 18 Bolt

ZJIA0032J

MTC-80

REAR BLOWER FAN MOTOR

REAR BLOWER FAN MOTOR PFP:27220


REMOVAL1. Remove roof headlining.2. Disconnect coolant hose and connectors.3. Remove bracket 1.4. Remove screws, and remove cover.

5. Remove rear blower fan motor from rear A/C unit assembly.

INSTALLATIONCAUTION:Make sure that locating pins (2 locations) of rear A/C unit assembly (upper) and cover (lower) areinserted into holes of motor side.

ZJIA0030E

ZJIA0033E

REAR BLOWER FAN RESISTOR

MTC-81

C

D

E

F

G

H

I

K

L

M

A

B

MTC

REAR BLOWER FAN RESISTOR PFP:27761

Removal and Installation EJS0018A

1. Remove rear intake grille (RH).2. Disconnect rear A/C relay.

3. Remove connector and screws, and remove resistor.

ZJIA0078E

ZJIA0034E

MTC-82

DRAIN HOSE

DRAIN HOSE PFP:92591

Removal and Installation EJS0018B

DRAIN HOSE (RH)1. Remove roof headlining.2. Disconnect drain hoses from rear A/C unit assembly.CAUTION:When disconnecting drain hoses, be careful to avoid spillingwater.

3. Remove grommet, and pull out drain hoses upward.4. Disconnect drain hose from clip.

DRAIN HOSE (LH)1. Disconnect drain hose (LH), high-pressure flexible hose 2, and

low-pressure flexible hose 2.2. Remove band clip, and pull out drain hose.

ZJIA0028E

ZJIA0035E

ZJIA0076E

ZJIA0077E

REAR A/C CONTROLLER

MTC-83

C

D

E

F

G

H

I

K

L

M

A

B

MTC

REAR A/C CONTROLLER PFP:27571

Removal and Installation EJS0018C

1. Push clip side of rear A/C controller, and pull it out in the direc-tion shown by arrow.

Disassembly and Assembly EJS0018D

ZJIA0037E

1 Finisher 2 Clips 3 Clips

4 Fan switch dial 5 Control assembly 6 Screw

7 Fan switch 8 Valve

ZJIA0038J

MTC-84

REAR HEATER UNIT ASSEMBLY

REAR HEATER UNIT ASSEMBLY PFP:27300

Removal and Installation EJS0018E

BUILT-IN TYPE REAR HEATER (4 DOOR AND 5 DOOR)1. Drain engine coolant.CAUTION:Be sure to drain rear heater coolant from rear heater pipe under vehicle.2. Remove rear side finisher.3. Disconnect connectors of blower fan and fan resistor.

4. Disconnect rear heater core hose.CAUTION:● Some coolant may spill when the heater hoses are disconnected.● Close coolant inlet/outlet on heater core (2 locations), and air bleeding hose with shop cloths.5. Remove rear heater mounting bolts and nuts, and remove rear heater unit.

FOOR-TYPE REAR HEATER (MICROBUS)1. Drain engine coolant.2. Remove third seat.3. Disconnect rear heater unit hose.

4. Remove rear heater mounting bolts and rear heater connectors,and remove rear heater unit.

RJIA0359E

RJIA0360E

RJIA0361E


MTC-85

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Disassembly and Assembly EJS0018F

BUILT-IN TYPE REAR HEATER (4 DOOR AND 5 DOOR)

RJIA0362J

1 Blower fan motor 2 Washer 3 Blower fan

4 Nut 5 Screw 6 Blower fan resistor

7 Rear heater case 1 8 Screw 9 Rear heater core (4 door)

10 Rear heater case 2 11 Rear heater cover 12 Adapter case

13 Heater core support 14 Screw 15 Screw (5 door)

16 Rear heater duct (5 door) 17 Screw (5 door) 18 Tube bracket (5 door)

19 Tube clip (5 door) 20 Rear heater hose (5 door) 21 Screw (5 door)

22 Rear heater core (5 door)

MTC-86


FOOR-TYPE REAR HEATER (MICROBUS)

Rear Blower Fan Motor EJS001EA

REMOVAL AND INSTALLATIONBuilt-in type rear heater (4 door and 5 door)1. Remove rear side finisher.2. Remove connectors and mounting screws (3) of rear blower fan motor.3. Remove rear blower fan motor.

RJIA0363J

1 Sub-harness 2 Nut 3 Blower fan

4 Washer 5 Blower fan motor 6 Screw

7 Screw 8 Bracket “A” 9 Screw

10 Blower fan resistor 11Heater pipe assembly (with watercock)

12 Bracket “B”

13 Screw 14 Screw 15 Heater case (upper)

16 Rear heater core 17 Bracket “C” 18 Heater case (lower)

19 Screw 20 Screw 21 Rear heater duct

22 Screw

RJIA0364E


MTC-87

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Floor-type rear heater (microbus)1. Drain engine coolant.2. Remove rear heater unit.3. Disassemble rear heater unit, and remove rear blower fan motor. Refer to MTC-85, "Disassembly and

Assembly" in “Rear Heater Unit”.

Rear Blower Fan Resistor EJS001EB

REMOVAL AND INSTALLATIONBuilt-in type rear heater (4 door and 5 door)1. Remove rear side finisher.2. Remove connectors and mounting screws of rear blower fan

resistor, and remove rear blower fan resistor.

Floor-type rear heater (microbus)1. Drain engine coolant.2. Remove rear heater unit, and disconnect connectors of rear blower fan resistor.3. Remove mounting screws of rear blower fan resistor, and remove rear blower fan resistor. Refer to MTC-

85, "Disassembly and Assembly" in “Rear Heater Unit”.

Rear Heater Duct (4 Door) EJS0018I

1. Drain engine coolant.2. Remove rear heater unit. Refer to MTC-84, "Removal and Installation" in “Rear Heater Unit”.3. Remove clips, and remove rear heater duct.

Rear Heater Control EJS0018J

REMOVAL AND INSTALLATION4 door, microbus1. Pull left side of rear heater control, and remove clips (2).2. Slide rear heater control to side (vehicle front), and remove rear

heater control.

RJIA0365E

RJIA0366E

RJIA0367E

MTC-88


5 door1. Remove rear side finisher.2. Remove rear heater control mounting screws, and remove rear

heater control.

DISASSEMBLY AND ASSEMBLY

Rear Heater Hose EJS0018K

REMOVAL AND INSTALLATION1. Drain engine coolant.2. Remove engine undercover.3. Remove clamp and screws (2), and disconnect heater tube. (ZD

engine)

RJIA0368E

RJIA0369J

1 Finisher (4 door) 2 Fan switch knob 3 Clip (4 door)

4 Screw 5 Control assembly 6 Clip (4 door)

7 Screw 8 Fan switch 9 Valve

RJIA0370E


MTC-89

C

D

E

F

G

H

I

K

L

M

A

B

MTC

4. Remove bolts (4), and bracket.5. Remove clamp and bolts (3).6. Release parking brake.CAUTION:When releasing parking brake, be sure to prevent vehicle frommoving by setting wheel blocks.

7. Remove heater hose assembly “A”.

8. Remove clamp and nut (1). (4 door)

9. Disconnect heater hose from rear heater unit. (4 door)10. Remove bolt (1), and remove heater hose assembly “B”. (4

door)

RJIA0371E

RJIA0372E

RJIA0373E

RJIA0374E

MTC-90

MODE DOOR

MODE DOOR PFP:27731

Adjustment of Cable EJS0018M

1. Remove outer cable from the clamp.2. Set mode adjustment dial to “DEF”.3. Push side link in the direction shown by arrow. Slightly pull outer

cable to controller side, and install it to clamp.CAUTION:When clamping the outer cable, do not move the innercable.

4. Operate mode adjustment dial, and check that inner cablemoves smoothly.

SJIA0100E

AIR MIX DOOR

MTC-91

C

D

E

F

G

H

I

K

L

M

A

B

MTC

AIR MIX DOOR PFP:27732

Adjustment of Cable EJS0018N

1. Remove outer cable from the clamp.2. Set temperature adjustment dial to “FULL COLD”.3. Push air mix door lever in the direction shown by arrow. Slightly

pull outer cable toward controller side, and install clamp.CAUTION:When clamping the outer cable, do not move the innercable.

4. Operate the temperature adjustment dial to insure that the innercable moves smoothly.

ZJIA0039E

MTC-92

DUCT AND GRILLE

DUCT AND GRILLE PFP:27860

Removal and Installation EJS0018O

VENTILATOR DUCT, DEFROSTER NOZZLE, AND DUCT

1. Remove instrument panel.Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in “IP Instrument Panel”.

CENTRAL VENTILATOR GRILLE1. Remove cluster lid “C”.

Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in “IPInstrument Panel”.

2. Remove central ventilator grille.

ZJIA0040J

1 Cluster lid “C” 2 Central ventilator grille (LH) 3 Central ventilator grille (RH)

4 Instrument panel assembly 5 Side ventilator duct (LH) 6 Side ventilator grille (LH)

7 Central ventilator duct (LH) 8 Central ventilator duct (RH) 9 Side ventilator grille (RH)

10 Side ventilator duct (RH) 11 Central ventilator adapter 12 Side defroster duct

13 Central defroster nozzle

ZJIA0041E

DUCT AND GRILLE

MTC-93

C

D

E

F

G

H

I

K

L

M

A

B

MTC

SIDE VENTILATOR GRILLE1. Remove instrument panel.

Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in “IPInstrument Panel”.

2. Remove side ventilator grille.

FOOT DUCT1. Remove foot duct.

REAR VENTILATOR GRILLE1. Remove rear ventilator grille.

REAR INTAKE GRILLE1. Remove rear intake grille from clip.

ZJIA0042E

ZJIA0043E

ZJIA0044E

ZJIA0045E

MTC-94

A/C CYCLE

A/C CYCLE PFP:92600

Component Parts Drawing EJS0018P

A/C CYCLE

MTC-95

C

D

E

F

G

H

I

K

L

M

A

B

MTC

WITHOUT REAR A/C

SJIA0097E

MTC-96

A/C CYCLE

WITH REAR A/C

SJIA0098E

A/C CYCLE

MTC-97

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Compressor EJS0018Q


refrigerant.3. Remove cover.4. Remove engine undercover.5. Remove auxiliary drive belt. KA20 and KA24 engines: EM-14,

"DRIVE BELTS" ZD engine:EM-107, "DRIVE BELTS"

6. Disconnect high-pressure flexible hose 1 and low-pressure flexi-ble hose 1 from compressor.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

7. Disconnect the connector of the compressor.8. Remove harness bracket fixing bolts, and clip, and remove vehi-

cle harness aside (ZD engine only).

9. Remove compressor mounting bolts.

ZJIA0048E

ZJIA0049E

ZJIA0051E

ZJIA0050E

MTC-98

A/C CYCLE

10. Remove compressor from underbody of vehicle, in case of KAengine, and from vehicle, in case of ZD engine.

INSTALLATIONCAUTION:● Replace O-rings on high-pressure flexible hose 1 and low-

pressure flexible hose 1 with new ones. Install new O-ringswith compressor oil applied.

● When charging refrigerant, check for refrigerant leaks.

ZJIA0052E

ZJIA0053E

Compressor mounting bolt (KA engine)

Tighteningtorque

: 57 - 66 N·m (5.8 - 6.7 kg·m, 42 - 48ft-lb)

Compressor mounting bolt (ZD engine)

Tighteningtorque

: 59 - 69 N·m (6.0 - 7.0 kg·m, 44 - 50ft-lb)

High-pressure flexible hose 1 mounting bolt

Tighteningtorque

: 8 - 10 N·m (0.8 - 1.0 kg·m, 70 - 95in-lb)

Low-pressure flexible hose 1 mounting bolt

Tighteningtorque

: 8 - 10 N·m (0.8 - 1.0 kg·m, 70 - 95in-lb)

ZJIA0054E

A/C CYCLE

MTC-99

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Overhaul EJS001FK

Removal EJS001FL

● When removing center bolt, hold clutch disc with clutch discwrench.

● Remove the drive plate using the clutch disc puller.Insert holder's three pins into the drive plate. Rotate the holderclockwise to hook it onto the plate. Tighten the center bolt toremove the drive plate.After removing the drive plate, remove the shims from either the

drive shaft or the drive plate.

● Remove the snap ring using external snap ring pliers.

SHA493F

SHA792E

SHA098EA

SHA794E

MTC-100

A/C CYCLE

● Pulley removal:Use a commercially available pulley puller. Position the center ofthe puller on the end of the drive shaft. Remove the pulleyassembly with the puller.For pressed pulleys:To prevent deformation of the pulley groove, the pullerclaws should be hooked under (not into) the pulley groove.For machine latched pulleys:Align the pulley puller groove with the pulley groove, andthen remove the pulley assembly.

● Remove the snap ring using external snap ring pliers.● Remove the field coil harness clip using a screwdriver. The three

field coil fixing screws and remove the field coil.

Inspection EJS001FM

CLUTCH DISCIf the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

PULLEYCheck the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving,replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitablesolvent before reinstallation.

COILCheck coil for loose connection or cracked insulation.

Installation EJS001FN

● Install the field coil.Be sure to align the coil pin with the hole in the compressorfront head.

SHA050F

SHA494F

RHA075C

SHA494F

A/C CYCLE

MTC-101

C

D

E

F

G

H

I

K

L

M

A

B

MTC

● Install the pulley assembly using the installer and a hand press,and then install the snap ring using snap ring pliers.

● Install the drive plate on the drive shaft, together with the originalshim(s). Press the drive plate down by hand.

● Using the holder to prevent drive plate rotation, tighten the boltto 12 to 14 N-m (1.2 to 1.4 kg-m, 9 to 10 ft-lb) torque.

● After tightening the bolt, check that the pulley rotates smoothly.● Check clearance all the way around the clutch disc.

If the specified clearance is not obtained, replace adjustingspacer and readjust.

BREAK-IN OPERATIONWhen replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.

SHA797EA

SHA798E

SHA799E

Disc-to-pulley clearance :

0.24 - 0.42 mm (0.0094 - 0.0165 in)

SHA052FA

MTC-102

A/C CYCLE

High-Pressure Flexible Hose 1 and Low-Pressure Flexible Hose 1 EJS0018R


refrigerant.3. Remove condenser.MTC-109, "Condenser Assembly"4. Remove cover.

5. Disconnect low-pressure flexible hose 1 from low-pressure pipe2.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

6. Remove fixing nuts of high-pressure flexible hose 1 and low-pressure flexible hose 1.

7. Remove mounting bolts of high-pressure flexible hose 1 andlow-pressure flexible hose 1, and remove hoses from vehicle.

ZJIA0048E

ZJIA0056E

ZJIA0055E

ZJIA0049E

A/C CYCLE

MTC-103

C

D

E

F

G

H

I

K

L

M

A

B

MTC

8. Remove band clip and clip. Disconnect high-pressure flexiblehose 1 and low-pressure flexible hose 1 from bracket, respec-tively.

INSTALLATIONCAUTION:● Replace O-rings on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new ones.

Install new O-rings with compressor oil applied.● Replace band clips on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new

ones.● When charging refrigerant, check for refrigerant leaks.

Low-Pressure Pipe 1 EJS0018S


refrigerant.3. Remove condenser.4. Remove mounting bolts of low-pressure pipe 1, and disconnect

it from blower and cooling unit.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

ZJIA0051E

ZJIA0075E

High-pressure flexible hose 1 mounting bolt


Low-pressure flexible hose 1 mounting bolt



Tightening torque : 14.7 - 24.5 N·m (1.5 - 2.5 kg·m, 11 - 18 ft-lb)



ZJIA0013E

MTC-104

A/C CYCLE

5. Disconnect low-pressure pipe 1 from low-pressure flexible hose1.

6. Disconnect low-pressure pipe 1 from low-pressure pipe 2. (Formodels with rear A/C only)

7. Remove clip fixing bolts, and remove low-pressure pipe 1.

INSTALLATIONCAUTION:● O-rings on low-pressure pipe 1 and low-pressure flexible hose 1 must be replaced with new ones.

Install new O-rings with compressor oil applied.● When charging refrigerant, check for refrigerant leaks.

Low-Pressure Pipe 2 EJS0018T


refrigerant.3. Remove front LH wheel.4. Remove condenser.5. Remove splash board (LH).6. Disconnect low-pressure pipe 2 from low-pressure pipe 1.

CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

7. Remove clip fixing bolts, and disconnect low-pressure pipe 2from low-pressure flexible hose 2.

8. Disconnect high-pressure pipe 4 from clip of low-pressure pipe2.

9. Remove clip fixing bolts and clips, and remove low-pressurepipe 2 from wheel housing.

INSTALLATIONCAUTION:● Replace O-rings on low-pressure pipe 1 and low-pressure flexible hose 2 with new ones. Install

new O-rings with compressor oil applied.● When charging refrigerant, check for refrigerant leaks.

ZJIA0056E

Low-pressure pipe 1 union nut


Low-pressure pipe 1 mounting bolts




ZJIA0056E

ZJIA0057E

A/C CYCLE

MTC-105

C

D

E

F

G

H

I

K

L

M

A

B

MTC

High-Pressure Pipe 1 EJS0018U


refrigerant.3. Remove undercover.4. Disconnect high-pressure pipe 1 from liquid tank.


5. Disconnect high-pressure pipe 1 from the condenser.

6. Remove connector and clip fixing bolts, and remove high-pres-sure pipe 1.

INSTALLATIONCAUTION:● Replace O-rings on high-pressure pipe 1 with new ones. Install new O-rings with compressor oil

applied.● When charging refrigerant, check for refrigerant leaks.

Low-pressure pipe 1 union nut




ZJIA0059E

ZJIA0061E

ZJIA0060E

High-pressure pipe 1 mounting bolt


MTC-106

A/C CYCLE

High-Pressure Pipe 2 EJS0018V


refrigerant.3. Remove undercover.4. Disconnect high-pressure pipe 2 from liquid tank.


5. Disconnect high-pressure pipe 2 from blower and cooling unit.

6. Remove clip fixing bolts, and disconnect high-pressure pipe 2from high-pressure pipe 3. (For models with rear A/C only)

INSTALLATIONCAUTION:● Replace O-rings on high-pressure pipes with new ones. Install new O-rings with compressor oil


ZJIA0059E

ZJIA0013E

ZJIA0060E

High-pressure pipe 2 mounting bolts


High-pressure pipe union nut


A/C CYCLE

MTC-107

C

D

E

F

G

H

I

K

L

M

A

B

MTC

High-Pressure Pipe 3 EJS0018W


refrigerant.3. Remove undercover.4. Disconnect high-pressure pipe 2 from high-pressure pipe 3. (For

models with rear A/C only)CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

5. Disconnect high-pressure pipe 3 from high-pressure pipe 4.6. Remove clip fixing bolts, and remove high-pressure pipe 3.

INSTALLATIONCAUTION:● Replace O-rings on high-pressure pipes 3 and 4 with new ones. Install new O-rings with compres-

sor oil applied.● When charging refrigerant, check for refrigerant leaks.

High-Pressure Flexible Hose 2 and Low-Pressure Flexible Hose 2 (Rear A/CSide) EJS0018Y


refrigerant.3. Remove splash board (LH).4. Remove roof headlining.5. Remove insulator, and disconnect high-pressure flexible hose 2

and low-pressure flexible hose 2 from rear A/C unit assembly.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

6. Disconnect drain hose (LH).CAUTION:When disconnecting drain hoses, be careful to avoid spilling water.

ZJIA0060E

ZJIA0061E

High-pressure pipe 3 unit nut


ZJIA0029E

MTC-108

A/C CYCLE

7. Disconnect high-pressure flexible hose 2 from high-pressurepipe 4.

8. Disconnect low-pressure flexible hose 2 from low-pressure pipe2.

9. Remove clips and grommets. Pull out high-pressure flexiblehose 2, low-pressure flexible hose 2, and drain hose (LH) alltogether in upward direction.

INSTALLATIONCAUTION:● O-rings on high-pressure flexible hose 2 and low-pressure flexible hose 2 must be replaced with

new ones. Install new O-rings with compressor oil applied.● Replace insulator on connections of rear A/C unit assembly and low-pressure flexible hose 2 with

new ones.● When charging refrigerant, check for refrigerant leaks.

High-Pressure Pipe 4 EJS0018X


refrigerant.3. Remove front LH wheel.4. Remove splash board (LH).5. Disconnect high-pressure pipe 4 from high-pressure pipe 3.


ZJIA0057E

ZJIA0036E





ZJIA0061E

A/C CYCLE

MTC-109

C

D

E

F

G

H

I

K

L

M

A

B

MTC

6. Disconnect high-pressure pipe 4 from high-pressure flexiblehose 2, and remove clips.

7. Remove clip fixing bolts and clips, and remove high-pressurepipe 4 from wheel housing.

INSTALLATIONCAUTION:● Replace O-rings on high-pressure pipe 4 and high-pressure flexible hose 2 with new ones. Install


Pressure Switch EJS0018Z

REMOVAL AND INSTALLATION1. Use refrigerant collecting equipment (for HFC134a) to discharge

refrigerant.2. Remove liquid tank.3. Using a vise, secure liquid tank, and remove pressure switch.

CAUTION:● Wrap shop cloths around liquid tank to avoid any damage

to it.● When installing, apply compressor oil to O-rings on pres-

sure switch.

Condenser Assembly EJS00190

REMOVAL AND INSTALLATION1. Remove front grille.2. Use refrigerant collecting equipment (for HFC134a) to discharge

refrigerant.3. Remove undercover.4. Remove lower cover.

ZJIA0057E

High-pressure pipe 4 union nut




Pressure switch


SJIA0101E

ZJIA0062E

MTC-110

A/C CYCLE

5. Disconnect high-pressure flexible hose 1 from condenserassembly.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

6. Disconnect high-pressure pipe 1 from condenser assembly.

7. Disconnect condenser fan connector.

8. Remove condenser assembly mounting bolts and clips. Remove condenser assembly from lower front ofvehicle.

CAUTION:● Replace O-rings on high-pressure flexible hose 1 and high-pressure pipe 1 with new ones. Install


ZJIA0063E

ZJIA0061E

ZJIA0060E



ZJIA0064E

A/C CYCLE

MTC-111

C

D

E

F

G

H

I

K

L

M

A

B

MTC

DISASSEMBLY AND ASSEMBLY

Rear Evaporator EJS00191

REMOVAL AND INSTALLATION1. Remove front grille.2. Use refrigerant collecting equipment (for HFC134a) to discharge

refrigerant.3. Remove roof headlining.4. Disconnect high-pressure flexible hose 2 and low-pressure flexi-

ble hose 2 from rear A/C assembly.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

5. Remove lower case of rear A/C assembly.6. Remove screws, and remove rear evaporator.

High-pressure pipe 1 mounting bolt


ZJIA0065J

1 Bracket (RH) 2 Lower cover 3 Bolt

4 Bracket (LH) 5 Condenser 6 Bolt

7 Air guide 8 Bolt 9 Condenser fan motor

10 Bolt 11 Bolt 12 Condenser fan

13 Nut 14 Fan shroud

ZJIA0069E

MTC-112

A/C CYCLE

CAUTION:● O-rings on high-pressure flexible hose 2 and low-pressure flexible hose 2 must be replaced with

new ones. Install new O-rings with compressor oil applied.● When charging refrigerant, check for refrigerant leaks.

Front Expansion Valve EJS00192

REMOVAL AND INSTALLATION1. Remove blower and cooling unit.2. Remove insulator.3. Remove piping block and expansion valve.CAUTION:● Replace O-rings on piping block and evaporator with new

ones. Install new O-rings with compressor oil applied.● When charging refrigerant, check for refrigerant leaks.

Rear Expansion Valve EJS00193

REMOVAL AND INSTALLATION1. Remove rear evaporator.2. Remove insulator, and then rear expansion valve.

CAUTION:● Replace O-rings on rear expansion valve inlet tube and

rear evaporator with new ones. Install new O-rings withcompressor oil applied.

● Replace the insulator with new one.





ZJIA0070E

Mounting bolts of piping block (expansion valve)


ZJIA0071E

Rear evaporator inlet tube union nut


Rear evaporator union nut


A/C CYCLE

MTC-113

C

D

E

F

G

H

I

K

L

M

A

B

MTC

Liquid Tank EJS00194

REMOVAL AND INSTALLATION1. Remove front grille.2. Using a refrigerant recovery unit (for HFC134a), remove refrig-

erant.3. Disconnect connector, and disconnect high-pressure pipes 1

and 2 from liquid tank.CAUTION:Seal the connecting points of the pipes with caps and vinyltape, etc. to prevent them from being exposed to the atmo-sphere.

4. Remove bracket fixing bolts, and pull out liquid tank from lowerside.

CAUTION:● Replace O-ring on high-pressure pipe with new one. Install new O-ring with compressor oil


Mounting bolts of high-pressure pipes 1 and 2


ZJIA0059E

MTC-114

A/C CYCLE

Documents

Urvan.pdf