MANUAL AIR CONDITIONER

J AIR CONDITIONER

SECTION
MANUAL AIR CONDITIONER
MTC B

E
CONTENTS
PRECAUTIONS .......................................................... 3 OPERATION ........................................................ 15 F
Precautions for Supplemental Restraint System LUBRICANT LEVEL ADJUSTMENT WHEN
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- REPLACING COMPONENTS OTHER THAN
SIONER” .................................................................. 3 COMPRESSOR .................................................. 16 G
Precautions for Working with HFC-134a (R-134a)..... 3 LUBRICANT LEVEL ADJUSTMENT WHEN
General Refrigerant Precautions .............................. 3 REPLACING COMPRESSOR ............................. 16
Lubricant Precautions .............................................. 4 TROUBLE DIAGNOSIS ............................................ 17
H
Precautions for Refrigerant Connection ................... 4 CONSULT-II Functions ........................................... 17
FEATURES OF NEW TYPE REFRIGERANT CONSULT-II BASIC OPERATION ....................... 17
CONNECTION ...................................................... 4 DATA MONITOR ................................................. 18
O-RING AND REFRIGERANT CONNECTION..... 5 Diagnosis Procedure .............................................. 19 I
Precautions for Servicing Compressor ..................... 6 DIAGNOSIS CHART BY SYMPTOM .................. 19
Precautions for Service Equipment .......................... 7 Component Parts Location ..................................... 20
RECOVERY/RECYCLING EQUIPMENT .............. 7 CR ENGINE MODELS ........................................ 20 MTC
ELECTRONIC LEAK DETECTOR ........................ 7 HR ENGINE MODELS ........................................ 21
VACUUM PUMP ................................................... 7 K9K ENGINE MODELS ....................................... 22
MANIFOLD GAUGE SET ...................................... 7 Wiring Diagram —HEATER— ................................ 23
K
SERVICE HOSES ................................................. 8 Wiring Diagram —A/C— CR Engine Models .......... 24
SERVICE COUPLERS .......................................... 8 Wiring Diagram —A/C— HR Engine Models .......... 26
REFRIGERANT WEIGHT SCALE ........................ 8 Wiring Diagram —A/C— K9K Engine Models ........ 28
CALIBRATING ACR4 WEIGHT SCALE ................ 8 Wiring Diagram —PTC/H— .................................... 30 L
CHARGING CYLINDER ........................................ 9 Function Inspection ................................................ 31
Precautions for Leak Detection Dye ......................... 9 Blower Fan Motor System ...................................... 32
IDENTIFICATION .................................................. 9 INSPECTION PROCEDURE .............................. 32 M
IDENTIFICATION LABEL FOR VEHICLE ............. 9 Magnetic Clutch System ......................................... 34
PREPARATION ......................................................... 10 INSPECTION PROCEDURE .............................. 34
Special Service Tools ............................................. 10 Component Inspection ............................................ 40
HFC-134a (R-134a) Service Tools and Equipment... 10 REFRIGERANT PRESSURE SENSOR .............. 40
REFRIGERATION SYSTEM ..................................... 14 Insufficient Cooling ................................................. 40
Refrigerant Cycle ................................................... 14 CHECK FUNCTION (FOR GASOLINE ENGINE)... 40
REFRIGERANT FLOW ....................................... 14 DIAGNOSIS BY PRESSURE GAUGE ................ 42
FREEZE PROTECTION ..................................... 14 DIAGNOSIS OF COMPRESSOR ....................... 44
Refrigerant System Protection ............................... 14 Detecting Leaks With Fluorescent Indicator ........... 45
REFRIGERANT PRESSURE SENSOR ............. 14 METHOD FOR DETECTING REFRIGERANT
PRESSURE RELIEF VALVE ............................... 14 LEAKAGE ............................................................ 45
LUBRICANT ............................................................. 15 CONTROL UNIT ....................................................... 46
Adjustment of Compressor Lubricant Amount ....... 15 Removal and Installation ........................................ 46
LUBRICANT ........................................................ 15 REMOVAL ........................................................... 46
PROCEDURES FOR LUBRICANT RETURN INSTALLATION ................................................... 46
Disassembly and Assembly .................................... 46

MTC-1
A/C UNIT ASSEMBLY .............................................. 48 Removal and Installation for Compressor ...............68
Removal and Installation ........................................ 48 REMOVAL ............................................................68
REMOVAL ........................................................... 48 INSTALLATION ....................................................68
INSTALLATION .................................................... 49 Removal and Installation for Compressor Clutch
Disassembly and Assembly .................................... 50 (CR Engine Models) ................................................69
HEATER CORE ......................................................... 52 REMOVAL ............................................................69
Removal and Installation ........................................ 52 INSTALLATION ....................................................71
REMOVAL ........................................................... 52 Removal and Installation for Pipe and Hose ...........72
INSTALLATION .................................................... 52 REMOVAL ............................................................72
BLOWER MOTOR .................................................... 53 INSTALLATION ....................................................72
Removal and Installation ........................................ 53 Removal and Installation for Refrigerant Pressure
REMOVAL ........................................................... 53 Sensor .....................................................................73
INSTALLATION .................................................... 53 REMOVAL AND INSTALLATION .........................73
BLOWER FAN RESISTOR ....................................... 54 Removal and Installation for Condenser (Models
Removal and Installation ........................................ 54 without Integrated Condenser) ................................74
REMOVAL ........................................................... 54 REMOVAL ............................................................74
INSTALLATION .................................................... 54 INSTALLATION ....................................................74
AIR CONDITIONER FILTER ..................................... 55 Removal and Installation for Condenser (Models
Removal, Replacement and Installation ................. 55 with Integrated Condenser) .....................................74
REMOVAL ........................................................... 55 REMOVAL ............................................................74
REPLACEMENT .................................................. 55 INSTALLATION ....................................................75
INSTALLATION .................................................... 55 RemovalandInstallationforLiquidTank(CREngine
INTAKE DOOR .......................................................... 56 with A/T Models) .....................................................75
Intake Door Cable Adjustment ................................ 56 REMOVAL ............................................................75
MODE DOOR ............................................................ 57 INSTALLATION ....................................................75
Mode Door Cable Adjustment ................................ 57 RemovalandInstallationforLiquidTank(ExceptCR
AIR MIX DOOR ......................................................... 58 Engine with A/T Models) .........................................76
Air Mix Door Cable Adjustment .............................. 58 REMOVAL ............................................................76
INTAKE SENSOR ..................................................... 59 INSTALLATION ....................................................76
Removal and Installation ........................................ 59 Removal and Installation for Evaporator .................76
REMOVAL ........................................................... 59 REMOVAL ............................................................76
INSTALLATION .................................................... 59 INSTALLATION ....................................................78
DUCTS AND GRILLES ............................................. 60 Removal and Installation for Expansion Valve ........78
Removal and Installation ........................................ 60 REMOVAL ............................................................78
COMPONENT PARTS LOCATION ..................... 60 INSTALLATION ....................................................78
CENTRAL VENTILATOR GRILLE ....................... 60 Checking for Refrigerant Leaks ..............................78
SIDE VENTILATOR GRILLE ............................... 60 Checking System for Leaks Using the Fluorescent
DEFROSTER NOZZLE AND DUCT .................... 61 Leak Detector ..........................................................79
SIDE VENTILATOR DUCT .................................. 62 Dye Injection ...........................................................79
CENTER VENTILATOR DUCT ............................ 63 Electronic Refrigerant Leak Detector ......................79
FOOT DUCT ........................................................ 63 PRECAUTIONS FOR HANDLING LEAK
REFRIGERANT LINES ............................................. 64 DETECTOR .........................................................79
HFC-134a (R-134a) Service Procedure ................. 64 CHECKING PROCEDURE ..................................80
SETTING OF SERVICE TOOLS AND EQUIP- SERVICE DATA AND SPECIFICATIONS (SDS) ......82
MENT .................................................................. 64 COMPRESSOR ......................................................82
Component Parts Location ..................................... 65 LUBRICANT ............................................................82
CR ENGINE MODELS ........................................ 65 REFRIGERANT ......................................................82
HR ENGINE MODELS ........................................ 66 ENGINE IDLING SPEED ........................................82
K9K ENGINE MODELS ....................................... 67 BELT TENSION ......................................................82

MTC-2
 PRECAUTIONS

PRECAUTIONS PFP:00001
A
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EJS004G7

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual. C
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. D
● 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 Air
Bag Module, see the SRS section. E
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors. F
Precautions for Working with HFC-134a (R-134a) EJS002FU

WARNING: G
● 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- H
lowing handling precautions must be observed:
● When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
I
● When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
ble to minimize the entry of moisture into system.
● Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri- MTC
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 and
throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meet- K
ing requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-
134a) recovery equipment). If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be obtained from refrigerant and L
lubricant manufacturers.
● Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam
parts. Damage may result. M
General Refrigerant Precautions EJS002FV

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.
● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
● 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 HFC-134a (R-134a)

MTC-3
 PRECAUTIONS

have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
injury or property damage. Additional health and safety information may be obtained from refriger-
ant manufacturers.
Lubricant Precautions EJS002FW

● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
If lubricant other than that specified is used, compressor malfunction is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following
handling precautions must be observed:
● When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize
the entry of moisture from the atmosphere.
● When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before con-
necting the components. Connect all refrigerant loop components as quickly as possible to minimize the
entry of moisture into system.
● Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. 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 HFC-134a (R-134a) from the A/C system, using certified service equipment meeting require-
ments of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-134a) recovery
equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional
health and safety information may be obtained from refrigerant and lubricant manufacturers.
● Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage
may result.
Precautions for Refrigerant Connection EJS002FX

A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
● Expansion valve to cooling unit
● Refrigerant pressure sensor 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 of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
● 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.

SHA815E

MTC-4
 PRECAUTIONS

O-RING AND REFRIGERANT CONNECTION

CAUTION: A
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection. B
O-Ring Part Numbers and Specifications (CR Engine Models)
Connection type Piping connection point Part number Qty. Remarks
C
Low-pressure flexible hose to heater & cooling unit 92473 BC700 1
High-pressure pipe to heater & cooling unit 92471 BC700 1
Condenser to high-pressure flexible hose 92472 BC700 1 D
New Condenser to high-pressure pipe 92471 BC700 1
Compressor to low-pressure flexible hose 92474 BC700 1
E
Compressor to high-pressure flexible hose 92472 BC700 1
Liquid tank to condenser pipe 92471 N8210 1
Refrigerant pressure sensor — – F
Former Inlet 92477 AX000 1
Expansion valve to evaporator
Outlet 92477 AX005 1
G
O-Ring Part Numbers and Specifications (HR Engine Models)
Connection type Piping connection point Part number Qty. Remarks
Low-pressure flexible hose to heater & cooling unit 92473 BC700 1 H
High-pressure pipe to heater & cooling unit 92471 BC700 1
Condenser to high-pressure flexible hose 92472 BC700 1
I
New Condenser to high-pressure pipe 92471 BC700 1
Compressor to low-pressure flexible hose 92474 N8210 1
Compressor to high-pressure flexible hose 92472 N8210 1 MTC
Liquid tank to condenser pipe 92471 N8210 1
Refrigerant pressure sensor — –
K
Former Inlet 92477 AX000 1
Expansion valve to evaporator
Outlet 92477 AX005 1

O-Ring Part Numbers and Specifications (All K9K Engine Models) L

Connection type Piping connection point Part number Qty. Remarks
Low-pressure flexible hose to heater & cooling unit 92473 BC700 1
M
Low-pressure flexible hose to Low-pressure pipe 92473 BC700 1
High-pressure pipe to heater & cooling unit 92471 BC700 1
Condenser to high-pressure flexible hose 92472 BC700 1
New
Condenser to high-pressure pipe 92471 BC700 1
Compressor to low-pressure flexible hose 92474 BC700 1
Compressor to high-pressure flexible hose 92472 BC700 1
Liquid tank to condenser pipe 92471 N8210 1
Refrigerant pressure sensor — –
Former Inlet 92477 AX000 1
Expansion valve to evaporator
Outlet 92477 AX005 1
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.

MTC-5
 PRECAUTIONS

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.
Malfunction to do so will cause lubricant to enter the low pressure chamber.
● When connecting tubes, always use a torque wrench and a back-up wrench.
● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
● Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
● Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
● Always replace used O-rings.
● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
KC59G Compressor
Lubricant name: Nissan A/C System Oil Type R
Part number: KLH00-PAGR0
● O-ring must be closely attached to dented portion of tube.
● When replacing the O-ring, be careful not to damage O-ring and tube.
● Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
● After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten con-
nections of seal seat to the specified torque.

RHA861F

Precautions for Servicing Compressor EJS002FY

● 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-15, "Adjustment of Compressor Lubricant Amount" .
● 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.

MTC-6
 PRECAUTIONS

● After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor A
is installed, let the engine idle and operate the compressor for one hour.
● After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation. B
Precautions for Service Equipment EJS002FZ

RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never C
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
D
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible E
with 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 pump
F
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows. G
● Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump. H
● For pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump. I
● If the hose has an automatic shut off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate. MTC
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
K

RHA270DA

MANIFOLD GAUGE SET L

Be certain that the gauge face indicates HFC-134a (R-134a) or
134a. Be sure the gauge set has 1/2″-16 ACME threaded connec-
tions for service hoses. Confirm the set has been used only with M
refrigerant HFC-134a (R-134a) and specified lubricants.

SHA533D

MTC-7
 PRECAUTIONS

SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shut
off devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.

RHA272D

SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close

RHA273D

REFRIGERANT WEIGHT SCALE

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

RHA274D

CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press Shift/Reset and Enter at the same time.
2. Press 8787 . “A1 ” will be displayed.
3. Remove all weight from the scale.
4. Press 0 , then press Enter . “0.00 ” will be displayed and change to “A2 ”.
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of
the weight scale.
6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50)
7. Press Enter — the display returns to the vacuum mode.
8. Press Shift/Reset and Enter at the same time.
9. Press 6 — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00 ” will be displayed.
11. Press Shift/Reset to return the ACR4 to the program mode.

MTC-8
 PRECAUTIONS

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve A
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.
B
Precautions for Leak Detection Dye EJS002G0

● 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.
C
● Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of
the fluorescent dye.
● The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo- D
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 instructions
E
and precautions prior to performing the work.
● A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
● Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis F
during a future service.
● Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period G
of time cannot be removed.
● Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
● Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 CC) per A/C system. H
● Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C systems or A/C system damage may result. I
● The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.
MTC
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label. K

IDENTIFICATION LABEL FOR VEHICLE

Vehicles with factory installed fluorescent dye have this identification L
label on the front side of hood.

SHA436FA

MTC-9
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EJS002G9

Tool number
Description
Tool name

KV99231260
Removing shaft nut and clutch disc
Clutch disc wrench

RJIA0475E

KV992T0001
Removing clutch disc
Clutch disc puller

RJIA0476E

KV992T0002
Installing pulley
Pulley installer

RJIA0477E

KV99233130
Removing pulley
Pulley puller

RJIA0478E

HFC-134a (R-134a) Service Tools and Equipment EJS002GA

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

MTC-10
 PREPARATION

Tool number
Tool name
Description A

Container color: Light blue B

Container marking: HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size: Thread size
● large container 1/2″ -16 ACME C
S-NT196

D
Type: Poly alkaline glycol oil (PAG),
type R
KLH00-PAGR0 Application: HFC-134a (R-134a) vane
Nissan A/C System Oil Type R rotary compressors (Nissan only) E
Lubricity: 40 m (1.4 Imp fl oz.)
S-NT197

G
Recovery/Recycling Function: Refrigerant Recovery and
Recharging equipment (ACR4) Recycling and Recharging
H

RJIA0195E
I

MTC

Power supply:
Electrical leak detector K
● DC 12V (Power socket)

SHA705EB

(J-43926) M
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) Dye injector
Power supply:
Use with J-41447, 1/4 ounce
DC 12V (Battery terminal)
bottle
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872) ZHA200H

Refrigerant dye cleaner

MTC-11
 PREPARATION

Tool number
Description
Tool name

Power supply: DC 12V (Battery

terminal)
For checking refrigerant leak when
(J-42220)
fluorescent dye is installed in A/C
UV lamp and UV safety goggles
system.
Includes: UV lamp and UV safety
goggles
SHA438F

Application: For HFC-134a (R-134a)

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

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

SHA440F

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

SHA441F

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

RJIA0196E

Hose color:
Service hoses ● Low hose: Blue with black stripe

● High side hose ● High hose: Red with black stripe

● Low side hose ● Utility hose: Yellow with black stripe

or green with black stripe
● Utility hose Hose fitting to gauge:
S-NT201
● 1/2″ -16 ACME

MTC-12
 PREPARATION

Tool number
Description A
Tool name

Service couplers Hose fitting to service hose: B

● High side coupler ● M14 x 1.5 fitting is optional or
● Low side coupler permanently attached.
C
S-NT202

D
For measuring of refrigerant
Refrigerant weight scale Fitting size: Thread size
● 1/2″ -16 ACME E

S-NT200

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

MTC

MTC-13
 REFRIGERATION SYSTEM

REFRIGERATION SYSTEM PFP:KA990

Refrigerant Cycle EJS006G9

REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is
controlled by an externally equalized expansion valve, located at dash panel.
FREEZE PROTECTION
Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the SD6V12 displacement compressor to
prevent freeze up.
Refrigerant System Protection EJS006GA

REFRIGERANT PRESSURE SENSOR

The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sen-
sor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refriger-
ant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.
ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side
detected by refrigerant pressure sensor is over about 2,746 kPa (27.5 bar, 28 kg/cm2 , 398 psi), or below
about 134 kPa (1.37 bar, 1.4 kg/cm2 , 20 psi).
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (37.3 bar,
38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refriger-
ant into the atmosphere.

MJIB0355E

MTC-14
 LUBRICANT

LUBRICANT PFP:KLG00
A
Adjustment of Compressor Lubricant Amount EJS002GD

Compressor lubricant circulates through the system with refrigerant. When cooler system component is
replaced or after the large refrigerant leak, lubricant needs to be added to compressor. Also it is important to B
maintain lubricant level properly. If lubricant level is not proper, following might happen.
● Insufficient lubricant: Compressor adherence
● Lubricant overfill: Insufficient cooling (insufficient heat exchange) C
LUBRICANT
KC59G Compressor D
Lubricant name: Nissan A/C System Oil Type R
Part number: KLH00-PAGR0
E
PROCEDURES FOR LUBRICANT RETURN OPERATION
Follow the steps bellow to adjust the lubricant level.
F
1. CHECK A/C SYSTEM
1. Make sure A/C system operates normally.
2. Make sure a large amount of refrigerant or lubricant does not leak. G
OK or NG
OK >> GO TO 2.
H
NG >> GO TO 3.

2. LUBRICANT RETURN OPERATION

I
1. Start the engine. Put it in the following state.
– Engine speed: Idling - 1,200 rpm
– A/C switch: ON MTC
– Fan speed: HI
– Air intake: Recirculation
– Set temperature: FULL HOT K
2. Keep running for approximately 10 minutes.
3. Stop the engine.
L
CAUTION:
When a large leak of refrigerant or lubricant is found, do not perform lubricant return operation.
M
>> GO TO 3.

3. CHECK COMPRESSOR
Is compressor replaced?
YES >> GO TO MTC-16, "LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR" .
NO >> GO TO 4.

4. CHECK OTHER COMPONENTS

Is any other component to be replaced? (evaporator, condenser, liquid tank, large refrigerant or lubricant)
YES >> GO TO MTC-16, "LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS
OTHER THAN COMPRESSOR" .
NO >> GO TO MTC-40, "CHECK FUNCTION (FOR GASOLINE ENGINE)" .

MTC-15
 LUBRICANT

LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPONENTS OTHER THAN COM-

PRESSOR
Add compressor lubricant from the high-pressure port of the compressor according to the table below. α indi-
cates lubricant amount that spouts with refrigerant when refrigerant is discharged.
Components to be replaced Lubricant amount to be added
Evaporator 35+α cm3
Condenser 15+α cm3
Liquid tank 5+α cm3

CAUTION:
When replacing 2 or more parts, do not sum up α.
Ex. Lublicant amount to be added to evaporator and liquid tank (cm3 ) = 35 + 5 + α
LUBRICANT LEVEL ADJUSTMENT WHEN REPLACING COMPRESSOR
1. Drain the compressor lubricant from the removed compressor's high and low-pressure ports and measure
the amount of lubricant.

MJIB0133E

2. Drain the compressor lubricant from a new compressor according to the formula below. α indicates lubri-
cant amount that spouts with refrigerant when refrigerant is discharged.
Lubricant amount drained from new compressor3 )
= Lubricant amount contained in the new compressor (80) - Lubricant amount discharged from the
removed compressor - Lubricant amount that adheres to inside of compressor (20) - α
= 60 - Lubricant amount discharged from the removed compressor - α
3. When adding lubricant, add the appropriate amount of compressor lubricant from the compressor's high-
pressure port.

MTC-16
 TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS PFP:00004

A
CONSULT-II Functions EJS002FE

CONSULT-II has display functions for work support, self-diagnosis, data monitor, and active tests for each part
by combining data reception and command transmission via communication lines from the BCM. B
Inspection Item, Diagnosis
BCM trouble diagnosis item Description
Mode
Air conditioner Data monitor Displays BCM input data in real time. C

CONSULT-II BASIC OPERATION

D
CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. Turn ignition switch OFF. E
2. Connect CONSULT-II and CONSULT-II CONVERTER to the
data link connector.
3. Turn ignition switch ON. F

H
PBIA3525E

I
4. Touch “START (NISSAN BASED VHCL)”.

MTC

L
BCIA0029E

5. Touch “BCM” on the “SELECT SYSTEM” screen.

● If “BCM” is not displayed, print the “SELECT SYSTEM”
M
screen, and then refer to GI-36, "CONSULT-II Data Link Con-
nector (DLC) Circuit" .

BCIA0030E

MTC-17
 TROUBLE DIAGNOSIS

6. Touch “AIR CONDITIONER” on the “SELECT TEST ITEM”

screen.

RJIA1109E

7. Touch “DATA MONITOR” on the “SELET DIAG MODE” screen.

For details, refer to separate volume “CONSULT-II Operation
Manual”.

BCIA0031E

DATA MONITOR
Operation Procedure
1. Touch “AIR CONDITIONER” on the “SELECT TEST ITEM”
screen.
2. Touch “DATA MONITOR” on the “SELET DIAG MODE” screen.
For details, refer to separate volume “CONSULT-II Operation
Manual”.
3. Touch “All SIGNALS” on the “DATA MONITOR” screen.
4. Touch “START”.
5. Touch “RECORD” while monitoring to record the status of the
item being monitored. To stop recording, touch “STOP”.
RJIA1112E

Monitored Item
Monitor item “UNIT” Contents
Displays status “Blower fan on (ON)/blower fan off (OFF)” as judged by the BCM from
FAN ON SIG [ON/OFF]
the input from fan switch.
Displays status “Compressor on (ON)/compressor off (OFF)” as judged by the BCM
AIR COND SW [ON/OFF]
from the input from the controller.
Displays status “Thermal control amplifier on (ON)/thermal amplifier off (OFF)” judged
THERMO AMP [ON/OFF]
by the BCM from the input from thermal control amplifier.
Displays status “IGN position (ON)/OFF, ACC position (OFF)” as judged from the key
IGN ON SW [ON/OFF]
switch signal.

MTC-18
 TROUBLE DIAGNOSIS

Diagnosis Procedure EJS002FF

DIAGNOSIS CHART BY SYMPTOM A

Symptom Operation inspection Suspect systems Possible causes
No air comes out. Blower fan motor har- Refer to MTC-32, "Blower
Airflow volume does not change.
Check blower fan motor operation.
ness Fan Motor System" . B
● Improper air mix door
lever installation
● Air mix door system
C
Common items (Check malfunction (damage,
Operate temperature control dial. Con- locking, etc.)
these items for either of
firm that air mix door moves through Air mix door harness
two malfunctions listed
full stroke. ● Air mix door cable inop- D
below.) erative
● Refer to MTC-58, "Air
Inaccurate temperature control

Mix Door Cable Adjust- E

ment" .
With the fan setting dial and A/C switch
Refer to MTC-34, "Mag-
ON, check operation of the magnetic Magnetic clutch harness
clutch.
netic Clutch System" . F

● Refer to MTC-40,
"CHECK FUNCTION
(FOR GASOLINE G
No cold air comes out.
ENGINE)" in “Cooling
(Normal airflow amount)
● Check refrigerant level. malfunction”.
Cooler system
● Performance check ● Refer to MTC-42, H
"DIAGNOSIS BY
PRESSURE GAUGE"
in “Cooling malfunc-
tion”. I

No warm air comes out. After warming up engine, heater core ● Poor engine coolant
(Airflow volume is nor- inlet and outlet sides of the heater Coolant route ● Blockage of heater
mal.) hose do not become warm. hose or heater core
MTC

● Improper installation of
mode door lever
K
● Mode door system mal-
function (damage, lock-
Operate the mode dial to confirm that ing, etc.)
Unable to switch air outlets to
the mode door moves through the full Mode door harness
others. ● Mode door cable inop- L
stroke.
erative
● Refer to MTC-57,
"Mode Door Cable M
Adjustment" .
● Improper installation of
intake door lever
● Intake door system
malfunction (damage,
Operate the intake switch lever and locking, etc.)
Unable to switch intake inlets to
make sure the intake door moves Intake door harness
others. ● Intake door cable inop-
through a full stroke.
erative
● Refer to MTC-56,
"Intake Door Cable
Adjustment" .

MTC-19
 TROUBLE DIAGNOSIS

Component Parts Location EJS002FG

CR ENGINE MODELS

MJIA0175E

MTC-20
 TROUBLE DIAGNOSIS

HR ENGINE MODELS
A

MTC

MJIB0275E

MTC-21
 TROUBLE DIAGNOSIS

K9K ENGINE MODELS

MJIA0198E

MTC-22
 TROUBLE DIAGNOSIS

Wiring Diagram —HEATER— EJS002FH

MTC

MJWA0163E

MTC-23
 TROUBLE DIAGNOSIS

Wiring Diagram —A/C— CR Engine Models EJS002FN

MJWA0164E

MTC-24
TROUBLE DIAGNOSIS

MTC

MJWA0258E

MTC-25
 TROUBLE DIAGNOSIS

Wiring Diagram —A/C— HR Engine Models EJS006AE

MJWA0227E

MTC-26
TROUBLE DIAGNOSIS

MTC

MJWA0165E

MTC-27
 TROUBLE DIAGNOSIS

Wiring Diagram —A/C— K9K Engine Models EJS0057F

MJWA0166E

MTC-28
TROUBLE DIAGNOSIS

MTC

MJWA0263E

MTC-29
 TROUBLE DIAGNOSIS

Wiring Diagram —PTC/H— EJS005KI

MJWA0264E

PTC heater function is intended to improve the heating performance with CTP electrical system for air heating
system which is broken down into several stages controlled by relays.

MTC-30
 TROUBLE DIAGNOSIS

Function Inspection EJS0057G

1. CHECK FAN SPEED A

Operate the fan setting dial to make sure the fan speed changes. Confirm operation for all fan speeds.
OK or NG B
OK >> Switch fan speed to “4” and GO TO 2.
NG >> Refer to MTC-32, "Blower Fan Motor System" , MTC-34, "Magnetic Clutch System" .
C
2. CHECK A/C SWITCH
1. Push A/C switch.
D
2. Check visually that indicator lamp turns on. Check by sound that compressor is operating.
OK or NG
OK >> GO TO 3. E
NG >> Magnetic clutch system malfunction: Refer to MTC-34, "Magnetic Clutch System" .

3. CHECK AIR OUTLET

F
Operate the mode dial to make sure the air outlet changes.
OK or NG
OK >> GO TO 4. G
NG >> Mode door system malfunction: Refer to MTC-57, "Mode Door Cable Adjustment" .

4. CHECK AIR INLET H

Operate intake air control lever and listen to intake sound to confirm that inlet switches.
OK or NG
I
OK >> GO TO 5.
NG >> Intake door system malfunction: Refer to MTC-56, "Intake Door Cable Adjustment" .

5. CHECK WITH TEMPERATURE SETTING LOWERED MTC

1. Turn compressor ON.

2. Set temperature control dial to “FULL COLD”. K
3. Confirm cool air blows from outlets.
OK or NG
OK >> GO TO 6. L
NG >> Air mix door system malfunction: Refer to MTC-58, "Air Mix Door Cable Adjustment" .

6. CHECK WITH TEMPERATURE SETTING RAISED M

1. Warm up the engine.
2. Set temperature control dial to “FULL HOT”.
3. Confirm warm air blows from outlets.
OK or NG
OK >> If all function checks are normal (no phenomena reoccurrence), refer to MTC-19, "DIAGNOSIS
CHART BY SYMPTOM" and perform appropriate diagnosis.
NG >> Air mix door system malfunction: Refer to MTC-58, "Air Mix Door Cable Adjustment" .

MTC-31
 TROUBLE DIAGNOSIS

Blower Fan Motor System EJS0057H

INSPECTION PROCEDURE
Symptom: Blower fan motor does not operate.
1. START INSPECTION
Check blower fan motor operation at each fan speed.
1 : Blower fan motor does not operate at all.
2 : Blower fan motor does not operate at one of speeds 1 - 4.
Do inspection results indicate 1 or 2 above?
1 >> GO TO 2.
2 >> GO TO 6.

2. CHECK POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect blower fan motor connector.
3. Turn ignition switch ON.
4. Check voltage between blower fan motor connector terminal 1 and ground.
1 (L) – Ground : Battery voltage
OK or NG
OK >> GO TO 3.
NG >> Check power supply circuit and 15A fuses [Nos. 9 and
10, located in the fuse block (J/B)]. Refer to PG-5,
"POWER SUPPLY ROUTING" .
● If OK, check for open circuit in wiring harness. Repair
or replace as necessary.
● If NG, replace fuse and check wiring harness for short
MJIB0315E
circuit. Repair or replace as necessary.

3. CHECK GROUND CIRCUIT

1. Turn ignition switch OFF.
2. Check continuity between blower fan motor connector terminal 2
and ground.
2 (R) – Ground : Continuity should exist.
OK or NG
OK >> GO TO 4.
NG >> GO TO 5.

MJIB0316E

4. CHECK BLOWER FAN MOTOR

Check continuity between blower fan motor terminals 1 and 2.
1–2 : Continuity should exist.
OK or NG
OK >> End of trouble diagnosis
NG >> Replace the blower fan motor.

MJIB0126E

MTC-32
 TROUBLE DIAGNOSIS

5. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER FAN MOTOR AND BLOWER FAN RESISTOR A
1. Disconnect blower fan resistor harness connector.
2. Check continuity between blower fan motor connector terminal
and blower fan resistor terminal 1. B

2 (R) – 1 (L) : Continuity should exist.

OK or NG C
OK >> GO TO 6.
NG >> Repair harness or connector between blower fan motor
and blower fan resistor. D

MJIB0317E
E
6. CHECK BLOWER FAN RESISTOR
Check continuity between blower fan resistor terminals 1 and 2, 3, 4.
F
Terminals Continuity
2 Approx. 0.32Ω
G
1 3 Approx. 1.4Ω
4 Approx. 2.7Ω

OK or NG H
OK >> GO TO 7.
NG >> Replace blower fan resistor.
MJIB0128E
I
7. CHECK FAN SWITCH
1. Disconnect controller connector. MTC
2. Check continuity between controller terminals 1 and 2, 3, 4, 5, 6.

Terminals Condition Continuity K

1 Fan: OFF
5 Fan: Speed 4
L
6 4 Fan: Speed 3 Yes
3 Fan: Speed 2
2 Fan: Speed 1 M
OK or NG MJIA0181E

OK >> GO TO 8.
NG >> Replace controller.

8. CHECK CIRCUIT CONTINUITY BETWEEN CONTROLLER AND BLOWER FAN RESISTOR

Check continuity between the controller and the blower fan resistor
terminals.
5 (R) – 1 (L) : Continuity should exist.
4 (Y) – 2 (Y) : Continuity should exist.
3 (R) – 3 (R) : Continuity should exist.
2 (W) – 4 (W) : Continuity should exist.
OK or NG
OK >> GO TO 9.
NG >> Repair harness or connector. MJIB0129E

MTC-33
 TROUBLE DIAGNOSIS

9. CHECK FAN SWITCH GROUND CIRCUIT

Check continuity between controller terminal 6 and ground.
6 (B) – Ground : Continuity should exist.
OK or NG
OK >> End of trouble diagnosis
NG >> Repair harness or connector.

MJIA0183E

Magnetic Clutch System EJS0057I

INSPECTION PROCEDURE
Symptom: When A/C switch and fan switch are turned ON, magnetic clutch does not operate.
1. CHECK WITH AUTO ACTIVE TEST MODE
Perform auto active test to make sure magnetic clutch operates. Refer to PG-43, "Auto Active Test" .
OK or NG
OK >> GO TO 7.
NG >> GO TO 2.

2. CHECK MAGNETIC CLUTCH VOLTAGE

1. Disconnect compressor connector.
2. Turn ignition switch ON.
3. Check voltage between compressor terminal 1 and ground.
1 (Y) – Ground : Battery voltage
OK or NG
OK >> ● GO TO 4. (CR and HR engine models)
● GO TO 5. (K9K engine models)

NG >> After Checking the Fuse (#41), GO TO 3. For the Fuse

Block Layout, Refer to PG-5, "POWER SUPPLY ROUT- MJIB0146E

ING" .
● If fuse is OK, check for open circuit in harness.

● If a fuse is NG, determine the possible cause, repair circuit and replace blown fuse.

3. CHECK CIRCUIT CONTINUITY BETWEEN COMPRESSOR AND IPDM E/R

Disconnect the IPDM E/R connector, and check continuity between
compressor terminal 1 and IPDM E/R terminal 41.
1 (Y) – 41 (Y) : Continuity should exist.
OK or NG
OK >> ● GO TO 4. (CR and HR engine models)
● GO TO 5. (K9K engine models)

NG >> Repair harness or connector.

MJIB0147E

MTC-34
 TROUBLE DIAGNOSIS

4. CHECK MAGNETIC CLUTCH A

Check continuity between compressor terminal 1 and ground.
1 (Y) – Ground : Continuity should exist.
B
OK or NG
OK >> Apply battery voltage to magnetic clutch directly and
check operation sound.
C
1. If inspection results are NG, replace magnetic clutch.
2. If magnetic clutch is normal, replace IPDM E/R.
NG >> Replace magnetic clutch. D
RJIA1019E

5. CHECK GROUND CIRCUIT E

Check continuity between compressor terminal 2 and ground.

2 (B) – Ground : Continuity should exist. F
OK or NG
OK >> GO TO 6.
NG >> Repair harness or connector. G

MJIA0205E

6. CHECK MAGNETIC CLUTCH I

Check continuity between compressor terminals 1 and 2.

1–2 : Continuity should exist. MTC
OK or NG
OK >> Apply battery voltage to magnetic clutch directly and
K
check operation sound.
1. If inspection results are NG, replace magnetic clutch.
2. If magnetic clutch is normal, replace IPDM E/R. L
NG >> Replace magnetic clutch.
MJIA0206E

M
7. CHECK REFRIGERANT PRESSURE SENSOR
Check refrigerant pressure sensor.
Refer to EC-436, "REFRIGERANT PRESSURE SENSOR" . (CR engine with EURO–OBD)
Refer to EC-788, "REFRIGERANT PRESSURE SENSOR" . (CR engine without EURO–OBD)
Refer to EC-1231, "REFRIGERANT PRESSURE SENSOR" . (HR engine with EURO–OBD)
Refer to EC-1592, "REFRIGERANT PRESSURE SENSOR" . (HR engine without EURO–OBD)
Refer to EC–K9K–473.
OK or NG
OK >> Connect compressor and IPDM E/R connectors, then GO TO 8.
NG >> Repair or replace parts according to the inspection results.

MTC-35
 TROUBLE DIAGNOSIS

8. CHECK BCM INPUT SIGNAL

With CONSULT-II
● Check if the compressor ON-OFF, fan ON-OFF and thermal
amplifier ON-OFF using the BCM can “air conditioner” data
monitor Refer to MTC-17, "CONSULT-II Functions" .
Without CONSULT-II
● GO TO 9.
OK or NG
OK >> GO TO 21.
NG >> ● Blower fan switch malfunction: GO TO 9.
● A/C switch malfunction: GO TO 13.

● Thermal amplifier malfunction: GO TO 17. RJIA1112E

9. CHECK FAN ON SIGNAL

Check voltage between controller terminal 1 and ground.
Terminals (Wire color) Voltage [V]
Connector Condition
(+) (-) (Approx.)

Fan: ON Battery voltage

M58 1 (OR) Ground
Fan: OFF 1

OK or NG
OK >> GO TO 13.
NG >> GO TO 10.
MJIA0185E

10. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND CONTROLLER

Disconnect controller and BCM connectors, and check continuity
between BCM terminal 50 and controller terminal 1.
50 (OR) – 1 (OR) : Continuity should exist.
OK or NG
OK >> GO TO 11.
NG >> Repair harness or connector.

MJIB0148E

11. CHECK FAN SWITCH

Check continuity between controller terminals 1 and 6.
Terminal Condition Continuity
Fan: OFF Yes
1 6
Fan: ON No

OK or NG
OK >> GO TO 12.
NG >> Replace controller.

MJIA0187E

MTC-36
 TROUBLE DIAGNOSIS

12. CHECK GROUND CIRCUIT A

Check continuity between controller terminal 6 and ground.
6 (B) – Ground : Continuity should exist.
B
OK or NG
OK >> Connect controller connector, and GO TO 13.
NG >> Repair harness or connector.
C

D
MJIA0188E

13. CHECK AIR CONDITIONER SIGNAL E

Check voltage between controller terminal 12 and ground.

12 (P) – Ground : Battery voltage F
OK or NG
OK >> GO TO 14.
NG >> GO TO 16. G

MJIB0149E

14. CHECK A/C SWITCH I

Check continuity between controller terminals 10 and 12.

MTC
Terminal Condition Continuity
A/C switch: Only
10 12 Yes
during operation
K
OK or NG
OK >> GO TO 15.
NG >> Replace controller. L

MJIA0190E

M
15. CHECK GROUND CIRCUIT
Check continuity between controller terminal 10 and ground.
10 (B) – Ground : Continuity should exist.
OK or NG
OK >> GO TO 17.
NG >> Repair harness or connector.

MJIA0191E

MTC-37
 TROUBLE DIAGNOSIS

16. CHECK CIRCUIT CONTINUITY BETWEEN CONTROLLER AND BCM

Check continuity between controller terminal 12 and BCM terminal
61.
12 (P) – 61 (P) : Continuity should exist.
OK or NG
OK >> Replace BCM.
NG >> Repair harness or connector.

MJIB0150E

17. CHECK 1: INTAKE SENSOR POWER SUPPLY CIRCUIT

Disconnect intake sensor connector, turn ignition switch ON, and
check voltage between intake sensor terminal 1 and ground.
1 (Y) – Ground : Approx. 5V
OK or NG
OK >> GO TO 18.
NG >> GO TO 20.

MJIA0195E

18. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND BCM

Check continuity between intake sensor terminal 3 and BCM termi-
nal 35.
3 (Y) – 35 (Y) : Continuity should exist.
OK or NG
OK >> GO TO 19.
NG >> Repair harness or connector.

MJIB0137E

19. CHECK INTAKE SENSOR

Disconnect intake sensor connector and check the resistance
between terminals 1 to 3.
OK or NG
OK >> Replace BCM.
NG >> Replace the intake sensor.

MJIA0093E

MTC-38
 TROUBLE DIAGNOSIS

20. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND BCM A

1. Disconnect the BCM connector.
2. Check continuity between intake sensor terminal 1 and BCM
amp. terminal 45. B

1 (Y) – 45 (Y) : Continuity should exist.

3. Check continuity between intake sensor terminal 1 and ground. C
1 (Y) – Ground : Continuity should not exist.
OK or NG D
OK >> Replace BCM.
MJIB0138E
NG >> Repair harness or connector.

21. CHECK CAN COMMUNICATION CIRCUIT E

Check the CAN communication between the BCM and ECM control unit, and the ECM control unit and IPDM
E/R. Refer to BCS-30, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" and LAN-7, "CAN F
Communication Unit" .
OK or NG
OK >> End of trouble diagnosis G
NG >> Repair or replace parts based on the diagnosis results.

MTC

MTC-39
 TROUBLE DIAGNOSIS

Component Inspection EJS006AI

REFRIGERANT PRESSURE SENSOR

MJIB0274E

The refrigerant pressure sensor is attached to the liquid tank.

Make sure that the A/C refrigerant pressure and the sensor output
voltage are within the specified range as shown in the A/C operating
condition figure.

RJIA2954E

Refer to EC-436, "REFRIGERANT PRESSURE SENSOR" . CR (with EURO-OBD).

Refer to EC-788, "REFRIGERANT PRESSURE SENSOR" . CR (without EURO-OBD).
Refer to EC-1231, "REFRIGERANT PRESSURE SENSOR" . HR (with EURO-OBD).
Refer to EC-1592, "REFRIGERANT PRESSURE SENSOR" . HR (without EURO-OBD).
Refer to EC-K9K-473.
Insufficient Cooling EJS0057J

CHECK FUNCTION (FOR GASOLINE ENGINE)

Inspection Procedure
1. Connect manifold gauge to vehicle cooler system (service valve).
2. Attach a psychrometer to blower unit air inlet (under glove box). Attach a dry-bulb thermometer to right-
center of ventilator grille.
3. Start and warm up the engine.
4. After warming-up engine, make sure engine speed is the specified idle speed.
5. Operate compressor. Adjust controller to match conditions below.
Fan speed : HI
Inlet : Recirculation (REC)
Outlet : Ventilation (VENT)
Predetermined temperature : FULL COLD
6. Fully open the hood and door windows, and close all the doors.
7. Keep this state until the cooler system becomes stable (after approximately 10 minutes).
8. Keep the engine speed at idle.
9. Measure the temperature and humidity at the air inlets, temperature at the air outlets, and the high-pres-
sure and low-pressure of the cooler cycle, and compare them to “Ambient temperature - pressure charac-
teristic”, “Intake air temperature - outlet air temperature characteristic” for estimating.

MTC-40
 TROUBLE DIAGNOSIS

Performance Curve
A
Ambient Temperature - Pressure Characteristics

I
RJIA1024E

Intake Air Temperature - Pressure Characteristics MTC

RJIA1025E

MTC-41
 TROUBLE DIAGNOSIS

DIAGNOSIS BY PRESSURE GAUGE

Connect a manifold gauge to the cooler cycle (service valve), and determine faulty parts and possible causes
by pressure in the cooler cycle, then troubleshoot.
Symptom Cycle status Possible causes Action
Insufficient cooling of con-
denser
● Operation malfunction
● Repair or replace as nec-
of radiator and con-
essary
denser fan
● Clean and repair con-
● Improper installation of
They return to normal when denser fins.
air guide
condenser is cooled with water.
● Clogged condenser or
dirty fins

High-pressure and low-pressure Discharge refrigerant com-

are both high. Excessively charged pletely, evacuate again, and
refrigerant recharge with proper amount
of refrigerant.
When the compressor has been Discharge refrigerant com-
stopped, pressure drops quickly Mixed air in the cooler pletely, evacuate again, and
by approximately 2 kg/cm2 , and system recharge with proper amount
then decreases gradually. of refrigerant.
Temperature at low-pressure
Expansion valve opened
pipe is lower than that at evapo-
too far (excessive refriger- Replace expansion valve.
rator outlet, or low-pressure pipe
ant flow).
becomes frosted.
Crushed points or clogs in
Temperature differences occur
high-pressure pipe Repair or replace as neces-
High-pressure is extremely high. at points where high-pressure
between compressor and sary
pipe is crushed or clogged.
condenser
Expansion valve is
blocked.
Remove foreign materials
Evaporator outlet is not cold. ● Gas leakage around
from expansion valve or
Frost forms on evaporator inlet. sensor unit.
replace expansion valve.
● Clogged by foreign
material
Temperature differences occur
at the outlet and inlet pipe of the Liquid tank malfunction
Replace liquid tank
liquid tank or the liquid tank (strainer clogged)
High-pressure and low-pressure becomes frosted.
are both low (low-pressure occa-
Evaporator fins are
sionally becomes minus). Repair or replace.
clogged or crushed.
Evaporator becomes frosted.
Refer to MTC-32, "Blower
Insufficient airflow
Fan Motor System" .
● Check for refrigerant
Some temperature difference leaks.
occurs between high-pressure Insufficient refrigerant ● Discharge refrigerant com-
and low-pressure pipes of the amount pletely, evacuate again,
compressor. and recharge with proper
amount of refrigerant.

MTC-42
 TROUBLE DIAGNOSIS

Symptom Cycle status Possible causes Action

A
Discharge refrigerant com-
Water mixed in cooler sys- pletely, evacuate again to
Occasionally high-pressure Sometimes evaporator outlet is
tem. (Blockage caused by remove all moisture, and
becomes low, and low-pressure not cold and sometimes frost
moisture freezing at the recharge with proper amount B
becomes minus. forms on evaporator inlet.
expansion valve.) of refrigerant. Be certain to
replace liquid tank.

When compressor is stopped, Compressor malfunction

(improper compression)
C
pressure equalizes quickly and
High-pressure is low, and low- there is no temperature differ- ● Damage or breakage of
Replace compressor.
pressure is high. ence between compressor high- valve
pressure pipes and low-pres- ● Gasket worn or dam- D
sure pipes. aged

MTC

MTC-43
 TROUBLE DIAGNOSIS

DIAGNOSIS OF COMPRESSOR
If there is a compressor unit malfunction (internal noise, insufficient cooling), follow table below and perform
trouble diagnosis.
Symptom Checklist Inspection Method Result Action
Both high- and low-
Recharge with proper amount of
Cooler sys- pressure sides are
Check with a manifold refrigerant.
tem internal high. (Note 2)
Noise (rattling or roll- gauge.
ing sound) from pressure High/low-pressures
Replace compressor only.
compressor unit hunt. (Note 2)
when A/C is ON.
Check com-
Sample compressor oil
pressor oil
and judge.
condition.
Check rotation of com-
Compressor pressor. If seized or stuck, Diagnostic Result 1:
body sample compressor oil Replace compressor only.
Refer to the criteria
and judge.
shown in compres-
Diagnostic result 2:
Insufficient cooling Check with a manifold sor lubricant.
Replace compressor and liquid
(Note 1) gauge. If the difference
tank.
Cooler sys- between high-pressure
tem internal and low-pressure is small
pressure or almost the same, sam-
ple compressor oil and
judge.
Outlet air tempera-
ture rises tempo-
— — — Replace compressor only.
rarily while driving.
(Note 2)

Note 1: First conduct inspection according to trouble diagnosis for each malfunction.
Note 2: Applicable only to variable-capacity compressor

SJIA0232E

MTC-44
 TROUBLE DIAGNOSIS

Detecting Leaks With Fluorescent Indicator EJS0057K

METHOD FOR DETECTING REFRIGERANT LEAKAGE A

SJIA0233E
G

1. Wear goggles provided with the fluorescent detector.

2. Connect the UV lamp power cable to the negative battery termi- H
nal.
3. Press UV lamp switch. Check for cooler system leaks. (Light
green fluorescent will appear at the leak.) I
4. Repair or replace parts with refrigerant leaks and wipe off the
fluorescent indicator.
CAUTION: MTC
Completely wipe off all fluorescent indicators. Use a cotton
swab or something similar to remove indicator from gaps SJIA0234E
between parts, screw threads, and similar places.
K
5. After finishing work, use a UV lamp to make sure no fluorescent indicator remains.
CAUTION:
● Do not look directly into the UV lamp light source.
L
● For continuous operating time of UV lamp and other details, follow the Owner's Manual when
performing the operation.
● Dust, dirt, and adhesive of packing materials used in condenser, evaporator, and other locations
may fluoresce. Be careful to avoid misidentifying leaks. M

Inspection Procedure
● Shine UV lamp on pipe joints from different angles to make sure
there are no leaks.
● Use a cotton swab or something similar to wipe water off of drain
hoses. By shining UV lamp, a check can also be made to detect
leaks from evaporator.
● Use a mirror to check for refrigerant leaks in difficult to see
areas.

SJIA0235E

MTC-45
 CONTROL UNIT

CONTROL UNIT PFP:27500

Removal and Installation EJS002GE

REMOVAL
1. Remove cluster lid C. Refer to IP-4, "INSTRUMENT PANEL
ASSEMBLY" .
2. Remove the air intake lever.
3. Remove the screws and clips, and then remove the air condi-
tioner finisher.

MJIA0036E

4. Remove the air mix door cable, mode door cable, and intake
door cable from the air conditioner unit.
5. Remove screws, and pull out controller.
6. Disconnect connector and remove controller.
CAUTION:
Adjust the door cables during installation. Refer to MTC-56,
"Intake Door Cable Adjustment" , MTC-57, "Mode Door Cable
Adjustment" and MTC-58, "Air Mix Door Cable Adjustment" .

MJIA0037E

INSTALLATION
Install in the reverse order of removal.
Disassembly and Assembly EJS002GF

RJIA1073J

1. Rear window defogger switch 2. Air conditioner switch 3. Mode dial

4. Fan control dial 5. Temperature control dial 6. Air intake lever
7. Controller 8. Illumination bulb 9. Mode door cable
10. Intake door cable 11. Air mix door cable

MTC-46
 CONTROL UNIT

NOTE:
Install the inner cable of each door cable to the corresponding lever, A
as shown in the figure. Press the outer cable until it hooks on the
tabs and becomes fixed.
B

MJIA0038E D

MTC

MTC-47
 A/C UNIT ASSEMBLY

A/C UNIT ASSEMBLY PFP:27210

Removal and Installation EJS002GG

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R-
134a)] to discharge refrigerant.
2. Drain engine coolant.
3. Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere.
MJIA0039E

4. Pull out the heater hoses from the heater core.

CAUTION:
● Some coolant may spill when heater hoses are discon-
nected.
● Close off the coolant inlet and outlet on the heater core (2
locations) with waste.

MJIA0040E

5. Remove instrument panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .

6. Remove the vehicle harness clips and then remove the instru-
ment panel stay.

MJIA0041E

MTC-48
 A/C UNIT ASSEMBLY

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

MJIA0042E
G
7. Remove the ventilator duct mounting screws and clips.
8. Remove the air conditioner mounting bolts, steering member mounting bolts, column shaft mounting bolts,
and the harness clips. H
9. Remove the BCM. Refer to BCS-30, "Removal and Installation of BCM" .
10. Remove the steering member, and then remove the air conditioner unit.
INSTALLATION I
CAUTION:
● Replace all O-rings on the pipes with new ones. Apply a coat of compressor lubricant prior to
installation. MTC
● After charging with refrigerant, check for refrigerant leaks.
1. Install the air conditioner unit.
K
CAUTION:
Confirm that the air conditioner drain and drain hose posi-
tions match up.
L
Air conditioner unit mounting bolt.
Tightening : 5.98 - 7.65 N·m (0.61 - 0.78 kg-m,
torque 53 - 67 in-lb) M
2. Perform removal steps 3-10 in reverse order.
Steering member mounting nut and bolt
Tightening :11 - 13 N·m (1.1 - 1.4 kg-m, 8.2 -
torque 9.5 ft-lb) MJIA0043E

Mounting bolts for the low-pressure flexible hoses

and high-pressure pipes.
Tightening :2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26
torque - 52 in-lb)
3. Fill engine coolant.
4. Charge refrigerant using refrigerant recovery unit [for HFC-134a(R-134a)].

MTC-49
 A/C UNIT ASSEMBLY

Disassembly and Assembly EJS002GH

RJIA1075J

1. Blower fan motor case (RH) 2. Cover (RH) 3. Screw

4. Foot duct (RH) 5. Cooling hose 6. Blower fan motor
7. Air mix door 8. Foot duct (LH) 9. Screw
10. Clips 11. Screw 12. Cover (LH)
13. Blower fan motor case (LH) 14. Ventilation door 15. Defroster rod
16. Deflator door 17. Foot door 18. Heater core
19. Heater pipe cover 20. Screw 21. Thermal control amplifier
22. Heater pipe packing 23. Lower blower fan motor case 24. Screw
25. Bracket 26. Intake door link 27. Screw
28. Blower fan resistor 29. Screw 30. Attachment case
31. Air mix door lever 32. Spring 33. Screw
34. Heater pipe clip 35. Screw 36. Bolt

MTC-50
 A/C UNIT ASSEMBLY

37. Expansion valve 38. Insulator 39. Air conditioner filter

40. Intake lever 41. Intake case (LH) 42. Intake door A
43. Intake case (RH) 44. Evaporator 45. Expansion valve cover
46. Ventilation/ Deflator lever 47. Ventilation/ Deflator rod 48. Ventilation/ Deflator link
49. Washer 50. Screw 51. Washer B
52. Screw 53. Washer 54. Foot link
55. Foot lever 56. Main link
C

MTC

MTC-51
 HEATER CORE

HEATER CORE PFP:27140

Removal and Installation EJS002GI

REMOVAL
1. Remove the air conditioner unit. Refer to MTC-48, "A/C UNIT
ASSEMBLY" .
2. Remove the foot duct (LH), screws, and heater pipe cover.
3. Remove the main link and ventilation/defroster link.
4. Remove the heater pipe clip, and then pull out the heater core
from air conditioner unit.

MJIA0044E

INSTALLATION
Install in the reverse order of removal.

MTC-52
 BLOWER MOTOR

BLOWER MOTOR PFP:27226

A
Removal and Installation EJS002GJ

REMOVAL
1. Remove instrument panel assembly. Refer to IP-4, "INSTRU-
B
MENT PANEL ASSEMBLY" .
2. Remove the side ventilator duct (RH). Refer to MTC-62, "SIDE
VENTILATOR DUCT" .
C

MJIA0141E
E

3. Disconnect the cooling hose, and remove the blower fan motor.
CAUTION: F
When the blower fan and blower fan motor are assembled,
the balance is adjusted, so do not replace the individual
parts.
G

MJIA0142E

INSTALLATION I
Install in the reverse order of removal.
CAUTION:
Firmly fasten the blower fan motor assembly flange fastening hooks in the air conditioner unit. MTC

MTC-53
 BLOWER FAN RESISTOR

BLOWER FAN RESISTOR PFP:27150

Removal and Installation EJS002GL

REMOVAL
1. Remove the glove box cover assembly. Refer to IP-4, "INSTRU-
MENT PANEL ASSEMBLY" .
2. Remove the blower fan resistor.

MJIA0143E

INSTALLATION
Install in the reverse order of removal.

MTC-54
 AIR CONDITIONER FILTER

AIR CONDITIONER FILTER PFP:27277

A
Removal, Replacement and Installation EJS002JJ

REMOVAL
Following illustration is for RHD model. The layout for LHD model is symmetrically opposite. B
1. Remove the glove box cover assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .
2. Compress the air conditoner filter downward while sliding it to
the left side of the vehicle as shown in the figure 1. C
3. Turn the bottom of the air conditoner filter upward, and then
remove it as shown in the figure 2.
D

MJIA0144E

REPLACEMENT F
Following illustration is for RHD model. The layout for LHD model is symmetrically opposite.
Air conditoner filter : Once a year or every 12,000
G
Replacement interval km (7,500 miles)
Fill in the necessary information on the label, and stick it on the
inside of the glove box as shown in the figure. H

MJIA0145E
MTC
INSTALLATION
Install in the reverse order of removal.
K

MTC-55
 INTAKE DOOR

INTAKE DOOR PFP:27245

Intake Door Cable Adjustment EJS002GO

1. Remove the glove box cover assembly. Refer to IP-8, "P. Glove Box Cover Assembly" .
2. Remove the outer cable of intake door cable from the clamp.
3. Set the intake air control lever to “RECIRCULATION”.
4. Push the intake door link in the direction shown by the arrow
while carefully pulling the outer cable to the controller side and
attaching the clamp.
5. Operate the intake air control lever and check if the intake door
cable moves smoothly.
CAUTION:
When clamping the outer cable, do not move the inner cable.
MJIA0146E

MTC-56
 MODE DOOR

MODE DOOR PFP:27181

A
Mode Door Cable Adjustment EJS002HO

1. Remove the instrument panel stay cover. Refer to IP-8, "N.

Instrument Panel Stay Cover" . B
2. Remove the outer cable of mode door cable from the clamp.
3. Set mode dial to “ventilation” position.
4. Push the main link in the direction shown by the arrow, then C
carefully pull outer cable to the controller side, and install the
clamp.
5. Operate the mode dial to insure that the inner cable moves D
smoothly.
CAUTION: MJIA0147E
When clamping the outer cable, do not move the inner E
cable.

MTC

MTC-57
 AIR MIX DOOR

AIR MIX DOOR PFP:27180

Air Mix Door Cable Adjustment EJS002HP

1. Remove the instrument panel stay cover. Refer to IP-8, "N.

Instrument Panel Stay Cover" .
2. Remove the outer cable of air mix door cable from the clamp.
3. Set temperature control dial to “full cold” position.
4. Push the air mix door lever in the direction shown by arrow and
then carefully pull the outer cable toward controller side, and
install the clamp.
5. Operate the temperature control dial to insure that the inner
cable moves smoothly.
CAUTION: MJIA0148E
When clamping the outer cable, do not move the inner
cable.

MTC-58
 INTAKE SENSOR

INTAKE SENSOR PFP:27723

A
Removal and Installation EJS002GR

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a(R134a)] to discharge refrigerant.
B
2. Remove the air conditioner unit. Refer to MTC-48, "A/C UNIT ASSEMBLY" .
3. Remove the air conditioner filter and foot duct (RH). Refer to MTC-55, "AIR CONDITIONER FILTER" and
MTC-60, "DUCTS AND GRILLES" .
C
4. Remove the lower blower fun motor case and expansion valve
cover.
D

F
MJIA0149E

5. Slide the evaporator and door blower case downward, and

remove the intake sensor. G

MJIA0017E
MTC

INSTALLATION
Install in the reverse order of removal. K
CAUTION:
● Replace the low-pressure and high-pressure flexible hoses and high-pressure pipe O-rings with
new ones. Apply compressor lubricant to them during installation.
L
● When replacing the intake sensor, install the intake sensor thermistor in the same position as the
removed intake sensor.
● When removing and installing the thermal amplifier, do not rotate the thermistor's insertion part.
M
● After charging with refrigerant, check for refrigerant leaks.
High-pressure flexible hose and high-pressure pipe mounting bolts
Tightening torque : 2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26 - 52 in-lb)

MTC-59
 DUCTS AND GRILLES

DUCTS AND GRILLES PFP:27860

Removal and Installation EJS002GT

COMPONENT PARTS LOCATION

NOTE:
Following illustration is for RHD model. The layout for LHD model is symmetrically opposite.

RJIA1048J

1. Side ventilator grille (LH) 2. Central ventilator grille (LH) 3. Central ventilator grille (RH)
4. Side ventilator grille (RH) 5. Instrument panel assembly 6. Side ventilator duct (RH)
7. Side defroster duct (RH) 8. Defroster nozzle 9. Side defroster duct (LH)
10. Side ventilator duct (LH)

CENTRAL VENTILATOR GRILLE

1. Remove cluster lid C. Refer to IP-7, "L. Cluster Lid C" .
2. Remove the audio. Refer to AV-15, "Removal and Installation of
Audio Unit" .
3. Remove the center ventilator grille (LH/RH).

MJIA0150E

SIDE VENTILATOR GRILLE

NOTE:
Following illustration is for RHD model. The layout for LHD model is symmetrically opposite.
1. Remove the upper instrument panel. Refer to IP-6, "C. Upper
Instrument Panel" .
2. Remove the switch panel finisher. Refer to IP-6, "F. Switch Panel
Finisher" .
3. Remove the side ventilator grille (RH) hooks from the back side
of the instrument panel, and then remove the side ventilator
grille (RH).
4. Remove the glove box cover assembly. Refer to IP-8, "P. Glove
Box Cover Assembly" .
MJIA0151E

MTC-60
 DUCTS AND GRILLES

5. Remove the side ventilator grille (LH) hooks from the back side
of the instrument panel, and then remove the side ventilator A
grille (LH).

MJIA0152E

D
DEFROSTER NOZZLE AND DUCT
NOTE:
Following illustration is for RHD model. The layout for LHD model is symmetrically opposite.
E
1. Remove the upper instrument panel. Refer to IP-6, "C. Upper Instrument Panel" .

MTC

K
MJIA0153E

2. Remove the side defroster ducts (LH/RH) and defroster nozzles from the upper instrument panel.
L

MTC-61
 DUCTS AND GRILLES

SIDE VENTILATOR DUCT

NOTE:
Following illustration is for RHD model. The layout for LHD model is symmetrically opposite.
1. Remove the glove box cover assembly. Refer to IP-8, "P. Glove Box Cover Assembly" .
2. Remove the side ventilator duct (LH).
3. Remove instrument panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" .
4. Remove the BCM. Refer to BCS-30, "Removal and Installation of BCM" .
5. Remove the air conditioner mounting bolts, steering member mounting bolts, column shaft mounting bolts,
and the harness clips.

MJIA0042E

6. Remove the steering member, and then remove the side ventilator duct (RH).

MJIA0154E

Steering member mounting nut and bolt

Tightening torque :11 - 13 N·m (1.1 - 1.4 kg-m, 8.2 - 9.5 ft-lb)

MTC-62
 DUCTS AND GRILLES

CENTER VENTILATOR DUCT

1. Remove cluster lid “C”. Refer to IP-7, "L. Cluster Lid C" . A
2. Remove the screws and then remove the center ventilator ducts
(LH/RH).
B

MJIA0155E
D

FOOT DUCT
1. Remove the glove box cover assembly. Refer to IP-8, "P. Glove
E
Box Cover Assembly" .
2. Remove the screws and then remove the food duct (LH).
F

MJIA0156E
H

3. Remove the instrument panel under tray. Refer to IP-6, "E.

Instrument Panel Under Tray" .
I
4. Remove the screws and thermal control amplifier connector, and
then remove the foot duct (RH).
MTC

MJIA0157E

MTC-63
 REFRIGERANT LINES

REFRIGERANT LINES PFP:92600

HFC-134a (R-134a) Service Procedure EJS002HN

SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.

SHA539DE

Evacuating System and Charging Refrigerant

SHA540DC

MTC-64
 REFRIGERANT LINES

Component Parts Location EJS002GU

CR ENGINE MODELS A

I
MJIB0114E

1. High-pressure flexible hose 2. Condenser 3. Condenser (Radiator)

4. Compressor 5. High-pressure pipe 6. Low-pressure flexible hose MTC
7. Liquid tank

MTC-65
 REFRIGERANT LINES

HR ENGINE MODELS

MJIB0132E

1. High-pressure flexible hose 2. Radiator (Condenser) 3. Liquid tank

4. Compressor 5. High-pressure pipe 6. Low-pressure flexible hose
7. Service valve (High pressure) 8. Service valve (Low pressure) 9. Refrigerant pressure sensor

MTC-66
 REFRIGERANT LINES

K9K ENGINE MODELS

A

MTC

L
MJIB0115E

1. High-pressure flexible hose 2. Refrigerant pressure sensor 3. Liquid tank

4. Radiator (Condenser) 5. Condenser 6. Compressor M
7. Service valve (Low pressure) 8. Low-pressure flexible hose 9. High-pressure pipe
10. Service valve (High pressure)

MTC-67
 REFRIGERANT LINES

Removal and Installation for Compressor EJS002GV

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R134a)] to discharge refrigerant.
2. Remove air duct (fresh air intake side). Refer to EM-18, "AIR CLEANER AND AIR DUCT" .
3. Disconnect compressor connector.
4. Remove the high-pressure and low-pressure flexible hose mounting bolts, and disconnect the compres-
sor.

MJIB0273E

CAUTION:
● Cover the compressor high and low-pressure ports with caps to keep the lubricant from spilling.
● Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
5. Remove the air conditioner compressor belt and alternator belt. Refer to EM-14, "DRIVE BELTS" .
6. Remove compressor mounting bolts.

MJIB0134E

7. Remove the compressor from under the vehicle.

INSTALLATION
Install in the reverse order of removal.
CAUTION:
● Replace O-rings on high-pressure and low-pressure flexible hoses with new ones. Apply compres-
sor oil when installing new O-rings.
● After installing the air conditioner compressor alternator belt, adjust the belt tension. Refer to EM-
14, "DRIVE BELTS" .
● When charging refrigerant, check for refrigerant leaks.
Compressor mounting bolt
Tightening torque : 16.6 - 23.5 N·m (1.7 - 2.3 kg-m, 13 - 17 ft-lb)
High-pressure flexible hose mounting bolt
Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 6 - 14 ft-lb)
Low-pressure flexible hose mounting bolt
Tightening torque : 7.8 - 19.6 N·m (0.8 - 1.9 kg-m, 6 - 14ft-lb)

MTC-68
 REFRIGERANT LINES

Removal and Installation for Compressor Clutch (CR Engine Models) EJS002HA

REMOVAL A
Overhaul (KC59G Compressor)
1. Remove the two screws holding the connector bracket, thermal
protector to the compressor. B

RHA669H
E
2. When removing center bolt, hold clutch disc with clutch disc
wrench.
F

H
SHA097EA

3. Remove the drive plate using the clutch disc puller. I

4. Insert holder's three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate.
5. Tighten the center bolt to remove the drive plate. MTC
6. While tightening the center bolt, insert a screwdriver between
two of the pins (as shown in the figure) to prevent rotation.
7. After removing the drive plate, remove the shims from either the K
drive shaft or the drive plate.

ZHA093H L

8. Remove the snap ring using external snap ring pliers.

M

RHA072C

MTC-69
 REFRIGERANT LINES

9. Remove the pulley assembly with the puller using a commer-

cially available pulley puller. (Position the center of the puller on
the end of the drive shaft)
For pressed pulleys:
To prevent deformation of the pulley groove, the puller claws
should be hooked under (not into) the pulley groove.
For machine lathed pulleys:
Align the pulley puller groove with the pulley groove, and then
remove the pulley assembly.

SHA099EA

10. Remove the field coil harness clip using a screwdriver.

11. Then remove the three field coil fixing screws and remove the
field coil.

RHA074C

Inspection
Clutch disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.

RJIA0582E

Pulley
Check the appearance of the pulley assembly. If the contact surface
of pulley sows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.

RJIA0583E

Coil
Check coil for loose connection or cracked insulation.

MTC-70
 REFRIGERANT LINES

INSTALLATION
KC59G Compressor A
1. Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head. B
2. Install the field coil harness clip using a screwdriver.

D
RHA076C

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

ZHA094H H

4. Install the drive plate on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.
I

MTC

RHA078C

L
5. Using the holder to prevent clutch disc rotation.
Tightening : 12 - 15 N-m (1.2 - 1.5 kg-m, 9 - 10 ft-lb)
torque M
After tightening the bolt, check that the pulley rotates smoothly.

SHA101EA

MTC-71
 REFRIGERANT LINES

6. Check clearance around the entire periphery of clutch disc.

Disc to pulley clear- : 0.2 - 0.5 mm (0.008 - 0.020 in)
ance
If the specified clearance is not obtained, replace adjusting
spacer and readjust.

RHA080CA

Break-In Operation
When replacing compressor clutch assembly, always carry out 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.
Removal and Installation for Pipe and Hose EJS0057L

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
2. Remove the low-pressure flexible hose bracket mounting bolt and nut.
3. Remove the high-pressure pipe and low-pressure flexible hose mounting bolts (air conditioner unit side).
CAUTION:
Seal the connecting points of the pipe and hose with caps and vinyl tape, etc. to prevent them from
being exposed to the atmosphere.
4. Remove the low-pressure flexible hose mounting bolt (compressor side) and then remove the low-pres-
sure flexible hose.
CAUTION:
Seal the connecting points of the hose with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
5. Remove the front bumper and air guide (RH). Refer to EI-5, "FRONT BUMPER" .
6. Remove the high-pressure pipe mounting bolt (liquid tank side) and then remove the high-pressure pipe.
CAUTION:
Seal the connecting points of the pipe with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
7. Remove the high-pressure flexible hose mounting bolts and then remove the high-pressure flexible hose.
CAUTION:
Seal the connecting points of the hoses with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
INSTALLATION
Install in the reverse order of removal.
CAUTION:
● Replace the O-rings on the high-pressure pipe, low-pressure flexible hose, and high-pressure flex-
ible hose with new ones, and apply compressor lubricant to O-rings before installing.
● When charging refrigerant, check for refrigerant leaks.

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 REFRIGERANT LINES

High-pressure pipe mounting bolt A

Tightening torque : 2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26 - 52 in-lb)
Low-pressure flexible hose and high-pressure pipe mounting bolts (evaporator side)
Tightening torque : 2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26 - 52 in-lb) B
Low-pressure flexible hose mounting bolts (compressor side)
Tightening torque : 7.8 - 19.6 N·m (0.80 - 1.9 kg-m, 69 - 173 in-lb)
C
Low-pressure flexible hose bracket mounting bolt/nut
Tightening torque : 3.82 - 4.51 N·m (0.39 - 0.46 kg-m, 34 - 39 in-lb)
High-pressure flexible hose mounting bolt D
Tightening torque : 7.8 - 19.6 N·m (0.80 - 1.9 kg-m, 69 - 173 in-lb)

E
Removal and Installation for Refrigerant Pressure Sensor EJS002GZ

REMOVAL AND INSTALLATION

1. Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
F

I
MJIB0274E

2. Remove the front bumper and air guide (RH). Refer to EI-5, "FRONT BUMPER" .
3. Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then MTC
remove the refrigerant pressure sensor from the condenser (CR and HR engine models) or high-pressure
flexible hose (K9K engine models).
CAUTION:
● Be careful when working so as not to damage the condenser core.
K
● When installing refrigerant pressure sensor, apply compressor lubricant to the O-rings.

Refrigerant-pressure sensor L
Tightening torque : 9.8 - 11.7 N·m (1.0 - 1.2 kg-m, 87 - 103 in-lb)

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 REFRIGERANT LINES

Removal and Installation for Condenser (Models without Integrated Condenser)

EJS002H0

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
2. Remove the front bumper and air guide (RH). Refer to EI-5, "FRONT BUMPER" .
3. Disconnect the high-pressure flexible hose and high-pressure
pipe from the condenser.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere.
4. Disconnect the refrigerant pressure sensor connector, and then
remove the harness clip.

MJIA0169E

5. Use cord, etc., to hold the condenser and radiator to each radia-
tor core support upper.
NOTE:
To prevent the condenser and radiator from being dropped when
the radiator core lower support is removed.
6. Remove the mounting bolts, and then remove the radiator core
lower support.
7. Remove the condenser from underneath the vehicle.
CAUTION:
Do not damage the condenser core. MJIA0170E

INSTALLATION
Install in the reverse order of removal.
CAUTION:
● Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply
compressor lubricant to O-rings when installing them.
● When charging refrigerant, check for refrigerant leaks.
High-pressure flexible hose bolt
Tightening torque : 7.8 - 19.6 N·m (0.80 - 1.9 kg-m, 69 - 173 in -lb)
High-pressure pipe mounting bolt
Tightening torque : 2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26 - 52 in-lb)
Radiator core lower support mounting bolts.
Tightening torque : 43.4 - 58.7 N·m (4.5 -5.9 kg-m, 32 - 43 ft-lb)

Removal and Installation for Condenser (Models with Integrated Condenser)

EJS0057M

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
2. Remove the front bumper and air guide (RH). Refer to EI-5, "FRONT BUMPER" .

MTC-74
 REFRIGERANT LINES

3. Disconnect the high-pressure flexible hose from the condenser.

Disconnect the high-pressure pipe from the liquid tank. A
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo- B
sphere.
4. Remove the radiator assembly. Refer to CO-64, "RADIATOR" .
CAUTION: C
Do not damage the radiator and condenser core.
MJIA0214E

D
INSTALLATION
Install in the reverse order of removal.
CAUTION: E
● Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply
compressor lubricant to O-rings when installing them.
● When charging refrigerant, check for refrigerant leaks.
F

Removal and Installation for Liquid Tank (CR Engine with A/T Models) EJS002H1

REMOVAL
G
1. Use recovery/recycling recharging equipment [for HFC-134a
(R143a)] to discharge refrigerant.
2. Remove condenser. Refer to MTC-74, "Removal and Installation
H
for Condenser (Models without Integrated Condenser)" .
3. Clean around the liquid tank to remove foreign material and cor-
rosion.
I
4. Remove the liquid tank mounting bolts.

MTC
MJIA0171E

5. Lift up the liquid tank bracket, and remove it from the condenser K
protruding area.
6. Lift up the liquid tank and remove it.
CAUTION: L
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere.
M

MJIA0172E

INSTALLATION
Install the liquid tank and liquid tank bracket in the condenser.
CAUTION:
● Make sure the liquid tank bracket is correctly inserted into
the condenser's protruding area (the liquid tank bracket
does not move below the center of the liquid tank).
● Replace the condenser pipe O-rings with new ones. Apply a
coat of compressor lubricant to the O-rings prior to installa-
tion.

MJIA0173E

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 REFRIGERANT LINES

Liquid tank bracket (upper) mounting bolts

Tightening torque : 2.94 - 3.82 N·m (0.30 - 0.38 kg-m, 26 - 33 in-lb)
Liquid tank bracket (lower) mounting bolts
Tightening torque : 5.0 - 6.47 N·m (0.51 - 0.65 kg-m, 45 - 57 in-lb)

Removal and Installation for Liquid Tank (Except CR Engine with A/T Models)
EJS0057N

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a
(R143a)] to discharge refrigerant.
2. Clean around the liquid tank to remove foreign material and cor-
rosion.
3. Remove the high-pressure pipe from the liquid tank.
4. Remove the condenser pipe mounting bolt from the liquid tank,
and remove pipe from the condenser protruding area.
5. Remove the liquid tank bracket bolts and then remove the liquid
tank.
CAUTION: MJIA0215E
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
INSTALLATION
Install the liquid tank and liquid tank bracket in the condenser.
CAUTION:
Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the O-
rings prior to installation.
Removal and Installation for Evaporator EJS002H2

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant.
2. Remove the air conditioner unit. Refer to MTC-48, "A/C UNIT ASSEMBLY" .
CAUTION:
Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being
exposed to the atmosphere.
3. Remove the air conditioner filter and foot duct (RH). Refer to MTC-55, "AIR CONDITIONER FILTER" and
MTC-63, "FOOT DUCT" .
4. Remove the lower blower case and expansion valve cover.

MJIA0149E

MTC-76
 REFRIGERANT LINES

5. Slide the evaporator and door blower case downward, and

remove the thermal amplifier. A
6. Remove the evaporator from the lower blower case.

MJIB0057E

MTC

MTC-77
 REFRIGERANT LINES

INSTALLATION
Install in the reverse order of removal.
CAUTION:
● Replace low-pressure flexible hose and high-pressure pipe O-rings with new ones. Apply a coat of
compressor lubricant prior to installation.
● When installing a new evaporator, install the thermal amplifier thermistor in the same position as
the removed thermal amplifier.
● When removing and installing the thermal amplifier, do not rotate the thermistor's insertion part.
Mounting bolts for the low-pressure flexible hoses and
high-pressure pipes.
Tightening torque : 2.9 - 5.9 N·m (0.3 - 0.6 kg-m)

Removal and Installation for Expansion Valve EJS002H3

REMOVAL
1. Use recovery/recycling recharging equipment [for HFC-134a (R-
134a)] to discharge refrigerant.
2. Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere.
3. Remove the bolts from the expansion valve, and then remove
the expansion valve.
MJIA0174E

INSTALLATION
Install in the reverse order of removal.
CAUTION:
Replace the removed O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior
to installation.
Expansion valve mounting bolts
Tightening torque : 2.9 - 5.0 N·m (0.30 - 0.51 kg-m, 26 - 44 in-lb)
Mounting bolts for the low-pressure flexible hoses and high-pressure pipes.
Tightening torque : 2.9 - 5.9 N·m (0.30 - 0.60 kg-m, 26 - 52 in-lb)

Checking for Refrigerant Leaks EJS002HJ

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.

MTC-78
 REFRIGERANT LINES

Checking System for Leaks Using the Fluorescent Leak Detector EJS002HK

A
1. Check A/C system for leaks using the UV lamp and safety goggles (J-42220) in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak. B
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag- C
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector. D
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be E
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector. F

Dye Injection EJS002HL

(This procedure is only necessary when recharging the system or when the compressor has seized and was G
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (50 psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459). H
3. Connect the injector tool to the A/C LOW PRESSURE side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye I
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture's operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting. MTC
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures. K
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible. L
Electronic Refrigerant Leak Detector EJS002HM

PRECAUTIONS FOR HANDLING LEAK DETECTOR

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

SHA705EB

MTC-79
 REFRIGERANT LINES

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

be checked.

SHA707EA

2. When testing, circle each fitting completely with probe.

SHA706E

3. Move probe along component approximately 25 to 50 mm (1 to

2 in)/sec.

SHA708EA

CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm2 , 50 psi) above 16°C (61°F). If less
than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.54
kg/cm2 , 50 psi).
4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet g) to the low side
(evaporator drain hose h to shaft seal k). Refer to MTC-20, "Component Parts Location" \. Perform a leak
check for the following areas carefully. Clean the component to be checked and move the leak detected
probe completely around the connection/component.
Compressor
Check the fitting of high and low pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor or dual pressure switch.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).

MTC-80
 REFRIGERANT LINES

NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any A
false readings by leak detector.

Cooling unit (Evaporator) B

With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer's recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water C
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above. D
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine. E
8. Set the heater A/C control as follows;
a. A/C switch: ON
F
b. Face mode
c. Intake position: Recirculation
d. Max cold temperature G
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4 through 6 above. H

Refrigerant leaks should be checked immediately after stopping the

engine. Begin with the leak detector at the compressor. The pres-
I
sure on the high pressure side will gradually drop after refrigerant
circulation stops and pressure on the low pressure side will gradually
rise, as shown in the graph. Some leaks are more easily detected
when pressure is high. MTC

SHA839E

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

MTC-81
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Compressor EJS002H4

CR engine models HR engine models K9K engine models

Model ZEXEL VALEO CLIMATE
CR-10 SANDEN make SD6V12
CONTROL make KC59G
Type Vane rotary Variable volume piston
Displace- Max.
ment 125.1 (7.63)
80 (4.88) 96 (5.86)
cm3 (cu Min. 6.2 (0.38)
in)/rev
Cylinder bore × stroke mm (in) 5 vanes, φ51.0 × 7.28 5 vanes, φ50.2 × 8.5 —
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V (4grooves) V-Ribbed (7 grooves) Poly V (6 grooves)

Lubricant EJS002H5

CR engine models HR engine models K9K engine models

Model ZEXEL VALEO CLIMATE CON-
CR-10 SANDEN make SD6V12
TROL make KC59G
Name Nissan A/C System Oil Type R SP-10
Part number KLH00-PAGR0 —
Total in system 80 (2.8) 120 (4.2) 135 (4.8)
Capacity Compressor
m (lmp fl (Service part)
oz) 80 (2.8) 120 (4.2) 135 (4.8)
charging
amount

Refrigerant EJS002H6

CR engine models HR engine models K9K engine models

Model ZEXEL VALEO CLIMATE CON-
CR-10 SANDEN make SD6V12
TROL make KC59G
Type HFC-134a (R-134a)
Capacity A/T 0.45 ± 0.05 (0.99 ± 0.11)
0.45 ± 0.05 (0.99 ± 0.11) 0.55 ± 0.05 (1.21 ± 0.11)
kg (lb) M/T 0.50 ± 0.05 (1.10 ± 0.11)

Engine idling speed EJS002H7

Refer to EC-450, "SERVICE DATA AND SPECIFICATIONS (SDS)" . CR (with EURO−OBD).

Refer to EC-802, "SERVICE DATA AND SPECIFICATIONS (SDS)" . CR (without EURO−OBD).
Refer to EC-1239, "SERVICE DATA AND SPECIFICATIONS (SDS)" . HR (with EURO−OBD).
Refer to EC-1601, "SERVICE DATA AND SPECIFICATIONS (SDS)" . HR (without EURO−OBD).
Refer to EC-K9K-53, “Idle speed adjustment”, “DIESEL INJECTION” (K9K engine models).
Belt tension EJS002H8

Refer to MA-38, "Tension Adjustment" . (CR engine models).

Refer to MA-49, "Tension Adjustment" . (HR engine models).
Refer to MA-60, "TENTION ADJUSTMENT" . (K9K engine models).

MTC-82