VENTILATION, HEATER & AIR CONDITIONER

HEATER & AIR CONDITIONING SYSTEM

SECTION HA B

E
CONTENTS
2.0L TURBO GASOLINE ENGINE System Description ..................................................17 F

PRECAUTION ............................................... 4 BASIC INSPECTION ................................... 18

DIAGNOSIS AND REPAIR WORKFLOW ........ 18 G
PRECAUTIONS ................................................... 4
Precaution for Supplemental Restraint System Work Flow ................................................................18
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 4
REFRIGERANT ................................................. 20 H
Precautions for Removing Battery Terminal ............. 4 Description ...............................................................20
Precaution for Procedure without Cowl Top Cover...... 5 Leak Test .................................................................20
Precautions For Refrigerant System Service ............ 5 Recycle Refrigerant .................................................22
HA
Service Equipment .................................................... 8 Charge Refrigerant ..................................................22

LUBRICANT ...................................................... 24
PREPARATION ........................................... 10
Description ...............................................................24 J
PREPARATION ..................................................10 Inspection ................................................................24
Special Service Tool ............................................... 10 Perform Lubricant Return Operation .......................24
Commercial Service Tool ........................................ 12 Lubricant Adjusting Procedure for Components K
Sealant or/and Lubricant ......................................... 12 Replacement Except Compressor ...........................24
Lubricant Adjusting Procedure for Compressor
SYSTEM DESCRIPTION ............................. 14 Replacement ...........................................................25
L
COMPONENT PARTS .......................................14 PERFORMANCE TEST .................................... 26
Inspection ................................................................26
REFRIGERATION SYSTEM ...................................... 14
M
REFRIGERATION SYSTEM : Component Parts SYMPTOM DIAGNOSIS .............................. 28
Location ................................................................... 14
REFRIGERATION SYSTEM SYMPTOMS ........ 28
HEATER & COOLING UNIT ASSEMBLY ................. 14 Trouble Diagnosis For Unusual Pressure ................28 N
HEATER & COOLING UNIT ASSEMBLY : Heater Symptom Table .......................................................28
& Cooling Unit ......................................................... 15
HEATER & COOLING UNIT ASSEMBLY : Evap- NOISE ................................................................ 30
O
orator ....................................................................... 15 Symptom Table .......................................................30
HEATER & COOLING UNIT ASSEMBLY : Expan-
sion Valve ................................................................ 15 REMOVAL AND INSTALLATION ............... 31
P
CONDENSER ............................................................ 15 COMPRESSOR ................................................. 31
CONDENSER : Condenser ..................................... 15 Exploded View .........................................................31
CONDENSER : Liquid Tank .................................... 16 Removal and Installation .........................................31
Compressor ............................................................. 16 Inspection ................................................................32

SYSTEM .............................................................17 COOLER PIPE AND HOSE .............................. 33

System Diagram ...................................................... 17 Exploded View .........................................................33

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LOW-PRESSURE FLEXIBLE HOSE ........................ 34 PRECAUTIONS ................................................. 53
LOW-PRESSURE FLEXIBLE HOSE : Removal Precaution for Supplemental Restraint System
and Installation ....................................................... 34 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................. 53
HIGH-PRESSURE FLEXIBLE HOSE ....................... 34 Precautions for Removing Battery Terminal ........... 53
HIGH-PRESSURE FLEXIBLE HOSE : Removal Precaution for Procedure without Cowl Top Cover... 54
and Installation ....................................................... 34
Precautions For Refrigerant System Service .......... 54
LOW-PRESSURE PIPE ............................................ 35 Service Equipment .................................................. 57
LOW-PRESSURE PIPE : Removal and Installa-
tion .......................................................................... 35
PREPARATION .......................................... 59

HIGH-PRESSURE PIPE ............................................ 36 PREPARATION ................................................. 59

HIGH-PRESSURE PIPE : Removal and Installa- Special Service Tool ............................................... 59
tion .......................................................................... 36 Commercial Service Tool ........................................ 61
Sealant or/and Lubricant ......................................... 61
CONDENSER .................................................... 38
Exploded View ........................................................ 38 SYSTEM DESCRIPTION ........................... 63
CONDENSER ............................................................ 38 COMPONENT PARTS ....................................... 63
CONDENSER : Removal and Installation .............. 38
REFRIGERATION SYSTEM ..................................... 63
CONDENSER PIPE ASSEMBLY .............................. 39 REFRIGERATION SYSTEM : Component Parts
CONDENSER PIPE ASSEMBLY : Removal and Location .................................................................. 63
Installation .............................................................. 40
HEATER & COOLING UNIT ASSEMBLY ................ 63
REFRIGERANT PRESSURE SENSOR .................... 40 HEATER & COOLING UNIT ASSEMBLY : Heater
REFRIGERANT PRESSURE SENSOR : Remov- & Cooling Unit ......................................................... 64
al and Installation .................................................... 40 HEATER & COOLING UNIT ASSEMBLY : Evap-
orator ....................................................................... 64
HEATER & COOLING UNIT ASSEMBLY ......... 42 HEATER & COOLING UNIT ASSEMBLY : Expan-
Exploded View ........................................................ 42 sion Valve ............................................................... 64
HEATER & COOLING UNIT ASSEMBLY ................ 44 CONDENSER ............................................................ 64
HEATER & COOLING UNIT ASSEMBLY : Re- CONDENSER : Condenser .................................... 64
moval and Installation ............................................. 44 CONDENSER : Liquid Tank ................................... 65
Compressor ............................................................ 65
HEATER CORE ......................................................... 46
HEATER CORE : Removal and Installation ........... 46 SYSTEM ............................................................ 66
System Diagram ..................................................... 66
EVAPORATOR ......................................................... 47
System Description ................................................. 66
EVAPORATOR : Removal and Installation ............ 47

EVAPORATOR PIPE ASSEMBLY ........................... 48 BASIC INSPECTION .................................. 67

EVAPORATOR PIPE ASSEMBLY : Removal and DIAGNOSIS AND REPAIR WORKFLOW ......... 67
Installation .............................................................. 48
Work Flow ............................................................... 67
EXPANSION VALVE ................................................. 49
REFRIGERANT ................................................. 69
EXPANSION VALVE : Removal and Installation ... 50
Description .............................................................. 69
SERVICE DATA AND SPECIFICATIONS Leak Test ................................................................ 69
Recycle Refrigerant ................................................ 71
(SDS) ........................................................... 52
Charge Refrigerant ................................................. 71
SERVICE DATA AND SPECIFICATIONS
LUBRICANT ...................................................... 73
(SDS) .................................................................. 52 Description .............................................................. 73
Compressor ............................................................ 52
Inspection ................................................................ 73
Lubricant ................................................................. 52
Perform Lubricant Return Operation ....................... 73
Refrigerant .............................................................. 52 Lubricant Adjusting Procedure for Components
Engine Idling Speed ............................................... 52 Replacement Except Compressor .......................... 73
Belt Tension ............................................................ 52 Lubricant Adjusting Procedure for Compressor
VR30DDTT Replacement ........................................................... 74
PRECAUTION ............................................. 53 PERFORMANCE TEST ..................................... 75

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 Inspection ................................................................ 75 CONDENSER .............................................................88
CONDENSER : Removal and Installation ...............88 A
SYMPTOM DIAGNOSIS .............................. 77
CONDENSER PIPE ASSEMBLY ..............................90
REFRIGERATION SYSTEM SYMPTOMS .........77 CONDENSER PIPE ASSEMBLY : Removal and
Trouble Diagnosis For Unusual Pressure ............... 77 Installation ...............................................................90 B
Symptom Table ....................................................... 77
REFRIGERANT PRESSURE SENSOR .....................90
NOISE .................................................................79 REFRIGERANT PRESSURE SENSOR : Remov- C
Symptom Table ....................................................... 79 al and Installation .....................................................90

REMOVAL AND INSTALLATION ............... 80 HEATER & COOLING UNIT ASSEMBLY ........ 92
Exploded View .........................................................92 D
COMPRESSOR ..................................................80
Exploded View ........................................................ 80 HEATER & COOLING UNIT ASSEMBLY .................94
Removal and Installation ......................................... 80 HEATER & COOLING UNIT ASSEMBLY : Re-
E
Inspection ................................................................ 82 moval and Installation ..............................................94

COOLER PIPE AND HOSE ...............................83 HEATER CORE .........................................................96

Exploded View ........................................................ 83 HEATER CORE : Removal and Installation ............96 F

LOW-PRESSURE FLEXIBLE HOSE ........................ 83 EVAPORATOR ..........................................................97

LOW-PRESSURE FLEXIBLE HOSE : Removal EVAPORATOR : Removal and Installation .............97
and Installation ........................................................ 84 G
EVAPORATOR PIPE ASSEMBLY ............................98
HIGH-PRESSURE FLEXIBLE HOSE ........................ 84 EVAPORATOR PIPE ASSEMBLY : Removal and
HIGH-PRESSURE FLEXIBLE HOSE : Removal Installation ...............................................................99
H
and Installation ........................................................ 84
EXPANSION VALVE ............................................... 100
LOW-PRESSURE PIPE 1 .......................................... 85 EXPANSION VALVE : Removal and Installation .. 100
LOW-PRESSURE PIPE 1 : Removal and Installa- HA
tion .......................................................................... 85
SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 102
LOW-PRESSURE PIPE 2 .......................................... 86
SERVICE DATA AND SPECIFICATIONS J
LOW-PRESSURE PIPE 2 : Removal and Installa-
tion .......................................................................... 86 (SDS) ............................................................... 102
Compressor ........................................................... 102
HIGH-PRESSURE PIPE ............................................ 86 Lubricant ................................................................ 102 K
HIGH-PRESSURE PIPE : Removal and Installa- Refrigerant ............................................................. 102
tion .......................................................................... 86 Engine Idling Speed .............................................. 102
Belt Tension ........................................................... 102 L
CONDENSER .....................................................88
Exploded View ........................................................ 88

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 PRECAUTIONS
< PRECAUTION > [2.0L TURBO GASOLINE ENGINE]

PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000012794026

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, it is recommended that all maintenance
and repair be performed by an authorized NISSAN/INFINITI dealer.
• Improper repair, including incorrect removal and installation of the SRS, can lead to personal injury
caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module,
see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery or batteries, and wait at least 3 minutes before performing any service.
Precautions for Removing Battery Terminal INFOID:0000000013525344

When disconnecting the battery terminal, pay attention to the following.

• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running.
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi-
nal after a lapse of the specified time:

BR08DE : 4 minutes V9X engine : 4 minutes

D4D engine : 20 minutes YD25DDTi : 2 minutes
HR09DET : 12 minutes YS23DDT : 4 minutes
HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
SEF289H
M9R engine : 4 minutes ZD30DDTT : 60 seconds
R9M engine : 4 minutes
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:

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 PRECAUTIONS
< PRECAUTION > [2.0L TURBO GASOLINE ENGINE]
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving A
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
B
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
nected, then DTC may be detected. C
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error. D
Precaution for Procedure without Cowl Top Cover INFOID:0000000012794027

When performing the procedure after removing cowl top cover, cover E
the lower end of windshield with urethane, etc to prevent damage to
windshield.
F

PIIB3706J H
Precautions For Refrigerant System Service INFOID:0000000013525347

GENERAL REFRIGERANT PRECAUTION HA

WARNING:
• Never breathe 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 J
requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R-134a)
recovery equipment]. Ventilate work area before resuming service if accidental system discharge
occurs. Additional health and safety information may be obtained from refrigerant and lubricant K
manufacturers.
• Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to cap-
ture the refrigerant each time an air conditioning system is discharged.
• Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or air L
conditioning system.
• Never store or heat refrigerant containers above 52°C (126°F).
• Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm M
pail of water if container warming is required.
• Never intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns.
N
• Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo-
cation.
• Never pressure test or leakage 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) O
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.
P
WORKING WITH HFC-134a (R-134a)
CAUTION:
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. Compressor mal-
function is likely to occur if the refrigerants are mixed, refer to “CONTAMINATED REFRIGERANT”
below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refriger-
ant recovery/recycling recharging equipment and Refrigerant Identifier.

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 PRECAUTIONS
< PRECAUTION > [2.0L TURBO GASOLINE ENGINE]
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. Compressor malfunction is likely to occur if lubricant other than that specified is used.
• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
- Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere when
removing refrigerant components from a vehicle.
- Never remove the caps (unseal) until just before connecting the components when installing refrig-
erant components to a vehicle. Connect all refrigerant loop components as quickly as possible to
minimize the entry of moisture into system.
- Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant.
Lubricant becomes moisture saturated and should not be used without proper sealing.
- Never allow lubricant to come in contact with styrene foam parts. Damage may result.
CONTAMINATED REFRIGERANT
Take appropriate steps shown below if a refrigerant other than pure HFC-134a (R-134a) is identified in
a vehicle:
• Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into
the atmosphere.
• Explain that recovery of the contaminated refrigerant could damage service equipment and refrigerant sup-
ply.
• Suggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
• In case of repairing, recover the refrigerant using only dedicated equipment and containers. Never
recover contaminated refrigerant into the existing service equipment. Contact a local refrigerant prod-
uct retailer for available service if the facility does not have dedicated recovery equipment. This refrigerant
must be disposed of in accordance with all federal and local regulations. In addition, replacement of all
refrigerant system components on the vehicle is recommended.
• The air conditioner warranty is void if the vehicle is within the warranty period. Please contact Nissan Cus-
tomer Affairs for further assistance.
REFRIGERANT CONNECTION
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
• Expansion valve to evaporator
• Refrigerant pressure sensor to condenser & liquid tank assembly
WARNING:
Check that all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
Observe the following when replacing or cleaning refrigerant cycle components.
• Store it in the same way at it is when mounted on the car when the compressor is removed. Failure
to do so will cause lubricant to enter the low-pressure chamber.
• Use always a torque wrench and a back-up wrench when connecting tubes.
• Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes.
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle.
Never remove the seal caps of pipes and other components until just before required for connection.
• Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
• Remove thoroughly moisture from the refrigeration system before charging the refrigerant.
• Replace always used O-rings.
• Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to
apply lubricant to threaded portion.

Name : ND-OIL 12
• O-ring must be closely attached to the groove portion of tube.
• Be careful not to damage O-ring and tube when replacing the O-ring.
• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is
installed to tube correctly.

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 PRECAUTIONS
< PRECAUTION > [2.0L TURBO GASOLINE ENGINE]
• Perform leakage test and make sure that there is no leakage from connections after connecting line.
Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tighten A
connections of seal seat to the specified torque.

RHA861F

COMPRESSOR G
CAUTION:
• Plug all openings to prevent moisture and foreign matter from entering.
• Store it in the same way at it is when mounted on the car when the compressor is removed. H
• Follow “Maintenance of Lubricant Quantity in Compressor” exactly when replacing or repairing
compressor. Refer to HA-24, "Description".
• Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth
moistened with thinner if the surface is contaminated with lubricant. HA
• Turn the compressor shaft by hand more than five turns in both directions after compressor service
operation. This distributes equally lubricant inside the compressor. Let the engine idle and operate
the compressor for one hour after the compressor is installed. J
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet
clutch.
LEAK DETECTION DYE K
CAUTION:
• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An
ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages. L
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of
the fluorescent dye.
• The fluorescent dye leak detector is not a replacement for an electrical leak detector (SST: J-41995).
The fluorescent dye leak detector should be used in conjunction with an electrical leak detector M
(SST: J-41995) to pin-point refrigerant leakages.
• Read and follow all manufacture’s operating instructions and precautions prior to performing the
work for the purpose of safety and customer’s satisfaction. N
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres-
sor shaft seal should only be repaired after confirming the leakage with an electrical leak detector
(SST: J-41995).
• Remove always any remaining dye from the leakage area after repairs are completed to avoid a mis- O
diagnosis during a future service.
• Never allow dye to come into contact with painted body panels or interior components. Clean imme-
diately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for an P
extended period of time cannot be removed.
• Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
• Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system.
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C system, or A/C system damage may result.
• The fluorescent properties of the dye remains for three or more years unless a compressor malfunc-
tion occurs.

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 PRECAUTIONS
< PRECAUTION > [2.0L TURBO GASOLINE ENGINE]
Service Equipment INFOID:0000000013525348

RECOVERY/RECYCLING RECHARGING EQUIPMENT

Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRICAL LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched
OFF after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as per the following.
• Vacuum pumps usually have a manual isolator valve as part of the
pump. Close this valve to isolate the service hose from the pump.
• Use a hose equipped with a manual shut-off valve near the pump
end for pumps without an isolator. Close the valve to isolate the
hose from the pump.
• Disconnect the hose from the pump if the hose has an automatic
shut-off valve. As long as the hose is connected, the valve is open
and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.

RHA270DA

MANIFOLD GAUGE SET

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

SHA533D

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

RHA272D

SERVICE COUPLERS

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 PRECAUTIONS
< PRECAUTION > [2.0L TURBO GASOLINE ENGINE]
Never attempt to connect HFC-134a (R-134a) service couplers to
the CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers A
do not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
B

Shut-off valve rotation A/C service valve

Clockwise Open C
Counterclockwise Close
RHA273D

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

RHA274D

CHARGING CYLINDER H
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment. HA

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 PREPARATION
< PREPARATION > [2.0L TURBO GASOLINE ENGINE]

PREPARATION
PREPARATION
Special Service Tool INFOID:0000000012794031

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
HFC-134a (R-134a) Service Tool and Equipment
• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.

Tool number
(Kent-Moore No.) Description
Tool name

(ACR2005-NI) Function: Refrigerant recovery, recycling

ACR5 A/C Service Center and recharging

WJIA0293E

(J-41995) Power supply:

Electrical leak detector DC 12 V (Battery terminal)

AHA281A

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

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 PREPARATION
< PREPARATION > [2.0L TURBO GASOLINE ENGINE]
Tool number
(Kent-Moore No.) Description A
Tool name

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

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

(J-41459) G
HFC-134a (R-134a) dye injector For injecting 1/4 ounce of fluorescent leak
Use with J-41447, 1/4 ounce detection dye into A/C system
bottle
H
SHA440F

HA

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

SHA441F
K

L
Identification:
(J-39183) • The gauge face indicates HFC-134a (R-
Manifold gauge set (with hoses 134a).
and couplers) Fitting size: Thread size M
• 1/2″-16 ACME

N
RJIA0196E

Hose color:
Service hoses • Low-pressure side hose: Blue with black O
• High-pressure side hose stripe
(J-39501-72) • High-pressure side hose: Red with black
• Low-pressure side hose stripe
(J-39502-72) • Utility hose: Yellow with black stripe or P
• Utility hose green with black stripe
(J-39476-72) Hose fitting to gauge:
S-NT201
• 1/2″-16 ACME

Revision: November 2016 HA-11 2016 Q50

 PREPARATION
< PREPARATION > [2.0L TURBO GASOLINE ENGINE]
Tool number
(Kent-Moore No.) Description
Tool name

Service couplers
• High-pressure side coupler Hose fitting to service hose:
(J-39500-20) M14 x 1.5 fitting is optional or permanently
• Low-pressure side coupler attached.
(J-39500-24)

S-NT202

For measuring of refrigerant

(J-39650) Fitting size: Thread size
Refrigerant weight scale
1/2″-16 ACME

S-NT200

Capacity:
• Air displacement: 4 CFM
(J-39649) • Micron rating: 20 microns
Vacuum pump • Oil capacity: 482 g (17 oz)
(Including the isolator valve) Fitting size: Thread size
• 1/2″-16 ACME
S-NT203

Commercial Service Tool INFOID:0000000012794032

Tool name Description

Checking for refrigerant purity and

Refrigerant identifier equipment
system contamination

RJIA0197E

Sealant or/and Lubricant INFOID:0000000012794033

HFC-134a (R-134a) Service Tool and Equipment

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

Revision: November 2016 HA-12 2016 Q50

 PREPARATION
< PREPARATION > [2.0L TURBO GASOLINE ENGINE]

Tool name Description A

Container color: Light blue

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

Type: Polyalkylene glycol oil (PAG), D

Application:
A/C System Oil HFC-134a (R-134a) swash plate com-
ND-OIL 12 pressors
Capacity:
E
40 m (1.4 US fl oz., 1.4 Imp fl oz)
JMIIA1759ZZ

HA

Revision: November 2016 HA-13 2016 Q50

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [2.0L TURBO GASOLINE ENGINE]

SYSTEM DESCRIPTION
COMPONENT PARTS
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM : Component Parts Location INFOID:0000000012794034

JMIIA2971ZZ

In the heater & cooling unit assembly

No. Location Function

Liquid tank (Condenser & liquid tank assembly) Refer to HA-16, "CONDENSER : Liquid Tank".

Condenser (Condenser & liquid tank assembly) Refer to HA-15, "CONDENSER : Condenser".

Refrigerant pressure sensor Refer to HAC-16, "Refrigerant Pressure Sensor".

Compressor Refer to HA-16, "Compressor".

Refer to HA-15, "HEATER & COOLING UNIT ASSEMBLY : Evapora-
Evaporator
tor".
Refer to HA-15, "HEATER & COOLING UNIT ASSEMBLY : Expansion
Expansion valve
Valve".

HEATER & COOLING UNIT ASSEMBLY

Revision: November 2016 HA-14 2016 Q50

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [2.0L TURBO GASOLINE ENGINE]
HEATER & COOLING UNIT ASSEMBLY : Heater & Cooling Unit INFOID:0000000012794035

A
This system utilizes a heater & cooling unit that combines blower
unit, heater unit, and cooling unit.
B
: Vehicle front

D
JMIIA3045ZZ

HEATER & COOLING UNIT ASSEMBLY : Evaporator INFOID:0000000012794036

E
• A thin laminate pipeless evaporator is used.
• The mist from liquid refrigerant transforms to gas by evaporation
by the air conveyed from blower motor. The air is cooled by the F
heat by evaporation.

JSIIA0295GB

HA
HEATER & COOLING UNIT ASSEMBLY : Expansion Valve INFOID:0000000012794037

The refrigerant temperature is detected by the temperature sensing

part located in low-pressure refrigerant path inside expansion valve. J
The lift amount of high-pressure side ball valve is changed to regu-
late the refrigerant flow.
K

JSIIA0244GB
M
CONDENSER
CONDENSER : Condenser INFOID:0000000012794038

N
DESCRIPTION
• A sub-cool condenser that combines a parallel-flow condenser and liquid tank in the sub-cool cycle is used.
• Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant. O
STRUCTURE AND OPERATION
P

Revision: November 2016 HA-15 2016 Q50

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [2.0L TURBO GASOLINE ENGINE]
The sub-cool section is installed on the condenser, and the liquid refrigerant that exits the liquid tank is further
cooled by the condenser sub-cool section, increasing the amount of heat that the liquid refrigerant can absorb
and improving cooling performance.

JMIIA3047GB

CONDENSER : Liquid Tank INFOID:0000000012794039

• A liquid tank compatible with HFC-134a refrigerant is used.

• Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.
Compressor INFOID:0000000012794040

Intakes, compresses, and discharges refrigerant, to circulate refrig-

erant inside the refrigerant cycle.

JMIIA3051ZZ

Revision: November 2016 HA-16 2016 Q50

 SYSTEM
< SYSTEM DESCRIPTION > [2.0L TURBO GASOLINE ENGINE]
SYSTEM
A
System Diagram INFOID:0000000012794041

JPIIA1671GB
HA

System Description INFOID:0000000012794042

J
REFRIGERANT CYCLE
Refrigerant Flow
The refrigerant from the compressor, flows the condenser & liquid tank assembly, the evaporator, and returns K
to the compressor. The refrigerant evaporation in the evaporator is controlled by an expansion valve.
Freeze Protection
To prevent evaporator from freezing up, the evaporator air temperature is monitored, and the voltage signal to L
the A/C auto amp. makes the A/C relay go OFF and stop the compressor.
REFRIGERANT SYSTEM PROTECTION
M
Refrigerant Pressure Sensor
• The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure
sensor, located to the condenser & liquid tank assembly. The refrigerant pressure sensor detects the pres-
N
sure inside the refrigerant line and sends the voltage signal to the ECM if the system pressure rises above,
or falls below the specifications.
• ECM turns the A/C relay to OFF and stops the compressor when the high-pressure side detected by refriger-
ant pressure sensor is following conditions; O
- Approximately 3,120 kPa (31.8 kg/cm2, 452 psi) or more (Engine speed is 1,500 rpm or more.)
- Approximately 2,740 kPa (27.9 kg/cm2, 397 psi) or more (Engine speed is less than 1,500 rpm.)
- Approximately 120 kPa (1.2 kg/cm2, 17 psi) or less P

Pressure Relief Valve

The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere
when the pressure of refrigerant in the system increases to an unusual level [more than 3,800 kPa (38.8 kg/
cm2, 551 psi)].

Revision: November 2016 HA-17 2016 Q50

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]

BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000012794043

OVERALL SEQUENCE

JPIIA1365GB

DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.

Revision: November 2016 HA-18 2016 Q50

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
>> GO TO 2.
2.SYMPTOM CHECK A

Check the symptom from the customer's information. Check that any symptom occurs other than the inter-
viewed symptom.
B

Insufficient cooling/heating>>GO TO 3.
Refrigerant leakage>>GO TO 6.
C
Noise >> GO TO 7.
3.CONTROL SYSTEM DIAGNOSIS
Perform the system diagnosis for the A/C control system. Refer to HAC-70, "Work Flow". D
Is A/C control system normal?
YES >> GO TO 4.
NO >> GO TO 8. E
4.PERFORMANCE TEST
Perform the performance test. Check the operation of each part. Refer to HA-26, "Inspection". F

>> GO TO 5.
5.TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE G
Diagnose using a manifold gauge whenever system's high and/or low side pressure(s) is/are unusual. Specify
the malfunctioning part. Refer to HA-28, "Symptom Table".
H

Low refrigerant charge>>GO TO 6.

Except above>>GO TO 8.
HA
6.CHECK REFRIGERANT FOR LEAKAGES
Check refrigerant for leakages. Specify the malfunctioning part. Refer to HA-20, "Leak Test".
J
>> GO TO 8.
7.TROUBLE DIAGNOSIS FOR NOISE K
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-30, "Symptom Table".

>> GO TO 8. L
8.MALFUNCTION PART REPAIR
Repair or replace the malfunctioning part.
M

>> GO TO 9.
9.REPAIR CHECK (OPERATION CHECK) N
Check the operation of each part.
Does it operate normally?
O
YES >> INSPECTION END
NO >> GO TO 2.

Revision: November 2016 HA-19 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
REFRIGERANT
Description INFOID:0000000012794044

CONNECTION OF SERVICE TOOLS AND EQUIPMENT

JSIIA0239ZZ

Recovery/recycling/recharging
Shut-off valve A/C service valve
equipment
Refrigerant container (HFC-134a) Weight scale (J-39650) Vacuum pump (J-39649)
Manifold gauge set (J-39183)
Preferred (best) method Alternative method For charging

Leak Test INFOID:0000000012794045

CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE

RJIA3815J

1. Install a fender cover .

2. Wear UV safety goggles provided with refrigerant dye leak detection kit (J-43926).
3. Connect power cable of UV lamp to positive and negative terminals of the battery .
4. Press UV lamp switch and check A/C system for refrigerant leakage. (Where refrigerant leakage
occurs, fluorescent leak detection dye appears in green color.)

Revision: November 2016 HA-20 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
WARNING:
Never look directly into UV lamp light source. A
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Illuminate piping joints from different angles using UV lamp and check that there is no leakage.
B
• Use a mirror in area that is difficult to see to check refrigerant leakage.
• Refrigerant leakage from evaporator can be detected by soaking cotton swab or a similar material with
drain hose water and illuminating it using UV lamp.
• Dust, dirt, and packing materials adhesive used for condenser, evaporator, and other locations may flu- C
oresce. Be careful not to misidentify leakage.
5. Repair or replace parts where refrigerant leakage occurs and wipe off fluorescent leak detection dye.
NOTE: D
Completely wipe off fluorescent leak detection dye from gaps between parts, screw threads, and others
using a cotton swab or similar materials.
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work. E
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions. F
• Dust, dirt, and packing materials adhesive used for condenser, evaporator, and other locations may flu-
oresce. Be careful not to misidentify leakage.
G
CHECK REFRIGERANT LEAKAGE USING ELECTRICAL LEAK DETECTOR
WARNING:
Never check refrigerant leakage while the engine is running.
H
CAUTION:
Be careful of the following items so that inaccurate checks or misidentifications are avoided.
• Never allow refrigerant vapor, shop chemical vapors, cigarette smoke, or others around the vehicle.
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse HA
when leakage occurs.
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set (J-39183) to A/C service valve. J
3. Check that A/C refrigerant pressure is 345 kPa (3.52 kg/cm2, 50 psi) or more when temperature is 16°C
(61°F) or more. When pressure is lower than the specified value, recycle refrigerant completely and fill
refrigerant to the specified level. K
NOTE:
Leakages may not be detected if A/C refrigerant pressure is 345 kPa (3.52 kg/cm2, 50 psi) or less when
temperature is less than 16°C (61°F). L
4. Clean area where refrigerant leakage check is performed, and check refrigerant leakage along all sur-
faces of pipe connections and A/C system components using electrical leak detector (J-41995) probe.
CAUTION: M
• Continue checking when a leakage is found. Always continue and complete checking along all
pipe connections and A/C system components for additional leakage.
• When a leakage is detected, clean leakage area using compressed air and check again.
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the N
probe surface may not be exposed to water or dirt.
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side. O
• When checking leakage of cooling unit inside, operate blower fan motor for 15 minutes or more at the
maximum fan speed while the engine is stopped, and then insert electrical leak detector probe into drain
hose and hold for 10 minutes or more.
• When disconnecting shut-off valve that is connected to A/C service valve, always evacuate remaining P
refrigerant so that misidentification can be avoided.
5. Repair or replace parts where refrigerant leakage is detected. (Leakage is detected but leakage area is
unknown. GO TO 6.)
6. Start the engine and set A/C control in the following conditions.
• A/C switch ON
• Air flow: VENT (ventilation)

Revision: November 2016 HA-21 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
• Intake door position: Recirculation
• Temperature setting: Full cold
• Fan (blower) speed: Maximum speed set
7. Run the engine at approximately 1,500 rpm for 2 minutes or more.
8. Stop the engine. Check again for refrigerant leakage. GO TO 4.
WARNING:
Be careful not to get burned when the engine is hot.
NOTE:
• Start refrigerant leakage check immediately after the engine is
stopped.
• When refrigerant circulation is stopped, pressure on the low-
pressure side rises gradually, and after this, pressure on the
high-pressure side falls gradually.
• The higher the pressure is, the easier it is to find the refriger-
ant leakage.

SHA839E

Recycle Refrigerant INFOID:0000000012794046

WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, or
throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1. Perform lubricant return operation. Refer to HA-24, "Perform Lubricant Return Operation". (If refrigerant or
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is
detected.
2. Check gauge pressure readings of recovery/recycling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose.
NOTE:
Follow manufacturer instructions for the handling or maintenance of the equipment. Never fill the equip-
ment with non-specified refrigerant.
3. Remove A/C service valve cap from the vehicle.
4. Connect recovery/recycling/recharging equipment to A/C service valve.
5. Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
6. Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated to compressor lubri-
cant, etc.
7. Refrigerant recycle operation is complete.
Charge Refrigerant INFOID:0000000012794047

WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure my irritate eyes, nose, or throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.

Revision: November 2016 HA-22 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
1. Connect recovery/recycling/recharging equipment to the A/C service valve.
2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or A
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced. B
3. Check the airtightness of A/C system for 25 minutes or more. If pressure raises more than the specified
level, charge A/C system with approximately 200 g refrigerant and check that there is no refrigerant leak-
age. Refer to HA-20, "Leak Test".
C
CAUTION:
Check the airtightness for 15 minutes or more if the parts are replaced.
4. If parts other than compressor are replaced, fill compressor lubricant according to parts that are replaced.
D
5. Charge the specified amount of refrigerant to A/C system.
6. Check that A/C system operates normally.
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose E
and low-pressure hose of recovery/recycling/recharging equipment.)
8. Install A/C service valve cap.
9. Refrigerant charge is complete. F

HA

Revision: November 2016 HA-23 2016 Q50

 LUBRICANT
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
LUBRICANT
Description INFOID:0000000012794048

MAINTENANCE OF LUBRICANT LEVEL

The compressor lubricant is circulating in the system together with the refrigerant. It is necessary to fill com-
pressor with lubricant when replacing A/C system parts or when a large amount of refrigerant leakage is
detected. It is important to always maintain lubricant level within the specified level. Or otherwise, the following
conditions may occur.
• Insufficient lubricant amount: Stuck compressor
• Excessive lubricant amount: Insufficient cooling (caused by insufficient heat exchange)

Name : ND-OIL 12

Inspection INFOID:0000000012794049

If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.COMPRESSOR OIL JUDGMENT
1. Remove compressor. Refer to HA-31, "Removal and Installation".
2. Sample a compressor oil and judge on the figure.

JSIIA0927GB

Judgement result 1>>Replace compressor only.

Judgement result 2>>Replace compressor and condenser & liquid tank assembly.
Perform Lubricant Return Operation INFOID:0000000012794050

CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera-
tion.
1. Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm
• A/C switch: ON
• Fan (blower) speed: Maximum speed set
• Intake door position: Recirculation
• Temperature setting: Full cold
2. Perform lubricant return operation for approximately 10 minutes.
3. Stop the engine.
4. Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000012794051

Fill with lubricant for the amount that is calculated according to the following conditions.
Example: Lubricant amount to be added when replacing evaporator and condenser & liquid tank assembly
[m (US fl oz., Imp fl oz.)] = 45 (1.5, 1.6) + 15 (0.5, 0.5) + α

Revision: November 2016 HA-24 2016 Q50

 LUBRICANT
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]

Lubricant amount to be added to A/C system A

Conditions
m (US fl oz., Imp fl oz.)
Replace evaporator 45 (1.5, 1.6)
Replace condenser & liquid tank assembly 30 (1.0, 1.1) B
Large amount leakage 30 (1.0, 1.1)
Refrigerant leakage is detected
Small amount leakage —
C
Lubricant amount that is recycled together with refrigerant during recycle operation α

Lubricant Adjusting Procedure for Compressor Replacement INFOID:0000000012794052

D
1. Drain lubricant from removed compressor and measure lubri-
cant amount.
• Drain lubricant from high-pressure port and low-pressure E
port while rotating magnet clutch.
• Measure total amount of lubricant that is drained from
removed compressor. F

G
JMIIA2974ZZ

H
2. Drain lubricant from a new compressor that is calculated accord-
ing to the following conditions.
HA
Amount to be drained (A) [m (Imp fl oz.)]
= F − (D + S + R + α)
F : Lubricant amount that a new compres- J
sor contains [120 (4.1, 4.2)]
D : Lubricant amount that is drained from
removed compressor K
S : Lubricant amount that remains inside JPIIA1455GB

of removed compressor [20 (0.7, 0.7)]

L
R : Lubricant amount to be added accord-
ing to components that are removed ex-
cept compressor
M
α : Lubricant amount that is recycled to-
gether with refrigerant during recycle
operation
N
CAUTION:
If lubricant amount that is drained from removed compressor is less than 60 m (2.0 US fl oz., 2.1
Imp fl oz.), perform calculation by setting “D” as 40 m (1.4 US fl oz., 1.4 Imp fl oz.).
O

Lubricant amount to be added to A/C system

Conditions
m (US fl oz., Imp fl oz.)
P
Replace evaporator 45 (1.5, 1.6)
Replace condenser & liquid tank assembly 30 (1.0, 1.1)
Example: Lubricant amount to be drained from a new compressor when replacing compressor and con-
denser & liquid tank assembly [m (US fl oz., Imp fl oz.)] [D = 60 (2.0, 2.1), α = 5 (0.2, 0.2)]
120 (4.1, 4.2) − [60 (2.0, 2.1) + 20 (0.7, 0.7) + 30 (1.0, 1.1) + 5 (0.2, 0.2)] = 5 (0.2, 0.2)
3. Install compressor and check the operation.

Revision: November 2016 HA-25 2016 Q50

 PERFORMANCE TEST
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
PERFORMANCE TEST
Inspection INFOID:0000000012794053

INSPECTION PROCEDURE
1. Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge. Refer to HA-20,
"Description".
2. Start the engine, and set to the following condition.
Test condition
Surrounding condition Indoors or in the shade (in a well-ventilated place)
Door Closed
Door glass Full open
Vehicle condition
Hood Open
Engine speed Idle speed
Temperature control switch or dial Full cold
A/C switch ON
A/C condition Air outlet VENT (ventilation)
Intake door position Recirculation
Fan (blower) speed Maximum speed set
3. Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4. Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to-
operating pressure” are within the specified value.
5. When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to HA-28,
"Symptom Table".
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE

Inside air (Recirculating air) at blower assembly inlet

Discharge air temperature from center ventilator
Relative humidity Air temperature °C (°F)
% °C (°F)
20 (68) 8.3 – 10.4 (47 – 51)
25 (77) 8.1 – 10.6 (47 – 51)
50 – 60
30 (86) 14.5 – 17.5 (58 – 64)
35 (95) 18.6 – 22.1 (65 – 72)
20 (68) 10.4 – 12.4 (51 – 54)
25 (77) 10.6 – 13.1 (51 – 56)
60 – 70
30 (86) 17.5 – 20.5 (64 – 69)
35 (95) 22.1 – 25.6 (72 – 78)

AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE

Revision: November 2016 HA-26 2016 Q50

 PERFORMANCE TEST
< BASIC INSPECTION > [2.0L TURBO GASOLINE ENGINE]
Fresh air
High-pressure (Discharge side) Low-pressure (Suction side) A
Relative humidity Air temperature kPa (kg/cm2, psi) kPa (kg/cm2, psi)
% °C (°F)
1,262 – 1,542 247 – 301
25 (77) B
(12.9 – 15.9, 183.0 – 223.6) (2.5 – 3.1, 35.8 – 43.6)
1,293 – 1,580 260 – 318
30 (86)
(13.2 – 16.1, 187.4 – 229.0) (2.7 – 3.2, 37.7 – 46.1)
50 – 70 C
1,494 – 1,826 297 – 363
35 (95)
(15.2 – 18.6, 216.7 – 264.7) (3.0 – 3.7, 43.1 – 52.6)
1,698 – 2,075 334 – 407
40 (104)
(17.3 – 21.2, 246.2 – 300.8) (3.4 – 4.2, 48.4 – 59.1) D

HA

Revision: November 2016 HA-27 2016 Q50

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [2.0L TURBO GASOLINE ENGINE]

SYMPTOM DIAGNOSIS
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000012794054

Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer to
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how-
ever, differs from vehicle to vehicle.
Symptom Table INFOID:0000000012794055

Gauge indication Refrigerant cycle Probable cause Corrective action

Collect all refrigerant, evacuate
The pressure returns to nor-
refrigerant cycle again, and
mal soon after sprinkling wa- Overfilled refrigerant.
then refill it with the specified
ter on condenser.
amount of refrigerant.
Insufficient condenser cooling
performance.
• Poor fan rotation of radiator • Repair or replace malfunc-
Both high- and low-pressure sides
Air flow to condenser is insuf- and condenser. tioning parts.
are too high.
ficient. • Improper installation of air • Clean and repair condenser
guide. fins.
• Clogged or dirty condenser
fins.
When compressor is stopped,
a high-pressure reading Collect all refrigerant, evacuate
quickly drops by approximate- refrigerant cycle again, and
Air mixed in refrigerant cycle.
AC359A then refill it with the specified
ly 196 kPa (2 kg/cm2, 28 psi). amount of refrigerant.
It then gradually decreases.
• Low-pressure pipe is cooler
than the outlet of evapora- Expansion valve opened too
tor. much (excessive flow of refrig- Replace expansion valve.
• Low-pressure pipe is frost- erant).
ed.
High-pressure side is excessively
high and low-pressure side is too
low.
High-pressure pipe and upper
Clogged or crushed high-pres-
side of condenser become Repair or replace the malfunc-
sure pipe located between
hot, however, liquid tank does tioning parts.
compressor and condenser.
not become so hot.

AC360A

High-pressure side is too low and

low-pressure side is too high. • The readings of both sides
Malfunction in compressor sys-
become equal soon after
tem (insufficient compressor
compressor operation
pressure operation).
stops. Replace compressor.
• Damage or breakage of
• There is no temperature dif-
valve.
ference between high- and
• Malfunctioning gaskets.
low-pressure sides.
AC356A

Revision: November 2016 HA-28 2016 Q50

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [2.0L TURBO GASOLINE ENGINE]
Gauge indication Refrigerant cycle Probable cause Corrective action
A
• The area around evapora-
Clogged expansion valve.
tor outlet does not become
• Breakage of temperature Eliminate foreign material from
cold.
sensor. expansion valve, or replace it.
• The area around evapora- B
• Clogging by foreign material.
tor inlet becomes frosted.
• There is a temperature dif-
Both high- and low-pressure sides ference between the areas
around outlet and inlet Malfunction in inner liquid tank
C
are too low. Replace condenser assembly.
pipes of liquid tank. (clogged strainer).
• Liquid tank becomes frost-
ed. D
Clogged or crushed low-pres- Repair or replace malfunction-
sure pipe. ing parts.
Evaporator becomes frosted. Check intake sensor system. E
Malfunction in intake air tem-
AC353A Refer to HAC-92, "Diagnosis
perature sensor.
Procedure".
• Check for leakage.
There is a small temperature
• Collect all refrigerant, evacu-
F
difference between the high • Shortage of refrigerant.
ate refrigerant cycle again,
and low pressure pipes for re- • Leakage of refrigerant.
and then refill it with the spec-
frigerant cycle.
ified amount of refrigerant. G
Low-pressure side sometimes be-
comes negative.
• Sometimes the area • Collect all refrigerant.
around evaporator outlet • Icing caused by the mixing of • Evacuate refrigerant cycle H
does not become cold. water in cooler cycle. completely, and then refill it
• Sometimes the area • Deteriorated dryer in liquid with the specified amount of
around evaporator inlet is tank. refrigerant. At this time, al-
frosted. ways replace liquid tank.
HA

AC354A

There is no temperature dif-

• Replace compressor. J
Malfunctioning variable valve • Check ECV system. Refer to
Hunting in high-pressure side. ference between high- and
in compressor. HAC-124, "Diagnosis Proce-
low-pressure sides.
dure".
K

Revision: November 2016 HA-29 2016 Q50

 NOISE
< SYMPTOM DIAGNOSIS > [2.0L TURBO GASOLINE ENGINE]
NOISE
Symptom Table INFOID:0000000012794056

Symptom Noise source Probable cause Corrective action

Wear, breakage, or clogging of foreign Check compressor oil. Re-
Inside of compressor
material in inner parts. fer to HA-24, "Inspection".
Check clearance between
Unusual noise from compressor Magnet clutch Contact of clutch disc with pulley. clutch disc and pulley. Refer
when A/C is ON. to HA-32, "Inspection".
Check bolts for tightness.
Compressor body Loosened compressor mounting bolts. Refer to HA-31, "Exploded
View".
Check the installation condi-
Cooler piping (pipe and Improper installation of clip and brack- tion of the cooler piping. Re-
Unusual noise from cooler piping.
flexible hose) et. fer to HA-33, "Exploded
View".
• Check for leakage.
• Collect all refrigerant,
evacuate refrigerant cycle
Shortage of refrigerant.
again, and then refill it
Unusual noise from expansion with the specified amount
Expansion valve
valve when A/C is ON. of refrigerant.
Eliminate foreign material
Wear, breakage, or clogging of foreign
from expansion valve, or re-
material in inner parts.
place it.
Check belt tension. Refer to
Loosened belt
Unusual noise from belt. — EM-17, "Inspection".
Internal compressor parts get locked Replace compressor.

Revision: November 2016 HA-30 2016 Q50

 COMPRESSOR
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]

REMOVAL AND INSTALLATION A

COMPRESSOR
Exploded View INFOID:0000000012794057
B

REMOVAL
C

JMIIA2975GB

H
Compressor

: N·m (kg-m, ft-lb)

HA
Removal and Installation INFOID:0000000012794058

REMOVAL J
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation". K
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Remove drive belt. Refer to EM-16, "Removal and Installation". L

3. Remove mounting bolts , and then disconnect low-pressure

flexible hose and high-pressure flexible hose from com-
pressor. M
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air. N

O
JMIIA3068ZZ

4. Disconnect harness connector, and then remove mounting bolts from compressor. P
5. Remove compressor from lower side of the vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.

Revision: November 2016 HA-31 2016 Q50

 COMPRESSOR
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
• Check tension of the drive belt after installing compressor. Refer to EM-17, "Inspection".
Inspection INFOID:0000000012794059

CHECK DISC TO PULLEY CLEARANCE

Check the clearance (B) between pulley assembly and clutch disc
along the entire periphery with a feeler gauge (A).

Clearance : Refer to HA-52, "Compressor".

CAUTION:
Replace compressor if specified clearance is not obtained,
replace adjusting spacer and readjust.

SJIA1918E

Revision: November 2016 HA-32 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
COOLER PIPE AND HOSE
A
Exploded View INFOID:0000000012794060

HA

JMIIA3143GB

P
A/C unit assembly O-ring Low-pressure flexible hose
Compressor High-pressure flexible hose Condenser assembly
High-pressure pipe Low-pressure pipe
: Always replace after disassembly.

Revision: November 2016 HA-33 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

LOW-PRESSURE FLEXIBLE HOSE

LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000012794061

REMOVAL
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Remove mounting bolts , and then disconnect low-pressure
flexible hose from low-pressure pipe .
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JMIIA3070ZZ

3. Remove mounting bolt , and then remove low-pressure flexi-

ble hose from compressor.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

: High-pressure flexible hose

JMIIA3068ZZ

4. Remove low-pressure flexible hose from the vehicle.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
HIGH-PRESSURE FLEXIBLE HOSE
HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000012794062

REMOVAL
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".

Revision: November 2016 HA-34 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
2. Remove engine cover. Refer to EM-22, "Removal and Installation".
3. Remove mounting bolt , and then disconnect high-pressure A
flexible hose from condenser pipe assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- B
rial such as vinyl tape to avoid the entry of air.

: High-pressure pipe
C
: Vehicle front

JMIIA3078ZZ
D

4. Remove mounting bolt , and then disconnect high-pressure

flexible hose from compressor. E
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.
F
: Low-pressure flexible hose

JMIIA3068ZZ

5. Remove high-pressure flexible hose from the vehicle. H

INSTALLATION
Note the following items, and then install in the reverse order of removal.
HA
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant". J
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
LOW-PRESSURE PIPE
K
LOW-PRESSURE PIPE : Removal and Installation INFOID:0000000012794063

REMOVAL L
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation". M
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Remove cowl top cover. Refer to EXT-27, "Removal and Installation". N
3. Remove mounting bolts , and then low-pressure flexible hose
from low-pressure pipe .
CAUTION: O
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
P

JMIIA3070ZZ

Revision: November 2016 HA-35 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
4. Remove mounting bolt , and then disconnect low-pressure
pipe from evaporator pipe assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: High-pressure pipe

JMIIA3019ZZ

5. Remove low-pressure pipe from the vehicle.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000012794064

REMOVAL
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
1. Remove low-pressure pipe. Refer to HA-35, "LOW-PRESSURE PIPE : Removal and Installation".
2. Disconnect vacuum hose and vacuum piping. Refer to BR-49, "2.0L TURBO GASOLINE ENGINE :
Removal and Installation".
3. Remove power steering oil pump mounting bolts. Refer to ST-50, "Exploded View". (HYDRAULIC PUMP
ELECTRIC P/S models)
4. Move power steering oil pump to secure work space.
5. Remove mounting bolt , and then disconnect high-pressure
pipe and high-pressure flexible hose from condenser pipe
assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA3078ZZ

6. Disconnect high-pressure pipe from evaporator pipe assembly.

Revision: November 2016 HA-36 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
7. Disengage high-pressure pipe from vehicle clips , and then
remove high-pressure pipe from the vehicle. A

JMIIA3069ZZ

D
INSTALLATION
Note the following items, then install in the reverse order of removal.
CAUTION: E
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test". F

HA

Revision: November 2016 HA-37 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
CONDENSER
Exploded View INFOID:0000000012794065

JMIIA3003GB

Condenser upper bracket LH Condenser Condenser upper bracket RH

Condenser lower bracket RH Condenser lower bracket LH Refrigerant pressure sensor
Condenser pipe assembly O-ring
: Always replace after disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CONDENSER
CONDENSER : Removal and Installation INFOID:0000000012794066

REMOVAL
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Remove cooling fan. Refer to CO-13, "Removal and Installation".
3. Removal front bumper upper retainer. Refer to DLK-188, "2.0L TURBO GASOLINE ENGINE : Removal
and Installation".

Revision: November 2016 HA-38 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
4. Remove mounting bolt , and then disconnect condenser pipe
assembly from condenser. A

JMIIA3076ZZ

D
5. Disconnect refrigerant pressure sensor harness connector .

G
JMIIA3077ZZ

6. Move top of the condenser and radiator to vehicle rear side.

H
7. Disengage condenser fixing pawls.

HA

K
JMIIA3082ZZ

8. Lift the condenser upwards, and then remove condenser from

vehicle. L

JMIIA3073ZZ
O
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION: P
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
CONDENSER PIPE ASSEMBLY

Revision: November 2016 HA-39 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
CONDENSER PIPE ASSEMBLY : Removal and Installation INFOID:0000000012794067

REMOVAL
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Remove front bumper fascia assembly. Refer to EXT-15, "Removal and Installation".
3. Remove mounting bolt , and then disconnect high-pressure
flexible hose and high-pressure pipe from condenser pipe
assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA3078ZZ

4. Remove mounting bolt , and then disconnect condenser pipe

assembly from condenser.
CAUTION:
Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

JMIIA3076ZZ

5. Remove condenser pipe assembly from the vehicle

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
REFRIGERANT PRESSURE SENSOR
REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000012794068

REMOVAL
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Remove front bumper fascia assembly. Refer to EXT-15, "Removal and Installation".

Revision: November 2016 HA-40 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
3. Remove mounting bolt , and then disconnect condenser pipe
from condenser. A
CAUTION:
Cap or wrap the joint of condenser pipe and condenser with
suitable material such as vinyl tape to avoid the entry of air.
B

JMIIA3076ZZ

D
4. Clean refrigerant pressure sensor and its surrounding area, and then remove dust and rust from refriger-
ant pressure sensor.
CAUTION:
E
Be sure to clean carefully.
5. Disconnect refrigerant presser sensor connector.
6. Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then
F
remove the refrigerant pressure sensor from the condenser.
CAUTION:
• Never to damage core surface of condenser.
• Cap or wrap the joint of the condenser with suitable material such as vinyl tape avoid the entry G
of air.
INSTALLATION
Note the following items, and then install in the reverse order of removal. H
CAUTION:
• Replace O-ring with new one. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22, HA
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
J

Revision: November 2016 HA-41 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
HEATER & COOLING UNIT ASSEMBLY
Exploded View INFOID:0000000012794069

REMOVAL

JMIIA3018GB

Heater & cooling unit assembly Steering member Knee protector

Instrument stay LH Instrument stay RH Blower unit assembly

: N·m (kg-m, in-lb)

: N·m (kg-m, in-lb)

DISASSEMBLY

Revision: November 2016 HA-42 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]

HA

L
JMIIA3001GB

Ventilator packing RH Defroster packing RH Drain hose M

Foot duct RH Heater case RH Intake sensor
Case cover Evaporator pipe assembly Evaporator pipe grommet
N
O-ring Expansion valve Insulator
Insulator Lower case Evaporator
Insulator Heater pipe bracket Heater pipe grommet RH O
Heater pipe grommet LH Heater pipe cover Heater core
Heater case LH Foot duct LH Aspirator
P
Aspirator duct In-vehicle sensor Defroster packing LH
Ventilator packing LH Foot door LH Foot door RH
Ventilator door Defroster door LH Defroster door RH
Air guide Center case Air mix door LH
Air mix door RH

Revision: November 2016 HA-43 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
: Always replace after disassembly.

: N·m (kg-m, in-lb)

HEATER & COOLING UNIT ASSEMBLY

HEATER & COOLING UNIT ASSEMBLY : Removal and Installation INFOID:0000000012794070

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
24, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-22, "Recy-
cle Refrigerant".
2. Drain engine coolant from cooling system. Refer to CO-7, "Draining".
3. Remove wiper drive assembly. Refer to WW-59, "WIPER DRIVE ASSEMBLY : Removal and Installation".
4. Remove engine cover. Refer to EM-22, "Removal and Installation".
5. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from evaporator pipe assem-
bly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JMIIA3019ZZ

6. Remove fixing clamps , and then disconnect heater hoses .

JSIIA1412ZZ

7. Remove instrument panel assembly. Refer to IP-13, "Removal and Installation".

8. Remove front defroster nozzle, side defroster nozzle and ventilator duct. Refer to VTL-10, "FRONT
DEFROSTER NOZZLE : Removal and Installation", VTL-9, "SIDE DEFROSTER NOZZLE : Removal and
Installation" and VTL-8, "VENTILATOR DUCT : Removal and Installation".
9. Remove front floor duct LH and RH. Refer to VTL-12, "FRONT FLOOR DUCT : Removal and Installation".
10. Remove mounting nuts , and then remove instrument stay LH and RH .

JMIIA3026ZZ

Revision: November 2016 HA-44 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
11. Disconnect drain hose from A/C unit assembly.
12. Remove ground wire mounting bolts . A

JMIIA3024ZZ
D

13. Remove mounting bolts , and then remove knee protector.

E

JMIIA3052ZZ

H
14. Remove harness connector, harness clips, and bracket necessary to remove steering member. Move
vehicle harness aside.
15. Remove steering column mounting bolts and nuts, and then move steering column assembly to secure HA
work space. Refer to the following.
• HYDRAULIC PUMP ELECTRIC P/S
- WITHOUT ELECTRIC MOTOR: Refer to ST-33, "WITHOUT ELECTRIC MOTOR : Exploded View".
- WITH ELECTRIC MOTOR: Refer to ST-36, "WITH ELECTRIC MOTOR : Exploded View". J
• DUAL PINION ELECTRIC P/S: Refer to ST-85, "WITH ELECTRIC MOTOR : Exploded View".
• DIRECT ADAPTIVE STEERING: Refer to ST-135, "Exploded View".
K

Revision: November 2016 HA-45 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
16. Remove steering member mounting bolts , heater & cooling unit mounting bolts and blower unit
mounting bolt .

JMIIA3025ZZ

17. Remove steering member from vehicle.

18. Remove A/C unit assembly from vehicle.
19. Remove fixing screw, and then separate blower unit and heater & cooling unit assembly.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
NOTE:
Refer to CO-8, "Refilling" when filling radiator with engine coolant.
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000012794071

REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-44, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
2. Remove foot duct LH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".

Revision: November 2016 HA-46 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
3. Remove heater pipe grommet.
4. Remove fixing screws , and then remove heater pipe bracket. A

JMIIA3035ZZ
D

5. Remove fixing screws , and then remove heater pipe cover.

E

JMIIA3036ZZ

H
6. Slide heater core to left side, and then remove heater core.

HA

K
JMIIA3037ZZ

INSTALLATION L
Note the following item, and then install in the reverse order of removal.
NOTE:
Refer to CO-8, "Refilling" when filling radiator with engine coolant.
M
EVAPORATOR
EVAPORATOR : Removal and Installation INFOID:0000000012794072

N
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-44, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation". O
2. Remove heater core. Refer to HA-46, "HEATER CORE : Removal and Installation".
3. Remove foot duct RH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".
P
4. Remove air mix door motor LH and RH. Refer to HAC-145, "AIR MIX DOOR MOTOR : Removal and
Installation".
5. Remove fixing screw, and then remove aspirator.

Revision: November 2016 HA-47 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
6. Remove fixing screws , and then remove lower case.

JMIIA3032ZZ

7. Remove evaporator pipe grommet.

8. Remove fixing screws , and then remove case cover.

JMIIA3033ZZ

9. Remove evaporator assembly from lower case.

JMIIA3034ZZ

10. Remove the following parts after removing evaporator.

• Evaporator pipe assembly
• Expansion valve
• Intake sensor
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sensor
can be located in the same position.
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
EVAPORATOR PIPE ASSEMBLY
EVAPORATOR PIPE ASSEMBLY : Removal and Installation INFOID:0000000012794073

REMOVAL

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 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
1. Remove heater & cooling unit assembly. Refer to HA-44, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation". A
2. Remove heater core. Refer to HA-46, "HEATER CORE : Removal and Installation".
3. Remove foot duct RH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".
4. Remove air mix door motor LH and RH. Refer to HAC-145, "AIR MIX DOOR MOTOR : Removal and B
Installation".
5. Remove fixing screw, and then remove aspirator.
6. Remove fixing screws , and then remove lower case. C

JMIIA3032ZZ

7. Remove evaporator pipe grommet. H

8. Remove fixing screws , and then remove case cover.

HA

JMIIA3033ZZ

9. Remove mounting bolt , and then disconnect evaporator pipe L

assembly from expansion valve.
CAUTION:
Cap or wrap the joint of evaporator pipe assembly and M
expansion valve with suitable material such as vinyl tape to
avoid the entry of air.
N

JMIIA3031ZZ
O

INSTALLATION
Note the following items, and then install in the reverse order of removal. P
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test".
EXPANSION VALVE

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 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
EXPANSION VALVE : Removal and Installation INFOID:0000000012794074

REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-44, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
2. Remove heater core. Refer to HA-46, "HEATER CORE : Removal and Installation".
3. Remove foot duct RH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".
4. Remove air mix door motor LH and RH. Refer to HAC-145, "AIR MIX DOOR MOTOR : Removal and
Installation".
5. Remove fixing screw, and then remove aspirator.
6. Remove fixing screws , and then remove lower case.

JMIIA3032ZZ

7. Remove evaporator pipe grommet.

8. Remove fixing screws , and then remove case cover.

JMIIA3033ZZ

9. Remove mounting bolt , and then disconnect evaporator pipe

assembly from expansion valve.
CAUTION:
Cap or wrap the joint of evaporator pipe assembly and
expansion valve with suitable material such as vinyl tape to
avoid the entry of air.

JMIIA3031ZZ

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 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [2.0L TURBO GASOLINE ENGINE]
10. Remove mounting bolts , and then remove expansion valve
from evaporator. A
CAUTION:
Cap or wrap the joint of evaporator and expansion valve
with suitable material such as vinyl tape to avoid the entry
B
of air.

JMIIA3030ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION: E
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-22,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-20, "Leak Test". F

HA

Revision: November 2016 HA-51 2016 Q50

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [2.0L TURBO GASOLINE ENGINE]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Compressor INFOID:0000000012794075

DENSO make
Model
6SBU16C
Type Variable displacement swash plate
Displacement
Maximum 170 (10.4)
cm3 (cu in)/rev
Number of cylinders 6
Cylinder bore × stroke (Maximum)
34.8 (1.37) × 29.8 (1.17)
mm (in.)
Direction of rotation Clockwise (viewed from clutch)
Drive belt Poly V
Disc to pulley clearance
Standard 0.3 – 0.6 (0.012 – 0.024)
mm (in.)

Lubricant INFOID:0000000012794076

Name ND-OIL12
Total in system 120 (4.1, 4.2)
Capacity
m (US fl oz., Imp fl oz.) Compressor (service part) charging
120 (4.1, 4.2)
amount

Refrigerant INFOID:0000000012794077

Type HFC-134a (R-134a)

Capacity
0.5 (1.1)
kg (lb)

Engine Idling Speed INFOID:0000000012794078

Refer to EC4-973, "Idle Speed".

Belt Tension INFOID:0000000012794079

Refer to EM-17, "Adjustment".

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 PRECAUTIONS
< PRECAUTION > [VR30DDTT]

PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000013611488

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS
system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front
air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. D
Information necessary to service the system safely is included in the “SRS AIR BAG” and “SEAT BELT” of this
Service Manual.
WARNING: E
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, it is recommended that all maintenance
F
and repair be performed by an authorized NISSAN/INFINITI dealer.
• Improper repair, including incorrect removal and installation of the SRS, can lead to personal injury
caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module,
see “SRS AIR BAG”. G
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. H
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation. HA
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing J
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery or batteries, and wait at least 3 minutes before performing any service.
K
Precautions for Removing Battery Terminal INFOID:0000000013611489

When disconnecting the battery terminal, pay attention to the following.

L
• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running.
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds. M
• For vehicles with the engine listed below, remove the battery termi-
nal after a lapse of the specified time:
N
BR08DE : 4 minutes V9X engine : 4 minutes
D4D engine : 20 minutes YD25DDTi : 2 minutes
HR09DET : 12 minutes YS23DDT : 4 minutes
O
HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
SEF289H
M9R engine : 4 minutes ZD30DDTT : 60 seconds
P
R9M engine : 4 minutes
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:

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 PRECAUTIONS
< PRECAUTION > [VR30DDTT]
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Precaution for Procedure without Cowl Top Cover INFOID:0000000013611490

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

PIIB3706J

Precautions For Refrigerant System Service INFOID:0000000013611491

GENERAL REFRIGERANT PRECAUTION

WARNING:
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting
requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment], or J-2209 [HFC-134a (R-134a)
recovery equipment]. Ventilate work area before resuming service if accidental system discharge
occurs. Additional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
• Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to cap-
ture the refrigerant each time an air conditioning system is discharged.
• Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or air
conditioning system.
• Never store or heat refrigerant containers above 52°C (126°F).
• Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm
pail of water if container warming is required.
• Never intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns.
• Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo-
cation.
• Never pressure test or leakage 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)
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.
WORKING WITH HFC-134a (R-134a)
CAUTION:
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. Compressor mal-
function is likely to occur if the refrigerants are mixed, refer to “CONTAMINATED REFRIGERANT”
below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refriger-
ant recovery/recycling recharging equipment and Refrigerant Identifier.

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 PRECAUTIONS
< PRECAUTION > [VR30DDTT]
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. Compressor malfunction is likely to occur if lubricant other than that specified is used. A
• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
- Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere when
B
removing refrigerant components from a vehicle.
- Never remove the caps (unseal) until just before connecting the components when installing refrig-
erant components to a vehicle. Connect all refrigerant loop components as quickly as possible to
minimize the entry of moisture into system. C
- Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant.
Lubricant becomes moisture saturated and should not be used without proper sealing.
- Never allow lubricant to come in contact with styrene foam parts. Damage may result. D
CONTAMINATED REFRIGERANT
Take appropriate steps shown below if a refrigerant other than pure HFC-134a (R-134a) is identified in
a vehicle: E
• Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into
the atmosphere.
• Explain that recovery of the contaminated refrigerant could damage service equipment and refrigerant sup-
ply. F
• Suggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
• In case of repairing, recover the refrigerant using only dedicated equipment and containers. Never G
recover contaminated refrigerant into the existing service equipment. Contact a local refrigerant prod-
uct retailer for available service if the facility does not have dedicated recovery equipment. This refrigerant
must be disposed of in accordance with all federal and local regulations. In addition, replacement of all
H
refrigerant system components on the vehicle is recommended.
• The air conditioner warranty is void if the vehicle is within the warranty period. Please contact Nissan Cus-
tomer Affairs for further assistance.
HA
REFRIGERANT CONNECTION
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
• Expansion valve to evaporator
• Refrigerant pressure sensor to condenser & liquid tank assembly J
WARNING:
Check that 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. K
CAUTION:
Observe the following when replacing or cleaning refrigerant cycle components.
• Store it in the same way at it is when mounted on the car when the compressor is removed. Failure L
to do so will cause lubricant to enter the low-pressure chamber.
• Use always a torque wrench and a back-up wrench when connecting tubes.
• Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes.
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle. M
Never remove the seal caps of pipes and other components until just before required for connection.
• Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components. N
• Remove thoroughly moisture from the refrigeration system before charging the refrigerant.
• Replace always used O-rings.
• Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to
apply lubricant to threaded portion. O

Name : SP-10
• O-ring must be closely attached to the groove portion of tube. P
• Be careful not to damage O-ring and tube when replacing the O-ring.
• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is
installed to tube correctly.

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 PRECAUTIONS
< PRECAUTION > [VR30DDTT]
• Perform leakage test and make sure that there is no leakage from connections after connecting line.
Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tighten
connections of seal seat to the specified torque.

RHA861F

COMPRESSOR
CAUTION:
• Plug all openings to prevent moisture and foreign matter from entering.
• Store it in the same way at it is when mounted on the car when the compressor is removed.
• Follow “Maintenance of Lubricant Quantity in Compressor” exactly when replacing or repairing
compressor. Refer to HA-73, "Description".
• Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth
moistened with thinner if the surface is contaminated with lubricant.
• Turn the compressor shaft by hand more than five turns in both directions after compressor service
operation. This distributes equally lubricant inside the compressor. Let the engine idle and operate
the compressor for one hour after the compressor is installed.
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet
clutch.
LEAK DETECTION DYE
CAUTION:
• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An
ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages.
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of
the fluorescent dye.
• The fluorescent dye leak detector is not a replacement for an electrical leak detector (SST: J-41995).
The fluorescent dye leak detector should be used in conjunction with an electrical leak detector
(SST: J-41995) to pin-point refrigerant leakages.
• Read and follow all manufacture’s operating instructions and precautions prior to performing the
work for the purpose of safety and customer’s satisfaction.
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres-
sor shaft seal should only be repaired after confirming the leakage with an electrical leak detector
(SST: J-41995).
• Remove always any remaining dye from the leakage area after repairs are completed to avoid a mis-
diagnosis during a future service.
• Never allow dye to come into contact with painted body panels or interior components. Clean imme-
diately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for an
extended period of time cannot be removed.
• Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
• Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system.
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C system, or A/C system damage may result.
• The fluorescent properties of the dye remains for three or more years unless a compressor malfunc-
tion occurs.

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 PRECAUTIONS
< PRECAUTION > [VR30DDTT]
Service Equipment INFOID:0000000013611492

A
RECOVERY/RECYCLING RECHARGING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine. B
ELECTRICAL LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
C
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
D
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched
OFF after evacuation (vacuuming) and hose is connected to it. E
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as per the following.
• Vacuum pumps usually have a manual isolator valve as part of the F
pump. Close this valve to isolate the service hose from the pump.
• Use a hose equipped with a manual shut-off valve near the pump
end for pumps without an isolator. Close the valve to isolate the
hose from the pump. G
• Disconnect the hose from the pump if the hose has an automatic
shut-off valve. As long as the hose is connected, the valve is open
and lubricating oil may migrate. H
Some one-way valves open when vacuum is applied and close
under no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
HA

RHA270DA
J

MANIFOLD GAUGE SET

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

SHA533D
N
SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must equip positive shut- O
off devices (either manual or automatic) near the end of the hoses
opposite to the manifold gauge.
P

RHA272D

SERVICE COUPLERS

Revision: November 2016 HA-57 2016 Q50

 PRECAUTIONS
< PRECAUTION > [VR30DDTT]
Never attempt to connect HFC-134a (R-134a) service couplers to
the CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
do 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. The hose fitting must
be 1/2″-16 ACME if the scale controls refrigerant flow electronically.

RHA274D

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

Revision: November 2016 HA-58 2016 Q50

 PREPARATION
< PREPARATION > [VR30DDTT]

PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000013611493
B
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
HFC-134a (R-134a) Service Tool and Equipment C
• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/
lubricant. D
• 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. E
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.
F
Tool number
(Kent-Moore No.) Description
Tool name
G

(ACR2005-NI) Function: Refrigerant recovery, recycling H

ACR5 A/C Service Center and recharging

WJIA0293E
HA

(J-41995) Power supply:

K
Electrical leak detector DC 12 V (Battery terminal)

AHA281A

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

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 PREPARATION
< PREPARATION > [VR30DDTT]
Tool number
(Kent-Moore No.) Description
Tool name

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

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

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

SHA440F

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

SHA441F

Identification:
(J-39183) • The gauge face indicates HFC-134a (R-
Manifold gauge set (with hoses 134a).
and couplers) Fitting size: Thread size
• 1/2″-16 ACME

RJIA0196E

Hose color:
Service hoses • Low-pressure side hose: Blue with black
• High-pressure side hose stripe
(J-39501-72) • High-pressure side hose: Red with black
• Low-pressure side hose stripe
(J-39502-72) • Utility hose: Yellow with black stripe or
• Utility hose green with black stripe
(J-39476-72) Hose fitting to gauge:
S-NT201
• 1/2″-16 ACME

Revision: November 2016 HA-60 2016 Q50

 PREPARATION
< PREPARATION > [VR30DDTT]
Tool number
(Kent-Moore No.) Description A
Tool name

B
Service couplers
• High-pressure side coupler Hose fitting to service hose:
(J-39500-20) M14 x 1.5 fitting is optional or permanently
• Low-pressure side coupler attached. C
(J-39500-24)

S-NT202

For measuring of refrigerant

(J-39650) Fitting size: Thread size E
Refrigerant weight scale
1/2″-16 ACME

S-NT200 F

Capacity:
• Air displacement: 4 CFM G
(J-39649) • Micron rating: 20 microns
Vacuum pump • Oil capacity: 482 g (17 oz)
(Including the isolator valve) Fitting size: Thread size
H
• 1/2″-16 ACME
S-NT203

Commercial Service Tool INFOID:0000000013611494 HA

Tool name Description

J

Checking for refrigerant purity and

Refrigerant identifier equipment
system contamination L

M
RJIA0197E

Sealant or/and Lubricant INFOID:0000000013611495

N

HFC-134a (R-134a) Service Tool and Equipment

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/ O
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles P
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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.

Revision: November 2016 HA-61 2016 Q50

 PREPARATION
< PREPARATION > [VR30DDTT]

Tool name Description

Container color: Light blue

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

S-NT196

Type:
Polyalkylene glycol oil (PAG),
Application:
A/C System Oil
HFC-134a (R-134a) swash plate com-
SP-10
pressors
Capacity:
40 m (1.4 US fl oz., 1.4 Imp fl oz.)
JMIIA1759ZZ

Revision: November 2016 HA-62 2016 Q50

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [VR30DDTT]

SYSTEM DESCRIPTION A
COMPONENT PARTS
REFRIGERATION SYSTEM
B
REFRIGERATION SYSTEM : Component Parts Location INFOID:0000000013611496

HA

J
JMIIA2971ZZ

In the heater & cooling unit assembly K

No. Location Function

L
Liquid tank (Condenser & liquid tank assembly) Refer to HA-65, "CONDENSER : Liquid Tank".

Condenser (Condenser & liquid tank assembly) Refer to HA-64, "CONDENSER : Condenser".
M
Refrigerant pressure sensor Refer to HAC-16, "Refrigerant Pressure Sensor".

Compressor Refer to HA-65, "Compressor".

Refer to HA-64, "HEATER & COOLING UNIT ASSEMBLY : Evapora- N
Evaporator
tor".
Refer to HA-64, "HEATER & COOLING UNIT ASSEMBLY : Expansion
Expansion valve
Valve". O
HEATER & COOLING UNIT ASSEMBLY
P

Revision: November 2016 HA-63 2016 Q50

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [VR30DDTT]
HEATER & COOLING UNIT ASSEMBLY : Heater & Cooling Unit INFOID:0000000013611497

This system utilizes a heater & cooling unit that combines blower
unit, heater unit, and cooling unit.

: Vehicle front

JMIIA3045ZZ

HEATER & COOLING UNIT ASSEMBLY : Evaporator INFOID:0000000013611498

• A thin laminate pipeless evaporator is used.

• The mist from liquid refrigerant transforms to gas by evaporation
by the air conveyed from blower motor. The air is cooled by the
heat by evaporation.

JSIIA0295GB

HEATER & COOLING UNIT ASSEMBLY : Expansion Valve INFOID:0000000013611499

The refrigerant temperature is detected by the temperature sensing

part located in low-pressure refrigerant path inside expansion valve.
The lift amount of high-pressure side ball valve is changed to regu-
late the refrigerant flow.

JSIIA0244GB

CONDENSER
CONDENSER : Condenser INFOID:0000000013611500

DESCRIPTION
• A sub-cool condenser that combines a parallel-flow condenser and liquid tank in the sub-cool cycle is used.
• Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant.
STRUCTURE AND OPERATION

Revision: November 2016 HA-64 2016 Q50

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [VR30DDTT]
The sub-cool section is installed on the condenser, and the liquid refrigerant that exits the liquid tank is further
cooled by the condenser sub-cool section, increasing the amount of heat that the liquid refrigerant can absorb A
and improving cooling performance.

JMIIA3047GB

CONDENSER : Liquid Tank INFOID:0000000013611501 G

• A liquid tank compatible with HFC-134a refrigerant is used.

• Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant. H
Compressor INFOID:0000000013611502

Intakes, compresses, and discharges refrigerant, to circulate refrig- HA

erant inside the refrigerant cycle.

JMIIA3048ZZ L

Revision: November 2016 HA-65 2016 Q50

 SYSTEM
< SYSTEM DESCRIPTION > [VR30DDTT]
SYSTEM
System Diagram INFOID:0000000013611503

JPIIA1671GB

System Description INFOID:0000000013611504

REFRIGERANT CYCLE
Refrigerant Flow
The refrigerant from the compressor, flows the condenser & liquid tank assembly, the evaporator, and returns
to the compressor. The refrigerant evaporation in the evaporator is controlled by an expansion valve.
Freeze Protection
To prevent evaporator from freezing up, the evaporator air temperature is monitored, and the voltage signal to
the A/C auto amp. makes the A/C relay go OFF and stop the compressor.
REFRIGERANT SYSTEM PROTECTION
Refrigerant Pressure Sensor
• The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure
sensor, located to the condenser & liquid tank assembly. The refrigerant pressure sensor detects the pres-
sure inside the refrigerant line and sends the voltage signal to the ECM if the system pressure rises above,
or falls below the specifications.
• ECM turns the A/C relay to OFF and stops the compressor when the high-pressure side detected by refriger-
ant pressure sensor is following conditions;
- Approximately 3,120 kPa (31.8 kg/cm2, 452 psi) or more (Engine speed is 1,500 rpm or more.)
- Approximately 2,740 kPa (27.9 kg/cm2, 397 psi) or more (Engine speed is less than 1,500 rpm.)
- Approximately 120 kPa (1.2 kg/cm2, 17 psi) or less
Pressure Relief Valve
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere
when the pressure of refrigerant in the system increases to an unusual level [more than 3,800 kPa (38.8 kg/
cm2, 551 psi)].

Revision: November 2016 HA-66 2016 Q50

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [VR30DDTT]

BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000013611505
B

OVERALL SEQUENCE
C

HA

P
JPIIA1365GB

DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.

Revision: November 2016 HA-67 2016 Q50

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [VR30DDTT]
>> GO TO 2.
2.SYMPTOM CHECK
Check the symptom from the customer's information. Check that any symptom occurs other than the inter-
viewed symptom.

Insufficient cooling/heating>>GO TO 3.
Refrigerant leakage>>GO TO 6.
Noise >> GO TO 7.
3.CONTROL SYSTEM DIAGNOSIS
Perform the system diagnosis for the A/C control system. Refer to HAC-70, "Work Flow".
Is A/C control system normal?
YES >> GO TO 4.
NO >> GO TO 8.
4.PERFORMANCE TEST
Perform the performance test. Check the operation of each part. Refer to HA-75, "Inspection".

>> GO TO 5.
5.TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE
Diagnose using a manifold gauge whenever system's high and/or low side pressure(s) is/are unusual. Specify
the malfunctioning part. Refer to HA-77, "Symptom Table".

Low refrigerant charge>>GO TO 6.

Except above>>GO TO 8.
6.CHECK REFRIGERANT FOR LEAKAGES
Check refrigerant for leakages. Specify the malfunctioning part. Refer to HA-69, "Leak Test".

>> GO TO 8.
7.TROUBLE DIAGNOSIS FOR NOISE
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-79, "Symptom Table".

>> GO TO 8.
8.MALFUNCTION PART REPAIR
Repair or replace the malfunctioning part.

>> GO TO 9.
9.REPAIR CHECK (OPERATION CHECK)
Check the operation of each part.
Does it operate normally?
YES >> INSPECTION END
NO >> GO TO 2.

Revision: November 2016 HA-68 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [VR30DDTT]
REFRIGERANT
A
Description INFOID:0000000013611506

CONNECTION OF SERVICE TOOLS AND EQUIPMENT B

JSIIA0239ZZ

H
Recovery/recycling/recharging
Shut-off valve A/C service valve
equipment
Refrigerant container (HFC-134a) Weight scale (J-39650) Vacuum pump (J-39649)
HA
Manifold gauge set (J-39183)
Preferred (best) method Alternative method For charging
J
Leak Test INFOID:0000000013611507

CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE K

P
RJIA3815J

1. Install a fender cover .

2. Wear UV safety goggles provided with refrigerant dye leak detection kit (J-43926).
3. Connect power cable of UV lamp to positive and negative terminals of the battery .
4. Press UV lamp switch and check A/C system for refrigerant leakage. (Where refrigerant leakage
occurs, fluorescent leak detection dye appears in green color.)

Revision: November 2016 HA-69 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [VR30DDTT]
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Illuminate piping joints from different angles using UV lamp and check that there is no leakage.
• Use a mirror in area that is difficult to see to check refrigerant leakage.
• Refrigerant leakage from evaporator can be detected by soaking cotton swab or a similar material with
drain hose water and illuminating it using UV lamp.
• Dust, dirt, and packing materials adhesive used for condenser, evaporator, and other locations may flu-
oresce. Be careful not to misidentify leakage.
5. Repair or replace parts where refrigerant leakage occurs and wipe off fluorescent leak detection dye.
NOTE:
Completely wipe off fluorescent leak detection dye from gaps between parts, screw threads, and others
using a cotton swab or similar materials.
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work.
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Dust, dirt, and packing materials adhesive used for condenser, evaporator, and other locations may flu-
oresce. Be careful not to misidentify leakage.
CHECK REFRIGERANT LEAKAGE USING ELECTRICAL LEAK DETECTOR
WARNING:
Never check refrigerant leakage while the engine is running.
CAUTION:
Be careful of the following items so that inaccurate checks or misidentifications are avoided.
• Never allow refrigerant vapor, shop chemical vapors, cigarette smoke, or others around the vehicle.
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse
when leakage occurs.
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set (J-39183) to A/C service valve.
3. Check that A/C refrigerant pressure is 345 kPa (3.52 kg/cm2, 50 psi) or more when temperature is 16°C
(61°F) or more. When pressure is lower than the specified value, recycle refrigerant completely and fill
refrigerant to the specified level.
NOTE:
Leakages may not be detected if A/C refrigerant pressure is 345 kPa (3.52 kg/cm2, 50 psi) or less when
temperature is less than 16°C (61°F).
4. Clean area where refrigerant leakage check is performed, and check refrigerant leakage along all sur-
faces of pipe connections and A/C system components using electrical leak detector (J-41995) probe.
CAUTION:
• Continue checking when a leakage is found. Always continue and complete checking along all
pipe connections and A/C system components for additional leakage.
• When a leakage is detected, clean leakage area using compressed air and check again.
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the
probe surface may not be exposed to water or dirt.
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side.
• When checking leakage of cooling unit inside, operate blower fan motor for 15 minutes or more at the
maximum fan speed while the engine is stopped, and then insert electrical leak detector probe into drain
hose and hold for 10 minutes or more.
• When disconnecting shut-off valve that is connected to A/C service valve, always evacuate remaining
refrigerant so that misidentification can be avoided.
5. Repair or replace parts where refrigerant leakage is detected. (Leakage is detected but leakage area is
unknown. GO TO 6.)
6. Start the engine and set A/C control in the following conditions.
• A/C switch ON
• Air flow: VENT (ventilation)

Revision: November 2016 HA-70 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [VR30DDTT]
• Intake door position: Recirculation
• Temperature setting: Full cold A
• Fan (blower) speed: Maximum speed set
7. Run the engine at approximately 1,500 rpm for 2 minutes or more.
8. Stop the engine. Check again for refrigerant leakage. GO TO 4. B
WARNING:
Be careful not to get burned when the engine is hot.
NOTE: C
• Start refrigerant leakage check immediately after the engine is
stopped.
• When refrigerant circulation is stopped, pressure on the low-
pressure side rises gradually, and after this, pressure on the D
high-pressure side falls gradually.
• The higher the pressure is, the easier it is to find the refriger-
ant leakage. E

F
SHA839E

Recycle Refrigerant INFOID:0000000013611508

G
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication. H
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, or
throat. HA
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1. Perform lubricant return operation. Refer to HA-73, "Perform Lubricant Return Operation". (If refrigerant or J
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is K
detected.
2. Check gauge pressure readings of recovery/recycling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose. L
NOTE:
Follow manufacturer instructions for the handling or maintenance of the equipment. Never fill the equip-
ment with non-specified refrigerant.
3. Remove A/C service valve cap from the vehicle. M
4. Connect recovery/recycling/recharging equipment to A/C service valve.
5. Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
N
6. Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated to compressor lubri-
cant, etc.
7. Refrigerant recycle operation is complete.
O
Charge Refrigerant INFOID:0000000013611509

WARNING: P
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure my irritate eyes, nose, or throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.

Revision: November 2016 HA-71 2016 Q50

 REFRIGERANT
< BASIC INSPECTION > [VR30DDTT]
1. Connect recovery/recycling/recharging equipment to the A/C service valve.
2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced.
3. Check the airtightness of A/C system for 25 minutes or more. If pressure raises more than the specified
level, charge A/C system with approximately 200 g refrigerant and check that there is no refrigerant leak-
age. Refer to HA-69, "Leak Test".
CAUTION:
Check the airtightness for 15 minutes or more if the parts are replaced.
4. If parts other than compressor are replaced, fill compressor lubricant according to parts that are replaced.
5. Charge the specified amount of refrigerant to A/C system.
6. Check that A/C system operates normally.
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose
and low-pressure hose of recovery/recycling/recharging equipment.)
8. Install A/C service valve cap.
9. Refrigerant charge is complete.

Revision: November 2016 HA-72 2016 Q50

 LUBRICANT
< BASIC INSPECTION > [VR30DDTT]
LUBRICANT
A
Description INFOID:0000000013611510

MAINTENANCE OF LUBRICANT LEVEL B

The compressor lubricant is circulating in the system together with the refrigerant. It is necessary to fill com-
pressor with lubricant when replacing A/C system parts or when a large amount of refrigerant leakage is
detected. It is important to always maintain lubricant level within the specified level. Or otherwise, the following C
conditions may occur.
• Insufficient lubricant amount: Stuck compressor
• Excessive lubricant amount: Insufficient cooling (caused by insufficient heat exchange)
D
Name : SP-10

Inspection INFOID:0000000013611511 E

If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.COMPRESSOR OIL JUDGMENT F
1. Remove compressor. Refer to HA-80, "Removal and Installation".
2. Sample a compressor oil and judge on the figure.
G

HA

JSIIA0927GB

J
Judgement result 1>>Replace compressor only.
Judgement result 2>>Replace compressor and condenser & liquid tank assembly.
K
Perform Lubricant Return Operation INFOID:0000000013611512

CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera- L
tion.
1. Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm M
• A/C switch: ON
• Fan (blower) speed: Maximum speed set
• Intake door position: Recirculation
• Temperature setting: Full cold N
2. Perform lubricant return operation for approximately 10 minutes.
3. Stop the engine.
O
4. Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000013611513 P
Fill with lubricant for the amount that is calculated according to the following conditions.
Example: Lubricant amount to be added when replacing evaporator and condenser & liquid tank assembly
[m (US fl oz., Imp fl oz.)] = 45 (1.5, 1.6) + 30 (1.0, 1.1) + α

Revision: November 2016 HA-73 2016 Q50

 LUBRICANT
< BASIC INSPECTION > [VR30DDTT]

Lubricant amount to be added to A/C system

Conditions
m (US fl oz., Imp fl oz.)
Replace evaporator 45 (1.5, 1.6)
Replace condenser & liquid tank assembly 30 (1.0, 1.1)
Large amount leakage 30 (1.0, 1.1)
Refrigerant leakage is detected
Small amount leakage —
Lubricant amount that is recycled together with refrigerant during recycle operation α

Lubricant Adjusting Procedure for Compressor Replacement INFOID:0000000013611514

1. Drain lubricant from removed compressor and measure lubri-

cant amount.
• Drain lubricant from high-pressure port and low-pressure
port while rotating magnet clutch.
• Measure total amount of lubricant that is drained from
removed compressor.

JMIIA3049ZZ

2. Drain lubricant from a new compressor that is calculated accord-

ing to the following conditions.

Amount to be drained (A) [m (Imp fl oz.)]

= F − (D + S + R + α)
F : Lubricant amount that a new com-
pressor contains [90 (3.0, 3.2)]
D : Lubricant amount that is drained from
removed compressor
S : Lubricant amount that remains inside JPIIA1455GB

of removed compressor [20 (0.7, 0.7)]

R : Lubricant amount to be added accord-
ing to components that are removed
except compressor
α : Lubricant amount that is recycled to-
gether with refrigerant during recycle
operation
CAUTION:
If lubricant amount that is drained from removed compressor is less than 60 m (2.0 US fl oz., 2.1
Imp fl oz.), perform calculation by setting “D” as 40 m (1.4 US fl oz., 1.4 Imp fl oz.).

Lubricant amount to be added to A/C system

Conditions
m (US fl oz., Imp fl oz.)
Replace evaporator 30 (1.0, 1.1)
Replace condenser & liquid tank 30 (1.0, 1.1)
Example: Lubricant amount to be drained from a new compressor when replacing compressor and con-
denser & liquid tank [m (US fl oz., Imp fl oz.)] [D = 60 (2.0, 2.1), α = 5 (0.2, 0.2)]
90 (3.0, 3.2) − [60 (2.0, 2.1) + 20 (0.7, 0.7) + 5 (0.2, 0.2)] = 5 (0.2, 0.2)
3. Install compressor and check the operation.

Revision: November 2016 HA-74 2016 Q50

 PERFORMANCE TEST
< BASIC INSPECTION > [VR30DDTT]
PERFORMANCE TEST
A
Inspection INFOID:0000000013611515

INSPECTION PROCEDURE B
1. Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge. Refer to HA-69,
"Description".
2. Start the engine, and set to the following condition. C
Test condition
Surrounding condition Indoors or in the shade (in a well-ventilated place)
D
Door Closed
Door glass Full open
Vehicle condition
Hood Open E
Engine speed Idle speed
Temperature control switch or dial Full cold
A/C switch ON F
A/C condition Air outlet VENT (ventilation)
Intake door position Recirculation
G
Fan (blower) speed Maximum speed set
3. Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4. Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to- H
operating pressure” are within the specified value.
5. When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to HA-77, HA
"Symptom Table".
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE
J
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature from center ventilator
Relative humidity Air temperature °C (°F)
% °C (°F) K
20 (68) 4.7 – 6.7 (40 – 44)
25 (77) 8.6 – 11.1 (47 – 52)
50 – 60 L
30 (86) 12.6 – 15.6 (55 – 60)
35 (95) 19.0 – 22.5 (66 – 73)
20 (68) 6.7 – 8.7 (44 – 48) M
25 (77) 11.1 – 13.6 (52 – 56)
60 – 70
30 (86) 15.6 – 18.6 (60 – 65)
N
35 (95) 22.5 – 26.0 (73 – 79)

AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE

O

Revision: November 2016 HA-75 2016 Q50

 PERFORMANCE TEST
< BASIC INSPECTION > [VR30DDTT]
Fresh air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (kg/cm2, psi) kPa (kg/cm2, psi)
% °C (°F)
909 – 1,112 159 – 194
25 (77)
(9.2 – 11.3, 131.8 – 161.2) (1.6 – 2.0, 23.1 – 28.1)
1,073 -– 1,312 211 – 259
30 (86)
(10.9 – 13.4, 155.6 – 190.2) (2.2 – 2.6, 30.6 – 37.6)
50 – 70
1,445 – 1,766 247 – 300
35 (95)
(14.7 – 18.0, 209.5 – 256.1) (2.5 – 3.1, 35.8 – 43.5)
1,650 – 2,017 290 – 355
40 (104)
(16.8 – 20.6, 239.3 – 292.5) (3.0 – 3.6, 42.1 – 51.5)

Revision: November 2016 HA-76 2016 Q50

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [VR30DDTT]

SYMPTOM DIAGNOSIS A
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000013611516
B
Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer to
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how- C
ever, differs from vehicle to vehicle.
Symptom Table INFOID:0000000013611517
D

Gauge indication Refrigerant cycle Probable cause Corrective action

E
The pressure returns to nor- Collect all refrigerant, evacuate
mal soon after sprinkling wa- refrigerant cycle again, and
Overfilled refrigerant.
ter on condenser & liquid tank then refill it with the specified
assembly. amount of refrigerant. F
Insufficient condenser cooling
performance.
• Poor fan rotation of radiator • Repair or replace malfunc-
Both high- and low-pressure sides G
Air flow to condenser is insuf- and condenser. tioning parts.
are too high.
ficient. • Improper installation of air • Clean and repair condenser
guide. & liquid tank assembly fins.
• Clogged or dirty condenser H
& liquid tank assembly fins.
When compressor is stopped,
a high-pressure reading Collect all refrigerant, evacuate
quickly drops by approximate- refrigerant cycle again, and HA
Air mixed in refrigerant cycle.
AC359A then refill it with the specified
ly 196 kPa (2 kg/cm2, 28 psi). amount of refrigerant.
It then gradually decreases.
• Low-pressure pipe is cooler J
than the outlet of evapora- Expansion valve opened too
tor. much (excessive flow of refrig- Replace expansion valve.
• Low-pressure pipe is frost- erant).
ed. K
High-pressure side is excessively
high and low-pressure side is too
low. L
High-pressure pipe and upper
Clogged or crushed high-pres-
side of condenser become
sure pipe located between Repair or replace the malfunc-
hot, however, condenser &
compressor and condenser & tioning parts. M
liquid tank assembly does not
liquid tank assembly.
become so hot.

AC360A N
High-pressure side is too low and
low-pressure side is too high. • The readings of both sides
Malfunction in compressor sys-
become equal soon after O
tem (insufficient compressor
compressor operation
pressure operation).
stops. Replace compressor.
• Damage or breakage of
• There is no temperature dif-
valve. P
ference between high- and
• Malfunctioning gaskets.
low-pressure sides.
AC356A

Revision: November 2016 HA-77 2016 Q50

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [VR30DDTT]
Gauge indication Refrigerant cycle Probable cause Corrective action
• The area around evapora-
Clogged expansion valve.
tor outlet does not become
• Breakage of temperature Eliminate foreign material from
cold.
sensor. expansion valve, or replace it.
• The area around evapora-
• Clogging by foreign material.
tor inlet becomes frosted.
• There is a temperature dif-
ference between the areas
Both high- and low-pressure sides around outlet and inlet Malfunction in inner condenser
are too low. Replace condenser & liquid
pipes of condenser & liquid & liquid tank assembly.
tank assembly.
tank assembly. (clogged strainer).
• Liquid tank becomes frost-
ed.
Clogged or crushed low-pres- Repair or replace malfunction-
sure pipe. ing parts.
Evaporator becomes frosted. Check intake sensor system.
AC353A Malfunction in intake air tem-
Refer to HAC-92, "Diagnosis
perature sensor.
Procedure".
• Check for leakage.
There is a small temperature
• Collect all refrigerant, evacu-
difference between the high • Shortage of refrigerant.
ate refrigerant cycle again,
and low pressure pipes for re- • Leakage of refrigerant.
and then refill it with the spec-
frigerant cycle.
ified amount of refrigerant.
Low-pressure side sometimes be-
comes negative. • Collect all refrigerant.
• Sometimes the area
• Evacuate refrigerant cycle
around evaporator outlet • Icing caused by the mixing of
completely, and then refill it
does not become cold. water in cooler cycle.
with the specified amount of
• Sometimes the area • Deteriorated dryer in liquid
refrigerant. At this time, al-
around evaporator inlet is tank.
ways replace condenser &
frosted.
liquid tank assembly.
AC354A

• Replace compressor.
There is no temperature dif-
Malfunctioning variable valve • Check ECV system. Refer to
Hunting in high-pressure side. ference between high- and
in compressor. HAC-124, "Diagnosis Proce-
low-pressure sides.
dure".

Revision: November 2016 HA-78 2016 Q50

 NOISE
< SYMPTOM DIAGNOSIS > [VR30DDTT]
NOISE
A
Symptom Table INFOID:0000000013611518

B
Symptom Noise source Probable cause Corrective action
Wear, breakage, or clogging of foreign Check compressor oil. Re-
Inside of compressor
material in inner parts. fer to HA-73, "Inspection".
C
Check clearance between
Unusual noise from compressor Magnet clutch Contact of clutch disc with pulley. clutch disc and pulley. Refer
when A/C is ON. to HA-82, "Inspection".
D
Check bolts for tightness.
Compressor body Loosened compressor mounting bolts. Refer to HA-80, "Exploded
View".
Check the installation condi-
E
Cooler piping (pipe and Improper installation of clip and brack- tion of the cooler piping. Re-
Unusual noise from cooler piping.
flexible hose) et. fer to HA-83, "Exploded
View".
F
• Check for leakage.
• Collect all refrigerant,
evacuate refrigerant cycle
Shortage of refrigerant. G
again, and then refill it
Unusual noise from expansion with the specified amount
Expansion valve
valve when A/C is ON. of refrigerant.
Eliminate foreign material H
Wear, breakage, or clogging of foreign
from expansion valve, or re-
material in inner parts.
place it.
Check belt tension. Refer to HA
Loosened belt
Unusual noise from belt. — EM-17, "Inspection".
Internal compressor parts get locked Replace compressor.
J

Revision: November 2016 HA-79 2016 Q50

 COMPRESSOR
< REMOVAL AND INSTALLATION > [VR30DDTT]

REMOVAL AND INSTALLATION

COMPRESSOR
Exploded View INFOID:0000000013611519

REMOVAL

JMIIA3075GB

Compressor

: N·m (kg-m, ft-lb)

Removal and Installation INFOID:0000000013611520

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Remove air duct (bank 2). Refer to EM-165, "Exploded View".
3. Disconnect harness connectors .

: Vehicle front

JMIIA4621ZZ

Revision: November 2016 HA-80 2016 Q50

 COMPRESSOR
< REMOVAL AND INSTALLATION > [VR30DDTT]
4. Remove mounting bolt , and then disconnect low-pressure
flexible hose. A
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
B

JMIIA4622ZZ

D
5. Remove mounting nut , and then disconnect high-pressure
flexible hose.
CAUTION: E
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

G
JMIIA4623ZZ

6. Remove front under cover. Refer to EXT-35, "FRONT UNDER COVER : Removal and Installation".
H
7. Disengage fixing clamp, and then disconnect radiator hose (lower) from water inlet. Refer to CO-39,
"Exploded View".
8. Disengage fixing hose clamp, and then disconnect water hose A or water hose B from heater tube. Refer HA
to TM-320, "VR30DDTT : Exploded View".
9. Remove cooling fan assembly. Refer to CO-45, "Removal and Installation".
10. Remove drive belt. Refer to EM-154, "Removal and Installation". J
11. Remove mounting bolts , and then remove compressor and
low-pressure pipe 2 as a set from lower side of the vehicle.
K

M
JMIIA4624ZZ

12. Remove mounting nut , and then remove low-pressure pipe 2 N

from compressor.
CAUTION:
Cap or wrap the joint of the compressor with suitable mate-
rial such as vinyl tape to avoid the entry of air. O

JMIIA4628ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.

Revision: November 2016 HA-81 2016 Q50

 COMPRESSOR
< REMOVAL AND INSTALLATION > [VR30DDTT]
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-74, "Lubricant
Adjusting Procedure for Compressor Replacement".
• Check tension of the drive belt after installing compressor. Refer to EM-155, "Inspection".
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
Inspection INFOID:0000000013611521

CHECK DISC TO PULLEY CLEARANCE

Check the clearance (B) between pulley assembly and clutch disc
along the entire periphery with a feeler gauge (A).

Clearance : Refer to HA-102, "Compressor".

CAUTION:
Replace compressor if specified clearance is not obtained,
replace adjusting spacer and readjust.

JSIIA0087ZZ

Revision: November 2016 HA-82 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [VR30DDTT]
COOLER PIPE AND HOSE
A
Exploded View INFOID:0000000013611522

HA

L
JMIIA4630GB

Low-pressure pipe 1 O-ring Low-pressure flexible hose M

Low-pressure pipe 2 Compressor Tube clip
Grommet High-pressure pipe High-pressure flexible hose
Pipe bracket Tube mounting rubber
N

To expansion valve To condenser pipe assembly

: Vehicle front O
: Always replace after disassembly.

: N·m (kg-m, in-lb)

P
: N·m (kg-m, ft-lb)

, , : Indicates that the part is connected at points with same symbol in actual vehicle.

LOW-PRESSURE FLEXIBLE HOSE

Revision: November 2016 HA-83 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [VR30DDTT]
LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000013611523

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Remove air duct (bank 2). Refer to EM-165, "Exploded View".
3. Remove monting bolts , and then remove low-pressure flexi-
ble hose and pipe bracket as a set.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA4625ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
HIGH-PRESSURE FLEXIBLE HOSE
HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000013611524

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Remove engine cover. Refer to EM-163, "Removal and Installation".
3. Remove air duct (bank 2). Refer to EM-165, "Exploded View".
4. Remove mounting bolt , and then disconnect high-pressure
pipe and high-pressure flexible hose as a set from con-
denser pipe assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA3078ZZ

Revision: November 2016 HA-84 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [VR30DDTT]
5. Remove mounting nut , and then disconnect high-pressure
flexible hose. A
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.
B
: Vehicle front

JMIIA4626ZZ

D
6. Remove high-pressure flexible hose from the vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal. E
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant". F
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
LOW-PRESSURE PIPE 1
G
LOW-PRESSURE PIPE 1 : Removal and Installation INFOID:0000000013611525

CAUTION: H
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
HA
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant". J
2. Remove cowl top cover. Refer to EXT-27, "Removal and Installation".
3. Remove mounting bolt , and then disconnect low-pressure
pipe 1 from low-pressure flexible hose . K
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air. L
: Vehicle front

JMIIA4627ZZ

N
4. Remove mounting bolt , and then disconnect low-pressure
pipe 1 and high-pressure pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve O
with suitable material such as vinyl tape to avoid the entry
of air.
P

JMIIA3019ZZ

5. Remove low-pressure pipe 1 from the vehicle.

INSTALLATION

Revision: November 2016 HA-85 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [VR30DDTT]
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
LOW-PRESSURE PIPE 2
LOW-PRESSURE PIPE 2 : Removal and Installation INFOID:0000000013611548

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Remove compressor. Refer to HA-80, "Removal and Installation".
3. Remove mounting nut , and then remove low-pressure pipe 2.
CAUTION:
Cap or wrap the joint of the compressor with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JMIIA4628ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000013611526

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Remove low-pressure pipe 1. Refer to HA-85, "LOW-PRESSURE PIPE 1 : Removal and Installation".
3. Disconnect vacuum hose and vacuum piping. Refer to BR-49, "2.0L TURBO GASOLINE ENGINE :
Removal and Installation".

Revision: November 2016 HA-86 2016 Q50

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [VR30DDTT]
4. Remove ground bolts .
A

JMIIA3023ZZ

D
5. Remove mounting bolt , and then disconnect high-pressure
pipe and high-pressure flexible hose from condenser pipe
assembly. E
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
F
: Vehicle front

G
JMIIA3078ZZ

6. Remove mounting bolt , and then disconnect low-pressure

H
pipe 1 and high-pressure pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry HA
of air.

JMIIA3019ZZ
K
7. Disengage high-pressure pipe fixing clips , and then remove
high-pressure pipe from the vehicle.
L

N
JMIIA3027ZZ

INSTALLATION O
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. P
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".

Revision: November 2016 HA-87 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [VR30DDTT]
CONDENSER
Exploded View INFOID:0000000013611527

JMIIA4631GB

Condenser upper bracket RH Condenser & liquid tank assembly Condenser lower bracket RH
Radiator seal lower Condenser lower bracket LH Refrigerant pressure sensor
Condenser pipe assembly O-ring Condenser upper bracket LH
: Vehicle front
: Always replace after disassembly.

: N·m (kg-m, in-lb)

: N·m (kg-m, ft-lb)

CONDENSER
CONDENSER : Removal and Installation INFOID:0000000013611528

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Removal air cleaner body (bank 2) and air cleaner cover (bank 2) as a set. Refer to EM-165, "Exploded
View".
3. Removal front bumper upper retainer. Refer to DLK-194, "VR30DDTT : Removal and Installation".

Revision: November 2016 HA-88 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [VR30DDTT]
4. Remove mounting bolt , and then disconnect condenser pipe
assembly. A

JMIIA3076ZZ

D
5. Disconnect harness connector .

G
JMIIA3077ZZ

6. Remove sub radiator mounting bolt and fixing clips, and then move sub radiator to secure work space.
H
Refer to CO-49, "Exploded View".
CAUTION:
Be careful not damage sub radiator core surface.
7. Move top of the condenser and radiator to vehicle rear side. HA
8. Remove condenser mounting bolts .
J

L
JMIIA3038ZZ

: Vehicle front M

9. Lift the condenser upwards, and then remove condenser from

vehicle. N
CAUTION:
Be careful not damage condenser core surface.
O

JMIIA3039ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:

Revision: November 2016 HA-89 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [VR30DDTT]
• Perform lubricant adjusting procedure after installing new condenser & liquid tank assembly. Refer
to HA-73, "Lubricant Adjusting Procedure for Components Replacement Except Compressor".
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
CONDENSER PIPE ASSEMBLY
CONDENSER PIPE ASSEMBLY : Removal and Installation INFOID:0000000013611529

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Remove front bumper fascia assembly. Refer to EXT-15, "Removal and Installation".
3. Remove mounting bolt , and then disconnect high-pressure
flexible hose and high-pressure pipe from condenser pipe
assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA3078ZZ

4. Remove mounting bolt , and then disconnect condenser pipe

assembly from condenser.
CAUTION:
Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

JMIIA3076ZZ

5. Remove condenser pipe assembly from the vehicle

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
REFRIGERANT PRESSURE SENSOR
REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000013611530

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL

Revision: November 2016 HA-90 2016 Q50

 CONDENSER
< REMOVAL AND INSTALLATION > [VR30DDTT]
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant". A
2. Remove front bumper fascia assembly. Refer to EXT-15, "Removal and Installation".
3. Remove mounting bolt , and then disconnect condenser pipe
from condenser. B
CAUTION:
Cap or wrap the joint of condenser pipe and condenser with
suitable material such as vinyl tape to avoid the entry of air. C

JMIIA3076ZZ
E
4. Clean refrigerant pressure sensor and its surrounding area, and then remove dust and rust from refriger-
ant pressure sensor.
CAUTION:
F
Be sure to clean carefully.
5. Disconnect refrigerant presser sensor connector.
6. Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then G
remove the refrigerant pressure sensor from the condenser.
CAUTION:
• Never to damage core surface of condenser.
• Cap or wrap the joint of the condenser with suitable material such as vinyl tape avoid the entry H
of air.
INSTALLATION
HA
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-ring with new one. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71, J
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
K

Revision: November 2016 HA-91 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
HEATER & COOLING UNIT ASSEMBLY
Exploded View INFOID:0000000013611531

REMOVAL

JMIIA3018GB

Heater & cooling unit assembly Steering member Knee protector

Instrument stay LH Instrument stay RH Blower unit assembly

: N·m (kg-m, in-lb)

: N·m (kg-m, in-lb)

DISASSEMBLY

Revision: November 2016 HA-92 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]

HA

L
JMIIA3001GB

Ventilator packing RH Defroster packing RH Drain hose M

Foot duct RH Heater case RH Intake sensor
Case cover Evaporator pipe assembly Evaporator pipe grommet
N
O-ring Expansion valve Insulator
Insulator Lower case Evaporator
Insulator Heater pipe bracket Heater pipe grommet RH O
Heater pipe grommet LH Heater pipe cover Heater core
Heater case LH Foot duct LH Aspirator
P
Aspirator duct In-vehicle sensor Defroster packing LH
Ventilator packing LH Foot door LH Foot door RH
Ventilator door Defroster door LH Defroster door RH
Air guide Center case Air mix door LH
Air mix door RH

Revision: November 2016 HA-93 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
: Always replace after disassembly.

: N·m (kg-m, in-lb)

HEATER & COOLING UNIT ASSEMBLY

HEATER & COOLING UNIT ASSEMBLY : Removal and Installation INFOID:0000000013611532

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
73, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-71, "Recy-
cle Refrigerant".
2. Drain engine coolant from cooling system. Refer to CO-7, "Draining".
3. Remove wiper drive assembly. Refer to WW-59, "WIPER DRIVE ASSEMBLY : Removal and Installation".
4. Remove engine cover. Refer to EM-22, "Removal and Installation".
5. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from evaporator pipe assem-
bly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JMIIA3019ZZ

6. Remove fixing clamps , and then disconnect heater hoses .

JSIIA1412ZZ

7. Remove instrument panel assembly. Refer to IP-13, "Removal and Installation".

8. Remove front defroster nozzle, side defroster nozzle and ventilator duct. Refer to VTL-10, "FRONT
DEFROSTER NOZZLE : Removal and Installation", VTL-9, "SIDE DEFROSTER NOZZLE : Removal and
Installation" and VTL-8, "VENTILATOR DUCT : Removal and Installation".
9. Remove front floor duct LH and RH. Refer to VTL-12, "FRONT FLOOR DUCT : Removal and Installation".
10. Remove mounting nuts , and then remove instrument stay LH and RH .

JMIIA3026ZZ

Revision: November 2016 HA-94 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
11. Disconnect drain hose from A/C unit assembly.
12. Remove ground wire mounting bolts . A

JMIIA3024ZZ
D

13. Remove mounting bolts , and then remove knee protector.

E

JMIIA3052ZZ

H
14. Remove harness connector, harness clips, and bracket necessary to remove steering member. Move
vehicle harness aside.
15. Remove steering column mounting bolts and nuts, and then move steering column assembly to secure HA
work space. Refer to the following.
• HYDRAULIC PUMP ELECTRIC P/S
- WITHOUT ELECTRIC MOTOR: Refer to ST-33, "WITHOUT ELECTRIC MOTOR : Exploded View".
- WITH ELECTRIC MOTOR: Refer to ST-36, "WITH ELECTRIC MOTOR : Exploded View". J
• DUAL PINION ELECTRIC P/S: Refer to ST-85, "WITH ELECTRIC MOTOR : Exploded View".
• DIRECT ADAPTIVE STEERING: Refer to ST-135, "Exploded View".
K

Revision: November 2016 HA-95 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
16. Remove steering member mounting bolts , heater & cooling unit mounting bolts and blower unit
mounting bolt .

JMIIA3025ZZ

17. Remove steering member from vehicle.

18. Remove A/C unit assembly from vehicle.
19. Remove fixing screw, and then separate blower unit and heater & cooling unit assembly.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
NOTE:
Refer to CO-8, "Refilling" when filling radiator with engine coolant.
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000013611533

REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-94, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
2. Remove foot duct LH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".

Revision: November 2016 HA-96 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
3. Remove heater pipe grommet.
4. Remove fixing screws , and then remove heater pipe bracket. A

JMIIA3035ZZ
D

5. Remove fixing screws , and then remove heater pipe cover.

E

JMIIA3036ZZ

H
6. Slide heater core to left side, and then remove heater core.

HA

K
JMIIA3037ZZ

INSTALLATION L
Note the following item, and then install in the reverse order of removal.
NOTE:
Refer to CO-8, "Refilling" when filling radiator with engine coolant.
M
EVAPORATOR
EVAPORATOR : Removal and Installation INFOID:0000000013611534

N
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-94, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation". O
2. Remove heater core. Refer to HA-96, "HEATER CORE : Removal and Installation".
3. Remove foot duct RH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".
P
4. Remove air mix door motor LH and RH. Refer to HAC-145, "AIR MIX DOOR MOTOR : Removal and
Installation".
5. Remove fixing screw, and then remove aspirator.

Revision: November 2016 HA-97 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
6. Remove fixing screws , and then remove lower case.

JMIIA3032ZZ

7. Remove evaporator pipe grommet.

8. Remove fixing screws , and then remove case cover.

JMIIA3033ZZ

9. Remove evaporator assembly from lower case.

JMIIA3034ZZ

10. Remove the following parts after removing evaporator.

• Evaporator pipe assembly
• Expansion valve
• Intake sensor
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Mark the mounting position of intake sensor bracket prior to removal so that the reinstalled sensor
can be located in the same position.
• Perform lubricant adjusting procedure after installing new evaporator. Refer to HA-73, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
EVAPORATOR PIPE ASSEMBLY

Revision: November 2016 HA-98 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
EVAPORATOR PIPE ASSEMBLY : Removal and Installation INFOID:0000000013611535

A
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-94, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation". B
2. Remove heater core. Refer to HA-96, "HEATER CORE : Removal and Installation".
3. Remove foot duct RH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".
C
4. Remove air mix door motor LH and RH. Refer to HAC-145, "AIR MIX DOOR MOTOR : Removal and
Installation".
5. Remove fixing screw, and then remove aspirator.
D
6. Remove fixing screws , and then remove lower case.

JMIIA3032ZZ
HA
7. Remove evaporator pipe grommet.
8. Remove fixing screws , and then remove case cover.
J

JMIIA3033ZZ

M
9. Remove mounting bolt , and then disconnect evaporator pipe
assembly from expansion valve.
CAUTION:
Cap or wrap the joint of evaporator pipe assembly and N
expansion valve with suitable material such as vinyl tape to
avoid the entry of air.
O

P
JMIIA3031ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.

Revision: November 2016 HA-99 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test".
EXPANSION VALVE
EXPANSION VALVE : Removal and Installation INFOID:0000000013611536

REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-94, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
2. Remove heater core. Refer to HA-96, "HEATER CORE : Removal and Installation".
3. Remove foot duct RH. Refer to VTL-11, "FOOT DUCT : Removal and Installation".
4. Remove air mix door motor LH and RH. Refer to HAC-145, "AIR MIX DOOR MOTOR : Removal and
Installation".
5. Remove fixing screw, and then remove aspirator.
6. Remove fixing screws , and then remove lower case.

JMIIA3032ZZ

7. Remove evaporator pipe grommet.

8. Remove fixing screws , and then remove case cover.

JMIIA3033ZZ

9. Remove mounting bolt , and then disconnect evaporator pipe

assembly from expansion valve.
CAUTION:
Cap or wrap the joint of evaporator pipe assembly and
expansion valve with suitable material such as vinyl tape to
avoid the entry of air.

JMIIA3031ZZ

Revision: November 2016 HA-100 2016 Q50

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [VR30DDTT]
10. Remove mounting bolts , and then remove expansion valve
from evaporator. A
CAUTION:
Cap or wrap the joint of evaporator and expansion valve
with suitable material such as vinyl tape to avoid the entry
B
of air.

JMIIA3030ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION: E
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Use a refrigerant collecting equipment (for HFC-134a) to charge the refrigerant. Refer to HA-71,
"Charge Refrigerant".
• Check for leakages when recharging refrigerant. Refer to HA-69, "Leak Test". F

HA

Revision: November 2016 HA-101 2016 Q50

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [VR30DDTT]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Compressor INFOID:0000000013611537

SANDEN make
Model
PXC14
Type Variable displacement swash plate
Displacement
Maximum 137.2 (8.4)
cm3 (cu in)/rev
Number of cylinders 6
Cylinder bore × stroke (Maximum)
31.6 (1.25) × 29.2 (1.16)
mm (in.)
Direction of rotation Clockwise (viewed from clutch)
Drive belt Poly V
Disc to pulley clearance
Standard 0.35 – 0.65 (0.014 – 0.026)
mm (in.)

Lubricant INFOID:0000000013611538

Name SP-10
Total in system 90 (3.0, 3.2)
Capacity
m (US fl oz., Imp fl oz.) Compressor (service part) charging
90 (3.0, 3.2)
amount

Refrigerant INFOID:0000000013611539

Type HFC-134a (R-134a)

Capacity
0.5 (1.1)
kg (lb)

Engine Idling Speed INFOID:0000000013611540

Refer to EC6-1017, "Idle Speed".

Belt Tension INFOID:0000000013611541

Refer to EM-155, "Adjustment".

Revision: November 2016 HA-102 2016 Q50