HEATER & AIR CONDITIONER GI

SECTION HA MA

EM

LC

EC
CONTENTS
FE
PRECAUTIONS AND PREPARATION............................2 Magnet Clutch Circuit ................................................33
Supplemental Restraint System (SRS) Triple-Pressure Switch ..........................................37
‘‘AIR BAG’’ ...................................................................2 Trouble Diagnosis Procedure For Insufficient CL
Precautions for Working with R-134a..........................2 Cooling.......................................................................39
...39
Contaminated Refrigerant .......................................3 Performance Test Diagnoses ....................................41
General Refrigerant Precautions .................................3 Performance Chart ....................................................43 MT
Precautions for Refrigerant Connection ......................4 Trouble Diagnoses for Abnormal Pressure ...............44
Precautions for Servicing Compressor........................7 Trouble Diagnosis for Insufficient Heating.................47
R-134a Service Tools and Equipment.........................8 Trouble Diagnosis for Noise ......................................49 AT
Special Service Tools ..................................................9 SERVICE PROCEDURES .............................................50
Commercial Service Tools .........................................10 Refrigerant Lines .......................................................50
Precautions for Service Equipment ...........................11 Checking Refrigerant Leaks ......................................51
TF
DESCRIPTION ...............................................................13 R-134a Service Procedure ........................................54
Refrigeration Cycle ....................................................13 Compressor Lubricant Quantity.................................56 PD
Control Operation ......................................................14 Compressor Mounting ...............................................58
Component Layout ....................................................15 Belt Tension ...............................................................58
Discharge Air Flow.....................................................16 Fast Idle Control Device (FICD) ................................58 FA
Component Location..................................................17 Condenser .................................................................58
Circuit Diagram ..........................................................19 Compressor ...............................................................60
Wiring Diagram –HEATER– ......................................20 Compressor Clutch ....................................................60 RA
Wiring Diagram −A/C−...............................................21 Thermal Protector ......................................................63
Operational Check .....................................................23 Heater Unit (Heater Core) .........................................64
TROUBLE DIAGNOSES ...............................................25 Cooling Unit (A/C Evaporator)...................................65 BR
How to Perform Trouble Diagnoses for Quick Blower Case and Motor.............................................66
and Accurate Repair ..................................................25 Fan Lever and Illumination Bulbs..............................67
Blower Motor Circuit ..................................................26 SERVICE DATA AND SPECIFICATIONS (SDS) ..........68
ST
Air Outlet....................................................................30 General Specifications...............................................68
Intake Door ................................................................32 Inspection and Adjustment ........................................68 RS

BT
When you read wiring diagrams:
● Read GI section, ‘‘HOW TO READ WIRING DIAGRAMS’’.
● See EL section, ‘‘POWER SUPPLY ROUTING’’ for power distribution circuit.
HA
When you perform trouble diagnoses, read GI section, ‘‘HOW TO FOLLOW FLOW
CHART IN TROUBLE DIAGNOSES’’ and ‘‘HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT’’. EL

IDX
 PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS)

‘‘AIR BAG’’
The Supplemental Restraint System ‘‘AIR BAG’’, used along with a seat belt, helps to reduce the risk or
severity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint System
consists of air bag modules (located in the center of the steering wheel and in the instrument panel on the
passenger side), a diagnosis sensor unit, a crash zone sensor (4WD models), warning lamp, wiring harness
and spiral cable.
The vehicle is equipped with a passenger air bag deactivation switch. Because no rear seat exists where a
rear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that a
rear-facing child restraint can be used in the front passenger seat. The switch is located in the center of the
instrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag is
enabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passenger
air bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instru-
ment panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabled
and is not affected by the passenger air bag deactivation switch.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance should be performed
by an authorized NISSAN dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses are covered with yellow insulation either just before the har-
ness connectors or on the complete harness, for easy identification.
● The vehicle is equipped with a passenger air bag deactivation switch which can be operated by the
customer. When the passenger air bag is switched OFF, the passenger air bag is disabled and will
not inflate in a frontal collision. When the passenger air bag is switched ON, the passenger air bag
is enabled and could inflate in a frontal collision. After SRS maintenance or repair, make sure the
passenger air bag deactivation switch is in the same position (ON or OFF) as when the vehicle
arrived for service.
Precautions for Working with R-134a
WARNING:
● CFC-12 (R-12) refrigerant and R-134a refrigerant are not compatible. If the refrigerants are mixed,
compressor malfunction is likely to occur, refer to ‘‘Contaminated Refrigerant’’. To determine the
purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/
Recycling Recharging equipment (ACR4) (J-39500-NI) and Refrigerant Identifier.
● Use only specified lubricant for the R-134a A/C system and R-134a components. If lubricant other
than that specified is used, compressor malfunction is likely.
● The specified R-134a lubricant rapidly absorbs moisture from the atmosphere. The following
handling precautions must be observed:
a: When removing refrigerant components from a vehicle, immediately cap (seal) the component
to minimize the entry of moisture from the atmosphere.
b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) until
just before connecting the components. Connect all refrigerant loop components as quickly
as possible to minimize the entry of moisture into the system.
c: Only use the specified lubricant from a sealed container. Immediately reseal containers of
lubricant. Without proper sealing, lubricant will become moisture saturated and should not
be used.
d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose
and throat. Remove R-134a from the A/C system using certified service equipment meeting
requirements of SAE J2210 (R-134a recycling equipment) or J2209 (R-134a recovery equip-
ment). If accidental system discharge occurs, ventilate work area before resuming service.
Additional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
e: Do not allow lubricant to contact styrofoam parts. Damage may result.

HA-2
 PRECAUTIONS AND PREPARATION
Precautions for Working with R-134a (Cont’d)
CONTAMINATED REFRIGERANT GI
If a refrigerant other than pure R-134a is identified in a vehicle, your options are:
● Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into MA
the atmosphere.
● Explain that recovery of the contaminated refrigerant could damage your service equipment and refriger-
ant supply.
EM
● Suggest the customer return the vehicle to the location of previous service where the contamination may
have occured.
● If you choose to perform the repair, recover the refrigerant using only dedicated equipment and contain-
ers. Do not recover contaminated refrigerant into your existing service equipment. If your facility
LC
does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for
available service. 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. EC
● If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan
Customer Affairs for further assistance.
FE
WARNING: General Refrigerant Precautions
● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the CL
refrigerant every time an air conditioner system is discharged. Always follow the manufacturers
recommendations for use of the recovery/recycling equipment.
● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or MT
air conditioner system.
● Do not store or heat refrigerant containers above 52°C (125°F).
● Do not heat a refrigerant container with an open flame; if container warming is required, place the AT
bottom of the container in a pail of warm water.
● Do not intentionally drop, puncture, or incinerate refrigerant containers.
● Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. TF
● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
● Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi- PD
tioning systems with compressed air during repair. Some mixtures of air and 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 refrigerant manu-
FA
facturers.

RA

BR

ST

RS

BT

HA

EL

IDX

HA-3
 PRECAUTIONS AND PREPARATION

Precautions for Refrigerant Connection

FEATURES OF NEW TYPE REFRIGERANT CONNECTION
A new type refrigerant connection has been introduced to all refrigerant lines except the following location:
● Expansion valve to cooling unit.
● The O-ring is relocated in a groove for proper installation. This eliminates the chance of the O-ring being
caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in rela-
tion to the contacting surface of the mating part to improve sealing characteristics.
● The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.

AHA022A

HA-4
 PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d) GI
O-RING AND REFRIGERANT CONNECTION
MA

EM

LC

EC

FE

CL

MT

AHA473A
AT
CAUTION:
Refrigerant connections in some systems use different O-ring configurations. Do not confuse O-rings
since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, TF
the connection.

PD

FA

O-ring part numbers and specifications RA

Connection O-ring
Part number D mm (in) W mm (in) BR
type size
New 92471 N8210 6.8 (0.268) 1.85 (0.0728)
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701) ST
New 92472 N8210 10.9 (0.429) 2.43 (0.0957)
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
RS
New 92473 N8210 13.6 (0.535) 2.43 (0.0957)
AHA049A
BT

HA

EL

IDX

HA-5
 PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system
is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove
it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
● Do not leave compressor on its side or upside down for more than 10 minutes. Compressor lubri-
cant will enter low pressure chamber.
● When connecting tubes, always use a torque wrench and a back-up wrench.
● After disconnecting tubes, plug all openings immediately to prevent entry of dirt and moisture.
● When installing an air conditioner unit in the vehicle, connect the pipes as the final stage of the
operation. Do not remove seal caps from pipes and other components until just before connec-
tion.
● Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
● Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
● Always replace used O-rings.
● When connecting tube, apply lubricant to portions shown in illustration. Be careful not to apply
lubricant to threaded portion.
Name: Nissan A/C System Lubricant Type R
Part No.: KLH00-PAGR0
● O-ring must be closely attached to inflated portion of tube.
● After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
● After connecting line, conduct leak test and make sure that there is no leakage. When the gas
leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal
seat to the specified torque.

AHA025A

HA-6
 PRECAUTIONS AND PREPARATION

Precautions for Servicing Compressor GI

● Plug all openings to prevent moisture and foreign matter from entering.
● Do not keep the compressor in the upside down position or laid on its side for more than 10 min- MA
utes.
● When replacing or repairing compressor, be sure to remove lubricant from the compressor and
check the lubricant quantity extracted.
EM
● When replacing or repairing compressor, follow lubricant checking and adjusting procedure
exactly. Refer to ‘‘Compressor Lubricant Quantity’’, ‘‘SERVICE PROCEDURES’’, HA-56.
● Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with oil, wipe
it off by using a clean waste cloth moistened with thinner.
LC
● After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour. EC
● After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

HA-7
 PRECAUTIONS AND PREPARATION

R-134a Service Tools and Equipment

Never mix 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 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 R-134a. This is to avoid mixed use of
the refrigerants/lubricants.
Adapters to convert from one size fitting to the other must never be used: refrigerant/lubricant contamination
will occur and compressor failure will result.

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

R-134a refrigerant Container color: Light blue

Container marking: R-134a
Fitting size: Thread size
● large container 1/29-16 ACME

NT196

KLH00-PAGR0 Type: Polyalkylene glycol oil (PAG), type R

( — ) Application: R-134a vane rotary compres-
Nissan A/C System Lubri- sors (Nissan only)
cant Type R Lubricity: 40 ml (1.4 US fl oz, 1.4 Imp fl oz)

NT197

(J-39500-NI) Function: Refrigerant Recovery and Recy-

Recovery/Recycling equip- cling and Recharging
ment (ACR4)

NT195

(J-41995) Power supply:

A/C leak detector ● DC 12 V (Cigarette lighter)
Function: Checks for refrigerant leaks.

AHA281A

(J-39183) Identification:
Manifold gauge set (with ● The gauge face indicates R-134a.
hoses and couplers) Fitting size: Thread size
● 1/29-16 ACME

NT199

HA-8
 PRECAUTIONS AND PREPARATION
R-134a Service Tools and Equipment (Cont’d)
GI
Tool number
(Kent-Moore No.) Description Note
Tool name
MA
Service hoses Hose color:
● High-side hose ● Low hose: Blue with black stripe
(J-39501-72) ● High hose: Red with black stripe EM
● Low-side hose ● Utility hose: Yellow with black stripe or
(J-39502-72) green with black stripe
● Utility hose Hose fitting to gauge: LC
(J-39476-72) ● 1/29-16 ACME
NT201

Service couplers Hose fitting to service hose: EC

● High-side coupler ● M14 x 1.5 fitting (optional) or
(J-39500-20) permanently attached
● Low-side coupler FE
(J-39500-24)

NT202 CL
(J-39650) For measuring of refrigerant
Refrigerant weight scale Fitting size: Thread size MT
● 1/29-16 ACME

AT
NT200
TF
(J-39649) Capacity:
Vacuum pump ● Air displacement: 4 CFM
(Including the isolator valve) ● Micron rating: 20 microns
PD
● Oil capacity: 482 g (17 oz)
Fitting size: Thread size
● 1/29-16 ACME
FA
NT203

Special Service Tools RA

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number BR
(Kent-Moore No.) Description
Tool name
ST
KV99231260 Removing shaft nut and clutch disc
(J-38874)
Clutch disc wrench RS

NT204
BT
KV99232340 Removing clutch disc
(J-38874)
Clutch disc puller HA

NT206
EL

IDX

HA-9
 PRECAUTIONS AND PREPARATION
Special Service Tools (Cont’d)
Tool number
(Kent-Moore No.) Description
Tool name

KV99234330 Installing pulley

(J-39024)
Pulley installer

NT207

KV99233130 Removing pulley

(J-39023)
Pulley puller

NT208

Commercial Service Tools

Tool name Description Note

Refrigerant identifier equip- Function: Checks refrigerant purity and for

ment system contamination

NT765

HA-10
PRECAUTIONS AND PREPARATION

Precautions for Service Equipment GI

RECOVERY/RECYCLING EQUIPMENT
Follow the manufacturer’s instructions for machine operation and MA
machine maintenance. Never introduce any refrigerant other than
that specified into the machine.
EM
ELECTRONIC LEAK DETECTOR
Follow the manufacturer’s instructions for tester operation and
tester maintenance.
LC

VACUUM PUMP EC
The lubricating oil contained inside the vacuum pump is not com-
patible with the specified lubricant for R-134a A/C systems. The
FE
vent side of the vacuum pump is exposed to atmospheric pressure.
Therefore, if the pump is switched off after evacuation the lubricat-
ing oil may migrate into the hose. To prevent this, isolate the pump
from the hose after evacuation (vacuuming).
CL
This migration is avoided by placing a manual shut-off valve near
the hose-to-pump connection, as follows:
● Usually vacuum pumps have a manual isolator valve as part MT
of the pump. Close this valve to isolate the service hose from
the pump.
● For pumps without an isolator valve, use a hose equipped with AT
a manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
● If the hose has an automatic shut-off valve, disconnect the TF
hose from the pump. As long as the hose is connected, the
valve is open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close PD
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
FA
RHA270D

MANIFOLD GAUGE SET RA

Be sure the gauge set has 1/29-16 ACME threaded connections for
service hoses. Confirm the set has been used only with refrigerant BR
R-134a along with specified lubricants.

ST

RS
SHA533D
BT
SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). Be certain that all hoses include HA
positive shut-off devices (either manual or automatic) near the end
of the hoses opposite the manifold gauge.
EL

IDX
RHA272D

HA-11
PRECAUTIONS AND PREPARATION
Precautions for Service Equipment (Cont’d)
SERVICE COUPLERS
Never attempt to connect R-134a service couplers to a CFC-12
(R-12) A/C system. The R-134a couplers will not properly connect
to the CFC-12 (R-12) system. However, if an improper connection
is attempted, discharging and contamination can occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close

RHA273D

REFRIGERANT WEIGHT SCALE

When using a scale which controls refrigerant flow electronically,
assure the following:
● Hose fitting size is 1/29-16 ACME
● No refrigerant other than R-134a (along with specified lubri-
cant) has been used with the scale.
Calibration
Calibrate the scale every 3 months.
To calibrate the weight scale on the ACR4 (J-39500):
AHA211
1. Press Shift/Reset and Enter at the same time.
2. Press 8787. ‘‘A1’’ will be displayed.
3. Remove all weight from the scale.
4. Press 0, then press Enter. ‘‘0.00’’ will be displayed and
change to ‘‘A2.’’
5. Place a known weight (dumbbell or similar weight), between 10
and 19 lbs., on the center of the weight scale.
6. Enter the known weight using 4 digits. (Example 10 lbs =
10.00, 10.5 lbs = 10.50)
7. Press Enter − the display returns to the vacuum mode.
8. Press Shift/Reset and Enter at the same time.
9. Press 6 − the known weight on the scale is displayed.
10. Remove the known weight from the scale. ‘‘0.00’’ will be dis-
played.
11. Press Shift/Reset to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be
vented into the air through the cylinder’s top valve when filling the
cylinder.

HA-12
 DESCRIPTION

Refrigeration Cycle GI
REFRIGERANT FLOW
The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser, liquid MA
tank, evaporator, and back to the compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion
valve, located inside the evaporator case. EM

FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the LC
evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compres-
sor operation. When the evaporator coil temperature rises above the specification, the thermo control ampli-
fier allows compressor operation. EC

REFRIGERANT SYSTEM PROTECTION

FE
Triple-pressure switch
The refrigerant system is protected against excessively high or low pressure. The protection is effected by the
triple-pressure switch located on the liquid tank. If the pressure rises or falls out of specifications, the switch CL
opens to interrupt the compressor operation.

Pressure relief valve MT

The refrigerant system is protected by a pressure relief valve. The valve is located on the end of the flexible
high pressure hose near the compressor. When refrigerant system pressure increases abnormally [over 3,727
AT
kPa (38 kg/cm2, 540 psi)], the relief valve’s port opens. The valve then releases refrigerant into the atmo-
sphere.
TF

PD

FA

RA

BR

ST

RS

BT

HA

EL
AHA399A

IDX

HA-13
 DESCRIPTION

Control Operation

AHA109A

FAN CONTROL LEVER

This lever turns the fan ON and OFF, and controls fan speed.

MODE CONTROL SWITCH

This switch controls the outlet air flow.

TEMPERATURE CONTROL SWITCH

This switch allows adjustment of the temperature of the outlet air.

RECIRCULATION (REC) CONTROL LEVER

FRESH position:
Outside air is drawn into the passenger compartment.
Recirculation REC position:
Interior air is recirculated inside the vehicle.

AIR CONDITIONER SWITCH

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

HA-14
 DESCRIPTION

Component Layout GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

AHA123A

HA-15
 DESCRIPTION

Discharge Air Flow

AHA290A

HA-16
 DESCRIPTION

Component Location GI
Engine compartment
MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

AHA400A

HA-17
 DESCRIPTION
Component Location (Cont’d)
Passenger Compartment

AHA148A

HA-18
 DESCRIPTION

Circuit Diagram GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

AHA444A

HA-19
 DESCRIPTION

Wiring Diagram –HEATER–

AHA447A

HA-20
 DESCRIPTION

Wiring Diagram −A/C− GI

MA

EM

LC

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

AHA448A

HA-21
 DESCRIPTION
Wiring Diagram −A/C− (Cont’d)

AHA501A

HA-22
 DESCRIPTION

Operational Check GI
The purpose of the operational check is to confirm that the system
operates properly. MA
After operational check is completed, go to SYMPTOM TABLE in
How to Perform Trouble Diagnoses for Quick and Accurate Repair,
HA-25.
EM
CONDITIONS:
● Engine running and at normal operating temperature. LC

PROCEDURE: EC
1. Check blower
a. Slide fan control lever to 1-speed. FE
Blower should operate on 1-speed.
b. Then slide fan control lever to 2-speed, and continue checking
blower speed until all speeds are checked. CL
c. Leave blower on 4-speed.

MT
AHA103A

2. Check discharge air AT

a. Turn mode switch to each mode.
b. Confirm that air discharge comes out each mode. TF

PD

FA
AHA104A

RA
NOTE:
Confirm that discharge air comes out according to the air dis-
tribution table at left. BR

ST

RS

BT

HA

EL

IDX
AHA983

HA-23
 DESCRIPTION
Operational Check (Cont’d)
3. Check recirculation
a. Slide REC control lever to REC position.
b. Listen for intake door position to change (you should hear
blower sound change slightly).

AHA101A

4. Check temperature decrease

a. Turn temperature switch to full cold.
b. Check for cold air at discharge air outlets.

AHA100A

5. Check temperature increase

a. Turn temperature control switch to full hot.
b. Check for hot air at discharge air outlets.

AHA099A

6. Check air conditioner switch

Slide the fan control lever to the desired (1 to 4 speed) posi-
tion and push the A/C switch to turn ON the air conditioner.
The indicator lamp should come on when air conditioner is ON.

AHA102A

HA-24
 TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick GI

and Accurate Repair
WORK FLOW MA
CHECK IN

EM
.
LISTEN TO CUSTOMER COMPLAINT
(Obtain detailed information about the environment LC
conditions when the symptom occured.)

. EC
Verify the symptom with Operational Check HA-23.
Also check related service bulletins for information.
FE
.

c Go to appropriate trouble diagnosis. CL

(Refer to SYMPTOM TABLE below.)

. MT
REPAIR/REPLACE

.
AT
NG FINAL CHECK
Confirm the repair result by Operational Check,
HA-23. TF
OK
.
PD
CHECK OUT

SYMPTOM TABLE FA
Symptom Reference page
● Blower motor does not rotate. ● Go to Blower Motor Circuit, HA-26. RA
● Air outlet does not change. ● Go to Air Outlet, HA-30.
● Intake door position does not change. ● Go to Trouble Diagnoses for Intake Door, HA-32.
● ●
BR
Magnet clutch does not engage when A/C Go to Magnet Clutch Circuit, HA-33.
switch and fan switch are ON.
● Insufficient cooling. ● Go to Trouble Diagnosis for Insufficient Cooling, HA-39. ST
● Go to Performance Test Diagnosis, HA-41.
● Go to Performance Chart, HA-43.
● Go to Trouble Diagnoses for Abnormal Pressure, HA-44. RS
● Insufficient heating. ● Go to Trouble Diagnoses for Insufficient Heating, HA-47.
● Noise. ● Go to Trouble Diagnoses for Noise, HA-49.
BT

HA

EL

IDX

HA-25
 TROUBLE DIAGNOSES

Blower Motor Circuit

SYMPTOM: Blower motor does not rotate.
INSPECTION FLOW
1. Confirm symptom by performing BLOWER MOTOR OPERATION CHECK shown
below.

.
If OK (symptom cannot be duplicated), perform complete Operational Check, HA-23.
If NG (symptom is confirmed), continue with STEP 2 below.

.
2. Check for any service bulletins.

OK
.
3. Go to Diagnostic Procedure for Blower Motor Circuit, HA-27.

BLOWER MOTOR OPERATION CHECK

1. Start engine.
2. Check blower motor.
3. Slide fan control lever to 1-speed and blower motor should
operate on 1-speed.
4. Slide fan control lever to 2-speed and continue checking
blower speed until all speeds are checked.

AHA105A

HA-26
 TROUBLE DIAGNOSES
Blower Motor Circuit (Cont’d)
DIAGNOSTIC PROCEDURE GI
INCIDENT Flow chart
1 Fan fails to rotate. Check if blower motor rotates properly at (Go to next page.)
2 Fan does not rotate at 1-speed.
each fan speed. s MA
c B
Conduct check as per flow chart at left.
3 Fan does not rotate at 2-speed.
4 Fan does not rotate at 3-speed. EM
5 Fan does not rotate at 4-speed.
.
No
CHECK POWER SUPPLY FOR BLOWER
c
Check 15A fuses No. LC
MOTOR. and , located in
Disconnect blower motor harness connec- fuse block (J/B).
tor. Turn ignition switch ON. Refer to EL section (‘‘Wir- EC
Does approx. 12 volts exist between ing Diagram’’, ‘‘POWER
s
blower motor harness terminal 1 and SUPPLY ROUTING’’).
body ground? FE
Yes

. CL
1. Slide fan control lever to 4-speed. OK Check blower motor.
c
2. Check circuit continuity between blower Refer to HA-29.
s
motor harness terminal 2 and body
NG
MT
ground.
AHA074A Continuity should exist.

NG
AT
.
Replace blower motor.
TF
.
Reconnect blower motor harness connec-
tor.
PD

. FA
CHECK BLOWER MOTOR CIRCUIT No Disconnect blower motor
c
AHA075A BETWEEN BLOWER MOTOR AND and resistor harness con-
RESISTOR. nectors. RA
Slide fan switch to OFF position.
Does approx. 12 volts exist between fan
s
resistor harness terminal 1 and body . Note BR
ground?
Check circuit continuity
Yes between blower motor har-
s
ness terminal 2 and ST
resistor harness terminal
s 1 .
Continuity should exist. RS
If OK, check harness for
AHA266A short.
BT
.

s
A
(Go to next page.) HA
Note:
If the result is NG or No after checking circuit continuity, repair harness
or connector. EL

IDX
AHA077A

HA-27
 TROUBLE DIAGNOSES
Blower Motor Circuit (Cont’d)
s
A s
B

. Note
CHECK GROUND CIRCUIT FOR FAN
SWITCH.
Disconnect fan switch harness connector.
Check circuit continuity between fan switch
s
harness terminal 6 and body ground.

OK
.
b
AHA078A CHECK BLOWER RESISTOR AFTER DIS-
CONNECTING IT.
(Refer to Electrical Components Inspection.) b
(HA-29).
b
OK NG
.
Replace resistor.

.
Reconnect resistor harness connector.

AHA079A
. . . .
CHECK FAN SWITCH CIRCUIT.
Does approx. 12 volts exist between each fan switch
harness terminal and body ground?

Flow chart Terminal No.

Voltage
No. ⊕ @

s
5

s
4
Body ground Approx. 12V
s
3

s
2

Yes No

. Note
Check circuit continuity
between fan switch harness
terminal and resistor harness
terminal.

Terminal No.
Continu-
Fan ity
switch Resistor

s
2 s
1

s
3 s
2
Yes
AHA080A
s
4 s
3

s
5 s
4

If OK, check harness for

short.

. .
NG
CHECK FAN SWITCH AFTER DISCON- c Replace fan switch.
NECTING IT.
(Refer to COMPONENT INSPECTION.)
(HA-29)

Note:
If the result is NG after checking circuit continuity, repair harness or
connector.

HA-28
 TROUBLE DIAGNOSES
Blower Motor Circuit (Cont’d)
COMPONENT INSPECTION GI
Fan switch
Check continuity between terminals at each position. MA
POSITION
TERMINAL
OFF 1 2 3 4 EM
1 j j j j
2 j
LC
3 j
AHA132A
4 j
EC
5 j
6 j j j j
FE

CL

MT

Blower motor AT
Confirm smooth rotation of the blower motor.
● Check that there are no foreign particles inside the intake unit. TF

PD

FA
AHA130A

Blower resistor RA
Check continuity between terminals.
BR

ST

RS
AHA117A
BT

HA

EL

IDX

HA-29
 TROUBLE DIAGNOSES

Air Outlet
SYMPTOM: Air outlet does not change.
INSPECTION FLOW
1. Confirm symptom by performing AIR OUTLET CONTROL DOORS OPERATION
CHECK.

.
If OK (symptom cannot be duplicated), perform complete Operational Check, HA-23.
If NG (symptom is confirmed), continue with STEP-2 below.

.
2. Check for any service bulletins.

.
3. Repair/adjust control linkage, refer to CONTROL LINKAGE ADJUSTMENT, HA-31.

AIR OUTLET CONTROL DOORS OPERATION CHECK

1. Start engine.
2. Slide fan control lever to 4-speed.
3. Check discharge air.
a. Turn mode control switch to posiiton
b. Confirm that all discharge air comes out of face vents.
c. Turn mode control switch to position.
d. Confirm that discharge air comes out of face vents and foot
vents.
e. Turn mode control switch to position.
AHA107A f. Confirm that discharge air comes out of foot vents, with some
air from defrost vents.
g. Turn mode control switch to position.
h. Confirm that discharge air comes out of foot vents with some
air from defrost vents.

i. Turn mode control switch to position.

j. Confirm that all discharge air comes out of defrost vents.
Note:
Confirm that discharge air comes out according to the air distribution
table, HA-23.

AHA106A

HA-30
 TROUBLE DIAGNOSES
Air Outlet (Cont’d)
CONTROL LINKAGE ADJUSTMENT GI
Mode control cable
● Turn mode control switch to position. MA
Set side link in DEF mode.
Pull on outer cable in direction of arrow and then clamp it.
● After positioning mode control cable, check that it oper- EM
ates properly.

LC
AHA121A

EC

FE

CL

MT

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

HA-31
 TROUBLE DIAGNOSES

Intake Door
SYMPTOM: Intake door position does not change.
INSPECTION FLOW
1. Confirm symptom by performing INTAKE DOOR OPERATION CHECK, shown below.

.
If OK (symptom cannot be duplicated), perform complete Operational Check, HA-23.
If NG (symptom is confirmed), continue with STEP-2 below.

.
2. Check for any service bulletins.

.
3. Repair/adjust control linkage, refer to CONTROL LINKAGE ADJUSTMENT, shown below.

INTAKE DOOR OPERATION CHECK

1. Start engine.
2. Slide fan control switch to 4-speed.
3. Check recirculation.
a. Slide recirculation control lever to the REC posiiton.
b. Listen for intake door position change (you should hear blower
sound change slightly).

AHA108A

CONTROL LINKAGE ADJUSTMENT

Recirculation control cable
● Move recirculation lever to REC position.
Set recirculation lever in REC mode.
Pull on outer cable in direction of arrow and then clamp it.
● After positioning recirculation control cable, check that it
operates properly.

AHA156A

HA-32
 TROUBLE DIAGNOSES

Magnet Clutch Circuit GI

SYMPTOM: Magnet clutch does not engage when A/C
switch and fan switch are ON. MA
INSPECTION FLOW
1. Confirm symptom by performing MAGNET CLUTCH OPERATION CHECK, shown below. EM

. LC
If OK (magnet clutch can be engaged), go to Trouble Diagnosis Procedure for Insufficient Cooling,
HA-39.
If NG (symptom is confirmed), continue with STEP 2 below. EC

.
2. Check for any service bulletins. FE

. CL
3. Check refrigeration cycle pressure with manifold gauge corrected.
Refer to Trouble Diagnoses for Abnormal Pressure, HA-44.
MT
.
4. Go to THERMO CONTROL AMP. CHECK, HA-34.
AT
.
Go to DIAGNOSES PROCEDURE, HA-35. TF

PD

FA

MAGNET CLUTCH OPERATION CHECK RA

1. Start engine.
2. Slide fan control lever to operate blower motor. BR
3. Push A/C switch to ON. Make sure that magnet clutch is
engaged. (You can hear magnet clutch engage sound.)
4. Push A/C switch to OFF. Make sure that magnet clutch is dis- ST
engaged.
Note: If magnet clutch sticks, check magnet clutch. Refer to
HA-35. RS
AHA102A
BT

HA

EL

IDX

HA-33
 TROUBLE DIAGNOSES
Magnet Clutch Circuit (Cont’d)
THERMO CONTROL AMP. CHECK
Power supply circuit check
Check power supply circuit for thermo control amp. with ignition
switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect voltmeter from harness side.
3. Measure voltage across terminal s1 and body ground.

Voltmeter terminal
Voltage
% @
AHA081A
s
1 Body ground Approx. 12V

Ground circuit check

Check body ground circuit for thermo control amp. with ignition
switch ON, air conditioner switch ON and fan switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect ohmmeter from harness side.
3. Check for continuity between terminal s 2 and body ground.

Ohmmeter terminal
Continuity
% @

s
4 Body ground Yes
AHA082A
If the ground circuit is NG, check the following.
● A/C switch (Refer to HA-37.)
● Fan switch (Refer to HA-29.)
● Harness for open or short between thermo control amp. and
A/C switch
● Harness for open or short between A/C switch and fan switch
● Fan switch ground circuit

HA-34
 TROUBLE DIAGNOSES
Magnet Clutch Circuit (Cont’d)
DIAGNOSTIC PROCEDURE GI

CHECK POWER SUPPLY FOR COM-

Yes Check the thermal protec- MA
c
PRESSOR. tor.
Disconnect compressor harness connec- Refer to HA-37.
tor. EM
Does approx. 12 volts exist between com- OK
s
pressor harness terminal 1 and body
.
Check the magnet clutch
ground?
coil. LC
No
AHA083A NG
. Note . EC
Check circuit continuity between A/C relay Replace magnet clutch.
s
harness terminal 3 and compressor har- Refer to HA-60.
s
ness terminal 1 . FE
Continuity should exist.
If OK, check harness for short.

OK CL
.
No
CHECK POWER SUPPLY FOR A/C Check power supply circuit
RELAY.
c
and 7.5A fuse (No. ,
MT
Does approx. 12 volts exist between A/C located in the fuse block).
s
AHA084A
relay harness terminal 5 and body (Refer to ‘‘POWER SUP-
ground? PLY ROUTING’’ in EL sec- AT
tion and Wiring Diagram.)
Yes
. TF
No
CHECK POWER SUPPLY FOR A/C Check power supply circuit
c
RELAY. and 7.5A fuse (No. ,
Does approx. 12 volts exist between A/C located in the fuse block). PD
s
relay harness terminal 2 and body (Refer to ‘‘POWER SUP-
ground? PLY ROUTING’’ in EL sec-
tion and Wiring Diagram.)
Yes FA
.
NG
AHA085A CHECK A/C RELAY AFTER DISCON- Replace A/C relay.
c
NECTING IT. RA
Refer to HA-38.

OK
BR
.
Reconnect A/C relay.
ST
.

s
A
(Go to next page.) RS
Note:
AHA086A
If the result is NG after checking circuit continuity, repair harness or
connector. BT

HA

EL

IDX

HA-35
 TROUBLE DIAGNOSES
Magnet Clutch Circuit (Cont’d)

s
A

.
No
CHECK COIL SIDE CIRCUIT OF A/C c
Check circuit continuity
RELAY. between A/C relay harness
Does approx. 12 volts exist between ECM s
terminal 1 and ECM har-
s
harness terminal 12 and body ground? s
ness terminal 12 .
Continuity should exist.
Yes If OK, check harness for
AHA087A
short.
.
CHECK POWER SUPPLY AND GROUND
CIRCUIT FOR THERMO CONTROL AMP.
Refer to HA-34.

OK

.
Yes
CHECK VOLTAGE FOR THERMO CON- c
Replace thermo control
TROL AMP. amp.
Does approx. 5 volts exist between
s
thermo control amp. harness terminal 2
AHA088A and body ground?

No

.
Check circuit continuity between thermo
s
control amp. harness terminal 2 and
triple-pressure switch harness terminal
s 3 .
Continuity should exist.
If OK, check harness for short.

OK
.
NG
CHECK TRIPLE-PRESSURE SWITCH. c
Replace thermo control
AHA089A Refer to HA-37. amp.

OK

. Note
Check circuit continuity between ECM har-
s
ness terminal 21 and triple-pressure
switch harness terminal 1 . s
Continuity should exist.
If NG, check harness or connector.

OK
.
CHECK ECM.
AHA271A Refer to EC section.

Note:
If the result is NG after checking circuit continuity, repair harness or
connector.

AHA272A

HA-36
 TROUBLE DIAGNOSES
Magnet Clutch Circuit (Cont’d)
ELECTRICAL COMPONENT INSPECTION GI
Air conditioner switch
Check continuity between terminals at each switch position MA
Switch condition Terminal No. Continuity
ON s
1 -s2 , Yes EM
OFF s s
1 - 3 No

LC
AHA092A

TRIPLE-PRESSURE SWITCH EC
High-pressure side line
Terminals pressure Operation Continuity FE
kPa (kg/cm2, psi)
Increasing to 157 - 226
ON Yes
Low- (1.6 - 2.3, 23 - 33) CL
pressure s s
1 - 3
Decreasing to 152.0 - 201.0
side OFF No
(1.55 - 2.05, 22.0 - 29.2)
MT
Increasing to 1,422 - 1,618
Medium- ON Yes
AHA401A (14.5 - 16.5, 206 - 235)
pressure s
2 -s
4
Decreasing to 1,128 - 1,422 AT
side* OFF No
(11.5 - 14.5, 164 - 206)
Decreasing to 1,667 - 2,059
High- (17 - 21, 242 - 299)
ON Yes TF
pressure s s
1 - 3
Increasing to 2,452 - 2,844
side OFF No
(25 - 29, 356 - 412) PD
*For cooling fan motor operation.

FA

Thermo control amp. RA

1. Run engine, and operate A/C system.
2. Connect the voltmeter from harness side. BR
3. Check thermo control amp. operation shown in the table.
Evaporator outlet air temperature Thermo amp.
Tester ST
°C (°F) operation
Decreasing to 2.5 - 3.5 (37 - 38) Turn OFF Approx. 12V
Increasing to 4.0 - 5.0 (39 - 41) Turn ON Approx. 0V RS
AHA093A
BT
Thermal protector
Temperature of compressor
Operation
°C (°F) HA
Increasing to approx. 145 - 155 (293 - 311) Turn OFF
Decreasing to approx. 130 - 140 (266 - 284) Turn ON EL
If NG, replace thermal protector.

IDX
AHA402A

HA-37
 TROUBLE DIAGNOSES
Magnet Clutch Circuit (Cont’d)
Air conditioner relay
Check circuit continuity between terminals by supplying 12 volts to
coil side terminals of air conditioner relay.

AHA233

HA-38
 TROUBLE DIAGNOSES

Trouble Diagnosis Procedure For Insufficient GI

Cooling
INSPECTION FLOW MA
1. Confirm symptom by performing COOLING OPERATION CHECK shown
below. EM
.
If NG (symptom can be duplicated), perform complete Operational Check LC
HA-23.
If NG (symptom is confirmed), continue with STEP-2 below.
EC
.
2. Check for any service bulletins.
FE
.
3. Check compressor belt tension. Refer to MA section (‘‘Checking Drive NG Adjust or replace compressor
c CL
Belts’’, ‘‘ENGINE MAINTENANCE’’). belt.

OK
. MT
4. Check Temperature Control Cable, HA-48. NG Repair/adjust.
c
OK
. AT
5. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant
pressure should be displayed. If NG, recover refrigerant from equipment
lines. TF

.
6. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identi- NG Refer to “CONTAMINATED
PD
c
fier. REFRIGERANT”, HA-3.

OK FA
.
7. Connect ACR4 to vehicle. NG Refer to ‘‘CONTAMINATED
c
Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant REFRIGERANT’’, HA-3.
RA
identifier.

OK
. BR
8. Check refrigeration cycle pressure with manifold gauge connected. NG Perform Performance Test Diag-
c
Refer to Trouble Diagnoses For Abnormal Pressure, HA-44. noses. Refer to HA-41.

OK
ST
. NG
(Freeze
9. CHECK FOR EVAPORATOR COIL FREEZE UP. up.) Check Compressor Circuit
c
HA-37 (A/C relay, thermo control RS
OK (Does not freeze up.)
amp and magnet clutch.)
.
10. Check ducts for air leaks. Repair air leaks.
BT
c

.
HA
INSPECTION END

EL

IDX

HA-39
 TROUBLE DIAGNOSES
Trouble Diagnosis Procedure For Insufficient
Cooling (Cont’d)
COOLING OPERATION CHECK
1. Start engine.
2. Slide fan control lever to 4-speed.
3. Turn air conditioner switch ON.
4. Check temperature decrease.
a. Turn temperature switch to full cold.
b. Check for cold air at discharge air outlets.

AHA102A

HA-40
 TROUBLE DIAGNOSES

Performance Test Diagnoses GI

INSUFFICIENT COOLING
MA
INSUFFICIENT COOLING

.
NG EM
CHECK AIR FLOW. c CHECK BLOWER MOTOR OPERATION.

OK OK . NG
. .
CHECK COMPRESSOR OPERATION. Clogged blower inlet/Clogged sA
(Go to
LC
duct/Loose duct connection/Air next page.)
OK NG leakage, etc.
.
EC
sB
(Go to
next page.)
. FE
Before connecting ACR4 to vehicle, check ACR4
gauges. No refrigerant pressure should be dis-
played. If NG, recover refrigerant from equip-
ment lines. CL
.
NG
Confirm refrigerant purity in supply tank using c Refer to “CONTAMINATED REFRIGERANT”, MT
ACR4 and refrigerant identifier. HA-3.

OK
.
NG AT
Connect ACR4 to vehicle. c Refer to “CONTAMINATED REFRIGERANT”,
Confirm refrigerant purity in vehicle A/C system HA-3.
using ACR4 and refrigerant identifier.

OK
TF
.
CHECK HIGH AND LOW-SIDE PRESSURE.
OK
USE PERFORMANCE CHART. Refer to HA-43.
PD
NG
.
RECOVER REGRIGERANT USING RECOVERY
RECYCLING EQUIPMENT AND CHARGE FA
SPECIFIED AMOUNT OF REFRIGERANT.
Note
.
NG
RA
CHECK HIGH AND LOW-SIDE PRESSURE. c BOTH HIGH AND LOW- c
Refer to HA-43. PRESSURE SIDES ARE
TOO HIGH. HA-44
.
OK BR
CHECK DISCHARGE AIR TEMPERATURE. HIGH-PRESSURE SIDE IS c
c USE PERFORMANCE CHART. Refer to HA-43. TOO HIGH AND LOW-
PRESSURE SIDE IS TOO HA-44 ST
NG OK LOW.
.
END HIGH-PRESSURE SIDE IS c RS
TOO LOW AND LOW-
PRESSURE SIDE IS TOO HA-45
HIGH.
. BT
Malfunctioning temperature control operation (air BOTH HIGH AND LOW- c
mix door position improperly adjusted) PRESSURE SIDES ARE
TOO LOW. HA-45
HA
LOW-PRESSURE SIDE c
SOMETIMES BECOMES
NEGATIVE. HA-46 EL

Note: - correspond to those in TROUBLE DIAGNOSES FOR LOW-PRESSURE SIDE c

ABNORMAL PRESSURE. BECOMES NEGATIVE. IDX
Refer to HA-44. HA-46

HA-41
 TROUBLE DIAGNOSES
Performance Test Diagnoses (Cont’d)
s
A

. . .
Malfunctioning blower motor fan Malfunctioning electrical circuit Malfunctioning blower motor internal
circuit

. .
Loose fan/Improper contact of fan Disconnected wiring or component
and case/Deformed fan circuits or poor connection/
Malfunctioning resistor, amplifier,
etc./ Burned out fuse or low battery
voltage

s
B

. . .
Magnet clutch does not engage Magnet clutch slipping Belt slipping

. .
CHECK MAGNET CLUTCH. Inspect CHECK COMPRESSOR BELT AND
coil circuit, disc-to-pulley clearance. BELT TENSION. Refer to MA sec-
tion (‘‘Checking Drive Belts’’,
‘‘ENGINE MAINTENANCE’’).

.
CHECK ELECTRICAL CIRCUIT. Malfunctioning internal parts of
c
Inspect wiring, components circuit. clutch, compressor

.
CHECK ACTIVATION OF SAFETY/ Foreign particles on clutch frictional
c
PROTECTION DEVICES. Inspect surface or excessive disc clearance
devices such as pressure switch,
etc.

Malfunctioning electrical circuit

c
(poor connection, low battery
voltage, etc.)

HA-42
 TROUBLE DIAGNOSES

Performance Chart GI
TEST CONDITION
Testing must be performed as follows: MA
Vehicle location: Indoors or in the shade (in a well-ventilated
place)
Doors: Closed EM
Door window: Open
Hood: Open
TEMP. setting: Max. COLD LC
Discharge Air: FACE VENT
INTAKE
lever position: (Recirculation) EC
FAN speed: 4-speed
Engine speed: 1,500 rpm
Operate the air conditioner system for 10 minutes before tak- FE
ing measurements.
TEST READING
Recirculating-to-discharge air temperature table CL

Inside air (Recirculating air)

at blower assembly inlet Discharge air temperature at center ventilator
MT
Relative humidity Air temperature °C (°F)
% °C (°F)
AT
20 (68) 6.6 - 8.3 (44 - 47)
25 (77) 10.4 - 12.4 (51 - 54)
TF
50 - 60 30 (86) 14.2 - 16.7 (58 - 62)
35 (95) 18.2 - 21.0 (65 - 70)
40 (104) 22.0 - 25.2 (72 - 77) PD
20 (68) 8.3 - 9.8 (47 - 50)
25 (77) 12.4 - 14.4 (54 - 58) FA
60 - 70 30 (86) 16.7 - 18.9 (62 - 66)
35 (95) 21.0 - 23.6 (70 - 74) RA
40 (104) 25.2 - 28.1 (77 - 83)

BR
Ambient air temperature-to-operating pressure table

Ambient air ST
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (kg/cm2, psi) kPa (kg/cm2, psi)
% °C (°F)
RS
20 (68) 961 - 1,187 (9.8 - 12.1, 139 - 172) 108 - 157 (1.1 - 1.6, 16 - 23)
25 (77) 1,295 - 1,599 (13.2 - 16.3, 188 - 232) 161.8 - 215.8 (1.65 - 2.2, 23.5 - 31.3)
50 - 70 30 (86) 1,285 - 1,569 (13.1 - 16, 186 - 228) 167 - 216 (1.7 - 2.2, 24 - 31) BT
35 (95) 1,520 - 1,863 (15.5 - 19, 220 - 270) 235 - 284 (2.4 - 2.9, 34 - 41)
40 (104) 1,765 - 2,158 (18 - 22, 256 - 313) 289.3 - 353.1 (2.95 - 3.6, 41.9 - 51.2) HA

EL

IDX

HA-43
 TROUBLE DIAGNOSES

Trouble Diagnoses for Abnormal Pressure

Whenever system’s high or low-side pressure is abnormal, diagnose using a manifold gauge. The marker above
the gauge scale in the following table indicates the standard (normal) pressure range. Since the standard normal
pressure differs from vehicle to vehicle, refer to HA-43 (‘‘Ambient air temperature-to-operating pressure table’’).
Pressure measurements are effective only when ambient temperature is in the range indicated under
the Performance Chart.

Gauge indication Refrigerant cycle Probable cause Corrective action

Both high and low-pressure ● Pressure is reduced soon Excessive refrigerant charge in Reduce refrigerant until speci-
sides are too high. after water is splashed on refrigeration cycle. fied pressure is obtained.
condenser.

● Air suction by radiator or

Insufficient condenser cooling ● Clean condenser.
cooling fan is insufficient.
performance. ● Check and repair radiator or
↓ cooling fan as necessary.
s
1 Condenser fins are
clogged.
s
2 Improper rotation of cool-
ing fan.
● Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and
cold. denser. recharge system.
● When compressor is stopped (After compressor operation
high-pressure value quickly stops, high-pressure decreases
AC359A drops by approximately 196 too slowly.)
kPa (2 kg/cm2, 28 psi). It ↓
then decreases gradually Air in refrigeration cycle.
thereafter.
Engine tends to overheat. Engine cooling systems mal- Check and repair each engine
function. cooling system.
● An area of the low-pressure ● Excessive liquid refrigerant Replace expansion valve.
pipe is colder than near the on low-pressure side.
evaporator outlet. ● Excessive refrigerant dis-
● Plates are sometimes cov- charge flow.
ered with frost. ● Expansion valve is open a
little compared with the
specification.
↓
s
1 Improper thermal valve
installation.
s
2 Improper expansion valve
adjustment.
High-pressure side is too high Upper side of condenser and High-pressure tube or parts ● Check and repair or replace
and low-pressure side is too high-pressure side are hot, located between compressor malfunctioning parts.
low. however, liquid tank is not as and condenser are clogged or ● Check lubricant for contami-
hot. crushed. nation.

AC360A

HA-44
 TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont’d) GI

Gauge indication Refrigerant cycle Probable cause Corrective action

High-pressure side is too low High and low-pressure sides Compressor pressure operation Replace compressor.
MA
and low-pressure side is too become equal soon after com- is improper.
high. pressor operation stops. ↓
Damaged inside compressor
EM
packings.

LC

No temperature difference Compressor pressure operation Replace compressor. EC

between high and low-pressure is improper.
sides. ↓
Damaged inside compressor FE
packings.

CL
AC356A
Both high and low-pressure ●
There is a big temperature Liquid tank is partly clogged. ● Replace liquid tank.
sides are too low. difference between liquid ● Check lubricant for contami- MT
tank outlet and inlet. Outlet nation.
temperature is extremely low.
● Liquid tank inlet and expan- AT
sion valve are frosted.
● Temperature of expansion High-pressure pipe located ● Check and repair malfunc-
valve inlet is extremely low between liquid tank and expan- tioning parts. TF
as compared with areas near sion valve is clogged. ● Check lubricant for contami-
liquid tank. nation.
● Expansion valve inlet may be PD
frosted.
● Temperature difference
occurs somewhere in high- FA
pressure side.
AC353A ● Expansion valve and liquid Low refrigerant charge. ● Check for refrigerant leaks.
tank are warm or only cool to ↓ Refer to ‘‘Checking Refriger- RA
the touch. Leaking fittings or components. ant Leaks’’, HA-51.
Both high and low-pressure There is a big temperature dif- Expansion valve closes a little ● Remove foreign particles by
sides are too low. ference between expansion compared with the specifica- using compressed air. BR
valve inlet and outlet while the tion. ● Check lubricant for contami-
valve itself is frosted. ↓ nation.
s 1 Improper expansion valve ST
adjustment.
s 2 Malfunctioning thermal
valve. RS
s 3 Outlet and inlet may be
clogged.
An area of low-pressure pipe is Low-pressure pipe is clogged ●
Check and repair malfunc- BT
colder than areas near the or crushed. tioning parts.
evaporator outlet. ● Check lubricant for contami-
nation. HA
Air flow volume is not enough Compressor pressure operation Replace compressor.
AC353A or is too low. is improper.
EL

IDX

HA-45
 TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont’d)
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side sometimes ● Air conditioner system does Refrigerant does not discharge ● Replace refrigerant.
becomes negative. not function and does not cyclically. ● Replace liquid tank.
cyclically cool the compart- ↓
ment air. Moisture is frozen at expansion
● The system constantly func- valve outlet and inlet.
tions for a certain period of ↓
time after compressor is Water is mixed with refrigerant.
stopped and restarted.

AC354A
Low-pressure side becomes Liquid tank or front/rear side of High-pressure side is closed Leave the system at rest . Start
negative. expansion valve’s pipe is and refrigerant does not flow. it again to check whether or not
frosted or dewed. ↓ the problem is caused by water
Expansion valve or liquid tank or foreign particles.
is frosted. ● If water is the cause, initially
cooling is okay. Then the
water freezes, causing a
blockage. Drain water from
refrigerant or replace refriger-
ant.
● If due to foreign particles,
remove expansion valve and
remove the particles with dry
and compressed air.
● If either of the above meth-
AC362A ods cannot correct the
problem, replace expansion
valve.
● Replace liquid tank.
● Check lubricant for contami-
nation.

HA-46
 TROUBLE DIAGNOSES

Trouble Diagnosis for Insufficient Heating GI

INSPECTION FLOW MA
1. Confirm symptom by performing HEATING
OPERATION CHECK HA-48.
EM

.
If OK (symptom can not be duplicated), perform LC
complete Operational Check, HA-23.
If NG (symptom is confirmed), continue with STEP
2 below. EC

. FE
2. Check for any service bulletins.

OK CL
.
3. Check the following: NG Repair/replace as necessary.
c
● Engine coolant level (Refer to MA section). MT
● Hoses for leaks or kinks.
● Radiator cap.
Refer to LC section AT
(“ENGINE COOLING SYSTEM”).
● Air in cooling system.

OK
TF
.
NG
4. Check air outlet. Refer to HA-30.
c
Repair/replace as necessary. PD
OK
.
NG
FA
5. Check ducts for air leaks. Repair leaks.
c
OK
.
RA
6. Check by feel the heater inlet and outlet hoses.

Hot inlet Both hoses BR

Warm outlet warm
. .
Check thermostat installation. Check heater hoses for proper installation.
ST
OK OK NG
. . .
Replace thermostat. Refer to LC sec- Back flush heater core, drain and refill cool- Repair or RS
tion (“Thermostat”, “ENGINE COOL- ant. Retest. replace.
ING SYSTEM”). Retest.
Hot inlet Both hoses BT
Hot inlet Warm outlet warm
. .
Warm outlet
c System OK. Replace heater core. Refill engine
m coolant. HA
(Refer to MA section) Retest.
Hot inlet
Warm outlet
EL

IDX

HA-47
 TROUBLE DIAGNOSES
Trouble Diagnosis for Insufficient Heating
(Cont’d)
HEATING OPERATION CHECK
1. Start and warm up engine.
2. Slide fan control lever to 4-speed.
3. Turn air conditioner switch OFF.
4. Check temperature increase.
a. Turn temperature switch to full hot.
b. Check hot air at discharge air outlets.

AHA099A

TEMPERATURE CONTROL LINKAGE ADJUSTMENT

Temperature control cable
● When adjusting ventilator door rod and defrost door rod,
first disconnect mode control cable from side link. Recon-
nect and readjust mode control cable.
● Move temperature control lever to max. COLD position. Set air
mix door lever in full hot mode. Pull on outer cable in direction
of arrow and then clamp it.
● After positioning temperature control cable, check that it
operates properly.
AHA120A

HA-48
 TROUBLE DIAGNOSES

Trouble Diagnosis for Noise GI

Confirm symptom by performing Operational
Check, HA-23.
MA
.
If OK (symptom cannot be duplicated), per- EM
form complete Operational Check.
If NG (symptom is confirmed), continue with
STEP-2 following.
LC
.
Check for any service bulletins.
EC
.
Check where noise comes from.
FE
.

. . . . . CL
Blower motor Compressor Expansion valve Refrigerant line Belt

MT
. . .
Check for noise in Inspect the com- Replace expansion
all modes and tem- pressor clutch and valve. AT
perature settings. pulley and idler pul-
ley.
Noise is
constant OK NG TF
. . . .
Check blower Replace com- The line is fixed The line is not
motor for foreign pressor clutch directly to the fixed.
particles. and pulley. body. PD
Refer to
HA-60.

. . . . FA
Check blower Check disc-to-pul- Fix line with rub- Fix the line tightly.
motor and fan for ley clearance. ber or some
wear. Refer to HA-63. vibration absorb-
ing material. RA
OK
.
Check and adjust . BR
compressor lubri-
cant.
Refer to HA-56.
ST
OK
. . .
Replace compres- The belt vibra- Side of belt is worn
sor and liquid tank. tion is intense. out. RS

Noise is . .
intermittent
BT
Readjust belt The pulley center
. tension. does not match.
Check air dis- Refer to MA sec- Readjust pulley
charge ducts for tion (‘‘Checking center. HA
obstructions, for- Drive Belts’’, Refer to HA-61.
eign materials or ‘‘ENGINE
air leakage. MAINTE-
NANCE’’). EL

IDX

HA-49
SERVICE PROCEDURES

Refrigerant Lines
● Refer to HA-5.

AHA403A

HA-50
 SERVICE PROCEDURES

Checking Refrigerant Leaks GI

PRELIMINARY CHECK
Perform a visual inspection of all refrigeration parts, fittings, hoses, MA
and components for signs of A/C lubricant leakage, damage and
corrosion. Take note of the areas with A/C lubricant leakage to
allow extra time in these areas with an electronic leak detector. EM

LC

PRECAUTIONS FOR HANDLING LEAK DETECTOR EC

When performing a refrigerant leak check, use a J41995 A/C leak
detector or equivalent. Ensure that the instrument is calibrated and
FE
set properly per the operating instructions.
The leak detector is a delicate device. In order to use the leak
detector properly, read the operating instructions and perform any
specified maintenance.
CL
Other gases in the work area or substances on the A/C
components, for example, anti-freeze, windshield washer fluid, sol-
vents and lubricants, may falsely trigger the leak detector. Make MT
AHA439A sure the surfaces to be checked are clean. Clean with a dry cloth
or blow off with shop air. Do not allow the sensor tip of the detec-
tor to contact any substance. This can also cause false readings AT
and may damage the detector.
1. Position probe approximately 5 mm (3/16 in) away from point
to be checked. TF

PD

FA
AHA951

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

BR

ST

RS
SHA706E

3. Move probe along component approximately 25-50 mm/sec.

BT
(1-2 in./sec.)
HA

EL

IDX
AHA597

HA-51
SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont’d)
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no
refrigerant vapor, shop chemicals or smoke in the vicinity of the
vehicle. Perform the leak test in calm area (low air/wind movement)
so that the leaking refrigerant is not dispersed.
1. Turn engine off.
2. Connect a suitable A/C manifold gauge set to the A/C service
ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (50
psi) above 16°C (60°F). If less than specification, recover/
evacuate and recharge the system with the specified amount
of refrigerant.
NOTE: At temperatures below 16°C (60°F), leaks may not be
detected since the system may not reach 345 kPa (50
psi).
4. Conduct the leak test from the high side (compressor dis-
charge s A to evaporator inlet s F ) to the low side (evaporator
drain hose s G to shaft seal s
I ). Refer to HA-50.
Perform a leak check for the following areas carefully. Clean
the component to be checked and move the leak detector
probe completely around the connection/component.
● Compressor
Check the fittings of high and low-pressure hoses, relief valve,
and shaft seal.
● Liquid tank
Check the pressure switch, tube fitting, weld seams and the
fusible plug mount.
● Service valves
Check all around the service valves. Ensure service valve caps
are secured on the service valves (to prevent leaks).
NOTE: After removing A/C manifold gauge set from service
valves, wipe any residue from valves to prevent any
false readings by leak detector.
● Cooling unit (Evaporator)
With engine off, turn blower fan on 4-speed for at least 15
seconds to dissipate any refrigerant trace in the cooling unit.
Wait a minimum of 10 minutes accumulation time (Refer to the
manufacturer’s recommended procedure for actual wait time.)
before inserting the leak detector probe into the drain hose.
(Keep the probe inserted for at least ten seconds.) Use cau-
tion not to contaminate the probe tip with water or dirt that may
be in the drain hose.
5. If the leak detector detects a leak, verify at least once by
blowing compressed air into area of suspected leak, then
repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for
additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows:
a. A/C switch ON
b. Face mode
c. Recirculation switch ON
d. Max cold temperature
e. Fan speed high
9. Run engine at 1500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps
4 - 6 above.

HA-52
 SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont’d)
Refrigerant leaks should be checked immediately after stopping the GI
engine. Begin with the leak detector at the compressor. The pres-
sure on the high pressure side will gradually drop after refrigerant
circulation stops and pressure on the low pressure side will gradu- MA
ally rise, as shown in the graph. Some leaks are more easily
detected when pressure is high.
EM

LC
AHA936

11. Before connecting ACR4 to vehicle, check ACR4 gauges. No EC

refrigerant pressure should be displayed. If NG, recover refrig-
erant from equipment lines.
12. Confirm refrigerant purity in supply tank using ACR4 and refrig- FE
erant identifier. If NG, refer to ‘‘CONTAMINATED
REFRIGERANT’’, HA-3.
13. Connect ACR4 to vehicle. Confirm refrigerant purity in vehicle CL
A/C system using ACR4 and refrigerant identifier. Refer to
‘‘CONTAMINATED REFRIGERANT’’, HA-3.
14. Discharge A/C system using approved refrigerant recovery MT
equipment. Repair the leaking fitting or component as neces-
sary.
15. Evacuate and recharge A/C system and perform the leak test AT
to confirm no refrigerant leaks.
16. Conduct A/C performance test to ensure system works prop-
erly. TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

HA-53
 SERVICE PROCEDURES

R-134a Service Procedure

DISCHARGING REFRIGERANT
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove R-134a from the A/C system using certified service equipment meeting requirements
of SAE J2210 (R-134a recycling equipment) or J2209 (R-134a recovery equipment). If accidental sys-
tem discharge occurs, ventilate work area before resuming service. Additional health and safety infor-
mation may be obtained from refrigerant and lubricant manufacturers.

AHA269A

EVACUATING SYSTEM AND CHARGING REFRIGERANT

AHA270A

HA-54
 SERVICE PROCEDURES
R-134a Service Procedure (Cont’d)
GI
Before connecting ACR4 to vehicle, check ACR4 gauges. No
refrigerant pressure should be displayed. If NG, recover refrig-
erant from equipment lines.
MA
.
Confirm refrigerant purity in supply tank using ACR4 and refrig- NG Refer to CONTAMI-
c EM
erant identifier (J-41810). NATED REFRIGER-
ANT. Refer to HA-3.
OK
.
Connect ACR4 to vehicle. Confirm refrigerant purity in vehicle NG Refer to CONTAMI- LC
c
A/C system using ACR4 and refrigerant identifier. NATED REFRIGER-
OK ANT. Refer to HA-3.
. EC
Set the recovery/recycling equipment.

. FE
Recovered lubricant Discharge refrigerant into recovery/ recycling equipment.

. CL
Repair or replace parts.

. MT
Evacuate (over 25 minutes). b

.
AT
NG
Check air tightness. c Repair.
m
.
OK
*1 TF
c Partial charging [approx. 200 g (7.05 oz)].

.
PD
Preliminary refrigerant leak check. ‘‘PRELIMINARY CHECK’’. NG c
HA-51).
FA
OK 1*
.
Complete charging (specified amount less partial charge
amount). RA
Refer to SDS.

. *2
BR
Check for refrigerant leaks. ‘‘CHECKING PROCEDURE’’. Refer NG
to HA-52.

.
OK ST
Check A/C operation and A/C cooling performance. .................. Performance Test
Diagnoses, HA-41.
RS
.
Remove service couplers from A/C service valves.

.
BT
Recover refrigerant in charging hoses.

HA
.
Remove service tools.
EL
.
Reinstall service valve caps.
IDX
Note: *1 Before charging refrigerant, ensure engine is off.
*2 Before checking for leaks, start engine to activate air conditioning system, then turn engine off.
Service valve caps must be installed to prevent leakage.

HA-55
 SERVICE PROCEDURES

Compressor Lubricant Quantity

The lubricant used to lubricate the compressor circulates through
the system with the refrigerant. Whenever any A/C component is
replaced or gas leakage occurs, lubricant must be added.
If lubricant quantity is not maintained properly, the following mal-
functions may result:
● Lack of lubricant: May lead to a seized compressor
● Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LUBRICANT
Name: Nissan A/C System Lubricant Type R
Part No.: KLH00-PAGR0
CHECKING AND ADJUSTING
Adjust the lubricant quantity according to the flowchart shown
below.
START

.
Yes
Can lubricant return operation be performed? c Perform lubricant return operation, proceeding as follows:
● A/C system works properly. 1. Start engine, and set the following conditions:
● There is no evidence of a large amount of ● Test condition
lubricant leakage. Engine speed: Idling to 1,200 rpm
A/C switch: ON
No RECIRCULATION switch: OFF
. Fan speed: Max. position
Should the compressor be replaced? Temp. control: (Optional) Set so that intake air temperature is
b
25 to 30°C (77 to 86°F).
No Yes 2. Perform lubricant return operation for 10 minutes.
3. Stop engine.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubri-
cant return operation.
.
sA
(Go to next page.)
.
Yes
Is there any part to be replaced? (Evaporator, c After replacing any of the following major components, add the correct
condenser, liquid tank or in case there is evi- amount of lubricant to the system.
dence of a large amount of lubricant leakage?) Amount of lubricant to be added:

No Lubricant to be added to sys-

tem
Part replaced Remarks
Amount of lubricant
ml (US fl oz, Imp fl oz)
Evaporator 75 (2.5, 2.6) —
Condenser 75 (2.5, 2.6) —
. Add if compressor is
Liquid tank 5 (0.2, 0.2)
Perform the A/C Performance Test. b
not replaced.*1
Refer to HA-41. 30 (1.0, 1.1) Large leak
In case of refrigerant leak
— Small leak*2

*1: If compressor is replaced, addition of lubricant is included in the

flow chart.
*2: If refrigerant leak is small, no addition of lubricant is needed.

HA-56
 SERVICE PROCEDURES
Compressor Lubricant Quantity (Cont’d)
GI
s
A

MA
.
1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrig-
erant from equipment lines. EM
2. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. If NG, refer to ‘‘CONTAMINATED
REFRIGERANT’’, HA-3.
3. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. If NG, refer to ‘‘CONTAMINATED LC
REFRIGERANT’’, HA-3.
4. Discharge refrigerant into refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling
equipment. EC
5. Drain the lubricant from the old (removed) compressor into a graduated container and record the amount of lubricant drained.
6. Drain the lubricant from the new compressor into a separate, clean container.
7. Measure an amount of new lubricant equal to amount drained from old compressor. Add this lubricant to new compressor FE
through the suction port opening.
8. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor
through the suction port opening. CL
9. If the liquid tank also needs to be replaced, add an additional 5 ml (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 ml (0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.
MT
Lubricant adjusting procedure for compressor replacement
AT

TF

PD

FA

RA

BR

ST

RS

BT

HA
AHA374

EL

IDX

HA-57
 SERVICE PROCEDURES

Compressor Mounting

AHA422A

Belt Tension
● Refer to MA section (‘‘Checking Drive Belts’’, ‘‘ENGINE
MAINTENANCE’’).
Fast Idle Control Device (FICD)
● Refer to EC section (‘‘IACV-FICD Solenoid Valve’’,
‘‘TROUBLE DIAGNOSIS FOR NON-DETECTABLE
ITEMS’’).

Condenser
REMOVAL
1. Discharge refrigerant using the recovery/recycling equipment
(ACR4).
2. Remove side marker lamps.
3. Remove front grille (4 fasteners).
4. Remove harness clip from hood lock stay, if equipped (gently
press out).
5. Remove grille apron (5 nuts).

6. Disconnect horn.
7. Disconnect ambient temperature switch.
8. Disconnect cooling fan motor.
9. Remove cooling fan (4 nuts).

AHA425A

HA-58
 SERVICE PROCEDURES
Condenser (Cont’d)
10. Remove hood lock stay brace (4 bolts). Remove hood latch (3 GI
bolts).
11. Remove hose (high-pressure) clamp bracket from radiator
core support. MA
12. Disconnect high-pressure hose at condenser.
13. Disconnect dual-pressure switch harness connector.
14. Disconnect high-pressure tube (liquid tank to cooling unit) at EM
liquid tank.
15. Remove liquid tank and bracket.
16. Remove lower core support seal (4 bolts). LC
17. Loosen windshield washer tank bolts.
AHA150A

18. Remove condenser mounting bolts (2 bolts). EC

19. Remove condenser assembly.
CAUTION:
Carefully lift condenser without damaging radiator (fin and FE
tube).
CL

MT
AHA151A

AT

TF

PD

FA

RA

BR

ST

RS

BT

HA

EL

IDX

HA-59
 SERVICE PROCEDURES

Compressor

AHA423A

Compressor Clutch
REMOVAL
● When removing center bolt, hold clutch disc with clutch disc
wrench.

AHA841

● Remove the drive plate using the clutch disc puller.

Insert holder’s three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Then, tighten the center bolt
to remove the drive plate.
While tightening the center bolt, insert a round bar
(screwdriver, etc.) between two of the pins (as shown in the
figure) to prevent drive plate rotation. After removing the drive
plate, remove the shims from either the drive shaft or the drive
plate.

AHA842

HA-60
 SERVICE PROCEDURES
Compressor Clutch (Cont’d)
● Remove the snap ring using external snap ring pliers. GI

MA

EM

LC
AHA843

● For pulley removal use pulley puller. EC

Use a commercially available pully puller. Position the center
of the puller on the end of the drive shaft. Remove the pully
assembly with the puller. FE
For Pressed Pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked under (not into) the pulley CL
groove.
● Remove the field coil harness clip using a screwdriver.
MT
AHA391

● Remove the three field coil fixing screws and remove the field AT
coil.
TF

PD

FA
RHA074C

INSPECTION RA
Clutch disc
If the contact surface shows signs of damage due to excessive BR
heat, replace clutch disc and pully.

Pulley ST
Check the appearance of the pulley assembly. If contact surface of
pulley shows signs of excessive grooving, replace clutch disc and RS
pulley. The contact surfaces of the pulley assembly should be
RHA075C cleaned with a suitable solvent before reinstallation.
BT
Coil
Check coil for loose connection or cracked insulation.
HA

EL

IDX

HA-61
 SERVICE PROCEDURES
Compressor Clutch (Cont’d)
INSTALLATION
● Install the field coil.
● Be sure to align the coil’s pin with the hole in the com-
pressor’s front head.
● Install the field coil harness clip using a screwdriver.

RHA076C

● Install the pulley assembly using the installer and a hand

press, and then install the snap ring using snap ring pliers.

AHA845

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

RHA078C

● Using the holder to prevent drive plate rotation, tighten the bolt
to 12 to 15 Nzm (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque.
● After tightening the bolt, check that the pulley rotates
smoothly.

AHA847

HA-62
 SERVICE PROCEDURES
Compressor Clutch (Cont’d)
● Check clearance all the way around the clutch disc. GI
Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting MA
spacer and recheck.

BREAK-IN OPERATION EM
When replacing compressor clutch assembly, always conduct the
break-in operation. This is done by engaging and disengaging the
clutch about 30 times. Break-in operation raises the level of trans- LC
mitted torque.
EC

FE

CL

MT
AHA848

Thermal Protector AT

INSPECTION
● When servicing, do not allow foreign matter to get into com- TF
pressor.
● Check continuity between two terminals.
PD

FA
AHA424A

RA

BR

ST

RS

BT

HA

EL

IDX

HA-63
SERVICE PROCEDURES

Heater Unit (Heater Core)

AHA118A

REMOVAL
1. Drain the cooling system. Refer to MA section, (“Changing
Engine Coolant”).
2. Disconnect the two heater hoses from inside the engine com-
partment.
3. Remove the cooling unit. Refer to HA-65.
4. Remove the steering member assembly. Refer to BT section
(“Instrument Panel”).
5. Remove the heater unit.
6. Remove the heater core.
INSTALLATION
Installation is basically the reverse order of removal.
When filling radiator with coolant, refer to MA section
(“Changing Engine Coolant”).

HA-64
 SERVICE PROCEDURES

Cooling Unit (A/C Evaporator) GI

MA

EM

LC

EC

FE

CL

MT

AHA124A
AT

TF

PD

FA

REMOVAL RA
1. Discharge the A/C system. Refer to HA-54.
2. Disconnect the two refrigerant lines from the engine compart- BR
ment.
● Cap the A/C lines to prevent moisture from entering the
system. ST
3. Remove the glove box and mating trim. Refer to BT section
(“Instrument Panel”).
4. Disconnect the thermal amp. connector. RS
5. Remove the cooling unit.
AHA125A 6. Separate the cooling unit case, and remove the evaporator.
INSTALLATION BT
Installation is basically the reverse order of removal.
Recharge the A/C system. Refer to HA-54. HA

EL

IDX

HA-65
 SERVICE PROCEDURES

Blower Case and Motor

REMOVAL
1. Remove the glove box and mating trim. Refer to BT section
(“Instrument Panel”).
2. Remove the cooling unit. Refer to HA-65.
3. Disconnect the fan motor resistor.
4. Disconnect the fan motor.
5. Remove the blower case and motor.
6. Remove the three bolts and remove the motor from the blower
case.
AHA130A
INSTALLATION
Installation is basically the reverse order of removal.
● Recharge the A/C system. Refer to HA-54.

HA-66
 SERVICE PROCEDURES

Fan Lever and Illumination Bulbs GI

MA

EM

LC

EC

FE

CL

MT
AHA134A

REMOVAL AT
1. Remove A/C & Heat control. Refer to BT section (‘‘Instrument
Panel’’). TF
2. Loosen illumination bulbs and wire and pull out.

PD

FA
AHA126A

RA

BR

ST

RS

BT

HA

EL

IDX

HA-67
 SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
COMPRESSOR LUBRICANT
Model DKV-14C ZEXEL make
Model
DKV-14C
Type Vane rotary
3
Nissan A/C System Lubricant
Displacement cm (cu in)/Rev 140 (8.54) Name
Type R
Clockwise (Viewed from drive
Direction of rotation Part No. KLH00-PAGR0
end)
Capacity ml (US fl oz, Imp fl oz)
Drive belt A type
Total in system 200 (6.8, 7.0)
Compressor (Service part)
200 (6.8, 7.0)
charging amount

REFRIGERANT
Type R-134a
Capacity kg (lb) 0.60 - 0.70 (1.32 - 1.54)
g (oz) 600 - 700 (21.16 - 24.69)

Inspection and Adjustment

ENGINE IDLING SPEED COMPRESSOR CLUTCH
When A/C is ON Model DKV-14C
● Refer to EC section (‘‘Inspection and Clutch disc-pulley clearance 0.3 - 0.6
Adjustment’’, ‘‘SERVICE DATA AND SPECIFI- mm (in) (0.012 - 0.024)
CATIONS’’).
BELT TENSION
● Refer to MA section (‘‘Checking Drive Belts’’,
‘‘ENGINE MAINTENANCE’’).

HA-68