Heater & Air Conditioner: SC EL

HEATER &
AIR CONDITIONER GI
SECTION HA MA
EM
LC
EC
CONTENTS FE
PRECAUTIONS ...............................................................2 Symptom Table ..........................................................28

CL
Supplemental Restraint System (SRS) ″AIR Operational Check .....................................................29
BAG″ and ″SEAT BELT PRE-TENSIONER″...............2 Blower Motor..............................................................31 MT
Precautions for Working with HFC-134a (R-134a) .....3 Mode Door .................................................................38
Contaminated Refrigerant............................................3 Intake Door Motor......................................................40
General Refrigerant Precautions .................................3 Magnet Clutch............................................................43 AT
Precautions for Leak Detection Dye............................4 Insufficient Cooling ....................................................55
A/C Identification Label................................................4 Insufficient Heating ....................................................63
Precautions for Refrigerant Connection ......................4 Noise..........................................................................65
TF
Precautions for Servicing Compressor........................8 SERVICE PROCEDURE................................................66
Precautions for Service Equipment .............................8 HFC-134a (R-134a) Service Procedure ....................66 PD
Wiring Diagrams and Trouble Diagnosis...................11 Maintenance of Lubricant Quantity in
PREPARATION .............................................................12 Compressor ...............................................................68
Special Service Tools ................................................12 Compressor ...............................................................72 AX
HFC-134a (R-134a) Service Tools and Magnet Clutch............................................................74
Equipment..................................................................13 Thermal Protector ......................................................78
Commercial Service Tool...........................................16 Refrigerant Lines .......................................................79 SU
DESCRIPTION ...............................................................17 Checking for Refrigerant Leaks.................................81
Refrigeration System .................................................17 Electronic Refrigerant Leak Detector ........................81
BR
Control Operation ......................................................18 Fluorescent Dye Leak Detector.................................84
Discharge Air Flow.....................................................19 Belt.............................................................................85
Component Layout ....................................................20 IACV-FICD Solenoid Valve ........................................85 ST
TROUBLE DIAGNOSES................................................21 Heater Core ...............................................................86
Component Location..................................................21 Evaporator Core ........................................................87
Wiring Diagram - Heater - .........................................25 SERVICE DATA AND SPECIFICATIONS (SDS) .........88 RS
Wiring Diagram - A/C - ..............................................26 Manual .......................................................................88
How to Perform Trouble Diagnoses for Quick
and Accurate Repair ..................................................28
BT
SC
EL
IDX
PRECAUTIONS
Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”
Supplemental Restraint System (SRS) “AIR

BAG” and “SEAT BELT PRE-TENSIONER” NEHA0060
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” 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), seat belt pre-tensioners, a diagnosis sensor unit, warn-
ing lamp, wiring harness, and spiral cable.
The vehicle (except Crew Cab model) 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 pas-
senger 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 instrument 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:
쐌 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 per-
formed by an authorized NISSAN dealer.
쐌 Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the RS section.
쐌 Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses (except “SEAT BELT PRE-TENSIONER”) cov-
ered with yellow insulation either just before the harness connectors or for the complete harness
are related to the SRS.
쐌 The vehicle (except Crew Cab model) 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 passen-
ger 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 posi-
tion (ON or OFF) as when the vehicle arrived for service.
HA-2
PRECAUTIONS
Precautions for Working with HFC-134a (R-134a)
Precautions for Working with HFC-134a

(R-134a)
WARNING:
=NEHA0061
GI
쐌 CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
are mixed, compressor failure is likely to occur. Refer to HA-3, “Contaminated Refrigerant”. To MA
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.
쐌 Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo- EM
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
쐌 The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed: LC
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
EC
before connecting the components. Connect all refrigerant loop components as quickly as pos-
sible to minimize the entry of moisture into system.
FE
c) Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
d) Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose CL
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 system discharge occurs, ventilate work area before resuming service. Additional MT
health and safety information may be obtained from refrigerant and lubricant manufacturers.
e) Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts.
Damage may result. AT
Contaminated Refrigerant NEHA0267
If a refrigerant other than pure R-134a is identified in a vehicle, your options are: TF
쐌 Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into
the atmosphere.
PD
쐌 Explain that recovery of the contaminated refrigerant could damage your service equipment and refriger-
ant supply.
쐌 Suggest the customer return the vehicle to the location of previous service where the contamination may AX
have occurred.
쐌 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 SU
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. BR
쐌 If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan
Customer Affairs for further assistance.
ST
General Refrigerant Precautions NEHA0062
WARNING:
쐌 Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the RS
refrigerant every time an air conditioning system is discharged.
쐌 Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or BT
air conditioning system.
쐌 Do not store or heat refrigerant containers above 52°C (125°F).
쐌 Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
쐌 Do not intentionally drop, puncture, or incinerate refrigerant containers.
쐌 Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
SC
쐌 Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation. EL
쐌 Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and R-134a have been
IDX
HA-3
PRECAUTIONS
Precautions for Leak Detection Dye
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-
facturers.
Precautions for Leak Detection Dye NEHA0292
쐌 The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultravio-
let (UV) lamp is required to illuminate the dye when inspecting for leaks.
쐌 Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of
the fluorescent dye.
쐌 A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
쐌 Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a
future service.
쐌 Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.
쐌 Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
쐌 Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system.
쐌 Leak detection dyes for R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye
in R-12 A/C system or R-12 leak detection dye in R-134a A/C systems or A/C system damage may result.
쐌 The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
occurs.
A/C Identification Label NEHA0293

Vehicles with factory installed fluorescent dye have this identifica-
tion label on the underside of hood.
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
LHA242
Precautions for Refrigerant Connection NEHA0063

A new type refrigerant connection has been introduced to all refrigerant lines except the following portion.
쐌 Thermal expansion valve connections.
FEATURES OF NEW TYPE REFRIGERANT CONNECTION NEHA0063S01
쐌 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.
쐌 The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby
facilitating piping connections.
HA-4
PRECAUTIONS
Precautions for Refrigerant Connection (Cont’d)
GI
MA
EM
LC
EC
FE
AHA534A CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-5
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION =NEHA0063S02

KA24DE Models NEHA0063S0203
LHA238
VG33E and VG33ER Models NEHA0063S0202
LHA239
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,
the connection.
HA-6
PRECAUTIONS
O-Ring Part Numbers and Specifications =NEHA0063S0201
Connec- O-ring GI
Part No.* D mm (in) W mm (in)
tion type size
New 92471 N8210 6.8 (0.268) 1.85 (0.0728)

MA
8
Former 92470 N8200 6.07 (0.23990) 1.78 (0.0701)
EM
New 92472 N8210 10.9 (0.429) 2.43 (0.0957)
12
Former 92475 71L00 11.0 (0.433) 2.4 (0.094) LC
New 16 92473 N8210 13.6 (0.535) 2.43 (0.0957)
EC
SHA814E New 19 92474-N8210 16.5 (0.650) 2.43 (0.0957)
*: Always check with the Parts Department for the latest parts information. FE
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 CL
it.
CAUTION: MT
When replacing or cleaning refrigerant cycle components, observe the following.
쐌 When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber. AT
쐌 When connecting tubes, always use a torque wrench and a back-up wrench.
쐌 After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
TF
쐌 When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection. PD
쐌 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.
쐌 Thoroughly remove moisture from the refrigeration system before charging the refrigerant. AX
쐌 Always replace used O-rings.
쐌 When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion. SU
Lubricant name: NISSAN A/C System Lubricant Type R
Part number: KLH00-PAGR0
BR
쐌 O-ring must be closely attached to inflated portion of tube.
쐌 After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
쐌 After connecting line, conduct leak test and make sure that there is no leakage. When the gas ST
leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal
seat to the specified torque.
RS
BT
SC
EL
IDX
HA-7
PRECAUTIONS
Precautions for Servicing Compressor
AHA514A
Precautions for Servicing Compressor NEHA0064

쐌 Plug all openings to prevent moisture and foreign matter from entering.
쐌 Do not keep the compressor in the upside down position or laid on its side for more than 10 min-
utes.
쐌 When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to “Maintenance of Lubricant Quantity in Compressor”, HA-68.
쐌 Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with
lubricant, wipe it off by using a clean waste cloth moistened with thinner.
쐌 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.
쐌 After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
Precautions for Service Equipment NEHA0065

RECOVERY/RECYCLING EQUIPMENT NEHA0065S01
Follow the manufacturer’s instructions for machine operation and
machine maintenance. Never introduce any refrigerant other than
that specified into the machine.
ELECTRONIC LEAK DETECTOR NEHA0065S02
Follow the manufacturer’s instructions for tester operation and
tester maintenance.
HA-8
PRECAUTIONS
Precautions for Service Equipment (Cont’d)
VACUUM PUMP NEHA0065S03
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems. GI
The vent side of the vacuum pump is exposed to atmospheric
pressure. So the vacuum pump lubricant may migrate out of the
pump into the service hose. This is possible when the pump is MA
switched off after evacuation (vacuuming) and hose is connected
to it.
To prevent this migration, use a manual valve situated near the EM
hose-to-pump connection, as follows.
쐌 Usually vacuum pumps have a manual isolator valve as part
of the pump. Close this valve to isolate the service hose from LC
the pump.
쐌 For pumps without an isolator, use a hose equipped with a EC
manual shut-off valve near the pump end. Close the valve to
isolate the hose from the pump.
쐌 If the hose has an automatic shut off valve, disconnect the FE
hose from the pump: when the hose is connected, the valve is
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close CL
under a no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
AHA559A
MT
MANIFOLD GAUGE SET NEHA0065S04
Be certain that the gauge face indicates R-134a or 134a. Make AT
sure the gauge set has 1/2″-16 ACME threaded connections for
service hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified lubricant. TF
PD
AX
SHA533D
SERVICE HOSES
Be certain that the service hoses display the markings described
NEHA0065S05 SU
(colored hose with black stripe). All hoses must include positive
shut off devices (either manual or automatic) near the end of the BR
hoses opposite the manifold gauge.
ST
RS
AHA560A
SERVICE COUPLERS NEHA0065S06

BT
Never attempt to connect HFC-134a (R-134a) service couplers to
an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
will not properly connect to the CFC-12 (R-12) system. However, if
an improper connection is attempted, discharging and contamina-
tion may occur.
SC
Shut-off valve rotation A/C service valve
Clockwise Open
EL
Counterclockwise Close
RHA273D
IDX
HA-9
PRECAUTIONS
Precautions for Service Equipment (Cont’d)
REFRIGERANT WEIGHT SCALE NEHA0065S07
Verify that no refrigerant other than HFC-134a (R-134a) and speci-
fied lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2″-16
ACME.
RHA274D
CALIBRATING ACR4 WEIGHT SCALE NEHA0065S10

Calibrate the scale every 3 months.
To calibrate the weight scale on the ACR4 (J-39500–NI):
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
changed 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 NEHA0065S08

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 equip-
ment.
THERMOMETER AND HYGROMETER NEHA0065S09

An etched stem-type thermometer and a hygrometer can be used
to check the air conditioning system performance. A hygrometer is
used because the air conditioning performance depends on the
humidity.
AHA274
HA-10
PRECAUTIONS
Wiring Diagrams and Trouble Diagnosis
Wiring Diagrams and Trouble Diagnosis NEHA0066

When you read wiring diagrams, refer to the following:
쐌 Refer to GI-11, “HOW TO READ WIRING DIAGRAMS”. GI
쐌 Refer to EL-9, “POWER SUPPLY ROUTING” .
When you perform trouble diagnosis, refer to the following: MA
쐌 Refer to GI-34, “How to Follow Test Groups in Trouble Diagnoses”.
쐌 Refer to GI-23, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-11
PREPARATION
Special Service Tools
Special Service Tools =NEHA0286

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

(J-38874)
Clutch disc wrench
NT204
KV99232340 Removing clutch disc

(J-38874)
Clutch disc puller
NT206
KV99234330 Installing pulley

(J-39024)
Pulley installer
NT207
KV99233130 Removing pulley

(J-39023)
Pulley puller
NT208
HA-12
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment
HFC-134a (R-134a) Service Tools and

Equipment =NEHA0068
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubri-
GI
cant with CFC-12 (R-12) refrigerant and/or its lubricant.
Separate and non-interchangeable service equipment must be MA
used for handling each type of refrigerant/lubricant.
Refrigerant container fittings, service hose fittings and service
equipment fittings (equipment which handles refrigerant and/or EM
lubricant) are different between CFC-12 (R-12) and HFC-134a
(R-134a). This is to avoid mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be LC
used: refrigerant/lubricant contamination will occur and compressor
failure will result.
Tool number
EC
Tool name
FE
HFC-134a (R-134a) Container color: Light blue
refrigerant Container marking: HFC-134a (R-134a)
Fitting size: Thread size CL
쐌 large container 1/2″-16 ACME
MT
NT196
KLH00-PAGR0 Type: Polyalkylene glycol oil (PAG), type R

( — ) Application: HFC-134a (R-134a) vane rotary com- AT
NISSAN A/C System pressors (NISSAN only)
Lubricant Type R Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz)
TF
NT197
(J-39500-NI) Function: Refrigerant Recovery and Recycling and PD

Recovery/Recycling Recharging
Recharging equipment
(ACR4) AX
SU
NT195 BR
(J-41995) Power supply:
Electrical leak detector 쐌 DC 12 V (Cigarette lighter)
Function: Checks for refrigerant leaks. ST
RS
BT
AHA281A
SC
EL
IDX
HA-13
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment (Cont’d)
Tool number
Tool name
(J-43926) Power supply:

Refrigerant dye leak DC 12V (Battery terminal)
detection kit
Kit includes:
(J-42220) UV lamp and
UV safety glasses
(J-41459) Refrigerant
dye injector
(J-41447) qty. 24
R-134a refrigerant dye
(J-43872) Refrigerant
dye cleaner
SHA437F
(J-42220) Power supply: DC 12V (Battery terminal)

Fluorescent dye leak For checking refrigerant leak when fluorescent dye
detector is installed in A/C system.
Includes: UV lamp and UV safety glasses
LHA177
(J-41447) Dye Application: For R-134a PAG oil

R134a Fluorescent Container: 1/4 ounce (7.4 cc) bottle
Leak Detection Dye (Includes self-adhesive dye identification labels for
(Box of 24, 1/4 ounce affixing to vehicle after charging system with dye.)
bottles)
SHA439F
(J-41459) Dye injector For injecting 1/4 ounce of Fluorescent Leak Detec-
R134a Dye Injector tion Dye into A/C system.
Use with J-41447, 1/4
ounce bottle
SHA440F
(J-43872) For cleaning dye spills.

Dye cleaner
SHA441F
(J-39183) Identification:
Manifold gauge set 쐌 The gauge face indicates R-134a.
(with hoses and cou- Fitting size: Thread size
plers) 쐌 1/2″-16 ACME
NT199
HA-14
PREPARATION
HFC-134a (R-134a) Service Tools and Equipment (Cont’d)
Tool number
Tool name GI
Service hoses Hose color:
쐌 High side hose 쐌 Low hose: Blue with black stripe MA
(J-39501-72) 쐌 High hose: Red with black stripe
쐌 Low side hose 쐌 Utility hose: Yellow with black stripe or green
(J-39502-72) with black stripe
쐌 Utility hose Hose fitting to gauge:
EM
(J-39476-72) 쐌 1/2″-16 ACME
NT201
Service couplers Hose fitting to service hose:

LC
쐌 High side coupler 쐌 M14 x 1.5 fitting is optional or permanently
(J-39500-20) attached.
쐌 Low side coupler EC
(J-39500-24)
NT202
FE
(J-39650) For measuring of refrigerant
Refrigerant weight scale Fitting size: Thread size CL
쐌 1/2″-16 ACME
MT
NT200 AT
(J-39649) Capacity:
Vacuum pump 쐌 Air displacement: 4 CFM
(Including the isolator 쐌 Micron rating: 20 microns TF
valve) 쐌 Oil capacity: 482 g (17 oz)
Fitting size: Thread size
쐌 1/2″-16 ACME PD
NT203 AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-15
PREPARATION
Commercial Service Tool
Commercial Service Tool =NEHA0067
Tool name Description Note
Refrigerant Identifier Checking refrigerant purity and for system contami-

Equipment nation
NT765
For details of handling methods, refer to the Instruction Manual attached to the service tool.
HA-16
DESCRIPTION
Refrigeration System
Refrigeration System
REFRIGERATION CYCLE NEHA0069
GI
Refrigerant Flow NEHA0069S01
The refrigerant flows in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank,
expansion valve, evaporator, and back to the compressor. The refrigerant evaporation through the evapora- MA
tor coil is controlled by an externally equalized expansion valve, located inside the evaporator case.
Freeze Protection NEHA0069S02
EM
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the
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- LC
fier allows compressor operation.
Refrigerant System Protection NEHA0069S03
EC
Dual Pressure Switch (KA24DE Models) or Triple Pressure Switch (VG33E and VG33ER Models) NEHA0069S0301
The refrigerant system is protected against excessively high or low pressure. The protection is effected by
either a dual pressure switch or a triple pressure switch located on the liquid tank. If the pressure falls out of FE
specifications, the switch opens to interrupt compressor operation.
Pressure Relief Valve NEHA0069S0302 CL
The refrigerant system is also protected by a pressure relief valve located on the flexible high pressure hose
near the compressor. When the pressure of refrigerant in the system increases to an abnormal level [more
than 3,727 kPa (38 kg/cm2, 540 psi)], the release port on the pressure relief valve automatically opens and MT
releases refrigerant into the atmosphere.
AT
TF
PD
AX
SU
BR
ST
RS
BT
LHA284
SC
EL
IDX
HA-17
DESCRIPTION
Control Operation
Control Operation NEHA0072
AHA488A
FAN CONTROL KNOB NEHA0072S01

This knob turns the fan ON and OFF, and controls fan speed.
MODE CONTROL KNOB NEHA0072S03
This knob controls the direction of air flow through the front discharge outlets.
TEMPERATURE CONTROL KNOB NEHA0072S04
This knob allows adjustment of the outlet air temperature.
RECIRCULATION (REC) SWITCH NEHA0072S05
OFF position: Outside air is drawn into the passenger compartment.
ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.
AIR CONDITIONER SWITCH NEHA0072S06
The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the A/C
relay is activated by the ECM allowing compressor operation. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running and ambient air tem-
perature is above 2°C (35°F).
HA-18
DESCRIPTION
Discharge Air Flow
Discharge Air Flow NEHA0073
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
WHA293
*1 HA-29 SC
EL
IDX
HA-19
DESCRIPTION
Component Layout
Component Layout NEHA0272
AHA123A
HA-20
TROUBLE DIAGNOSES
Component Location
Component Location NEHA0085

ENGINE COMPARTMENT NEHA0085S01
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
AHA452A
EL
IDX
HA-21
TROUBLE DIAGNOSES
Component Location (Cont’d)

VG33E Models =NEHA0085S0501
AHA453A
HA-22
TROUBLE DIAGNOSES

VG33ER Models =NEHA0085S0601
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
WHA273
SC
EL
IDX
HA-23
TROUBLE DIAGNOSES
PASSENGER COMPARTMENT NEHA0085S02
LHA231
HA-24
TROUBLE DIAGNOSES
Wiring Diagram — Heater —
Wiring Diagram — Heater — NEHA0288
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
AHA447A EL
IDX
HA-25
TROUBLE DIAGNOSES
Wiring Diagram — A/C —
Wiring Diagram — A/C — NEHA0274
LHA219
HA-26
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
WHA335
EL
IDX
HA-27
TROUBLE DIAGNOSES
How to Perform Trouble Diagnoses for Quick and Accurate Repair
How to Perform Trouble Diagnoses for Quick

and Accurate Repair NEHA0075
WORK FLOW NEHA0075S01
LHA244
*1: HA-29 *2: HA-28
Symptom Table NEHA0235
Symptom Reference page
쐌 Blower motor does not rotate. 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

HA-31
BLOWER MOTOR”.
쐌 Mode door does not change positions. 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR
HA-38
MODE DOOR”.
쐌 Intake door position does not change. 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR
HA-40
INTAKE DOOR”.
쐌 Magnet clutch does not engage when A/C switch and 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR
HA-43
fan switch are ON. MAGNET CLUTCH ”.
쐌 Insufficient cooling 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

HA-55
INSUFFICIENT COOLING”.
쐌 Insufficient heating 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

HA-63
INSUFFICIENT HEATING”.
쐌 Noise 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

HA-65
NOISE”.
HA-28
TROUBLE DIAGNOSES
Operational Check
Operational Check =NEHA0076

The purpose of the operational check is to confirm that the system
operates as it should. The systems which are checked are the GI
blower, mode (discharge air), intake air (recirculation), temperature
decrease, temperature increase, and A/C compressor.
MA
CONDITIONS: NEHA0076S01
Engine running at normal operating temperature.
EM
LC
PROCEDURE: NEHA0076S02
1. Check Blower Motor NEHA0076S0208 EC
1) Turn fan control knob to 1-speed.
Blower should operate on 1-speed.
2) Then turn fan control knob to 2-speed, and continue checking FE
blower speed until all four speeds are checked.
3) Leave blower on 4-speed.
If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR
CL
BLOWER MOTOR”, HA-31.
If OK, continue with the check. MT
AHA496A
2. Check Discharge Air NEHA0076S0202

1) Turn mode control knob to each mode position. AT
TF
PD
AX
AHA497A
2) Confirm that discharge air comes out according to the air dis-
tribution table at left. SU
Refer to “Discharge Air Flow”, HA-19.
If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR MODE BR
DOOR”, HA-38.
If OK, continue with next check.
ST
RS
BT
SC
EL
AHA983
IDX
HA-29
TROUBLE DIAGNOSES
Operational Check (Cont’d)
3. Check Recirculation NEHA0076S0203
1) Press recirculation switch.
Recirculation indicator should light.
2) Listen for intake door position to change (you should hear
blower sound change slightly).
If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE
DOOR”, HA-40.
AHA494A
4. Check Temperature Decrease NEHA0076S0204

1) Turn temperature control knob to full cold.
2) Check for cold air at discharge air outlets.
If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR INSUF-
FICIENT COOLING”, HA-55.
AHA499A
5. Check Temperature Increase NEHA0076S0205

1) Turn temperature control knob to full hot.
2) Check for hot air at discharge air outlets.
If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR INSUF-
FICIENT HEATING”, HA-63.
AHA498A
6. Check A/C Switch NEHA0076S0206

1) Turn fan control knob to the desired (1 to 4 speed) position.
2) Push the A/C switch to turn ON the air conditioner.
The indicator lamp should come on when air conditioner is ON.
3) Confirm that the compressor clutch engages (audio or visual
inspection).
4) Check for cold air at the appropriate discharge air outlets.
If NG, go to “TROUBLE DIAGNOSIS PROCEDURE FOR MAG-
NET CLUTCH”, HA-43.
AHA500A If all operational checks are OK (symptom cannot be duplicated),
go to GI-24, “Incident Simulation Tests”, and perform tests as out-
lined to simulate driving conditions environment. If symptom
appears, refer to “Symptom Table”, HA-28 and perform applicable
trouble diagnoses procedures.
HA-30
TROUBLE DIAGNOSES
Blower Motor
Blower Motor
TROUBLE DIAGNOSIS PROCEDURE FOR BLOWER MOTOR
Symptom:
=NEHA0138
GI
쐌 Blower motor does not rotate.
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
LHA245
AX
*1: HA-32 *2: HA-29 *3: HA-28
SU
BR
ST
RS
BT
SC
EL
IDX
HA-31
TROUBLE DIAGNOSES
Blower Motor (Cont’d)
BLOWER MOTOR CIRCUIT =NEHA0089

SYMPTOM:
쐌 Blower motor does not rotate.
1 DIAGNOSTIC PROCEDURE
Check if blower motor rotates properly at each fan speed.
Does not rotate 䊳 GO TO 2.
at any speed
Does not rotate 䊳 GO TO 6.
at 1-3 speed
Does not rotate at 4 䊳 GO TO 7.
speed
2 CHECK FUSES
Check 15A fuse [No. 19, located in the fuse block (J/B)] and 15A fuse [No. 24, located in the fuse block (J/B)]. For fuse
layout, refer to EL-9, “POWER SUPPLY ROUTING”.
Are fuses OK?
OK 䊳 GO TO 3.
NG 䊳 GO TO 9.
3 CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

1. Disconnect blower motor harness connector.
2. Check voltage between blower motor harness connector M62 terminal 1 and ground.
AHA485A
Does battery voltage exist?

Yes 䊳 GO TO 4.
No 䊳 Check the following.
If NG, repair harness or connector.
쐌 Harness for open or short between blower motor and fuse block (J/B).
쐌 Harness connectors M27 and M62
HA-32
TROUBLE DIAGNOSES
4 CHECK BLOWER MOTOR GROUND CIRCUIT

1. Disconnect blower motor harness connector. GI
2. Turn fan control knob to 4-speed.
3. Check continuity between blower motor harness connector M62 terminal 2 and ground.
MA
EM
LC
AHA460A EC
Continuity should exist.
OK or NG FE
OK 䊳 GO TO 5.
NG 䊳 Check the following. If NG, repair harness or connector.
쐌 Harness for open or short between blower motor and fuse block (J/B).
CL
쐌 Harness connectors M27 and M62
MT
5 CHECK BLOWER MOTOR
1. Disconnect blower motor harness connector.
2. Apply 12 volts to blower motor terminal 1 and ground to blower motor terminal 2.
AT
TF
PD
AHA455A AX
Does blower motor rotate?
Yes 䊳 Reconnect blower motor connector and go to “TROUBLE DIAGNOSIS PROCEDURE SU
FOR BLOWER MOTOR”, HA-31.
No 䊳 Replace blower motor.
BR
ST
RS
BT
SC
EL
IDX
HA-33
TROUBLE DIAGNOSES
6 CHECK FAN RESISTOR

1. Disconnect fan resistor harness connector M61.
2. Check resistance between fan resistor terminals.
AHA458A
AHA459A
OK or NG
OK 䊳 GO TO 7.
NG 䊳 Replace fan resistor.
HA-34
TROUBLE DIAGNOSES
7 CHECK FAN SWITCH

Disconnect fan switch harness connector M57 and check continuity between terminals at each fan switch position. GI
MA
EM
LC
AHA456A EC
FE
CL
MT
AHA457A AT
OK or NG
OK 䊳 GO TO 8. TF
NG 䊳 Replace fan switch.
PD
8 CHECK FAN SWITCH GROUND
1. Disconnect fan switch harness connector M57. AX
2. Check continuity between fan switch harness connector terminal 6 and ground.
SU
BR
ST
AHA078A RS
OK or NG
BT
OK 䊳 Check the following.
If NG, repair harness or connectors.
쐌 Harness connectors M57, M61 and M62
쐌 Harness for open or short between blower motor and fan switch, fan resistor
NG 䊳 Repair harness or connector.
SC
EL
IDX
HA-35
TROUBLE DIAGNOSES
9 REPLACE FUSE
1. Replace fuse(s).
2. Activate the blower motor system.
Do the fuses blow when the front blower motor is activated?
Yes 䊳 GO TO 10.
No 䊳 INSPECTION END
10 CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT FOR A SHORT

1. Disconnect battery cable and blower motor harness connector M62.
2. Check continuity between front blower motor harness terminal 1 and ground.
AHA485A
Continuity should not exist.
Does continuity exist?
Yes 䊳 Check the following. If NG, repair harness or connector.
Harness connectors M27 and M62
Harness for open or short between blower motor and fuse block (J/B).
No 䊳 Check front blower motor.
Refer to “Blower Motor”, HA-37.
If necessary, clear intake unit.
If OK, replace front blower motor.
ELECTRICAL COMPONENTS INSPECTION NEHA0246

Fan Switch NEHA0246S01
Check continuity between terminals at each switch position.
AHA456A
AHA457A
HA-36
TROUBLE DIAGNOSES
Blower Motor NEHA0246S02
Confirm smooth rotation of the blower motor.
쐌 Check that there are no foreign particles inside the intake unit. GI
MA
EM
AHA547A LC
Fan Resistor NEHA0246S04
Terminal No. Resistance EC

Ω
(+) (–) (Approx.)
FE
2 0.2 - 0.3
1 3 0.8 - 1.0
CL
4 2.0 - 2.4
Check resistance between terminals. MT

AHA458A
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-37
TROUBLE DIAGNOSES
Mode Door
Mode Door
TROUBLE DIAGNOSIS PROCEDURE FOR MODE DOOR =NEHA0240
Symptom:
쐌 Mode door does not change.
Inspection Flow
AHA480A
*1: HA-19 *3: HA-29 *4: HA-28

*2: HA-39
HA-38
TROUBLE DIAGNOSES
Mode Door (Cont’d)
MODE DOOR CONTROL LINKAGE ADJUSTMENT NEHA0242
Mode door control linkage
쐌 Turn mode door control knob to position. GI
쐌 Set side link in DEF mode.
쐌 Pull on outer cable in direction of arrow and then clamp it. MA
쐌 After positioning mode door control cable, check that it
operates properly.
EM
AHA121A LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-39
TROUBLE DIAGNOSES
Intake Door Motor
Intake Door Motor

TROUBLE DIAGNOSIS PROCEDURE FOR INTAKE DOOR =NEHA0135
Symptom:
쐌 Intake door position does not change in VENT, B/L or FOOT mode.
Inspection Flow
AHA481A
*1: HA-42 *2: HA-29 *3: HA-28
HA-40
TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)
INTAKE DOOR CIRCUIT =NEHA0299

SYMPTOM:
쐌 Intake door does not operate. GI
1 CHECK POWER FOR INTAKE DOOR MOTOR
1. Disconnect intake door motor harness connector. MA
2. Turn ignition switch ON.
3. Check voltage between intake door motor harness connector M96 terminals + (Y/B), – (Y) and ground as shown.
EM
LC
EC
FE
LHA268
OK or NG CL
OK 䊳 GO TO 3.
NG 䊳 GO TO 2. MT
2 CHECK INTAKE DOOR CIRCUIT AT

1. Turn ignition switch OFF.
2. Disconnect air control harness connector.
3. Check continuity between air control harness connector M95 terminals 2 (Y/B), 7 (Y) and intake door motor harness TF
connector M96 terminals + (Y/B), – (Y).
PD
AX
SU
BR
LHA269
NOTE:
Mode control knob should be in position. ST
OK or NG
OK 䊳 Check harness for open or short. RS
NG 䊳 Replace air control.
BT
SC
EL
IDX
HA-41
TROUBLE DIAGNOSES
Intake Door Motor (Cont’d)
3 CHECK INTAKE DOOR MOTOR

1. Reconnect intake door motor connector M96.
2. Turn ignition switch ON.
3. Observe intake door operation when the RECIRC switch is turned ON and OFF.
4. Intake door should change position.
AHA523A
OK or NG
OK 䊳 Check harness and connectors for open or short.
NG 䊳 Replace intake door motor.
CONTROL LINKAGE ADJUSTMENT NEHA0294

Intake Door Motor NEHA0294S01
1. Install intake door motor on intake unit.
Ensure that the intake door motor lever is fitted into the slit
portion of the intake door link.
2. Connect the intake door motor harness connector before
installing the intake door motor.
3. Turn ignition switch on and press the recirculation switch.
4. Turn the mode control knob to VENT, B/L or FOOT mode.
5. Check that intake door motor operates properly when RECIR-
AHA523A
CULATION switch is turned ON and OFF.
HA-42
TROUBLE DIAGNOSES
Magnet Clutch
Magnet Clutch
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH
Symptom:
=NEHA0119
GI
쐌 Magnet clutch does not engage when A/C switch and fan switch are ON.
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
LHA258
*1: HA-76 *4: HA-29 MA-25 (VG33E and VG33ER BR

*2: HA-81 *5: HA-28 models)
*3: HA-44 *6: MA-16 (KA24DE models) or
ST
RS
BT
SC
EL
IDX
HA-43
TROUBLE DIAGNOSES
Magnet Clutch (Cont’d)
MAGNET CLUTCH CIRCUIT =NEHA0091

SYMPTOM:
쐌 Magnet clutch does not engage when A/C switch and fan
switch are ON.
1 CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT
1. Disconnect A/C compressor harness connector F15–2.
2. Press the A/C switch ON.
3. Does approx. 12 volts exist between A/C compressor connector F15–2 terminal 1 (B) and ground?
WHA232
Yes or No
Yes 䊳 GO TO 2.
No 䊳 GO TO 3.
2 CHECK A/C COMPRESSOR GROUND

Check continuity between A/C compressor connector F15–2 terminal 1 and ground.
AHA466A
OK or NG
OK 䊳 Refer to “TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH,” HA-43.
NG 䊳 쐌 Check thermal protector. Refer to “Thermal Protector”, HA-53.
쐌 Check magnet clutch coil.
If NG, replace magnet clutch. Refer to “Magnet Clutch Mounting”, HA-74.
HA-44
TROUBLE DIAGNOSES
3 CHECK CIRCUIT CONTINUITY

1. Disconnect A/C relay. GI
2. Check circuit continuity between A/C relay connector E30 terminal 3 and A/C compressor connector F15–2 terminal 1.
MA
EM
LC
AHA084A EC
3. Also, check harness for short.
OK or NG FE
OK 䊳 GO TO 4.
NG 䊳 Repair harness or connector. CL
4 CHECK A/C RELAY POWER SUPPLY CIRCUIT MT

1. Disconnect A/C relay.
2. Does approx. 12 volts exist between A/C relay connector E30 terminals 2, 5 and ground?
AT
TF
PD
AHA467A
AX
Yes or No
Yes 䊳 GO TO 5.
SU
No 䊳 GO TO 13.
BR
5 CHECK A/C RELAY
Refer to “A/C Relay”, HA-52.
OK or NG
ST
OK 䊳 GO TO 6.
NG 䊳 Replace A/C relay.
RS
BT
SC
EL
IDX
HA-45
TROUBLE DIAGNOSES
6 CHECK A/C RELAY GROUND CONTROL CIRCUIT

1. Reconnect A/C relay.
2. Engine running and A/C ON.
3. Does approx. 12 volts exist between ECM harness connector F29 terminal 12 (P) and ground?
LHA234
Yes or No
Yes 䊳 GO TO 7.
No 䊳 Check the following. If NG, repair harness or connectors.
Harness connectors E30 and F29
Harness for open or short between A/C relay and ECM
7 CHECK ECM OUTPUT VOLTAGE

Does approx. 5 volts exist between thermo control amp. harness connector M60 terminal 2 and ground?
AHA089A
Yes or No
Yes 䊳 GO TO 16.
No 䊳 GO TO 8.
HA-46
TROUBLE DIAGNOSES

1. Disconnect dual pressure switch (KA24DE models) or triple pressure switch (VG33E and VG33ER models) harness GI
connector E3.
2. Check voltage from dual pressure switch E3 terminal 1 (G/R) to ground (KA24DE models) or from triple pressure
switch E3 terminal 1 (G/R) to ground (VG33E and VG33ER models). MA
EM
LC
EC
LHA275 FE
Do approx. 5 volts exist?
3. Also, check harness for short.
Yes or No CL
Yes (KA24DE models) 䊳 GO TO 9.
Yes (VG33E and 䊳 GO TO 11. MT
VG33ER models)
No 䊳 Repair harness or connector.
AT
9 CHECK DUAL PRESSURE SWITCH (KA24DE MODELS)
TF
Refer to “Dual Pressure Switch (KA24DE Models)”, HA-52.
OK or NG
PD
OK 䊳 GO TO 10.
NG 䊳 Replace dual pressure switch.
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-47
TROUBLE DIAGNOSES

1. Disconnect dual pressure switch harness connector E3.
2. Check circuit continuity between thermo control amp. harness connector M60 terminal 2 and dual pressure switch con-
nector E3 terminal 2.
AHA267A
3. Also check circuit continuity between dual pressure switch connector E3 terminal 1 and ECM connector F29 terminal
21.
AHA268A
OK or NG
OK 䊳 Check ECM. Refer to EC-39, “Description”.
11 CHECK TRIPLE PRESSURE SWITCH (VG33E AND VG33ER MODELS)

Refer to “Triple Pressure Switch (VG33E and VG33ER Models)”, HA-53.
OK or NG
OK 䊳 GO TO 12.
NG 䊳 Replace triple pressure switch.
HA-48
TROUBLE DIAGNOSES

1. Disconnect triple pressure switch harness connector E3. GI
2. Check circuit continuity between thermo control amp. harness connector M60 terminal 2 and triple pressure switch har-
ness connector E3 terminal 3.
MA
EM
LC
AHA271A EC
3. Also check circuit continuity between triple pressure switch connector E3 terminal 1 and ECM connector F29 terminal
21. FE
CL
MT
AT
AHA272A
TF
OK or NG
OK 䊳 Check ECM. Refer to EC-639 (VG33E models) or EC-1240 (VG33ER models), “Description”.
PD
13 CHECK FUSES AX
Check 7.5A fuse (No. 29, located in the fuse and fusible link box) and 7.5A fuse (No. 35, located in the fuse and fusible
link box). For fuse layout, refer to EL-9, “POWER SUPPLY ROUTING”. SU
Are fuses OK?
BR
쐌 Harness for open or short between fuse block and A/C relay
쐌 Harness connectors M55, M60 and E30
ST
NG 䊳 GO TO 14.
RS
14 REPLACE FUSE
Replace fuse.
Does fuse blow when A/C is activated?
BT
Yes 䊳 GO TO 15.
No 䊳 INSPECTION END
SC
EL
IDX
HA-49
TROUBLE DIAGNOSES
15 CHECK A/C RELAY POWER SUPPLY CIRCUITS FOR SHORT

1. Disconnect battery cable and A/C relay.
2. Check for continuity on A/C relay connector E30 terminals (2, 5) to ground.
AHA470A
Continuity should not exist.
OK or NG
쐌 Harness connectors M55, M60 and E30.
쐌 Harness for open or short between fuse and fusible link box and A/C relay, A/C switch,
or thermo control amplifier.
16 THERMO CONTROL AMP. GROUND CIRCUIT

1. Turn ignition switch OFF, A/C switch ON and fan switch ON.
2. Disconnect thermo control amp. connector M60.
3. Check continuity between thermo control amp. connector M60 terminal 4 (L) and ground.
LHA233
OK or NG
OK 䊳 GO TO 13.
NG 䊳 GO TO 17.
HA-50
TROUBLE DIAGNOSES
17 CHECK FAN SWITCH

1. Disconnect fan switch connector M57. GI
2. Turn fan control knob to ON (any speed position except OFF).
3. Check continuity between fan switch terminals 1 and 6.
MA
EM
LC
EC
LHA235
OK or NG
FE
쐌 Harness connectors M57 and M95. CL
쐌 Harness for open or short between fan switch and A/C switch.
쐌 If OK, replace air control.
NG 䊳 Replace fan switch. MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-51
TROUBLE DIAGNOSES
ELECTRICAL COMPONENTS INSPECTION =NEHA0092
A/C Relay NEHA0092S07
Check continuity between terminals 3 and 5.
Conditions Continuity
12V direct current supply between terminals 1 and

Yes
2
No current supply No
If NG, replace relay.

SEF090M
Dual Pressure Switch (KA24DE Models) NEHA0092S09

Check continuity between terminals.
High-pressure side line
Terminals pressure Operation Continuity
kPa (kg/cm2, psi)
Low-pres- Increasing to 157 - 216

ON Yes
sure side (1.6 - 2.2, 23 - 31)
Decreasing to 157 - 196

OFF No
(1.6 - 2.0, 23 - 28)
AHA128A
1-2 Increasing to 2,648 -
2,844 OFF No
High-pres- (27 - 29, 384 - 412)
sure side Decreasing to 1,373 -
1,765 ON Yes
(14 - 18, 199 - 256)
HA-52
TROUBLE DIAGNOSES
Triple Pressure Switch (VG33E and VG33ER Models)
=NEHA0092S10
Check continuity between terminals 1 and 3.
GI
High-pressure side line
Terminals pressure Operation Continuity
kPa (kg/cm2, psi)
MA
Low-pres- Increasing to 157 - 226
ON Yes
sure side (1.6 - 2.3, 23 - 31)
1-3 EM
Decreasing to 152.0 -
201.0 OFF No
(1.55 - 2.05, 22.0 - 29.2)
AHA401A LC
Increasing to 1,422 -
1,618 ON Yes
Medium- (14.5 - 16.5, 206 - 235) EC
pressure 2-4
side Decreasing to 1,128 -
1,422 OFF No
(11.5 - 14.5, 164 - 206)
FE
Decreasing to 1,667 -
2,059 ON Yes CL
High-pres- (17 - 21, 242 - 299)
1-3
sure side Increasing to 2,648 -
2,844 OFF No MT
(27 - 29, 384 - 412)
AT
TF
PD
AX
Thermal Protector
KA24DE Models
NEHA0092S11 SU
NEHA0092S1101
Temperature of compressor
°C (°F)
Operation BR
Increasing to approx. 145 - 155 (293 - 311) Turn OFF
Decreasing to approx. 130 - 140 (266 - 284) Turn ON

ST
RS
AHA135A
VG33E and VG33ER Models NEHA0092S1102 BT

Temperature of compressor
Operation
°C (°F)
Increasing to approx. 145 - 155 (293 - 311) Turn OFF
Decreasing to approx. 130 - 140 (266 - 284) Turn ON SC
EL
AHA402A
IDX
HA-53
TROUBLE DIAGNOSES
Thermo Control Amp. NEHA0092S12
1) Run engine and operate A/C system.
2) Connect the voltmeter from harness side.
3) Check the thermo control amp. operation as shown in the
table.
Evaporator outlet air temperature Thermo amp.
Tester (Approx.)
°C (°F) operation
Decreasing to 2.5 - 3.5 (37 - 38) Turn OFF 12V
Increasing to 4.0 - 5.0 (39 - 41) Turn ON 0V

AHA561A
HA-54
TROUBLE DIAGNOSES
Insufficient Cooling
Insufficient Cooling
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING
Symptom:
=NEHA0150
GI
쐌 Insufficient cooling
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
WHA292
*1: HA-38 *6: HA-72 EC-1072 (VG33E models with

*2: HA-59 *7: MA-16 (KA24DE models) or electric cooling fan), EC-1084
*3: HA-56 MA-25 (VG33E and VG33ER (VG33E models without electric
models) cooling fan) or EC-1670 (VG33ER SC
*4: HA-29 models)
*5: HA-28 *8: EC-574 (KA24DE models),
EL
IDX
HA-55
TROUBLE DIAGNOSES
Insufficient Cooling (Cont’d)
PERFORMANCE TEST DIAGNOSES =NEHA0295
MHA649A
*1: HA-58 *2: HA-58 *3: HA-59
HA-56
TROUBLE DIAGNOSES
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
LHA260
*1: HA-43 *2: MA-16 (KA24DE models) or models)

MA-25 (VG33E and VG33ER
SC
EL
IDX
HA-57
TROUBLE DIAGNOSES
PERFORMANCE CHART =NEHA0082

Test Condition NEHA0082S07
Testing must be performed as follows:
Vehicle location Indoors or in the shade (in a well-ventilated place)
Doors Closed
Door windows Open
Hood Open
TEMP. switch Max. COLD
Mode switch (Ventilation) set
REC switch (Recirculation) set
(blower) speed 4-speed
Engine speed 1,500 rpm
Operate the air conditioning system for 10 minutes before taking measurements.
Test Reading NEHA0082S06

Recirculating-to-Discharge Air Temperature Table NEHA0082S0601
Inside air (Recirculating air) at blower assembly inlet

Discharge air temperature at center ventilator °C (°F)
Relative humidity % Air temperature °C (°F)
20 (68) 6.6 - 8.3 (44 - 47)
25 (77) 10.4 - 12.4 (51 - 54)
50 - 60 30 (86) 14.2 - 16.7 (58 - 62)
35 (95) 18.2 - 21 (65 - 70)
40 (104) 22.0 - 25.2 (72 - 77)
20 (68) 8.3 - 9.8 (47 - 50)
25 (77) 12.4 - 14.4 (54 - 58)
60 - 70 30 (86) 16.7 - 18.9 (62 - 66)
35 (95) 21.0 - 23.6 (70 - 74)
40 (104) 25.2 - 28.1 (77 - 83)
HA-58
TROUBLE DIAGNOSES
Ambient Air Temperature-to-Operating Pressure Table =NEHA0082S0602
Ambient air GI
High-pressure (Discharge side) kPa (kg/ Low-pressure (Suction side) kPa (kg/cm2,
Relative humidity % Air temperature °C cm2, psi) psi)
(°F)
MA
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, 186 - 228) 161.8 - 215.8 (1.65 - 2.2, 23.5 - 31.3)
EM
50 - 70 30 (86) 1,285 - 1,599 (13.1 - 16.0, 186 - 228) 167 - 216 (1.7 - 2.2, 24 - 31)
35 (95) 1,520 - 1,863 (15.5 - 19.0, 220 - 279) 235 - 284 (2.4 - 2.9, 34 - 41)
LC
40 (104) 1,765 - 2,158 (18 - 22, 256 - 313) 289.3 - 353.1 (2.95 - 3.6, 41.9 - 51.2)
TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE NEHA0278

EC
Whenever system’s high and/or low side pressure is abnormal, diagnose using a manifold gauge. The marker
above the gauge scale in the following tables indicates the standard (normal) pressure range. Since the stan-
dard (normal) pressure, however, differs from vehicle to vehicle, refer to “Ambient Air Temperature-to-Operat- FE
ing Pressure Table”, HA-59.
Both High and Low-pressure Sides are Too High. NEHA0278S01
CL
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high and low-pressure sides 쐌 Pressure is reduced soon Excessive refrigerant charge Reduce refrigerant until
MT
are too high. after water is splashed on in refrigeration cycle specified pressure is
condenser. obtained.
AT
Air suction by cooling fan is Insufficient condenser cool- 쐌 Clean condenser.
insufficient. ing performance 쐌 Check and repair cooling
" fan as necessary. TF
1. Condenser fins are
clogged.
2. Improper fan rotation of
cooling fan
PD
쐌 Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and
cold. denser recharge system. AX
쐌 When compressor is (After compressor operation
stopped high-pressure stops, high pressure
AC359A value quickly drops by decreases too slowly.) SU
approximately 196 kPa (2 "
kg/cm2, 28 psi). It then Air in refrigeration cycle
decreases gradually there-
after.
BR
Engine tends to overheat. Engine cooling systems mal- Check and repair each
function. engine cooling system. ST
쐌 An area of the low-pres- 쐌 Excessive liquid refrigerant Replace expansion valve.
sure pipe is colder than on low-pressure side
areas near the evaporator 쐌 Excessive refrigerant dis-
RS
outlet. charge flow
쐌 Plates are sometimes cov- 쐌 Expansion valve is open a
ered with frost. little compared with the BT
specification.
"
1. Improper thermal valve
installation
2. Improper expansion valve
adjustment SC
EL
IDX
HA-59
TROUBLE DIAGNOSES
High-pressure Side is Too High and Low-pressure Side is Too Low. NEHA0278S02
High-pressure side is too high and Upper side of condenser and High-pressure tube or parts 쐌 Check and repair or
low-pressure side is too low. high-pressure side are hot, located between compressor replace malfunctioning
however, liquid tank is not so and condenser are clogged parts.
hot. or crushed. 쐌 Check lubricant for con-
tamination.
AC360A
High-pressure Side is Too Low and Low-pressure Side is Too High. NEHA0278S03
High-pressure side is too low and High and low-pressure sides Compressor pressure opera- Replace compressor.
low-pressure side is too high. become equal soon after tion is improper.
compressor operation stops. "
Damaged inside compressor
packings
No temperature difference Compressor pressure opera- Replace compressor.

between high and low-pres- tion is improper.
sure sides "
Damaged inside compressor
packings.
AC356A
HA-60
TROUBLE DIAGNOSES
Both High- and Low-pressure Sides are Too Low. NEHA0278S04
Gauge indication Refrigerant cycle Probable cause Corrective action GI

Both high- and low-pressure sides 쐌 There is a big temperature Compressor discharge 쐌 Replace liquid tank.
are too low. difference between capacity does not change. 쐌 Check lubricant for con-
receiver drier outlet and (Compressor stroke is set at tamination. MA
inlet. Outlet temperature is maximum.)
extremely low.
쐌 Liquid tank inlet and EM
expansion valve are
frosted.
쐌 Temperature of expansion High-pressure pipe located 쐌 Check and repair malfunc-

LC
valve inlet is extremely low between receiver drier and tioning parts.
as compared with areas expansion valve is clogged. 쐌 Check lubricant for con-
near liquid tank. tamination. EC
쐌 Expansion valve inlet may
be frosted.
AC353A
쐌 Temperature difference FE
occurs somewhere in high-
pressure side
쐌 Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
CL
tank are warm or only cool " Refer to “Checking for
when touched. Leaking fittings or compo- Refrigerant Leaks”, HA-81.
nents MT
There is a big temperature Expansion valve closes a 쐌 Remove foreign particles
difference between expan- little compared with the by using compressed air. AT
sion valve inlet and outlet specification. 쐌 Check lubricant for con-
while the valve itself is " tamination.
frosted. 1. Improper expansion valve
adjustment
TF
2. Malfunctioning thermal
valve
3. Outlet and inlet may be PD
clogged.
An area of the low-pressure Low-pressure pipe is clogged 쐌 Check and repair malfunc- AX
pipe is colder than areas or crushed. tioning parts.
near the evaporator outlet. 쐌 Check lubricant for con-
tamination.
SU
Air flow volume is not Evaporator is frozen. 쐌 Check thermo control
enough or is too low. " amp. operation.
Compressor discharge 쐌 Replace compressor. BR
capacity does not change.
(Compressor stroke is set at
maximum length.) ST
RS
BT
SC
EL
IDX
HA-61
TROUBLE DIAGNOSES
Low-pressure Side Sometimes Becomes Negative. NEHA0278S05
Low-pressure side sometimes 쐌 Air conditioning system Refrigerant does not dis- 쐌 Drain water from refriger-
becomes negative. does not function and charge cyclically. ant or replace refrigerant.
does not cyclically cool the " 쐌 Replace liquid tank.
compartment air. Moisture is frozen at expan-
쐌 The system constantly sion valve outlet and inlet.
functions for a certain "
period of time after com- Water is mixed with refriger-
pressor is stopped and ant.
restarted.
AC354A
Low-pressure Side Becomes Negative. NEHA0278S06
Low-pressure side becomes nega- Liquid tank or front/rear side High-pressure side is closed Leave the system at rest
tive. of expansion valve’s pipe is and refrigerant does not flow. until no frost is present. Start
frosted or dewed. " it again to check whether or
Expansion valve or liquid not the problem is caused by
tank is frosted. water or foreign particles.
쐌 If water is the cause, ini-
tially cooling is okay. Then
the water freezes causing
a blockage. Drain water
from refrigerant or replace
refrigerant.
쐌 If due to foreign particles,
remove expansion valve
and remove particles with
dry and compressed air
AC362A (not shop air).
쐌 If either of the above
methods cannot correct
the problem, replace
expansion valve.
쐌 Replace liquid tank.
쐌 Check lubricant for con-
tamination.
HA-62
TROUBLE DIAGNOSES
Insufficient Heating
Insufficient Heating
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING
Symptom:
=NEHA0140
GI
쐌 Insufficient heating
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
LHA261
*1: HA-64 *5: MA-17 (KA24DE models) or *7 LC-12 (KA24DE models) or LC-28
*2: HA-29 MA-27 (VG33E and VG33ER (VG33E and VG33ER models)
*3: HA-28 models)
*6: HA-86 SC
*4: LC-13 (KA24DE models) or LC-30
(VG33E and VG33ER models)
EL
IDX
HA-63
TROUBLE DIAGNOSES
Insufficient Heating (Cont’d)
TEMPERATURE CONTROL LINKAGE ADJUSTMENTNEHA0279
Temperature Control Cable
쐌 When adjusting ventilator door rod and defrost door rod,
first disconnect mode control cable from side link. Recon-
nect and readjust mode control cable.
쐌 Turn temperature control knob 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.
쐌 After positioning temperature control cable, check that it
operates properly.
AHA120A
HA-64
TROUBLE DIAGNOSES
Noise
Noise
TROUBLE DIAGNOSIS PROCEDURE FOR NOISE
Symptom:
=NEHA0080
GI
쐌 Noise
Inspection Flow MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
LHA262
*1: HA-74 *3: HA-68 MA-25 (VG33E and VG33ER

*2: HA-77 *4: MA-16 (KA24DE models) or models)
SC
EL
IDX
HA-65
SERVICE PROCEDURE
HFC-134a (R-134a) Service Procedure
HFC-134a (R-134a) Service Procedure NEHA0094

SETTING OF SERVICE TOOLS AND EQUIPMENT NEHA0094S01
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove R-134a form 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.
Discharging Refrigerant NEHA0094S0101
AHA508A
Evacuating System and Charging Refrigerant NEHA0094S0103
AHA562A
HA-66
SERVICE PROCEDURE
HFC-134a (R-134a) Service Procedure (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
AHA413A
*1 HA-68 *3 HA-82 *5 HA-3

*2 HA-81 *4 HA-56 SC
EL
IDX
HA-67
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor
Maintenance of Lubricant Quantity in

Compressor NEHA0095
The lubricant in the compressor circulates through the system with
the refrigerant. Add lubricant to compressor when replacing any
component or after a large gas leakage occurred. It is important to
maintain the specified amount.
If lubricant quantity is not maintained properly, the following mal-
functions may result:
쐌 Lack of lubricant: May lead to a seized compressor
쐌 Excessive lubricant: Inadequate cooling (thermal exchange
interference)
LUBRICANT NEHA0095S01
Name: NISSAN A/C System Lubricant Type R
Part number: KLH00-PAGR0
CHECKING AND ADJUSTING NEHA0095S02
Adjust the lubricant quantity according to the flowchart shown
below.
1 LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?
쐌 A/C system works properly.
쐌 There is no evidence of a large amount of lubricant leakage.
Yes or No
Yes 䊳 GO TO 2.
No 䊳 GO TO 3.
2 PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS

1. Start engine, and set the following conditions:
쐌 Test condition
Engine speed: Idling to 1,200 rpm
A/C switch: ON
RECIRCULATION switch: OFF
Fan speed: Max. position
Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).]
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
䊳 GO TO 3.
3 CHECK COMPRESSOR
Should the compressor be replaced?
Yes or No
Yes 䊳 Refer to “Lubricant Adjusting Procedure for Compressor Replacement”, HA-70.
No 䊳 GO TO 4.
HA-68
SERVICE PROCEDURE
Maintenance of Lubricant Quantity in Compressor (Cont’d)
4 CHECK ANY PART

Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of GI
lubricant leakage.)
Yes or No
MA
Yes 䊳 Refer to “Lubricant Adjusting Procedure for Components Replacement Except
Compressor”, HA-70.
No 䊳 Perform “PERFORMANCE TEST DIAGNOSES”, HA-56. EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-69
SERVICE PROCEDURE
Lubricant Adjusting Procedure for Components

Replacement Except Compressor =NEHA0095S0201
After replacing any of the following major components, add the
correct amount of lubricant to the system.
Amount of lubricant to be added
Lubricant to be added to
system
Part replaced Remarks
Amount of lubricant
m (US fl oz, Imp fl oz)
Evaporator 75 (2.5, 2.6) —
Condenser 75 (2.5, 2.6) —
Add if compressor is not

Liquid tank 5 (0.2, 0.2)
replaced. *1
In case of refrigerant 30 (1.0, 1.1) Large leak

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.
Lubricant Adjusting Procedure for Compressor

Replacement NEHA0095S0202
1) Before connecting ACR4 to vehicle, check ACR4 gauges. No
refrigerant pressure should be displayed, recover refrigerant
from equipment lines and then check refrigerant purity.
2) Confirm refrigerant purity in supply tank using ACR4 and refrig-
erant identifier.
3) Confirm refrigerant purity in vehicle A/C system using ACR4
and refrigerant identifier.
4) Discharge refrigerant into the refrigerant recovery/recycling
equipment. Measure lubricant discharged into the recovery/
recycling equipment.
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 installed equal to amount
drained from old compressor. Add this lubricant to new com-
pressor through the suction port opening.
8) Measure an amount of new lubricant equal to the amount
recovered during discharging. Add this lubricant to new com-
pressor through the suction port opening.
9) If the liquid tank also needs to be replaced, add an additional
5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubri-
cant if only replacing the compressor.
HA-70
SERVICE PROCEDURE
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
RHA065DD
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-71
SERVICE PROCEDURE
Compressor
Compressor
COMPRESSOR MOUNTING NEHA0096
LHA236
HA-72
SERVICE PROCEDURE
Compressor (Cont’d)
GI
MA
EM
LC
EC
FE
CL
MT
AT
LHA237
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-73
SERVICE PROCEDURE
Magnet Clutch
Magnet Clutch
MAGNET CLUTCH MOUNTING NEHA0098
AHA510A
HA-74
SERVICE PROCEDURE
GI
MA
EM
LC
EC
FE
CL
MT
AT
AHA507A
TF
PD
AX
REMOVAL
쐌 When removing center bolt, hold clutch disc with clutch disc
NEHA0280 SU
wrench.
BR
ST
RS
AHA841
쐌 Remove the drive plate using the clutch disc puller. BT

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 SC
plate, remove the shims from either the drive shaft or the drive
plate.
EL
AHA506A
IDX
HA-75
SERVICE PROCEDURE
쐌 Remove the snap ring using external snap ring pliers.
AHA843
쐌 For pulley removal use pulley puller.

Use a commercially available pulley puller. Position the center
of the puller on the end of the drive shaft. Remove the pulley
assembly with the puller.
For Pressed Pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked under (not into) the pulley
groove.
쐌 Remove the field coil harness clip using a screwdriver.
RHA139E
쐌 Remove the three field coil fixing screws and remove the field
coil.
RHA074C
INSPECTION NEHA0281
Clutch Disc NEHA0281S01
If the contact surface shows signs of damage due to excessive
heat, replace clutch disc and pulley.
Pulley NEHA0281S02
Check the appearance of the pulley assembly. If contact surface of
pulley shows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be
cleaned with a suitable solvent before reinstallation.
RHA075C
HA-76
SERVICE PROCEDURE
Coil NEHA0281S03
Check coil for loose connection or cracked insulation.
GI
MA
EM
LC
INSTALLATION NEHA0282
쐌 Install the field coil. EC
쐌 Be sure to align the coil’s pin with the hole in the com-
pressor’s front head.
쐌 Install the field coil harness clip using a screwdriver. FE
CL
RHA076C
MT
쐌 Install the pulley assembly using the installer and a hand
press, and then install the snap ring using snap ring pliers. AT
TF
PD
AX
AHA504A
쐌 Install the drive plate on the drive shaft, together with the
original shim(s). Press the drive plate down by hand. SU
BR
ST
RS
RHA078C
쐌 Using the holder to prevent drive plate rotation, tighten the bolt BT
to 12 to 15 N·m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque.
쐌 After tightening the bolt, check that the pulley rotates
smoothly.
SC
EL
AHA847
IDX
HA-77
SERVICE PROCEDURE
쐌 Check clearance all the way around the clutch disc.
Disc-to-pulley clearance:
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and recheck.
Break-in Operation NEHA0282S01
When replacing magnet 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-
mitted torque.
AHA505A
Thermal Protector
INSPECTION NEHA0284
쐌 When servicing, do not allow foreign matter to get into com-
pressor.
쐌 Check continuity between two terminals.
AHA849A
HA-78
SERVICE PROCEDURE
Refrigerant Lines
Refrigerant Lines
REMOVAL AND INSTALLATION NEHA0101
GI
MA
EM
LC
EC
FE
CL
MT
AT
TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
WHA286 IDX
HA-79
SERVICE PROCEDURE
Refrigerant Lines (Cont’d)
WHA287
HA-80
SERVICE PROCEDURE
Checking for Refrigerant Leaks
Checking for Refrigerant Leaks NEHA0296

PRELIMINARY CHECK
쐌
NEHA0296S01
Perform a visual inspection of all refrigeration parts, fittings,
GI
hoses and components for signs of A/C lubricant leakage,
damage and corrosion. A/C lubricant leakage may indicate an MA
area of refrigerant leakage. Allow extra inspection time in these
areas when using either an electronic refrigerant leak detector
or fluorescent dye leak detector. EM
쐌 If dye is observed, confirm the leak with an electronic refriger-
ant leak detector. It is possible a prior leak was repaired and
not properly cleaned. LC
쐌 When searching for leaks, do not stop when one leak is found
but continue to check for additional leaks at all system compo-
nents and connections. EC
쐌 When searching for refrigerant leaks using an electronic leak
detector, move the probe along the suspected leak area at 25
- 50 mm ( 1 - 2 in)/sec. and no further than 6 mm (1/4 in) from FE
the component.
NOTE: CL
Moving the electronic leak detector probe slower and closer to
the suspected leak area will improve the chances of finding a
leak. MT
Electronic Refrigerant Leak Detector NEHA0297
PRECAUTIONS FOR HANDLING LEAK DETECTORNEHA0297S01 AT
When performing a refrigerant leak check, use a J-41995 A/C leak
detector or equivalent. Ensure that the instrument is calibrated and TF
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 PD
specified maintenance.
쐌 Other gases in the work area or substances on the A/C
components, for example, anti-freeze, windshield washer AX
AHA535A fluid, solvents and lubricants, may falsely trigger the leak
detector. Make sure the surfaces to be checked are clean.
Clean with a dry cloth or blow off with shop air. SU
쐌 Do not allow the sensor tip of the detector to contact any
substance. This can also cause false readings and may
damage the detector. BR
ST
RS
1. Position probe approximately 5 mm (3/16 in) away from point BT

to be checked.
SC
EL
SHA707EA
IDX
HA-81
SERVICE PROCEDURE
Electronic Refrigerant Leak Detector (Cont’d)
2. When testing, circle each fitting completely with probe.
SHA706E
3. Move probe along component approximately 25 - 50 mm (1 -

2 in)/sec.
SHA708EA
CHECKING PROCEDURE NEHA0297S02

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 a calm area (low air/wind
movement) so that the leaking refrigerant is not dispersed.
1. Turn engine off.
2. Connect a suitable A/C manifold gauge set to the A/C service
ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52
kg/cm2, 50 psi) above 16°C (61°F). If less than specification,
recover/evacuate and recharge the system with the specified
amount of refrigerant. Refer to “HFC-134a (R-134a) Service
Procedure”, HA-66.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected
since the system may not reach 345 kPa (3.52 kg/cm2, 50 psi).
4. Conduct the leak test from the high side (compressor dis-
charge a to evaporator f) to the low side (evaporator drain hose
g to compressor suction k). Refer to “Refrigerant Lines”,
HA-79. Perform a leak check for the following areas carefully.
Clean the component to be checked and move the leak detec-
tor probe completely around the connection/component.
쐌 Compressor
Check the fitting of high and low pressure hoses, relief valve
and shaft seal.
쐌 Liquid tank
Check the pressure switch, tube fitting, weld seams and the
fusible plug mounts.
쐌 Service valves
Check all around the service valves. Ensure service valve caps
are secured on the service valves (to prevent leaks).
HA-82
SERVICE PROCEDURE
Electronic Refrigerant Leak Detector (Cont’d)
NOTE:
After removing A/C manifold gauge set from service valves, wipe
any residue from valves to prevent any false readings by leak GI
detector.
쐌 Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 MA
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) EM
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 LC
be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blow-
ing compressed air into area of suspected leak, then repeat EC
check as outlined above.
6. Do not stop when one leak is found. Continue to check for FE
additional leaks at all system components and connection.
If no leaks are found, perform steps 7 through 10.
7. Start engine. CL
8. Set the heater A/C control as follows:
a. A/C switch ON
b. Face mode
MT
c. Recirculation switch ON
d. Max cold temperature AT
e. Fan speed high
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps
TF
4 through 6 above.
PD
AX
Refrigerant leaks should be checked immediately after stop-
ping the engine. Begin with the leak detector at the compres- SU
sor. The pressure on the high pressure side will gradually
drop after refrigerant circulation stops and pressure on the
low pressure side will gradually rise, as shown in the graph. BR
Some leaks are more easily detected when pressure is high.
11. Before connecting ACR4 to vehicle, check ACR4 gauges. No ST
refrigerant pressure should be displayed. If pressure is
displayed, recover refrigerant from equipment lines and then
check refrigerant purity. RS
12. Confirm refrigerant purity in supply tank using ACR4 and refrig-
SHA839E
erant identifier. Refer to “Contaminated Refrigerant”, HA-3.
13. Confirm refrigerant purity in vehicle A/C system using ACR4 BT
and refrigerant identifier. Refer to “Contaminated Refrigerant”,
HA-3.
14. Discharge A/C system using approved refrigerant recovery
equipment. Refer to “Discharging Refrigerant”, HA-66. Repair
the leaking fitting or component as necessary.
15. Evacuate and recharge A/C system. Refer to “Evacuating Sys-
SC
tem and Charging Refrigerant”, HA-66. Perform the leak test
to confirm no refrigerant leaks. EL
16. Conduct A/C performance test to ensure system works
properly.
IDX
HA-83
SERVICE PROCEDURE
Fluorescent Dye Leak Detector
Fluorescent Dye Leak Detector NEHA0298

PRECAUTIONS FOR FLUORESCENT DYE LEAK
DETECTION NEHA0298S01
쐌 The fluorescent dye leak detector is not a replacement for an
electronic refrigerant leak detector. The fluorescent dye leak
detector should be used in conjunction with an electronic
refrigerant leak detector (J-41995) to pinpoint refrigerant leaks.
쐌 For your safety and your customer’s satisfaction, read and fol-
low all manufacturer’s operating instructions and precautions
prior to performing the work.
쐌 Refer to “Precautions for Leak Detection Dye”, HA-4.
CHECKING SYSTEM FOR LEAKS USING THE
FLUORESCENT LEAK DETECTOR NEHA0298S02
1. Check A/C system for leaks using the UV lamp and safety
glasses (J-42220) in a low sunlight area (area without windows
preferable). Illuminate all components, fittings and lines. The
dye will appear as a bright green/yellow area at the point of
leakage. Fluorescent dye observed at the evaporator drain
opening indicates an evaporator core assembly (tubes, core or
TXV) leak.
2. If the suspected area is difficult to see, use an adjustable mir-
ror or wipe the area with a clean shop rag or cloth, then check
the cloth with the UV lamp for dye residue.
3. Confirm any suspected leaks with an approved electronic
refrigerant leak detector.
4. After the leak is repaired, remove any residual dye using dye
cleaner (J-43872) to prevent future misdiagnosis.
5. Perform a system performance check and verify the leak repair
with an approved electronic refrigerant leak detector.
DYE INJECTION NEHA0298S03
(This procedure is only necessary when re-charging the system or
when the compressor has seized and was replaced.)
Refer to “Precautions for Leak Detection Dye”, HA-4.
1. Check A/C system static (at rest) Pressure. Pressure must be
at least 345 kPa (3.52 kg/cm2, 50 psi).
2. Pour one bottle (1/4 ounce /7.4 cc) of the A/C refrigerant dye
into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW PRESSURE side
service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one
bottle (1/4 ounce /7.4 cc) of fluorescent dye through the low-
pressure service valve using dye injector tool J-41459 (refer to
the manufacturer’s operating instructions).
6. With the engine still running, disconnect the injector tool from
the service fitting.
CAUTION:
Be careful not to allow dye to spray or drip when disconnect-
ing the injector from the system.
NOTE:
If repairing the A/C system or replacing a component, pour the
dye directly into the open system connection and proceed
with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix
HA-84
SERVICE PROCEDURE
Belt
the dye with the system oil. Depending on the leak size, oper-
ating conditions and location of the leak, it may take from min-
utes to days for the dye to penetrate a leak and become visible. GI
MA
EM
LC
Belt
TENSION ADJUSTMENT NEHA0103
EC
쐌 Refer to MA-16 (KA24DE models) or MA-25 (VG33E models
or VG33ER models), “Checking Drive Belts”.
FE
CL
MT
IACV-FICD Solenoid Valve
INSPECTION AT
NEHA0104
쐌 Refer to EC-609 (KA24DE models), EC-1210 (VG33E models) or
EC-1813 (VG33ER models), “Component Description”. TF
PD
AX
SU
BR
ST
RS
BT
SC
EL
IDX
HA-85
SERVICE PROCEDURE
Heater Core
Heater Core NEHA0171
AHA563A
REMOVAL NEHA0171S01
1. Drain cooling system. Refer to MA-17 (KA24DE models) or
MA-27 (VG33E and VG33ER models), “Changing Engine Cool-
ant”.
2. Disconnect the two heater hoses from the engine compartment
side.
3. Remove the cooling unit. Refer to “Evaporator Core”, HA-87.
4. Remove the steering member assembly. Refer to BT-20,
“Removal and Installation”.
5. Remove the heater unit.
6. Remove the heater core.
INSTALLATION NEHA0171S02
Installation is the reverse order of removal. Inspect system for
coolant leaks. Refer to MA-17 (KA24DE models) or MA-27 (VG33E
and VG33ER models), “Changing Engine Coolant”.
HA-86
SERVICE PROCEDURE
Evaporator Core
Evaporator Core NEHA0172
GI
MA
EM
LC
EC
FE
CL
AHA536A
MT
REMOVAL NEHA0172S01
1. Discharge the A/C system. Refer to “Discharging Refrigerant”, AT
HA-66.
2. Disconnect the two evaporator core refrigerant lines from the
engine compartment side. TF
쐌 Cap the refrigerant lines to prevent moisture from entering the
system.
PD
3. Remove the glove box and mating trim. Refer to BT-20,
“Removal and Installation”.
4. Disconnect the thermal amp. connector. AX
AHA557A 5. Remove the cooling unit.
6. Separate the cooling unit case, and remove the evaporator.
SU
BR
ST
RS
INSTALLATION NEHA0172S02
BT
Installation is the reverse order of removal.
Recharge the A/C system.
Inspect system for refrigerant leaks. Refer to “Checking for Refrig-
erant Leaks”, HA-81.
SC
EL
IDX
HA-87
SERVICE DATA AND SPECIFICATIONS (SDS)
Manual
Manual
GENERAL SPECIFICATIONS =NEHA0169
Compressor NEHA0169S01
Model DKV-14C
Type Vane rotary
Displacement
140 (8.54)
cm3 (cu in)/rev.
Direction of rotation Clockwise (Viewed from drive end)
Drive belt A type
Lubricant NEHA0169S02
ZEXEL make
Model
DKV-14C
Nissan A/C System Lubricant PAG

Name
Type R
Part No.* KLH00–PAGR0
Capacity Total in system 200 (6.8, 7.0)

m (US fl oz, Imp fl oz)
Compressor (Service Part) charg-
200 (6.8, 7.0)
ing amount
*: Always check with the Parts Department for the latest parts information.
Refrigerant NEHA0169S03
Type R-134a
kg (lb) 0.60 - 0.70 (1.32 - 1.54)

Capacity
g (oz) 600 - 700 (21.16 - 24.69)
INSPECTION AND ADJUSTMENT NEHA0170

Engine Idling Speed (When A/C is ON) NEHA0170S01
쐌 RefertoEC-59(KA24DEmodels),EC-662(VG33Emodels)orEC-1262(VG33ERmodels),“IdleSpeed/Ignition
Timing/Idle Mixture Ratio Adjustment”.
Belt Tension NEHA0170S02
쐌 Refer to MA-16 (KA24DE models) or MA-25 (VG33E models or VG33ER models), “Checking Drive Belts”.
Magnet Clutch NEHA0170S03
Model DKV-14C
Clutch disc-pulley clearance

0.3 - 0.6 (0.012 - 0.024)
mm (in)
HA-88

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HEATER &

PRECAUTIONS ...............................................................2 Symptom Table ..........................................................28

Supplemental Restraint System (SRS) “AIR

Precautions for Working with HFC-134a

A/C Identification Label NEHA0293

Precautions for Refrigerant Connection NEHA0063

O-RING AND REFRIGERANT CONNECTION =NEHA0063S02

VG33E and VG33ER Models NEHA0063S0202

O-Ring Part Numbers and Specifications =NEHA0063S0201

New 92471 N8210 6.8 (0.268) 1.85 (0.0728)

Precautions for Servicing Compressor NEHA0064

Precautions for Service Equipment NEHA0065

SERVICE COUPLERS NEHA0065S06

CALIBRATING ACR4 WEIGHT SCALE NEHA0065S10

CHARGING CYLINDER NEHA0065S08

THERMOMETER AND HYGROMETER NEHA0065S09

Wiring Diagrams and Trouble Diagnosis NEHA0066

Special Service Tools =NEHA0286

KV99231260 Removing shaft nut and clutch disc

KV99232340 Removing clutch disc

KV99234330 Installing pulley

KV99233130 Removing pulley

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

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

(J-39500-NI) Function: Refrigerant Recovery and Recycling and PD

(J-43926) Power supply:

(J-42220) Power supply: DC 12V (Battery terminal)

(J-41447) Dye Application: For R-134a PAG oil

(J-43872) For cleaning dye spills.

Service couplers Hose fitting to service hose:

Commercial Service Tool =NEHA0067

Tool name Description Note

Refrigerant Identifier Checking refrigerant purity and for system contami-

Control Operation NEHA0072

FAN CONTROL KNOB NEHA0072S01

Discharge Air Flow NEHA0073

Component Layout NEHA0272

Component Location NEHA0085

ENGINE COMPARTMENT NEHA0085S05

ENGINE COMPARTMENT NEHA0085S06

PASSENGER COMPARTMENT NEHA0085S02

Wiring Diagram — Heater — NEHA0288

Wiring Diagram — A/C — NEHA0274

How to Perform Trouble Diagnoses for Quick

*1: HA-29 *2: HA-28

Symptom Table NEHA0235

Symptom Reference page

쐌 Blower motor does not rotate. 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

쐌 Insufficient cooling 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

쐌 Insufficient heating 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

쐌 Noise 쐌 Go to “TROUBLE DIAGNOSIS PROCEDURE FOR

Operational Check =NEHA0076

2. Check Discharge Air NEHA0076S0202

4. Check Temperature Decrease NEHA0076S0204

5. Check Temperature Increase NEHA0076S0205

6. Check A/C Switch NEHA0076S0206

BLOWER MOTOR CIRCUIT =NEHA0089

3 CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

Does battery voltage exist?

1: HA-29 2: HA-28

1: HA-19 3: HA-29 *4: HA-28

1: HA-42 2: HA-29 *3: HA-28

1: HA-76 4: HA-29 MA-25 (VG33E and VG33ER BR

1: HA-38 6: HA-72 EC-1072 (VG33E models with

1: HA-58 2: HA-58 *3: HA-59

1: HA-43 2: MA-16 (KA24DE models) or models)