Heater & Air Conditioner

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HEATER &

AIR CONDITIONER GI

SECTION HA MA

EM

LC

EC

CONTENTS FE

PRECAUTIONS AND PREPARATION............................2 Trouble Diagnoses for Abnormal Pressure ...............29 CL


Supplemental Restraint System (SRS) ″AIR Harness Layout..........................................................32
BAG″ (4WD models) ...................................................2 Wiring Diagram - HEATER -......................................33
Supplemental Restraint System (SRS) ″AIR Circuit Diagram - Air Conditioner...............................35
MT
BAG″ (2WD models) ...................................................2 Wiring Diagram - A/C - ..............................................36
Precautions for Working with HFC-134a (R-134a) .....3 Main Power Supply and Ground Circuit Check ........43 TF
General Refrigerant Precautions .................................3 Diagnostic Procedure 1 .............................................44
Precautions for Refrigerant Connection ......................3 Diagnostic Procedure 2 .............................................46
Precautions for Servicing Compressor........................7 Electrical Components Inspection .............................50 PD
Special Service Tools ..................................................7 Control Linkage Adjustment.......................................52
HFC-134a (R-134a) Service Tools and SERVICE PROCEDURES .............................................55
Equipment....................................................................9 HFC-134a (R-134a) Service Procedure ....................55 FA
Precautions for Service Equipment ...........................11 Maintenance of Lubricant Quantity in
DESCRIPTION ...............................................................13 Compressor ...............................................................57
RA
Refrigeration Cycle ....................................................13 Refrigerant Lines .......................................................59
Component Layout ....................................................14 Checking Refrigerant Leaks ......................................64
Discharge Air Flow.....................................................15 Compressor Mounting ...............................................66 BR
Control Operation ......................................................17 Compressor - DKV-14C (ZEXEL make) ....................69
TROUBLE DIAGNOSES ...............................................18 Compressor Clutch - DKV-14C (ZEXEL make).........69
How to Perform Trouble Diagnoses for Quick Thermal Protector - DKV-14C (ZEXEL make)...........72 ST
and Accurate Repair ..................................................18 Compressor - DKS-17CH (ZEXEL make) .................73
Operational Check .....................................................19 Compressor Clutch - DKS-17CH (ZEXEL make)......73
Symptom Chart..........................................................21 SERVICE DATA AND SPECIFICATIONS (SDS) ..........76
RS
Preliminary Check......................................................22 General Specifications...............................................76
Performance Test Diagnoses ....................................25 Inspection and Adjustment ........................................76 BT
Performance Chart ....................................................27

When you read wiring diagrams: EL


I Read GI section, “HOW TO READ WIRING DIAGRAMS”.
I See EL section, “POWER SUPPLY ROUTING” for power distribution circuit.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW IDX
CHART IN TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS
FOR AN ELECTRICAL INCIDENT”.
PRECAUTIONS AND PREPARATION

Supplemental Restraint System (SRS) “AIR


BAG” (4WD models)
The Supplemental Restraint System “Air Bag”, used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag module
(located in the center of the steering wheel), diagnosis sensor unit, warning lamp, wiring harness and spiral
cable. Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
I 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
harness connectors or for the complete harness, for easy identification.

Supplemental Restraint System (SRS) “AIR


BAG” (2WD models)
The Supplemental Restraint System “Air Bag”, used along with a seat belt, helps to reduce the risk or sever-
ity of injury to the driver in a frontal collision. The Supplemental Restraint System consists of air bag module
(located in the center of the steering wheel), diagnosis sensor unit, warning lamp and spiral cable. Informa-
tion necessary to service the system safely is included in the RS section of this Service Manual.
WARNING:
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system.
I Do not use electrical test equipment on any circuit related to the SRS.

HA-2
PRECAUTIONS AND PREPARATION

Precautions for Working with HFC-134a


(R-134a)
GI
WARNING:
I CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refriger-
ants must never be mixed, even in the smallest amounts. If the refrigerants are mixed, compres- MA
sor failure is likely to occur.
I Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) com-
ponents. If lubricant other than that specified is used, compressor failure is likely to occur. EM
I The specified HFC-134a (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
LC
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
EC
as possible to minimize the entry of moisture into system.
c: Only use the specified lubricant from a sealed container. Immediately reseal containers of FE
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 CL
and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a)
refrigerant. If accidental system discharge occurs, ventilate work area before resuming ser-
vice. Additional health and safety information may be obtained from refrigerant and lubricant MT
manufacturers.
e: Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam
parts. Damage may result. TF

General Refrigerant Precautions PD


WARNING:
I Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged. FA
I Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
I Do not store or heat refrigerant containers above 52°C (125°F). RA
I 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.
I Do not intentionally drop, puncture, or incinerate refrigerant containers. BR
I Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
I Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent ST
suffocation.
I Do not introduce compressed air to any refrigerant container or refrigerant component.
RS
Precautions for Refrigerant Connection
A new type refrigerant connection has been introduced to all refrigerant lines except the following location. BT
I Expansion valve to cooling unit
I Condenser to liquid tank

FEATURES OF NEW TYPE REFRIGERANT CONNECTION


I The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of EL
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
I The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby IDX
facilitating piping connections.

HA-3
PRECAUTIONS AND PREPARATION
Precautions for Refrigerant Connection
(Cont’d)

SHA815E

CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse
O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-ring part numbers and specifications
Connection O-ring
Part number D mm (in) W mm (in)
type size
New 92471 N8210 6.8 (0.268) 1.87 (0.0736)
8
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
New 92472 N8210 10.9 (0.429) 2.43 (0.0957)
12
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New 92473 N8210 13.6 (0.535) 2.43 (0.0957)
16
SHA814E Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New 92474 N8210 16.5 (0.650) 2.43 (0.0957)
19
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)

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

EM

LC

EC

FE

CL

MT

RHA341G TF

RHD models PD

FA

RA

BR

ST

RS

BT

RHA342G
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.
I 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.
I When connecting tubes, always use a torque wrench and a back-up wrench.
I After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
I 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.
I 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.
I Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
I Always replace used O-rings.
I When connecting tube, apply lubricant to portions shown in illustration. Be careful not to apply
lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type R (Except for the Middle East)
Nissan A/C System Oil Type S (For the Middle East)
Part number: KLH00-PAGR0 (Except for the Middle East)
KLH00-PAGS0 (For the Middle East)
I O-ring must be closely attached to inflated portion of tube.
I After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
I After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.

RHA861F

HA-6
PRECAUTIONS AND PREPARATION

Precautions for Servicing Compressor


I Plug all openings to prevent moisture and foreign matter from entering. GI
I When the compressor is removed, store it in the same position as it is when mounted on the car.
I When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to HA-57. MA
I 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.
I After compressor service operation, turn the compressor shaft by hand more than five turns in EM
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.
I After replacing the compressor magnet clutch, apply voltage to the new one and check for normal LC
operation.

Special Service Tools EC


FOR DKV-14C COMPRESSOR
FE
Tool number
Description
Tool name
KV99231260 Removing shaft nut and clutch disc
CL
Clutch disc wrench
MT

TF
NT204

KV99232340 Removing clutch disc


Clutch disc puller PD

FA
NT206

KV99234330 Installing pulley


RA
Pulley installer
BR

ST
NT207

KV99233130 Removing pulley


Center pulley puller RS

BT
NT208

EL

IDX

HA-7
PRECAUTIONS AND PREPARATION
Special Service Tools (Cont’d)
FOR DKS-17CH COMPRESSOR
Tool number
Description
Tool name
KV99232022 Removing clutch disc
Clutch disc puller

NT210

KV99231010 Removing shaft nut and clutch disc


Clutch disc wrench

NT205

KV99233040 Removing pulley


Puller pilot

NT213

KV99234160 Installing pulley


Pulley installer

NT209

KV99235160 Removing lock nut


Nut wrench

NT677

HA-8
PRECAUTIONS AND PREPARATION

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


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

NT196
CL
Nissan A/C System Oil Type: Poly alkylene glycol oil (PAG), type R
Type R Application: HFC-134a (R-134a) vane rotary
compressors (Nissan only) MT
Lubricity: 40 m (1.4 Imp fl oz)
Nissan A/C System Oil Type: Poly alkylene glycol oil (PAG), type S
Type S Application: HFC-134a (R-134a) swash plate TF
NT197
(piston) compressors (Nissan only)
Lubricity: 40 m (1.4 Imp fl oz)
PD
Recovery/Recycling/ Function: Refrigerant Recovery and Recycling
Recharging equipment and Recharging
FA

RA

BR
NT195

Electrical leak detector Power supply:


I DC 12 V (Cigarette lighter) ST

RS

BT
NT198

Manifold gauge set (with Identification:


hoses and couplers) I The gauge face indicates R-134a.
Fitting size: Thread size
I 1/2″-16 ACME EL

IDX

NT199

HA-9
PRECAUTIONS AND PREPARATION
HFC-134a (R-134a) Service Tools and
Equipment (Cont’d)
Tool name Description Note
Service hoses Hose color:
I High side hose I Low hose: Blue with black stripe
I Low side hose I High hose: Red with black stripe
I Utility hose I Utility hose: Yellow with black stripe or green
with black stripe
Hose fitting to gauge:
I 1/2″-16 ACME

NT201

Service couplers Hose fitting to service hose:


I High side coupler I M14 x 1.5 fitting is optional or
I Low side coupler permanently attached.

NT202

Refrigerant weight scale For measuring of refrigerant


Fitting size: Thread size
I 1/2″-16 ACME

NT200

Vacuum pump Capacity:


(Including the isolator I Air displacement: 4 CFM
valve) I Micron rating: 20 microns
I Oil capacity: 482 g (17 oz)
Fitting size: Thread size
I 1/2″-16 ACME

NT203

HA-10
PRECAUTIONS AND PREPARATION

Precautions for Service Equipment


RECOVERY/RECYCLING EQUIPMENT GI
Be certain to follow the manufacturers instructions for machine
operation and machine maintenance. Never introduce any refriger-
ant other than that specified into the machine. MA
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester opera-
EM
tion and tester maintenance.
LC
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible EC
with the specified lubricant for HFC-134a (R-134a) A/C systems.
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 FE
switched off after evacuation (vacuuming) and hose is connected
to it.
To prevent this migration, use a manual valve placed near the CL
hose-to-pump connection, as follows.
I Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the MT
pump.
I For pumps without an isolator, use a hose equipped with a
manual shut-off valve near the pump end. Close the valve to TF
isolate the hose from the pump.
I If the hose has an automatic shut off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is PD
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump’s FA
ability to pull a deep vacuum and are not recommended.

RHA270D
RA
MANIFOLD GAUGE SET
Be certain that the gauge face indicates R-134a or 134a. Be sure
BR
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) and specified lubricants.
ST

RS

BT
SHA533D

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

IDX

RHA272D

HA-11
PRECAUTIONS AND PREPARATION
Precautions for Service Equipment (Cont’d)
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
will not properly connect to the CFC-12 (R-12) system. However, if
an improper connection is attempted, discharging and contamina-
tion may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
RHA273D

REFRIGERANT WEIGHT SCALE


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

RHA274D

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

HA-12
DESCRIPTION

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

FREEZE PROTECTION 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- LC
sor operation. When the evaporator coil temperature rises above the specification, the thermo control ampli-
fier allows compressor operation.
EC
REFRIGERANT SYSTEM PROTECTION
Triple-pressure switch
FE
The triple-pressure switch is located on the liquid tank. If the system pressure rises or falls out of specifications,
the switch opens to interrupt compressor clutch operation.
CL
Fusible plug
Open at temperature above 105°C (221°F), thereby discharging refrigerant to the atmosphere. If this plug is
melted and opened, check the refrigerant line and replace liquid tank. MT

TF

PD

FA

RA

BR

ST

RS

BT

SHA504DB
EL

IDX

HA-13
DESCRIPTION

Component Layout

RHA343G

HA-14
DESCRIPTION

Discharge Air Flow


LHD MODELS GI

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

RHA344G

HA-15
DESCRIPTION
Discharge Air Flow (Cont’d)
RHD MODELS

RHA358G

HA-16
DESCRIPTION

Control Operation
GI

MA

EM

LC
RHA345G

EC
FAN CONTROL LEVER
This lever turns the fan ON and OFF, and controls fan speed.
FE
MODE CONTROL LEVER
This lever controls the outlet air flow.
CL
TEMPERATURE CONTROL LEVER
This lever allows adjustment of the temperature of the outlet air. MT
RECIRCULATION CONTROL LEVER
FRESH position: TF
Outside air is drawn into the passenger compartment.
Recirculation (REC) position:
Interior air is recirculated inside the vehicle. PD

AIR CONDITIONER SWITCH


FA
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. RA

BR

ST

RS

BT

EL

IDX

HA-17
TROUBLE DIAGNOSES

How to Perform Trouble Diagnoses for Quick


and Accurate Repair

WORK FLOW
CHECK IN Reference item

H
LISTEN TO CUSTOMER COMPLAINT AND CON- ............ Operational Check
FIRM BY PERFORMING OPERATIONAL CHECK. Refer to HA-19.

H
INVESTIGATE ITEMS YOU SHOULD CARRY OUT ............ Symptom Chart
RELATED TO EACH SYMPTOM. Refer to HA-21.

E ELIMINATE GOOD SYSTEM(S)/PART(S). ............ Preliminary Check


Refer to HA-22.

H
CHECK MAIN POWER SUPPLY AND GROUND CIR- ............ Main Power Supply and
CUITS. Ground Circuit Check
Refer to HA-43.

H
I Diagnostic Proce- ............ ELIMINATE GOOD PART(S)/HARNESS(ES)/ ............ Harness Layout
dure(s) CONNECTOR(S) ELECTRICALLY. Refer to HA-32.
Refer to HA-44.
I Circuit Diagram Malfunctioning
Refer to HA-35. part(s)

H
Malfunctioning INSPECT EACH ............ Electrical Components
harness(es)/ COMPONENT. Inspection
connector(s) Refer to HA-50.

H H
REPAIR. REPAIR/REPLACE.

H H
FINAL CHECK
NG
OK
H
CHECK OUT

HA-18
TROUBLE DIAGNOSES

Operational Check
The purpose of the operational check is to confirm that the system
operates properly. GI

CONDITIONS: MA
I Engine running at normal operating temperature.

EM

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

RHA346G MT
2. Check discharge air
a. Slide mode control lever to position. TF
b. Confirm that all discharge air comes out of face vents.
c. Slide mode control lever to position.
d. Confirm that discharge air comes out of face vents and foot PD
vents.
e. Slide mode control lever to position.
f. Confirm that discharge air comes out of foot vents, with some FA
air from defrost vents.
g. Slide mode control lever to position.
RHA347G
h. Confirm that discharge air comes out of foot vents with some RA
air from defrost vents.
i. Slide mode control lever to position.
j. Confirm that all discharge air comes out of defrost vents. BR

ST

RS

BT

3. Check recirculation
a. Slide recirculation control lever to the REC position.
b. Listen for intake door position change (you should hear blower
sound change slightly). EL

IDX

RHA348G

HA-19
TROUBLE DIAGNOSES
Operational Check (Cont’d)
4. Check temperature decrease
a. Slide temperature control lever to full cold.
b. Check for cold air at discharge air outlets.

RHA349G

5. Check temperature increase


a. Slide temperature control lever to full hot.
b. Check for hot air at discharge air outlets.

RHA350G

6. Check A/C switch


Move fan control lever to the desired position (1 to 4) and press air
conditioner switch to turn ON air conditioner.
Indicator light will come on when air conditioner is ON.

RHA351G

HA-20
TROUBLE DIAGNOSES

Symptom Chart
DIAGNOSTIC TABLE GI
Main
Power
Supply
MA
Preliminary Diagnostic
PROCEDURE and Electrical Components Inspection
Check Procedure
Ground
Circuit
EM
Check
HA-22 LC
HA-23

HA-24

HA-44

HA-46

HA-43

HA-50

HA-50

HA-50

HA-50

HA-51

HA-51

HA-51

HA-69

HA-52
REFERENCE PAGE


EC

Compressor
15A Fuses (No. 19 and 20 )
Diagnostic procedure 1 FE
Diagnostic procedure 2

Triple-pressure switch
Thermo control amp.
7.5A Fuse (No. 21 )
Preliminary check 1

Preliminary check 2

Preliminary check 3

Thermal protector
CL

Blower resistor

Magnet clutch
Blower motor
SYMPTOM

Fan switch
A/C switch

A/C relay

Harness
MT

A/C does not blow cold air. q q q q q q q q q q q q q TF


Blower motor does not rotate. q q q q q q
Magnet clutch does not
PD
engage when A/C switch and q q q q q q q q q
fan switch are ON.
Noise. FA
Insufficient heating. q q

, : The number means checking order. RA


q: Checking order depends on malfunction in flow chart.

BR

ST

RS

BT

EL

IDX

HA-21
TROUBLE DIAGNOSES

Preliminary Check
PRELIMINARY CHECK 1
A/C does not blow cold air.
DOES AIR FLOW FROM VENTS? No IS BLOWER MOTOR OPERATING
E
Condition: NORMALLY?
I Engine running at operating tem-
perature. Yes No
I Ignition switch, A/C switch, and fan H
switch are ON. CHECK BLOWER
I Mode control lever is in FACE posi- MOTOR OPERATION.
tion and temperature control lever Go to Diagnostic Pro-
is in full cold position. cedure 1, HA-44.
Yes
H H
CHECK COMPRESSOR BELT TEN- F NG CHECK COMPRESSOR OPERA- CHECK FOR EVAPORATOR COIL
SION. TION. FREEZE UP.
Refer to MA section (“Checking Drive Remove intake unit. Check if evapo-
Belts”, “ENGINE MAINTENANCE”). OK rator freezes.
NG OK NG OK
H H
(Freezes up.) (Does not
Adjust or replace com- CHECK REFRIGERATION CYCLE freeze up.)
pressor belt. PRESSURE WITH MANIFOLD
GAUGE CONNECTED.
Refer to Performance Chart, HA-27.
NG OK
H H
CHECK REFRIGERANT. CHECK VENTILATOR
Connect manifold gauge then check DUCT FOR AIR
system pressure. LEAKS.
Refer to “Performance Chart”,
H H
HA-27.
Go to Performance CHECK THERMO CONTROL AMP.
OK NG Test Diagnoses, OPERATION.
HA-25. Refer to “Electrical Components
Inspection”, HA-51.
H H
CHECK FOR REFRIG- CHECK WATER COCK OPERA- NG Adjust or replace water cock.
E
ERANT LEAKS. TION.
Except for RHD models
Warm up engine before checking.
Refer to “Control Linkage
Adjustment”, HA-53.
OK
H H
Go to Diagnostic Procedure 2, CHECK TEMPERATURE CONTROL NG Adjust temperature control cable.
E
HA-46. CABLE.
Refer to “Control Linkage
Adjustment”, HA-54.
OK
H
VISUALLY INSPECT AIR MIX DOOR. NG Replace air mix door.
E
Access by removing instrument
panel.
OK
H
CHECK THERMO CONTROL AMP.
OPERATION.
Refer to “Electrical Components
Inspection”, HA-51.

HA-22
TROUBLE DIAGNOSES
Preliminary Check (Cont’d)
PRELIMINARY CHECK 2
Noise
GI
CHECK WHERE NOISE COMES FROM.

MA
H H H H H
Blower motor Compressor Expansion valve Refrigerant line Belt EM

LC
H H H
CHECK FOR Inspect the com- Replace expan-
NOISE IN ALL pressor clutch and sion valve. EC
MODES AND pulley and idler
TEMPERATURE pulley.
SETTINGS.
OK NG FE
Noise is
constant
H H H H CL
CHECK Replace com- Line is fixed Line is not fixed.
BLOWER pressor clutch directly to body.
MOTOR AND and pulley.
FAN FOR Refer to
MT
WEAR. HA-69 or 73.

OK NG TF
H H H H
Replace CHECK DISC-TO- Fix line with Fix line tightly. PD
blower PULLEY CLEAR- rubber or vibra-
motor or ANCE. tion absorbing
fan. Refer to HA-71 or material.
75. FA
OK

H H RA
CHECK CHECK AND
BLOWER ADJUST COM-
MOTOR FOR PRESSOR BR
FOREIGN PAR- LUBRICANT.
TICLES. Refer to HA-57.

NG OK ST
H H H H
Remove foreign Replace compres- Belt vibration is Side of belt is
particles from sor and liquid intense. worn out. RS
intake unit. tank.

Noise is H H BT
intermittent Readjust belt Pulley center
H tension. does not match.
CHECK AIR DIS- Refer to MA Readjust pulley
CHARGE DUCTS section center.
FOR OBSTRUC- (“Checking Refer to HA-70 or
TIONS, FOREIGN Drive Belts”, 74.
MATERIALS OR “ENGINE EL
AIR LEAKAGE. MAINTE-
NANCE”).
NG
H
IDX
Remove obstruc-
tions or repair air
leakage.

HA-23
TROUBLE DIAGNOSES
Preliminary Check (Cont’d)
PRELIMINARY CHECK 3
Insufficient heating
DOES AIR FLOW FROM FOOT AREA?
Condition:
I Vehicle at operating temperature. CHECK BLOWER MOTOR
I Ignition switch and fan switch are ON. No OPERATION.
I Mode control lever is in FOOT position and tem- E Go to Diagnostic Procedure

perature control lever is in full hot position. 1, HA-44.

Yes
H
Check the following:
I Engine coolant level. Refer to MA section.
I Hoses for leaks or kinks.
I Radiator cap. Refer to LC section (“ENGINE NG
E Repair/replace as necessary.
COOLING SYSTEM”).
I Air in cooling system.

OK
H
CHECK WATER COCK OPERATION.
Except for RHD models NG
Warm up engine before checking. E Adjust or replace water cock.
Refer to “Control Linkage Adjustment”, HA-53.

OK
H
CHECK TEMPERATURE CONTROL CABLE. NG
E Adjust temperature control
Refer to “Control Linkage Adjustment”, HA-54.
cable.
OK
H
VISUALLY INSPECT AIR MIX DOOR. NG
Access by removing instrument panel. E Replace air mix door.

OK
H
CHECK BY FEEL HEATER INLET AND OUTLET
HOSES.

Both hoses Both hoses


cold warm

H H
CHECK THERMOSTAT CHECK HEATER HOSES FOR
INSTALLATION. PROPER INSTALLATION.

OK OK

H H

Replace thermostat. Refer Back flush heater core, drain and refill coolant.
to LC section (“Thermostat”, Retest.
“ENGINE COOLING SYS-
Hot inlet Both hoses
TEM”).
Warm outlet warm

H
H
Replace heater
System OK
core.

HA-24
TROUBLE DIAGNOSES

Performance Test Diagnoses


INSUFFICIENT COOLING GI

INSUFFICIENT COOLING MA
H
CHECK AIR FLOW.
NG
E CHECK BLOWER MOTOR OPERATION. EM
OK OK H NG
H H
q
A LC
CHECK COMPRESSOR OPERATION. Clogged blower inlet/Clogged (Go to
duct/Loose duct connection/ next
OK NG Air leakage, etc. page.) EC
H
qB
(Go to
next page.) FE
H
OK
CHECK HIGH AND LOW-SIDE PRESSURE. USE
PERFORMANCE CHART. Refer to HA-27. CL
NG
H
RECOVER REFRIGERANT USING RECOVERY MT
RECYCLING EQUIPMENT AND CHARGE
SPECIFIED AMOUNT OF REFRIGERANT.
TF
H Note
NG
CHECK HIGH AND LOW-SIDE PRESSURE. USE E E
PERFORMANCE CHART. Refer to HA-27. BOTH HIGH AND LOW- PD
PRESSURE SIDES ARE
OK TOO HIGH.
H FA
CHECK DISCHARGE AIR TEMPERATURE. USE HIGH-PRESSURE SIDE E
E PERFORMANCE CHART. Refer to HA-27. IS TOO HIGH AND LOW-

NG OK
PRESSURE SIDE IS TOO RA
LOW.
H
END HIGH-PRESSURE SIDE E
BR
IS TOO LOW AND LOW-
PRESSURE SIDE IS TOO
HIGH.
ST
H
Malfunctioning temperature control operation (air BOTH HIGH AND LOW- E
mix door position improperly adjusted)/ PRESSURE SIDES ARE RS
Malfunctioning water cock operation (incorrect TOO LOW.
valve closure)

LOW-PRESSURE SIDE E
BT
SOMETIMES BECOMES
NEGATIVE.

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


ABNORMAL PRESSURE. BECOMES NEGATIVE.
Refer to HA-29. EL

IDX

HA-25
TROUBLE DIAGNOSES
Performance Test Diagnoses (Cont’d)
q
A

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

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

q
B

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

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

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

H
CHECK ACTIVATION OF SAFETY/ Foreign particles on clutch frictional
E
PROTECTION DEVICES. Inspect surface or excessive disc clear-
devices such as pressure switch, ance.
etc.

Malfunctioning electrical circuit


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

HA-26
TROUBLE DIAGNOSES

Performance Chart
TEST CONDITION GI
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well-ventilated place)
Doors: Closed MA
Door window: Open
Hood: Open
TEMP. setting: Max. COLD EM
Discharge Air: FACE VENT
INTAKE lever position: (Recirculation)
FAN speed: 4-speed LC
Engine speed: 1,500 rpm
Operate the air conditioner system for 10 minutes before taking measurements.
EC
TEST READING
Recirculating-to-discharge air temperature table FE
Inside air (Recirculating air)
Discharge air temperature at center ven-
Models
at blower assembly inlet
tilator
CL
Relative humidity Air temperature °C (°F)
% °C (°F)
20 (68) 6.6 - 9.4 (44 - 49)
MT
25 (77) 9.6 - 11.8 (49 - 53)
50 - 60 30 (86) 13.5 - 16.5 (56 - 62) TF
35 (95) 17.5 - 21.2 (64 - 70)

Except for the Middle 40 (104) 21.4 - 25.9 (71 - 79) PD


East 20 (68) 9.4 - 11.2 (49 - 52)
25 (77) 11.8 - 14.1 (53 - 57) FA
60 - 70 30 (86) 16.5 - 19.5 (62 - 67)
35 (95) 21.2 - 24.9 (70 - 77) RA
40 (104) 25.9 - 30.3 (79 - 87)
25 (77) 9.7 - 11.6 (49 - 53)
BR
30 (86) 14.4 - 16.4 (58 - 62)
50 - 60 35 (95) 19.1 - 21.2 (66 - 70)
ST
40 (104) 23.7 - 26.0 (75 - 79)
45 (113) 28.4 - 30.8 (83 - 87)
For the Middle East
25 (77) 11.6 - 13.5 (53 - 56)
RS
30 (86) 16.4 - 18.5 (62 - 65)
60 - 70 35 (95) 21.2 - 23.4 (70 - 74) BT
40 (104) 26.0 - 28.4 (79 - 83)
45 (113) 30.8 - 33.4 (87 - 92)

EL

IDX

HA-27
TROUBLE DIAGNOSES
Performance Chart (Cont’d)
Ambient air temperature-to-operating pressure table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Models Relative humidity Air temperature kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
% °C (°F)
971 - 1,187 (9.71 - 11.87, 59 - 69 (0.59 - 0.69,
20 (68)
9.9 - 12.1, 141 - 172) 0.6 - 0.7, 9 - 10)
991 - 1,206 (9.91 - 12.06, 69 - 78 (0.69 - 0.78,
25 (77)
10.1 - 12.3, 144 - 175) 0.7 - 0.8, 10 - 11)
Except for the 1,187 - 1,442 (11.87 - 14.42, 88 - 108 (0.88 - 1.08,
50 - 70 30 (86)
Middle East 12.1 - 14.7, 172 - 209) 0.9 - 1.1, 13 - 16)
1,402 - 1,716 (14.02 - 17.16, 108 - 127 (1.08 - 1.27,
35 (95)
14.3 - 17.5, 203 - 249) 1.1 - 1.3, 16 - 18)
1,628 - 1,981 (16.28 - 19.81, 127 - 157 (1.27 - 1.57,
40 (104)
16.6 - 20.2, 236 - 287) 1.3 - 1.6, 18 - 23)
951 - 1,157 (9.51 - 11.57, 69 - 88 (0.69 - 0.88,
25 (77)
9.7 - 11.8, 138 - 168) 0.7 - 0.9, 10 - 13)
1,138 - 1,393 (11.38 - 13.93, 88 - 108 (0.88 - 1.08,
30 (86)
11.6 - 14.2, 165 - 202) 0.9 - 1.1, 13 - 16)
For the Middle 1,324 - 1,618 (13.24 - 16.18 98 - 127 (0.98 - 1.27,
50 - 70 35 (95)
East 13.5 - 16.5, 192 - 235) 1.0 - 1.3, 14 - 18)
1,510 - 1,844 (15.10 - 18.44, 118 - 147 (1.18 - 1.47,
40 (104)
15.4 - 18.8, 219 - 267) 1.2 - 1.5, 17 - 21)
1,697 - 2,079 (16.97 - 20.79, 137 - 167 (1.37 - 1.67,
45 (113)
17.3 - 21.2, 246 - 301) 1.4 - 1.7, 20 - 24)

HA-28
TROUBLE DIAGNOSES

Trouble Diagnoses for Abnormal Pressure


Whenever system’s high or low-pressure side is abnormal, diagnose using a manifold gauge. The marker GI
above the gauge scale in the following table indicates the standard (normal) pressure range. Since the stan-
dard (normal) pressure differs from vehicle to vehicle, refer to HA-28 (“Ambient air temperature-to-operating
pressure table”). MA
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high and low-pressure I Pressure is reduced soon Excessive refrigerant charge in Reduce refrigerant until speci- EM
sides are too high. after water is splashed on refrigeration cycle. fied pressure is obtained.
condenser.
LC
Air suction by cooling fan is Insufficient condenser cooling I Clean condenser.
insufficient. performance. I Check and repair cooling fan
" as necessary. EC
q1 Condenser fins are clogged.
q2 Improper fan rotation of
cooling fan. FE
I Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and
cold. denser. recharge system.
I When compressor is stopped (After compressor operation
CL
high-pressure value quickly stops, high pressure decreases
drops by approximately 196 too slowly.)
AC359A kPa (2.0 bar, 2 kg/cm2, 28 "
MT
psi). It then decreases gradu- Air in refrigeration cycle.
ally thereafter.
TF
Engine tends to overheat. Engine cooling systems mal- Check and repair each engine
function. cooling system.
I An area of the low-pressure I Excessive liquid refrigerant Replace expansion valve. PD
pipe is colder than areas on low-pressure side.
near the evaporator outlet. I Excessive refrigerant dis-
I Plates are sometimes cov- charge flow. FA
ered with frost. I Expansion valve is open a
little compared with the
specification. RA
"
q1 Improper thermal valve
installation. BR
q2 Improper expansion valve
adjustment.
High-pressure side is too high Upper side of condenser and High-pressure tube or parts I Check and repair or replace ST
and low-pressure side is too high-pressure side are hot, located between compressor malfunctioning parts.
low. however, liquid tank is not so and condenser are clogged or I Check lubricant for contami-
hot. crushed. nation. RS

BT

EL

IDX
AC360A

HA-29
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont’d)
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low High and low-pressure sides Compressor pressure operation Replace compressor.
and low-pressure side is too become equal soon after com- is improper.
high. pressor operation stops. "
Damaged inside compressor
packings.

No temperature difference Compressor pressure operation Replace compressor.


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

AC356A
Both high and low-pressure I There is a big temperature Liquid tank inside is clogged a I Replace liquid tank.
sides are too low. difference between receiver little. I Check lubricant for contami-
drier outlet and inlet. Outlet nation.
temperature is extremely low.
I Liquid tank inlet and expan-
sion valve are frosted.
I Temperature of expansion High-pressure pipe located I Check and repair malfunc-
valve inlet is extremely low between liquid tank and expan- tioning parts.
as compared with areas near sion valve is clogged. I Check lubricant for contami-
liquid tank. nation.
I Expansion valve inlet may be
frosted.
I Temperature difference
occurs somewhere in high-
pressure side.
AC353A I Expansion valve and liquid Low refrigerant charge. Check refrigerant for leaks.
tank are warm or only cool " Refer to “Checking Refrigerant
when touched. Leaking fittings or components. Leaks”, HA-64.
There is a big temperature dif- Expansion valve closes a little I Remove foreign particles by
ference between expansion compared with the specifica- using compressed air.
valve inlet and outlet while the tion. I Check lubricant for contami-
valve itself is frosted. " nation.
q1 Improper expansion valve
adjustment.
q2 Malfunctioning thermal
valve.
q3 Outlet and inlet may be
clogged.
An area of the low-pressure Low-pressure pipe is clogged I Check and repair malfunc-
pipe is colder than areas near or crushed. tioning parts.
the evaporator outlet. I Check lubricant for contami-
nation.
Air flow volume is not enough Compressor pressure operation Replace compressor.
or is too low. is improper.

HA-30
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont’d)
Gauge indication Refrigerant cycle Probable cause Corrective action GI
Low-pressure side sometimes I Air conditioner system does Refrigerant does not discharge I Drain water from refrigerant
becomes negative. not function and does not cyclically. or replace refrigerant.
cyclically cool the compart- " I Replace liquid tank. MA
ment air. Moisture is frozen at expansion
I The system constantly func- valve outlet and inlet.
tions for a certain period of " EM
time after compressor is Water is mixed with refrigerant.
stopped and restarted.
LC

EC

FE
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 CL
frosted or dewed. " the problem is caused by water
Expansion valve or liquid tank or foreign particles.
is frosted. I If water is the cause, initially MT
cooling is okay. Then the
water freezes, causing a
blockage. Drain water from TF
refrigerant or replace refriger-
ant.
I If due to foreign particles, PD
remove expansion valve and
remove the particles with dry
and compressed air.
FA
I If either of the above meth-
AC362A ods cannot correct the
problem, replace expansion
RA
valve.
I Replace liquid tank.
I Check lubricant for contami-
BR
nation.
ST

RS

BT

EL

IDX

HA-31
TROUBLE DIAGNOSES

Harness Layout

RHA371G

HA-32
TROUBLE DIAGNOSES

Wiring Diagram — HEATER —


EXCEPT FOR AUSTRALIA GI

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HHA099

HA-33
TROUBLE DIAGNOSES
Wiring Diagram — HEATER — (Cont’d)
FOR AUSTRALIA

HHA100

HA-34
TROUBLE DIAGNOSES

Circuit Diagram — Air Conditioner


GI

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HHA091

HA-35
TROUBLE DIAGNOSES

Wiring Diagram — A/C —


EXCEPT FOR KA ENGINE MODELS

HHA092

HA-36
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HHA093

HA-37
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)

HHA094

HA-38
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HHA095

HA-39
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)
FOR KA ENGINE MODELS

HHA096

HA-40
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)

GI

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HHA097

HA-41
TROUBLE DIAGNOSES
Wiring Diagram — A/C — (Cont’d)

HHA098

HA-42
TROUBLE DIAGNOSES

Main Power Supply and Ground Circuit Check


POWER SUPPLY FUSE CHECK FOR A/C SYSTEM GI
Check the following fuses.
I 15A fuse (No. 19 and 20 ) for blower motor.
I 7.5A fuse (No. 21 ) for thermo control amp. MA
For detailed circuit, refer to “Wiring Diagram”.

EM

SHA877E
LC
THERMO CONTROL AMP. CHECK
Power supply circuit check EC
Check power supply circuit for thermo control amp. with ignition
switch ON.
1. Disconnect thermo control amp. harness connector. FE
2. Connect voltmeter from harness side.
3. Measure voltage across terminal No. q1 and body ground.
CL
Voltmeter terminal
Voltage
! @
MT
RHA319G
q
1 Body ground Approx. 12V

TF

PD

FA

RA
Ground circuit check
Check body ground circuit for thermo control amp. with ignition
BR
switch ON, air conditioner switch ON and fan switch ON.
1. Disconnect thermo control amp. harness connector.
2. Connect ohmmeter from harness side.
ST
3. Check for continuity between terminal No. q
2 and body ground.
Ohmmeter terminal RS
Continuity
! @
q
2 Body ground Yes BT
SHA871E
If the ground circuit is NG, check the following.
I A/C switch (Refer to HA-50.)
I Fan switch (Refer to HA-50.)
I Harness for open or short between thermo control amp. and
A/C switch EL
I Harness for open or short between A/C switch and fan switch
I Fan switch ground circuit
IDX

HA-43
TROUBLE DIAGNOSES

Diagnostic Procedure 1
Flow chart
INCIDENT
No. SYMPTOM: Blower motor does not rotate.
1 Fan fails to rotate.
I Perform PRELIMINARY CHECK 1 before referring to the
following flow chart.
2 Fan does not rotate at 1-speed.
Eq
E
3 Fan does not rotate at 2-speed. Check if blower motor rotates properly
Eq
at each fan speed. D
4 Fan does not rotate at 3-speed. Conduct checks as per flow chart at
left. Eq
C
5 Fan does not rotate at 4-speed.
EqB
(Go to next page.)
H
CHECK POWER SUPPLY FOR BLOWER No Check 15A fuses (No. 19
E
MOTOR. and No. 20 , located in the
Disconnect blower motor harness connec- fuse block).
tor. (Refer to “POWER SUPPLY
Do approx. 12 volts exist between blower ROUTING” in EL section
motor harness terminal No. q 1 and body and Wiring Diagram.)
ground?
Yes
H
1. Turn fan control knob to any position NG Reconnect blower motor
SHA872E E
except OFF. harness connector.
2. Check circuit continuity between blower
motor harness terminal No. q 2 and body
ground.
Continuity should exist.
OK
H
CHECK BLOWER MOTOR.
(Refer to Electrical Components Inspec-
tion.) (HA-50)
NG
H
Replace blower motor.
SHA873E

H
CHECK BLOWER MOTOR CIRCUIT No Disconnect blower motor
E
BETWEEN BLOWER MOTOR AND and resistor harness con-
RESISTOR. nectors.
Do approx. 12 volts exist between resistor
harness terminal No. q1 and body ground?

Yes
H
Disconnect fan switch harness connector. H Note
Check circuit continuity
between blower motor har-
RHA320G ness terminal No. q 2 and
resistor harness terminal
No. q1 .
Continuity should exist.
If OK, check harness for
short.
H
q
A
(Go to next page.)
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.

RHA321G

HA-44
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont’d)
q
A

GI
H Note
CHECK GROUND CIRCUIT FOR FAN
SWITCH.
Check circuit continuity between fan switch MA
harness terminal No. q 26 and body ground.

OK
H
EM
F q
B
CHECK BLOWER RESISTOR AFTER DIS-
CONNECTING IT.
RHA322G (Refer to Electrical Components Inspection.) F q
C LC
(HA-50)
F q
D
OK NG EC
H
q
E
Replace resistor.

H
FE
Reconnect resistor harness connector.
CL

RHA323G
H H H H MT
CHECK FAN SWITCH CIRCUIT.
Do approx. 12 volts exist between each fan switch har-
ness terminal and body ground?
TF
Flow chart Terminal No.
Voltage
No. ! @
q
24
PD
q
23
Body ground Approx. 12V
q
22 FA
q
21

Yes No RA
H Note
Check circuit continuity BR
between fan switch harness
terminal and resistor har-
ness terminal.
Terminal No.
ST
Continu-
Fan ity
switch Resistor

q
21 q
1
RS
q
22 q
2
Yes
q
23 q
3 BT
RHA324G q
24 q
4

If OK, check harness for


short.

H H
NG EL
CHECK FAN SWITCH AFTER DIS- E Replace fan switch.
CONNECTING IT.
(Refer to Electrical Components
Inspection.) (HA-50)
IDX
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.

HA-45
TROUBLE DIAGNOSES

Diagnostic Procedure 2
EXCEPT FOR KA ENGINE MODELS
SYMPTOM: Magnet clutch does not engage when A/C
switch and fan switch are ON.
I Perform PRELIMINARY CHECK 1 before referring to the
following flow chart.

Yes
RHA325G CHECK POWER SUPPLY FOR COM- E
Check the following.
PRESSOR. I Magnet clutch coil
Disconnect compressor harness connector. I Thermal protector (Except
Do approx. 12 volts exist between com- for the Middle East)
pressor harness terminal No. q1 and body
ground? NG
H
No Replace magnet clutch.
Refer to HA-69.

H Note
Check circuit continuity between A/C relay
harness terminal No. q 5 and compressor
harness terminal No. q 1 .
Continuity should exist.
RHA748FD If OK, check harness for short.
OK

H
No
CHECK POWER SUPPLY FOR A/C E
Check power supply circuit
RELAY. and 7.5A fuse (No. 21 ,
Do approx. 12 volts exist between A/C located in the fuse block).
relay harness terminal No. q3 and body (Refer to “POWER SUPPLY
ground? ROUTING” in EL section
and Wiring Diagram.)
Yes

H
Yes
CHECK POWER SUPPLY FOR A/C E
Check power supply circuit
RHA359G RELAY. and 7.5A fuse (No. 21 ,
Do approx. 12 volts exist between A/C located in the fuse block).
relay harness terminal No. q1 and body (Refer to “POWER SUPPLY
ground? ROUTING” in EL section
and Wiring Diagram.)
No
H
NG
CHECK A/C RELAY AFTER DISCON- E
Replace A/C relay.
NECTING IT.
Refer to HA-51.
OK
H
Reconnect A/C relay.

RHA375G

H Note
Check circuit continuity between A/C relay
harness terminal No. q 2 and triple-pressure
switch harness terminal No. q 4 .
Continuity should exist.
If OK, check harness for short.

H
OK
q
A
(Go to next page.)
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.
RHA327G

HA-46
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont’d)
q
A

H GI
CHECK TRIPLE-PRESSURE SWITCH. NG Check refrigerant charge
E
Refer to HA-51. amount.
OK OK
MA
H Note H
Check circuit continuity between triple- Replace triple-pressure EM
pressure switch harness terminal No. switch.
q1 and thermo control amp. harness termi-
RHA328G
nal No. q3 . LC
Continuity should exist. If OK, check har-
ness for short.
EC
OK
H
CHECK POWER SUPPLY AND GROUND
CIRCUIT FOR THERMO CONTROL AMP.
FE
Refer to HA-43.
OK CL
H
Replace thermo control amp.
MT
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor. TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HA-47
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont’d)
FOR KA ENGINE MODELS
SYMPTOM: Magnet clutch does not engage when A/C
switch and fan switch are ON.
I Perform PRELIMINARY CHECK 1 before referring to the
following flow chart.

CHECK POWER SUPPLY FOR COM- Yes Check the following.


E
PRESSOR. I Magnet clutch coil
RHA333G
Disconnect compressor harness connector. I Thermal protector
Do approx. 12 volts exist between com-
NG
pressor harness terminal No. q1 and body H
ground? Replace magnet clutch.
No Refer to HA-69.

H Note
Check circuit continuity between A/C relay
harness terminal No. q 5 and compressor
harness terminal No. q 1 .
Continuity should exist.
If OK, check harness for short.
RHA334G
OK

H
CHECK POWER SUPPLY FOR A/C No Check power supply circuit
E
RELAY. and 7.5A fuse (No. 21 ,
Do approx. 12 volts exist between A/C located in the fuse block).
relay harness terminal No. q3 and body (Refer to “POWER SUPPLY
ground? ROUTING” in EL section
and Wiring Diagram.)
Yes

H
CHECK POWER SUPPLY FOR A/C No Check power supply circuit
RHA359G E
RELAY. and 7.5A fuse (No. 21 ,
Do approx. 12 volts exist between A/C located in the fuse block).
relay harness terminal No. q1 and body (Refer to “POWER SUPPLY
ground? ROUTING” in EL section
and Wiring Diagram.)
Yes
H
CHECK A/C RELAY AFTER DISCON- NG Replace A/C relay.
E
NECTING IT.
Refer to HA-51.
OK
H
Reconnect A/C relay.
RHA375G

H
q
A
(Go to next page.)
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.

HA-48
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont’d)
q
A

H Note
GI
CHECK COIL SIDE CIRCUIT OF A/C No Check circuit continuity
E
RELAY. between A/C relay harness MA
Disconnect ECM (ECCS control module) terminal No. q2 and ECM
harness connector. (ECCS control module) har-
Do approx. 12 volts exist between ECM ness terminal No. q11 . EM
(ECCS control module) harness terminal Continuity should exist.
No. q
11 and body ground? If OK, check harness for
RHA335G
Yes
short. LC
H
Reconnect ECM (ECCS control module)
harness connector. EC
H
CHECK POWER SUPPLY AND GROUND FE
CIRCUIT FOR THERMO CONTROL AMP.
Refer to HA-43.
CL
OK

H
RHA336G CHECK VOLTAGE FOR THERMO CON-
MT
TROL AMP.
Do approx. 5 volts exist between thermo Yes
control amp. harness terminal No. q3 and E
Replace thermo control TF
amp.
body ground?
No PD
H
Check circuit continuity between thermo
FA
control amp. harness terminal No. q 3 and
triple-pressure switch harness terminal No.
q1 .
RHA338G
RA
Continuity should exist.
If OK, check harness for short.
OK BR
H
CHECK TRIPLE-PRESSURE SWITCH. NG Replace triple-pressure
E
Refer to HA-51. switch. ST
OK

H Note RS
Check circuit continuity between ECM
(ECCS control module) harness terminal
No. q41 and triple-pressure switch harness BT
RHA328G terminal No. q 4 .
Continuity should exist.
If OK, check harness for short.
OK
H
CHECK ECM (ECCS CONTROL MOD- EL
ULE).
Refer to EC section.
IDX
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.
RHA340G

HA-49
TROUBLE DIAGNOSES

Electrical Components Inspection


FAN SWITCH
Check continuity between terminals at each switch position.
Knob position Continuity between terminals
OFF
1 q
24 q
26 q
25

2 q
23 q
26 q
25

3 q
22 q
26 q
25
RHA360G
4 q
21 q
26 q
25

BLOWER MOTOR
Confirm smooth rotation of the blower motor.
I Ensure that there are no foreign particles inside the intake unit.

BLOWER RESISTOR
Check resistance between terminals.
Terminal No.
Resistance
! @
q
3 Approx. 1.4 - 1.6Ω
q
4 q
1 Approx. 2.5 - 2.8Ω
q
2 Approx. 0.5 - 0.6Ω

RHA361G

A/C SWITCH
Check continuity between terminals at each switch position.
Switch condition Terminal No.
Continuity
A/C ! @
ON Yes
q
13 q
12
OFF No

RHA362G

HA-50
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont’d)
A/C RELAY
Check continuity between terminal Nos. q
3 and q
5 .
GI
Conditions Continuity
12V direct current supply between terminal Nos.
Yes MA
q1 andq2

No current supply No

If NG, replace relay. EM

SEF090M
LC
TRIPLE-PRESSURE SWITCH
High-pressure side line EC
Terminals pressure Operation Continuity
kPa (bar, kg/cm2, psi)
Increasing to
152.0 - 201.0
FE
ON Exists.
(1.520 - 2.010,
Low-pres- 1.55 - 2.05, 22.0 - 29.2)
q
1 -q
4
sure side Decreasing to CL
152.0 - 201.0 Does not
OFF
(1.520 - 2.010, exist.
1.55 - 2.05, 22.0 - 29.2)
RHA364G
Increasing to
MT
1,422 - 1,618
ON Exists.
(14.22 - 16.18,
Medium- 14.5 - 16.5, 206 - 235) TF
pressure q
2 -q
3
side* Decreasing to
1,128 - 1,422 Does not
OFF
(11.28 - 14.22, exist. PD
11.5 - 14.5, 164 - 206)
Decreasing to
2,059 - 2,256
(20.6 - 22.6,
ON Exists. FA
High-pres- 21 - 23, 299 - 327)
q
1 -q
4
sure side Increasing to
2,648 - 2,844
OFF
Does not RA
(26.5 - 28.4, exist.
27 - 29, 384 - 412)

* For cooling fan motor operation BR

ST

RS

BT

THERMO CONTROL AMP.


Evaporator outlet air temperature Thermo amp.
Tester
°C (°F) operation
EL
Decreasing to 0.1 - 0.9 (32 - 34) Turn OFF Approx. 12V
Increasing to 2.5 - 3.5 (37 - 38) Turn ON Approx. 0V
IDX

RHA365G

HA-51
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont’d)
THERMAL PROTECTOR (For DKV-14C)
Temperature of compressor
Operation
°C (°F)
Increasing to approx. 145 - 155 (293 - 311) Turn OFF
Decreasing to approx. 130 - 140 (266 - 284) Turn ON

AHA849

Control Linkage Adjustment


VENTILATOR DOOR CONTROL ROD
I When adjusting door control rod, first disconnect mode
control cable from side link.
Reconnect and readjust mode control cable.
1. Move side link in direction of arrow.
2. With upper and lower ventilator door levers held in the direction
of the arrow, connect rods q 1 and q
2 to their corresponding
ventilator door levers in that order.
RHA267-A

RHA258-A

DEFROSTER DOOR CONTROL ROD


I When adjusting door control rod, first disconnect mode
control cable from side link.
Reconnect and readjust mode control cable.
1. Move side link in direction of arrow.
2. Connect rod to side link while pushing defroster door lever in
direction of arrow.

RHA268-A

RHA259-A

HA-52
TROUBLE DIAGNOSES
Control Linkage Adjustment (Cont’d)
MODE CONTROL CABLE
LHD models GI
I Move mode control lever to position.
Set side link in DEF mode.
Pull on outer cable in direction of arrow and then clamp it. MA
I After positioning mode control cable, check that it oper-
ates properly.
EM

RHA269-A
LC
RHD models
I Move mode control lever to position. EC
Set side link in FACE mode.
Pull on outer cable in direction of arrow and then clamp it.
I After positioning mode control cable, check that it oper- FE
ates properly.

CL

RHA260-A MT
WATER COCK CONTROL ROD
For the Middle East and LHD models TF
I When adjusting water cock control rod, first disconnect
temperature control cable from air mix door lever and then PD
adjust control rod. Reconnect temperature control cable
and readjust it. (Refer to next item.)
1. Push air mix door lever in direction of arrow. FA
2. Pull control rod of water cock in direction of arrow so as to make
clearance of about 2 mm (0.08 in) between ends of rod and link
lever and connect the rod to door lever. RA
AHA853
I After connecting water cock control rod, check that it oper-
ates properly.
BR

ST

RS

BT

EL

IDX

HA-53
TROUBLE DIAGNOSES
Control Linkage Adjustment (Cont’d)
TEMPERATURE CONTROL CABLE
LHD models
I Move temperature control lever to max. COLD position. Set air
mix door lever in full cold mode. Pull on outer cable in direction
of arrow and then clamp it.
I After positioning temperature control cable, check that it
operates properly.

RHA416-A

RHD models
I Move temperature control lever to max, HOT position.
Set air mix door lever in full hot mode. Pull on outer cable in
direction of arrow and then clamp it.
I After positioning temperature control cable, check that it
operates properly.

RHA417-A

INTAKE DOOR CONTROL CABLE


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

RHA374G

RHA355G

HA-54
SERVICE PROCEDURES

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


GI
Set the recovery/recycling equipment.
MA
H
Recovered lubricant. Refer to Discharge refrigerant into recovery/
“CHECKING AND ADJUSTING”, recycling equipment. EM
HA-57.

H
Repair or replace parts. LC

H
Evacuate (over 25 minutes).
EC
F

H FE
Check air tightness. E Repair.
NG G
OK
H *1 CL
Partial charging [approx. 200 g
E (7.05 oz)].
MT
H
Preliminary refrigerant leak check. E
Refer to “PRELIMINARY CHECK”, NG TF
HA-22.
OK
H
*1 PD
Complete charging (specified amount
less partial charge amount)
Refer to SDS. FA

H
*2
Check for refrigerant leaks.
RA
Refer to “CHECKING PROCEDURE”, NG
HA-65.
OK
BR
H
Check for A/C operation and A/C cool- .................. Performance Test Diagnoses
ing performance Refer to HA-25.
ST

H
RS
Remove service couplers from A/C
service valves.

BT
H
Recover refrigerant in charging hoses.

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

HA-55
SERVICE PROCEDURES
HFC-134a (R-134a) Service Procedure (Cont’d)
SETTING OF SERVICE TOOLS AND EQUIPMENT
DISCHARGING REFRIGERANT
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting require-
ments of HFC-134a (R-134a) recycling equipment or HFC-134a (R-134a) recovery equipment. If acci-
dental system discharge occurs, ventilate work area before resuming service. Additional health and
safety information may be obtained from refrigerant and lubricant manufacturers.

SHA539DC

EVACUATING SYSTEM AND CHARGING REFRIGERANT

SHA540DC

HA-56
SERVICE PROCEDURES

Maintenance of Lubricant Quantity in


Compressor
The lubricant used to lubricate the compressor circulates through GI
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.
MA
If lubricant quantity is not maintained properly, the following mal-
functions may result:
I Lack of lubricant: May lead to a seized compressor
EM
I Excessive lubricant: Inadequate cooling (thermal exchange
interference) LC
LUBRICANT
Name: Nissan A/C System Oil Type R (Except for the Middle
East) EC
Nissan A/C System Oil Type S (For the Middle East)
Part number: KLH00-PAGR0 (Except for the Middle East)
KLH00-PAGS0 (For the Middle East) FE
CHECKING AND ADJUSTING
Adjust the lubricant quantity according to the flowchart shown
START below. CL

H
Yes MT
Can lubricant return operation be per- E Perform lubricant return operation, proceeding as follows:
formed? ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
I A/C system works properly. 1. Start engine, and set the following conditions:
I There is no evidence of a large amount of I Test condition TF
lubricant leakage. Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON
No Blower speed: Max. position
Temp. control: Optional [Set so that intake air temperature is
PD
25 to 30°C (77 to 86°F).]
2. Next item is for V-5 or V-6 compressor. Connect the manifold
gauge, and check that the high pressure side pressure is 588 kPa FA
(5.9 bar, 6 kg/cm2, 85 psi) or higher.
If less than the reference level, attach a cover to the front face of
H the condenser to raise the pressure.
Should the compressor be replaced? 3. Perform lubricant return operation for about 10 minutes.
RA
F
4. Stop engine.
No Yes CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant BR
return operation.
H
qA
(Go to next page.)
ST
H
Yes
Is there any part to be replaced? E After replacing any of the following major components, add the correct
(Evaporator, condenser, liquid tank or in amount of lubricant to the system. RS
case there is evidence of a large amount of Amount of lubricant to be added
lubricant leakage.)
Lubricant to be added to sys-
No Part replaced
tem
Amount of lubricant
Remarks BT
m (Imp fl oz)
Evaporator 75 (2.6) —
Condenser 75 (2.6) —
Add if compressor is not
Liquid tank 5 (0.2)
H replaced. *1
30 (1.1) Large leak
Carry out the A/C performance test. F
In case of refrigerant leak
— Small leak*2 EL
*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. IDX

HA-57
SERVICE PROCEDURES
Maintenance of Lubricant Quantity in
Compressor (Cont’d)
q
A

H
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/
recycling equipment.
2. Remove the drain plug of the “old” (removed) compressor (applicable only to V-5, V-6, DKS-16H or DKS-17CH compressor).
Drain the lubricant into a graduated container and record the amount of drained lubricant.
3. Remove the drain plug and drain the lubricant from the “new” compressor into a separate, clean container.
4. Measure an amount of new lubricant installed equal to amount drained from “old” compressor. Add this lubricant to “new”
compressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to “new” compres-
sor through the suction port opening.
6. Torque the drain plug.
V-5 or V-6 compressor: 18 - 19 N⋅m (1.8 - 1.9 kg-m, 13 - 14 ft-lb)
DKS-16H compressor: 14 - 16 N⋅m (1.4 - 1.6 kg-m, 10 - 12 ft-lb)
DKS-17CH compressor: 14 - 16 N⋅m (1.4 - 1.6 kg-m, 10 - 12 ft-lb)
7. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz) of lubricant if only replacing the compressor.

RHA065DE

HA-58
SERVICE PROCEDURES

Refrigerant Lines
I Refer to page HA-3 regarding “Precautions for Refrigerant
Connection”. GI
RHD MODELS WITH DIESEL ENGINE
MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

RHA352G

HA-59
SERVICE PROCEDURES
Refrigerant Lines (Cont’d)
I Refer to page HA-3 regarding “Precautions for Refrigerant Con-
nection”.
RHD MODELS WITH KA24 ENGINE

RHA353G

HA-60
SERVICE PROCEDURES
Refrigerant Lines (Cont’d)
I Refer to page HA-3 regarding “Precautions for Refrigerant Con-
nection”.
GI
RHD MODELS WITH NA20 ENGINE

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

RHA354G

HA-61
SERVICE PROCEDURES
Refrigerant Lines (Cont’d)
I Refer to page HA-3 regarding “Precautions for Refrigerant Con-
nection”.
LHD MODELS WITH DIESEL ENGINE

RHA372G

HA-62
SERVICE PROCEDURES
Refrigerant Lines (Cont’d)
I Refer to page HA-3 regarding “Precautions for Refrigerant Con-
nection”.
GI
LHD MODELS WITH GASOLINE ENGINE

MA

EM

LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

RHA356G

HA-63
SERVICE PROCEDURES

Checking Refrigerant Leaks


PRELIMINARY CHECK
Perform a visual inspection of all refrigeration parts, fittings, hoses,
and components for signs of A/C lubricant leakage, damage and
corrosion.

PRECAUTIONS FOR HANDLING LEAK DETECTOR


When performing a refrigerant leak check, use an A/C leak detec-
tor or equivalent. Ensure that the instrument is calibrated and 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.
Other gases in the work area or substances on the A/C
components, for example, anti-freeze, windshield washer
fluid, solvents and cleaners, may falsely trigger the leak detec-
SHA705EB tor. Make sure the surfaces to be checked are clean. Do not
allow the sensor tip of the detector to come into contact with
any substance. This can also cause false readings and may
damage the detector.

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


to be checked.

SHA707EA

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

SHA706E

HA-64
SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont’d)
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
GI

MA

EM

SHA708EA
LC
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no EC
refrigerant vapor or tobacco smoke in the vicinity of the
vehicle. Perform the leak test in calm area (low air/wind move-
ment) so that the leaking refrigerant is not dispersed. FE
1. Turn engine off.
2. Connect a suitable A/C manifold gauge set to the A/C service
ports. CL
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.452
bar, 3.52 kg/cm2, 50 psi) above 16°C (61°F). If less than
specification, evacuate and recharge the system with the speci- MT
fied amount of refrigerant.
NOTE: At temperatures below 16°C (61°F), leaks may not be
detected since the system may not reach 345 kPa TF
(3.452 bar, 3.52 kg/cm2, 50 psi).
4. Conduct the leak test from the high side to the low side at points
qa through qn . Refer to HA-59. PD
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. FA
I Compressor
Check the fitting of high and low pressure hoses, relief valve
and shaft seal. RA
I Liquid tank
Check the pressure switch, tube fitting, weld seams and the
fusible plug mounts. BR
I Service valves
Check all around the service valves. Ensure service valve caps
are secured on the service valves (to prevent leaks). ST
NOTE: After removing A/C manifold gauge set from service
valves, wipe any residue from valves to prevent any
false readings by leak detector. RS
I Cooling unit (Evaporator)
Turn blower fan on “High” for at least 15 seconds to dissipate
any refrigerant trace in the cooling unit. Insert the leak detector BT
probe into the drain hose immediately after stopping the
engine. (Keep the probe inserted for at least ten seconds.)
5. If a leak detector detects a leak, verify at least once by blowing
compressed air into area of suspected leak, then repeat check.
6. Do not stop when one leak is found. Continue to check for
additional leaks at all system components. EL
7. Start engine.
8. Set the heater A/C control as follows:
a. A/C switch ON
IDX
b. Face mode
c. Recirculation switch ON
d. Max cold temperature
e. Fan speed high

HA-65
SERVICE PROCEDURES
Checking Refrigerant Leaks (Cont’d)
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4
through 6 above.

Refrigerant leaks should be checked immediately after stop-


ping the engine. Begin with the leak detector on the high pres-
sure line. The pressure in the high pressure line will gradually
drop after refrigerant circulation stops and pressure in the low
pressure line will gradually rise, as shown in the graph. Leaks
are more easily detected when pressure is high.

SHA839E

11. Discharge A/C system using approved refrigerant recovery


equipment. Repair the leaking fitting or component as neces-
sary.
12. Evacuate and recharge A/C system and perform the leak test
to confirm no refrigerant leaks.
13. Conduct A/C performance test to ensure system works prop-
erly.

Compressor Mounting

RHA376G

HA-66
SERVICE PROCEDURES
Compressor Mounting (Cont’d)

GI

MA

EM

LC

EC

FE

CL
RHA357G

MT

TF

PD

FA

RA

BR

ST

RS
RHA781B

BT

EL

IDX

HA-67
SERVICE PROCEDURES
Compressor Mounting (Cont’d)

RHA378G

HA-68
SERVICE PROCEDURES

Compressor — DKV-14C (ZEXEL make)


GI

MA

EM

LC

EC

FE

CL

SHA878E
MT

Compressor Clutch — DKV-14C (ZEXEL make) TF


REMOVAL
I When removing center bolt, hold clutch disc with clutch disc PD
wrench.

FA

RA
RHA366G

I Remove the clutch disc using Tool KV99232340. BR


Insert holder’s three pins into the clutch disc. Rotate the holder
clockwise to hook it onto the plate. Then, tighten the center bolt
to remove the clutch disc. ST
When tightening the center bolt, insert a round bar (screwdriver,
etc.) between two of the pins (as shown in the left-hand figure)
to prevent clutch disc rotation. After removing the clutch disc, RS
remove the shims from either the drive shaft or the clutch disc.
BT
RHA367G

I Remove the snap ring using external snap ring pliers.

EL

IDX

AHA843

HA-69
SERVICE PROCEDURES
Compressor Clutch — DKV-14C (ZEXEL make)
(Cont’d)
I Pulley removal
Use any commercially available pulley puller. Position the cen-
ter of it on the end of the drive shaft, and remove the pulley
assembly.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked under (not into) the pulley groove.
For machine latched pulleys:
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
RHA368G

I Remove the field coil harness clip using a screwdriver.


I Remove the three field coil fixing screws and remove the field
coil.

RHA074C

INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
heat, replace clutch disc and pulley.
Pulley
Check the appearance of the pulley assembly. If the contact sur-
face of the pulley shows signs of excessive grooving, replace both
the pulley and clutch disc. The contact surfaces of the pulley
assembly should be cleaned with a suitable solvent before reinstal-
RHA075C
lation.
Coil
Check coil for loose connection or cracked insulation.

INSTALLATION
I Install the field coil.
I Be sure to align the coil’s pin with the hole in the compres-
sor’s front head.
I Install the field coil harness clip using a screwdriver.

RHA076C

HA-70
SERVICE PROCEDURES
Compressor Clutch — DKV-14C (ZEXEL make)
(Cont’d)
I Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers. GI

MA

EM

RHA369G
LC
I Install the clutch disc on the drive shaft, together with the origi-
nal shim(s). Press the clutch disc down by hand.
EC

FE

CL

RHA373G MT
I Using the holder to prevent drive plate rotation, tighten the bolt
to 12 to 15 N⋅m (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque. TF
I After tightening the bolt, check that the pulley rotates
smoothly.
PD

FA

RHA370G
RA
I Check clearance around the entire periphery of clutch disc.
Disc-to-pulley clearance: BR
0.3 - 0.6 mm (0.012 - 0.024 in)
If the specified clearance is not obtained, replace adjusting
spacer and readjust. ST
BREAK-IN OPERATION
RS
When replacing compressor clutch assembly, always conduct the
break-in operation. This is done by engaging and disengaging the
clutch about thirty times. Break-in operation raises the level of BT
transmitted torque.

EL

IDX

RHA377G

HA-71
SERVICE PROCEDURES

Thermal Protector — DKV-14C (ZEXEL make)


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

AHA849

HA-72
SERVICE PROCEDURES

Compressor — DKS-17CH (ZEXEL make)


GI

MA

EM

LC

EC

FE

CL

SHA132DB
MT

Compressor Clutch — DKS-17CH (ZEXEL TF


make)
REMOVAL PD
I When removing shaft nut, hold clutch disc with clutch disc
wrench.
FA

RA
SHA802D

I Using clutch disc puller, clutch disc can be removed easily. BR

ST

RS

BT
SHA803D

I Bend down pawl of lock washer.


I When removing pulley, remove lock nut with nut wrench.
EL

IDX

SHA804D

HA-73
SERVICE PROCEDURES
Compressor Clutch — DKS-17CH (ZEXEL
make) (Cont’d)
I Remove the pulley by hand. If difficult, use puller pilot.

SHA805D

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

Pulley
Check the appearance of the pulley assembly. If the contact sur-
face of the pulley shows signs of excessive grooving, replace both
the clutch disc and pulley. The contact surfaces of the pulley
SHA703B
assembly should be cleaned with a suitable solvent before reinstal-
lation.

Coil
Check coil for loose connection or cracked insulation.

INSTALLATION
I Install the key in the kiwi on the compressor drive shaft.
I Install the coil to compressor (lead wire up) and tighten the
mounting screws.
I Install the lead wire into the holder correctly.

SHA806D

I Install lock washer and nut with nut wrench.


I Bend one pawl of the lock washer up against the nut to prevent
the nut from loosening.

SHA705B

HA-74
SERVICE PROCEDURES
Compressor Clutch — DKS-17CH (ZEXEL
make) (Cont’d)
I Check to ensure that the clutch clearance is between 0.3 to 0.6
mm (0.012 to 0.024 in). Adjust the clearance using shim(s) as GI
necessary.

BREAK-IN OPERATION MA
When replacing compressor clutch assembly, do not forget break-in
operation, accomplished by engaging and disengaging the clutch
about thirty times. EM
Break-in operation raises the level of transmitted torque.
SHA707B
LC

EC

FE

CL

MT

TF

PD

FA

RA

BR

ST

RS

BT

EL

IDX

HA-75
SERVICE DATA AND SPECIFICATIONS (SDS)

General Specifications
COMPRESSOR LUBRICANT
Middle East Other areas Middle East Other areas
Model ZEXEL make ZEXEL make Model ZEXEL make ZEXEL make
DKS-17CH DKV-14C DKS-17CH DKV-14C

Type Swash plate Vane rotary Type KLH00-PAGS0 KLH00-PAGR0


3
Displacement cm (cu in)/rev. 168 (10.25) 140 (8.54) Capacity m (lmp fl oz)

Cylinder bore x stroke 37.0 x 25.8 Total in system 200 (7.0)



mm (in) (1.457 x 1.016)
Compressor (Service parts)
200 (7.0)
Clockwise charging amount
Direction of rotation
(Viewed from drive end)

Drive belt A Type

Inspection and Adjustment


REFRIGERANT COMPRESSOR
Middle East Other areas Model DKS-17CH DKV-14C

Type HFC-134a (R-134a) Clutch disc-to-pulley 0.3 - 0.6 0.3 - 0.6


clearance mm (in) (0.012 - 0.024) (0.012 - 0.024)
0.65 - 0.75 0.60 - 0.70
Capacity kg (lb)
(1.43 - 1.65) (1.32 - 1.54)

ENGINE IDLING SPEED (When A/C is ON.)


I Refer to EC section.

BELT TENSION
I Refer to MA section (“Checking Drive Belts”,
“ENGINE MAINTENANCE”).

HA-76

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