Heater & Air Conditioner
Heater & Air Conditioner
Heater & Air Conditioner
AIR CONDITIONER GI
SECTION HA MA
EM
LC
EC
CONTENTS FE
HA-2
PRECAUTIONS AND PREPARATION
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
TF
NT204
FA
NT206
ST
NT207
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
NT205
NT213
NT209
NT677
HA-8
PRECAUTIONS AND PREPARATION
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
RS
BT
NT198
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
NT202
NT200
NT203
HA-10
PRECAUTIONS AND PREPARATION
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
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
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
BR
ST
RS
BT
EL
IDX
HA-17
TROUBLE DIAGNOSES
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.
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
RHA350G
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
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
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.
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
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.
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.
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)
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
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.
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
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
MA
EM
LC
EC
FE
CL
MT
TF
PD
FA
RA
BR
ST
RS
BT
EL
IDX
HHA091
HA-35
TROUBLE DIAGNOSES
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
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
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.
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
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
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)
ST
RS
BT
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
RHA258-A
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
RHA374G
RHA355G
HA-54
SERVICE PROCEDURES
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
SHA540DC
HA-56
SERVICE PROCEDURES
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
SHA707EA
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.
SHA839E
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
MA
EM
LC
EC
FE
CL
SHA878E
MT
FA
RA
RHA366G
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
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
AHA849
HA-72
SERVICE PROCEDURES
MA
EM
LC
EC
FE
CL
SHA132DB
MT
RA
SHA802D
ST
RS
BT
SHA803D
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
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
BELT TENSION
I Refer to MA section (“Checking Drive Belts”,
“ENGINE MAINTENANCE”).
HA-76