MTC PDF

MANUAL AIR CONDITIONER
J AIR CONDITIONER
B
SECTION
MANUAL AIR CONDITIONER C
E
CONTENTS
PRECAUTIONS .......................................................... 4 LUBRICANT .............................................................. 19 F
Precautions for Supplemental Restraint System Maintenance of Lubricant Quantity in Compressor... 19
(SRS) AIR BAG and SEAT BELT PRE-TEN- LUBRICANT ........................................................ 19
SIONER .................................................................. 4 LUBRICANT RETURN OPERATION .................. 19 G
Precautions for Working with HFC-134a (R-134a)..... 4 LUBRICANT AJUSTING PROCEDURE FOR
General Refrigerant Precautions .............................. 4 COMPONENTS REPLACEMENT EXCEPT
Lubricant Precautions .............................................. 5 COMPRESSOR .................................................. 20
H
Precautions for Leak Detection Dye ......................... 5 LUBRICANT ADJUSTING PROCEDURE FOR
IDENTIFICATION .................................................. 5 COMPRESSOR REPLACEMENT ....................... 20
IDENTIFICATION LABEL FOR VEHICLE ............. 6 AIR CONDITIONER CONTROL ............................... 22
Precautions for Refrigerant Connection ................... 6 Control Operation ................................................... 22 I
FEATURES OF NEW TYPE REFRIGERANT FAN CONTROL KNOB ........................................ 22
CONNECTION ...................................................... 6 MODE CONTROL KNOB .................................... 22
O-RING AND REFRIGERANT CONNECTION..... 7 TEMPERATURE CONTROL KNOB .................... 22 MTC
Precautions for Servicing Compressor ................... 10 RECIRCULATION (REC) SWITCH ..................... 22
Precautions for Service Equipment ........................ 10 AIR CONDITIONER SWITCH ............................. 22
RECOVERY/RECYCLING EQUIPMENT ............ 10 REAR COOLER FAN CONTROL
K
ELECTRONIC LEAK DETECTOR ...................... 10 KNOB(FRONT) ................................................... 23
VACUUM PUMP ..................................................11 REAR COOLER FAN SWITCH ........................... 23
MANIFOLD GAUGE SET .....................................11 Discharge Air Flow ................................................. 24
SERVICE HOSES ................................................11 Component Layout ................................................. 25 L
SERVICE COUPLERS ........................................ 12 Component Location .............................................. 26
REFRIGERANT WEIGHT SCALE ...................... 12 System Description ................................................. 27
CALIBRATING ACR4 WEIGHT SCALE .............. 12 SWITCHES AND THEIR CONTROL FUNCTION... 27 M
CHARGING CYLINDER ...................................... 12 TROUBLE DIAGNOSIS ............................................ 28
Wiring Diagrams and Trouble Diagnosis ................ 12 How to Perform Trouble Diagnoses for Quick and
PREPARATION ......................................................... 14 Accurate Repair ...................................................... 28
Special Service Tools ............................................. 14 WORK FLOW ...................................................... 28
HFC-134a (R-134a) Service Tools and Equipment... 14 SYMPTOM TABLE .............................................. 28
Commercial Service Tool ....................................... 17 Component Parts and Harness Connector Location... 29
REFRIGERATION SYSTEM ..................................... 18 ............................................................................ 29
Refrigerant Cycle ................................................... 18 Wiring Diagram HEATER ................................ 30
REFRIGERANT FIOW ........................................ 18 Schematic A/C ................................................. 31
Refrigerant System Protection ............................... 18 Wiring Diagram A/C ......................................... 32
DUAL PRESSURE SWITCH ............................... 18 Wiring Diagram R/COOL ................................. 36
PRESSURE RELIEF VALVE ............................... 18 Operational Check .................................................. 38
CONDITIONS: ..................................................... 38
PROCEDURE: .................................................... 38
Blower Motor Circuit ............................................... 40
Rear Cooler Fan Motor Circuit ................................ 44
MTC-1
Magnet Clutch Circuit ............................................. 50 5 DOOR) ..............................................................85
Intake Door Circuit .................................................. 55 FOOR-TYPE REAR HEATER (MICROBUS) .......86
Insufficient Cooling ................................................. 55 Rear Blower Fan Motor ...........................................86
INSPECTION FLOW ........................................... 56 REMOVAL AND INSTALLATION .........................86
PERFORMANCE TEST DIAGNOSES ................ 57 Rear Blower Fan Resistor .......................................87
PERFORMANCE CHART ................................... 59 REMOVAL AND INSTALLATION .........................87
TROUBLE DIAGNOSES FOR ABNORMAL Rear Heater Duct (4 Door) ......................................87
PRESSURE ......................................................... 60 Rear Heater Control ................................................87
Insufficient Heating ................................................. 63 REMOVAL AND INSTALLATION .........................87
INSPECTION FLOW ........................................... 64 DISASSEMBLY AND ASSEMBLY .......................88
Noise ...................................................................... 65 Rear Heater Hose ...................................................88
INSPECTION FLOW ........................................... 65 REMOVAL AND INSTALLATION .........................88
CONTROLLER .......................................................... 66 MODE DOOR ............................................................90
Removal and Installation ........................................ 66 Adjustment of Cable ................................................90
Disassembly and Assembly .................................... 67 AIR MIX DOOR ..........................................................91
BLOWER AND COOLING UNIT ASSEMBLY .......... 68 Adjustment of Cable ................................................91
Removal and Installation ........................................ 68 DUCT AND GRILLE ..................................................92
REMOVAL ........................................................... 68 Removal and Installation .........................................92
INSTALLATION .................................................... 69 VENTILATOR DUCT, DEFROSTER NOZZLE,
Disassembly and Assembly .................................... 70 AND DUCT ..........................................................92
BLOWER FAN MOTOR ............................................ 71 CENTRAL VENTILATOR GRILLE .......................92
Removal and Installation ........................................ 71 SIDE VENTILATOR GRILLE ...............................93
BLOWER FAN RESISTOR ....................................... 72 FOOT DUCT ........................................................93
Removal and Installation ........................................ 72 REAR VENTILATOR GRILLE ..............................93
INTAKE DOOR ACTUATOR ..................................... 73 REAR INTAKE GRILLE .......................................93
Removal and Installation ........................................ 73 A/C CYCLE ................................................................94
HEATER UNIT ASSEMBLY ...................................... 74 Component Parts Drawing ......................................94
Removal and Installation ........................................ 74 WITHOUT REAR A/C ..........................................95
REMOVAL ........................................................... 74 WITH REAR A/C ..................................................96
INSTALLATION .................................................... 75 Compressor ............................................................97
Disassembly and Assembly .................................... 76 REMOVAL ............................................................97
HEATER CORE ......................................................... 77 INSTALLATION ....................................................98
Removal and Installation ........................................ 77 Overhaul .................................................................99
REAR A/C UNIT ASSEMBLY ................................... 78 Removal ..................................................................99
Removal and Installation ........................................ 78 Inspection .............................................................. 100
INSTALLATION .................................................... 78 CLUTCH DISC ................................................... 100
INSTALLATION .................................................... 78 PULLEY ............................................................. 100
Disassembly and Assembly .................................... 79 COIL ................................................................... 100
REAR BLOWER FAN MOTOR ................................. 80 Installation ............................................................. 100
Removal and Installation ........................................ 80 BREAK-IN OPERATION .................................... 101
REMOVAL ........................................................... 80 High-Pressure Flexible Hose 1 and Low-Pressure
INSTALLATION .................................................... 80 Flexible Hose 1 ..................................................... 102
REAR BLOWER FAN RESISTOR ............................ 81 REMOVAL .......................................................... 102
Removal and Installation ........................................ 81 INSTALLATION .................................................. 103
DRAIN HOSE ............................................................ 82 Low-Pressure Pipe 1 ............................................. 103
Removal and Installation ........................................ 82 REMOVAL .......................................................... 103
DRAIN HOSE (RH) .............................................. 82 INSTALLATION .................................................. 104
DRAIN HOSE (LH) .............................................. 82 Low-Pressure Pipe 2 ............................................. 104
REAR A/C CONTROLLER ....................................... 83 REMOVAL .......................................................... 104
Disassembly and Assembly .................................... 83 High-Pressure Pipe 1 ............................................ 105
REAR HEATER UNIT ASSEMBLY ........................... 84 REMOVAL .......................................................... 105
BUILT-IN TYPE REAR HEATER (4 DOOR AND High-Pressure Pipe 2 ............................................ 106
5 DOOR) .............................................................. 84 REMOVAL .......................................................... 106
FOOR-TYPE REAR HEATER (MICROBUS) ....... 84 INSTALLATION .................................................. 106
Disassembly and Assembly .................................... 85 High-Pressure Pipe 3 ............................................ 107
BUILT-IN TYPE REAR HEATER (4 DOOR AND REMOVAL .......................................................... 107
MTC-2
INSTALLATION ................................................. 107 REMOVAL AND INSTALLATION ...................... 109
High-Pressure Flexible Hose 2 and Low-Pressure DISASSEMBLY AND ASSEMBLY ......................111 A
Flexible Hose 2 (Rear A/C Side) .......................... 107 Rear Evaporator ....................................................111
REMOVAL ......................................................... 107 REMOVAL AND INSTALLATION .......................111
INSTALLATION ................................................. 108 Front Expansion Valve .......................................... 112 B
High-Pressure Pipe 4 ........................................... 108 REMOVAL AND INSTALLATION ...................... 112
REMOVAL ......................................................... 108 Rear Expansion Valve .......................................... 112
INSTALLATION ................................................. 109 REMOVAL AND INSTALLATION ...................... 112
Pressure Switch ................................................... 109 Liquid Tank ........................................................... 113 C
REMOVAL AND INSTALLATION ...................... 109 REMOVAL AND INSTALLATION ...................... 113
Condenser Assembly ........................................... 109
D
MTC
MTC-3
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT
BELT PRE-TENSIONER EJS0011K
The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE-TENSIONER, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow harness connectors.
Precautions for Working with HFC-134a (R-134a) EJS0011L
WARNING:
CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
are mixed and compressor failure is likely to occur, refer to CONTAMINATED REFRIGERANT
below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refriger-
ant Recovery/Recycling Recharging equipment (ACR4) (J-39500-INF) and Refrigerant Identifier.
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
ble to minimize the entry of moisture into system.
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Remove R-134a from the A/C system, using certified service equipment meeting require-
ments of SAE J2210 (R-134a recycling equipment), or J2209 (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.
Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.
General Refrigerant Precautions EJS0011M
WARNING:
Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
Do not store or heat refrigerant containers above 52C (125F).
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.
Do not intentionally drop, puncture, or incinerate refrigerant containers.
Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
MTC-4
PRECAUTIONS
Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation. A
Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or B
property damage. Additional health and safety information may be obtained from refrigerant man-
ufacturers.
Lubricant Precautions EJS0011N C
Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
If lubricant other than that specified is used, compressor failure is likely to occur.
The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following D
handling precautions must be observed:
When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize
the entry of moisture from the atmosphere. E
When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before con-
necting the components. Connect all refrigerant loop components as quickly as possible to minimize the
entry of moisture into system. F
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. With-
out proper sealing, lubricant will become moisture saturated and should not be used.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. G
Remove R-134a from the A/C system, using certified service equipment meeting requirements of SAE
J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system dis-
charge occurs, ventilate work area before resuming service. Additional health and safety information may
H
be obtained from refrigerant and lubricant manufacturers.
Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage
may result.
I
Precautions for Leak Detection Dye EJS001FO
The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks. MTC
Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of
the fluorescent dye.
The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo- K
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J-
41995) pin-point refrigerant leaks.
For your safety and your Customer's satisfaction, read and follow all manufacture's operating instructions L
and precautions prior to performing the work.
A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). M
Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis
during a future service.
Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period
of time cannot be removed.
Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system.
Leak detection dyes for R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye
in R-12 A/C system or R-12 leak detector dye in R-134a A/C systems or A/C system damage may result.
The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
occurs.
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
MTC-5
PRECAUTIONS
IDENTIFICATION LABEL FOR VEHICLE

Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
SHA436FA
Precautions for Refrigerant Connection EJS0011O
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
Expansion valve to cooling unit
Dual pressure switch to liquid tank
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
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
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil-
itating piping connections.
SHA815E
MTC-6
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION

A
MTC
SJIA0001E
MTC-7
PRECAUTIONS
SJIA0002E
MTC-8
PRECAUTIONS
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O- A
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 B
Connec- O-ring
Part number D mm (in) W mm (in)
tion type size
New 92471 N8210 6.8 (0.268) 1.85 (0.0728) C
8
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
D
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) E
16
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
New 92474 N8210 16.5 (0.650) 2.43 (0.0957)
SHA814E 19 F
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
New 24 92195 AH300 21.8 (0.858) 2.4 (0.094)
WARNING: G
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: H
When replacing or cleaning refrigerant cycle components, observe the following.
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.
After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera- MTC
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
Allow components stored in cool areas to warm to working area temperature before removing seal K
caps. This prevents condensation from forming inside A/C components.
Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
Always replace used O-rings. L
When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S M
Part number: KLH00-PAGS0
O-ring must be closely attached to dented portion of tube.
When replacing the O-ring, be careful not to damage O-ring and tube.
Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
MTC-9
PRECAUTIONS
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 con-
nections of seal seat to the specified torque.
RHA861F
Precautions for Servicing Compressor EJS0011P
Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow Maintenance of Lubricant Quantity in Compres-
sor exactly. Refer to MTC-19, "Maintenance of Lubricant Quantity in Compressor" .
Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-
cant, wipe it off by using a clean waste cloth moistened with thinner.
After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.
Precautions for Service Equipment EJS0011Q
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
MTC-10
PRECAUTIONS
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible A
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump B
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows. C
Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump. D
For pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump. E
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
open and lubricating oil may migrate. F
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
G
RHA270DA
MANIFOLD GAUGE SET H

Be certain that the gauge face indicates R-134a or 134a. Be sure the
gauge set has 1/2-16 ACME threaded connections for service
hoses. Confirm the set has been used only with refrigerant HFC- I
134a (R-134a) and specified lubricants.
MTC
K
SHA533D
SERVICE HOSES L
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 hoses
M
opposite the manifold gauge.
RHA272D
MTC-11
PRECAUTIONS
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 contamination
may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
RHA273D
REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC-134a (R-134a) and speci-
fied lubricants have been used with the scale. If the scale controls
refrigerant flow electronically, the hose fitting must be 1/2-16
ACME.
RHA274D
CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale every three months.
To calibrate the weight scale on the ACR4 (J-39500-INF):
1. Press Shift/Reset and Enter at the same time.
2. Press 8787 . A1 will be displayed.
3. Remove all weight from the scale.
4. Press 0 , then press Enter . 0.00 will be displayed and change to A2 .
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of
the weight scale.
6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50)
7. Press Enter the display returns to the vacuum mode.
8. Press Shift/Reset and Enter at the same time.
9. Press 6 the known weight on the scale is displayed.
10. Remove the known weight from the scale. 0.00 will be displayed.
11. Press Shift/Reset to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into 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.
Wiring Diagrams and Trouble Diagnosis EJS0011T
When you read wiring diagrams, refer to the followings:

GI-13, "How to Read Wiring Diagrams" in GI section.
PG-3, "Wiring Diagram POWER "in PG section.
When you perform trouble diagnosis, refer to the followings:
GI-9, "How to Follow Trouble Diagnoses" in GI section.
MTC-12
PRECAUTIONS
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

A
MTC
MTC-13
PREPARATION
PREPARATION PFP:00002
Special Service Tools EJS0011U
Tool number
Description
Tool name
KV99231260 Removing shaft nut and clutch disc

Clutch disc wrench
NT204
RJIA0194E
KV992T0001 Removing clutch disc

Clutch disc puller
NT206
KV992T0002 Installing pulley

Pulley installer
NT207
HFC-134a (R-134a) Service Tools and Equipment EJS0011V
Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubri-
cant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-
cant.
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.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor failure will result.
MTC-14
PREPARATION
Tool number
(Kent-Moore No.) Description
A
Tool name
B
Container color:Light blue
Container marking:HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size:Thread size C
large container 1/22 -16 ACME
S-NT196
D
Type:Poly alkylene glycol oil (PAG),
type S
KLH00-PAGS0 Application:HFC-134a (R-134a)
(-) Swash plate compressors (Nissan E
Nissan A/C System Oil Type S only)
Lubricity:40 ml [Litre] (1.4 US fl oz,
S-NT197
1.4 Imp fl oz)
F
(J-39500-INF)
Function:Refrigerant Recovery and
Recovery/Recycling
Recycling and Recharging H
Recharging equipment (ACR4)
I
RJIA0195E
MTC
Power supply: K
(J-41995)
Electrical leak detector DC 12V (Cigarette lighter)
AHA281A
M
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses Power supply:
(J-41459) Refrigerant dye injector DC 12V (Battery terminal)
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleaner
SHA437F
MTC-15
PREPARATION
Tool number
(Kent-Moore No.) Description
Tool name
Power supply: DC 12V (Battery

terminal)
For checking refrigerant leak when
(J-42220)
fluorescent dye is installed in A/C
Fluorescent dye leak detector
system.
Includes: UV lamp and UV safety
SHA438F
glasses
Application: For HFC-134a (R-134a)

PAG oil
(J-41447)
Container: 1/4 ounce (7.4cc) bottle
HFC-134a (R-134a) Fluorescent
(Includes self-adhesive dye
leak detection dye
identification labels for affixing to
(Box of 24, 1/4 ounce bottles)
vehicle after charging system with
dye.)
SHA439F
(J-41459)
HFC-134a (R-134a) Dye injector For injecting 1/4 ounce of fluorescent
Use with J-41447, 1/4 ounce leak detection dye into A/C system.
bottle
SHA440F
(J-43872)
For cleaning dye spills.
Dye cleaner
SHA441F
Identification:
(J-39183)
Manifold gauge set (with hoses The gauge face indicates R-134a.
and couplers) Fitting size:Thread size
1/22 -16 ACME
RJIA0196E
Service hoses Hose color:

High side hose Low hose:Blue with black stripe
(J-39501-72) High hose:Red with black stripe
Low side hose Utility hose:Yellow with black stripe
(J-39502-72) or green with black stripe
Utility hose Hose fitting to gauge:
S-NT201
(J-39476-72) 1/22 -16 ACME
MTC-16
PREPARATION
Tool number
(Kent-Moore No.) Description A
Tool name
Service couplers B
High side coupler Hose fitting to service hose:
(J-39500-20) M14 x 1.5 fitting is optional or
Low side coupler permanently attached. C
(J-39500-24)
S-NT202
For measuring of refrigerant

(J-39650) Fitting size:Thread size
Refrigerant weight scale E
1/22 -16 ACME
S-NT200
F
Capacity:
Air displacement:4 CFM
(J-39649)
Micron rating:20 microns G
Vacuum pump
(Including the isolator valve) Oil capacity:482 g (17 oz)
Fitting size:Thread size
S-NT203 1/22 -16 ACME H
Commercial Service Tool EJS0011W
Tool name Description

I
MTC
For checks refrigerant purity and for K

Refrigerant identifier equipment
system contamination
RJIA0197E
MTC-17
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM PFP:KA990
Refrigerant Cycle EJS0011X
REFRIGERANT FIOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is
controlled by an externally equalized expansion valve, located inside the evaporator case.
Refrigerant System Protection EJS0011Y
DUAL PRESSURE SWITCH

The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the liquid tank. If the system pressure rises above or falls below the specifications, the dual-pres-
sure switch, located on the liquid tank.If the system pressure rises above or falls below the specifications,the
dual-pressure switch opens to interrupt the compressor operation.
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (38 kg/
cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into
the atmosphere.
SJIA0003E
MTC-18
LUBRICANT
LUBRICANT PFP:KLG00
A
Maintenance of Lubricant Quantity in Compressor EJS0011Z
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large gas leakage occurred. It is important to maintain the speci- B
fied amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
Lack of lubricant: May lead to a seized compressor C
Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
D
Name :Nissan A/C System Oil Type S
Part number :KLH00-PAGS0
LUBRICANT RETURN OPERATION E
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION F
Can lubricant return operation be performed?
A/C system works properly.
G
There is no evidence of a large amount of lubricant leakage.
Yes or No
Yes >> GO TO 2. H
No >> GO TO 3.
2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:

I
1. Start engine, and set the following conditions:
Test condition
Engine speed: Idling to 1,200 rpm MTC
A/C switch:ON
Blower speed:Max. position
Temp. control: Optional [Set so that intake air temperature is 25 to 30C (77 to 86F).]
Intake position:Recirculation (REC) K
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
L
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
M
>> GO TO 3.
3. CHECK COMPRESSOR
Should the compressor be replaced?
Yes or No
Yes >> Go to MTC-20, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
No >> GO TO 4.
MTC-19
LUBRICANT
4. CHECK ANY PART

Is there any part to be replaced? (Evaporator, condenser,liquid tank or in case there is evidence of a large
amount of lubricant leakage.)
Yes or No
Yes >> Go to MTC-20, "LUBRICANT AJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT
EXCEPT COMPRESSOR" .
No >> Carry out the A/C performance test.
LUBRICANT AJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-
PRESSOR
After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
Lubricant to be added to system
Part replaced Amount of lubricant Remarks
ml [Litre] (US fl oz, Imp fl oz)
Evaporator 75 (2.5, 2.6) -
Rear evaporator 20 (0.6, 0.7) -
Condenser 35 (1.2, 1.2) -
Liquid tank 10 (0.3, 0.4) -
30 (1.0, 1.1) Large leak
In case of refrigerant leak
- Small leak *1
*1:If refrigerant leak is small, no addition of lubricant is needed.
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
3. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
4. Drain the lubricant from the new compressor into a separate, clean container.
5. 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.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to new compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add an additional 5 ml [Litre] (0.2 US fl oz, 0.2 Imp fl oz) of
lubricant at this time.
Do not add this 5 ml(0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.
MTC-20
LUBRICANT
RHA065DD MTC
MTC-21
AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL PFP:27500
Control Operation EJS001ED
SJIA0004E
FAN CONTROL KNOB

This knob turns the fan ON and OFF, and controls fan speed.
MODE CONTROL KNOB
This knob controls the direction of air flow through the front discharge outlets.
TEMPERATURE CONTROL KNOB
This knob allows adjustment of the outlet air temperature.
RECIRCULATION (REC) SWITCH
OFF position: Outside air is drawn into the passenger compartment.
ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.
AIR CONDITIONER SWITCH
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.
MTC-22
REAR COOLER FAN CONTROL KNOB(FRONT)

The control of the rear blower speed can be obtained by rotating the rear cooler fan control knob. A
REAR COOLER FAN SWITCH

The rear cooler fan switch controls the rear blower speed regardless of the rear cooler fan control knob(front) B
position. In any other position(1-4), it allows the rear cooler fan switch to control the rear blower speed,
MTC
MTC-23
Discharge Air Flow EJS001EE
SJIA0005E
MTC-24
Component Layout EJS001EF
MTC
SJIA0006E
MTC-25
Component Location EJS001ES
ZJIA0003E
MTC-26
System Description EJS001ET
SWITCHES AND THEIR CONTROL FUNCTION A
I
SJIA0103E
MTC
SJIA0104E
MTC-27
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS PFP:00004
How to Perform Trouble Diagnoses for Quick and Accurate Repair EJS001FP
WORK FLOW
*1:Operational Check MTC-38
SHA900E
SYMPTOM TABLE
Symptom Reference Page
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor. MTC-40
Rear cooler fan motor operation is malfunc-
Go to Trouble Diagnosis Procedure for Rear cooler fan Motor. MTC-44
tioning.
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. MTC-50
Insufficient cooling. Go to Trouble Diagnosis Procedure for Insufficient Cooling. MTC-55
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor. MTC-55
Intake door motor does not operate normally.
Insufficient heating. Go to Trouble Diagnosis Procedure for Insufficient Heating. MTC-63
Noise. Go to Trouble Diagnosis Procedure for Noise. MTC-65
MTC-28
TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location EJS00121
MTC
ZJIA0003E
MTC-29
TROUBLE DIAGNOSIS
Wiring Diagram HEATER EJS00122
TJWH0001E
MTC-30
TROUBLE DIAGNOSIS
Schematic A/C EJS001GQ
MTC
TJWH0002E
MTC-31
TROUBLE DIAGNOSIS
Wiring Diagram A/C EJS001GR
TJWH0003E
MTC-32
TROUBLE DIAGNOSIS
MTC
TJWH0004E
MTC-33
TROUBLE DIAGNOSIS
TJWH0005E
MTC-34
TROUBLE DIAGNOSIS
MTC
TJWH0006E
MTC-35
TROUBLE DIAGNOSIS
Wiring Diagram R/COOL EJS00123
TJWH0007E
MTC-36
TROUBLE DIAGNOSIS
MTC
TJWH0008E
MTC-37
TROUBLE DIAGNOSIS
Operational Check EJS00124
The purpose of the operational check is to confirm that the system operates as it should. The systems which
are checked are the blower, mode (discharge air), intake air (recirculation), temperature decrease, tempera-
ture increase, and A/C compressor.
CONDITIONS:
Engine running at normal operating temperature.
PROCEDURE:
1. Check Blower Motor
1. Turn fan control knob to 1-speed.
Blower should operate on 1-speed.
2. Then turn fan control knob to 2-speed, and continue checking
blower speed until all four speeds are checked.
3. Leave blower on 4-speed.
If NG, go to MTC-40, "Blower Motor Circuit"
If OK, continue with the check.
SJIA0043E
2. Check A/C Switch

1. Turn fan control knob to the desired (1 to 4 speed) position.
2. Push the A/C switch to turn ON the air conditioner.
The indicator lamp should come on when air conditioner is ON.
3. Confirm that the compressor clutch engages (audio or visual
inspection).
4. Check for cold air at the appropriate discharge air outlets.
If NG, go to MTC-50, "Magnet Clutch Circuit" .
If OK, continue with next check.
If all operational checks are OK (symptom cannot be duplicated), go
to Incident Simulation Tests in MTC-28, "How to Perform Trouble SJIA0044E
Diagnoses for Quick and Accurate Repair" , and perform tests as
outlined to simulate driving conditions environment. If symptom appears, refer to MTC-28, "SYMPTOM
TABLE" and perform applicable trouble diagnoses procedures.
3. Check Discharge Air
1. Turn mode control knob to each mode position.
SJIA0045E
MTC-38
TROUBLE DIAGNOSIS
2. Confirm that discharge air comes out according to the air distri-
bution table at left. A
Refer to MTC-24, "Discharge Air Flow" .
If NG, go toMTC-90, "Adjustment of Cable" .
If OK, continue with next check. B
G
SJIA0046E
4. Check Recirculation
1. Press recirculation switch. H
Recirculation indicator should light.
2. Listen for intake door position to change (you should hear
blower sound change slightly). I
If NG, go to MTC-55, "Intake Door Circuit" .
MTC
SJIA0047E K
5. Check Temperature Decrease
1. Turn temperature control knob to full cold.
L
2. Check for cold air at discharge air outlets.
If NG, go toMTC-55, "Insufficient Cooling" .
M
SJIA0048E
MTC-39
TROUBLE DIAGNOSIS
6. Check Temperature Increase

1. Turn temperature control knob to full hot.
2. Check for hot air at discharge air outlets.
If NG, go to MTC-63, "Insufficient Heating" .
SJIA0049E
7. Check rear cooler

1. Turn fan control knob (front) to the desired (1 to 4 speed) posi-
tion.
2. Push A/C switch to turn ON the air conditioner is ON.
3. Push rear cooler switch.
Blower should operate on 1-speed.
4. Then turn fan control knob to 2-speed, and continue checking
blower speed until all four speeds are checked.
5. Leave blower on 3-speed.
If NG, go to MTC-44, "Rear Cooler Fan Motor Circuit" .
If OK, continue with the check. SJIA0050E
Blower Motor Circuit EJS00125
SYMPTOM:
Blower motor does not rotate.
1. DIAGNOSTIC PROCEDURE
Check if blower motor rotates properly at each fan speed.
Does not rotate at any speed>>GO TO 2

Does not rotate at 1-4 speed>>GO TO 8
2. CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

Disconnect blower motor harness connector.
Terminals
(+) Voltage
(-)
Connector Wire color
M223-1 L/R Ground Approx. 12V
OK or NG
OK >> GO TO 3
NG >> GO TO 13
SJIA0051E
MTC-40
TROUBLE DIAGNOSIS
3. CHECK BLOWER MOTOR GROUND CIRCUIT A

1. Disconnect blower motor connector.
2. Turn fan control knob to 4-speed.
B
Terminals
Continuity
Blower motor
Connector Wire color Ground C
Yes
M223-2 L/B
Continuity should exist. D

SJIA0052E
Yes or No
Yes >> GO TO 4
E
No >> GO TO 5
4. CHECK BLOWER MOTOR

F
Apply 12 volt to blower motor terminal 1 and ground to blower motor
terminal 2.
Dose blower motor rotate? G
Yes >> INSPECTION END
No >> Replace blower motor.
H
I
SJIA0053E
5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT MTC

1. Connect blower motor connector.
2. Disconnect resistor connector.
K
Terminals
Voltage
(+) (-)
L
Ground Approx. 12 V
M222 -2 L/B
OK or NG M
OK >> GO TO 7
NG >> GO TO 6
SJIA0054E
MTC-41
TROUBLE DIAGNOSIS
6. CHECK CIRCUIT CONTINUITY

Disconnect blower motor connector.
Terminals
Continuity
Blower motor Resistor
Connector Wire color Connector Wire color
Yes
M223-2 L/B M222-2 R
Continuity should exist.

Yes or No
Yes >> Check the following. SJIA0055E
If NG, repair harness or connectors.
Harness connectors M13, M222 and M223.
Harness for open or short between blower motor and fan switch, resistor.
No >> Repair harness or connector.
7. CHECK FAN SWITCH GROUND

Disconnect fan switch harness connector.
Terminals
Continuity
Fan switch
Connector Wire color Ground
Yes
M13-6 B

Yes or No
Yes >> GO TO 8 SJIA0056E
8. CHECK FAN RESISTOR CONTINUITY
Terminals
Continuity
Resistor
M222-1
M222-3
M222-2 Yes
M222-4
M222-6
Continuity should exist. SJIA0057E
Yes or No
Yes >> GO TO 9
No >> Replace resistor.
9. CHECK FAN RESISTOR

1. Reconnect fan resistor and resistor.
2. Check if blower motor rotates properly at each fan speed.

MTC-42
TROUBLE DIAGNOSIS
10. FAN SWITCH POWER SUPPLY CIRCUIT A

Turn fan control knob to off position.
Terminals
B
(+) (-) Voltage
Fan switch
Connectors Wire color C
M13-2 L/B
Ground
M13-3 L/W Approx. 12 V
D
M13-4 L/Y
SJIA0058E
M13-5 L/G
OK or NG E
OK >> GO TO 12
NG >> GO TO 11
F
G
Terminals
Continuity
Connectors Wire color Connectors Wire color H
M13-2 L/B M222-3 L/B
M13-3 L/W M222-6 L/W Yes
I
M13-4 L/Y M222-4 L/Y
M13-5 L/G M222-1 L/G
SJIA0059E
MTC
Yes or No
Yes >> Check the following. K
Harness for open or short between blower motor and fan switch, fan resistor
No >> Repair harness or connector. L
12. CHECK FAN SWITCH

M
Disconnect fan switch harness connector M13 and check continuity
between terminals at each fan switch position.
Terminals
Continuity
Fan switch position Fan switch
1 M13-2
2 M13-4
M13-6 Yes
3 M13-3
4 M13-2
SJIA0060E
Yes or No
No >> Replace fan switch
MTC-43
TROUBLE DIAGNOSIS
13. CHECK BLOWER MOTOR RELAY

1. Disconnect blower motor relay.
2. Apply 12 volt to blower motor relay terminal 3 and ground to
blower relay terminal 5.
Terminals
Continuity
Blower motor relay
M39 (J/B) -1 M39 (J/B) -2 Yes

Yes or No
Harness for open or short between blower motor relay and fuse block (J/B)
No >> Replace blower motor relay.

Rear Cooler Fan Motor Circuit EJS00126
SYMPTOM:
Rear cooler fan motor does not rotate.
1. DIAGNOSTIC PROCEDURE
1. Engine running and A/C ON.
2. Turn fan control knob (front) to the desired (1 to 4 speed) position.
3. Check if rear cooler fan motor rotate properly at each fan speed.

Magnet clutch does not engage>> MTC-50, "Magnet Clutch Circuit" .
2. CHECK REAR COOLER FAN MOTOR POWER SUPPLY CIRCUIT

Disconnect rear cooler fan motor connector.
Terminals
(+) Voltage
(-)
R107-1 L/R Ground Approx. 12V
OK or NG
OK >> GO TO 3
NG >> GO TO 13
SJIA0062E
MTC-44
TROUBLE DIAGNOSIS
3. CHECK REAR COOLER FAN MOTOR GROUND CIRCUIT A

Push rear cooler fan switch.
Terminals
B
(+) (-) Continuity
Blower motor
Connector Wire color Ground C
Yes
R107-2 L/B
Continuity should exist. D

Yes or No SJIA0063E
Yes >> GO TO 4
No >> GO TO 5 E
4. CHECK REAR COOLER FAN MOTOR

F
Apply 12 volts to rear cooler fan motor terminal 1 and ground to rear
cooler fan motor terminal 2.
Does rear cooler fan motor rotate?
G
No >> Replace rear blower fan motor.
H
I
SJIA0064E
5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT MTC

1. Connect rear cooler fan motor connector.
2. Disconnect resistor.
K
Terminals
(+) Voltage
(-)
Connector Wire color L
R104-1 L/R Ground Approx. 12V
OK or NG M
OK >> GO TO 7
NG >> GO TO 6
SJIA0065E
MTC-45
TROUBLE DIAGNOSIS

Disconnect rear cooler fan motor connector.
Terminals
Continuity
Yes
R107-2 L/B R104-2 R

OK or NG
OK >> Check the following. SJIA0066E
Harness connectors R102,R104 and R107.
Harness for open or short between rear cooler fan motor and fan switch, fan resistor.
NG >> Repair harness or connector.
7. CHECK REAR COOLER FAN SWITCH GROUND

1. Disconnect rear cooler fan switch connector.
2. Check continuity between rear cooler fan switch connector ter-
minal 6 and ground.
Terminals
Continuity
Fan switch
Connectors Wire color
Ground
R102-1 B Yes
R102-6 B
Yes or No
Yes >> GO TO 8
8. CHECK FAN RESISTOR CONTINUITY

1. Disconnect fan resistor connector.
2. Check continuity between fan resistor terminals.
Terminals
Continuity
Resistor
R104-1
R104-2 R104-4 Yes
R104-6

Yes or No SJIA0068E
Yes >> GO TO 9
No >> Replace resistor.
MTC-46
TROUBLE DIAGNOSIS
9. CHECK FAN RESISTOR A

1. Reconnect rear cooler fan resistor.
2. Check if rear cooler fan motor rotates properly at each fan speed.
B
C
10. REAR COOLER FAN SWITCH POWER SUPPLY CIRCUIT
Push rear cooler switch to off.
D
Terminals
Voltage
Fan switch
E
R102-2 L/B Ground
Approx. 12 V
R102-3 L/W F
R102-4 L/Y
OK or NG SJIA0069E
OK >> GO TO 12 G
NG >> GO TO 11
11. CHECK CIRCUIT CONTINUITY H
Check continuity between rear cooler fan switch and rear cooler
resister.
I
Terminals
Continuity
Fan switch Resistor
Connectors Wire color Connectors Wire color MTC
R102-2 L/B R104-1 L/B
Yes
R102-3 L/W R104-4 L/W
K
R102-4 L/Y R104-6 L/Y
SJIA0070E
L
Yes or No
Yes >> Check the following.
If NG, repair harness or connectors. M
Harness connectors R102, R104 and R107
Harness for open or short between blower motor and fan switch, fan resistor
MTC-47
TROUBLE DIAGNOSIS
12. CHECK REAR COOLER FAN SWITCH

Disconnect rear cooler fan switch connector and check continuity
between terminals at each fan switch position.
Terminals
Continuity
Fan switch position Fan switch
1 R102-2
2 R102-1 R102-3 Yes
3 R102-4

Yes or No
No >> Replace rear cooler fan switch
13. CHECK REAR COOLER RELAY
1. Disconnect rear cooler relay.

2. Apply 12 volt to rear cooler relay terminal 1 and ground to rear
cooler relay terminal 2.
Terminals
Continuity
Rear cooler relay
R106-3 R106-5 Yes

Yes or No
Harness for open or short between blower relay and fuse block (J/B).
If OK, GO TO 14
No >> Replace rear cooler relay.
14. CHECK REAR COOLER SWITCH (REAR)

Disconnect rear cooler switch (rear) connector.
Terminals
Continuity
Switch position Fan switch
ON-1 R103-5
R103-2 Yes
ON-2 R103-4

Yes or No
No >> Replace rear cooler fan switch (rear)
MTC-48
TROUBLE DIAGNOSIS
15. CHECK CIRCUIT CONTINUITY A

Disconnect rear cooler relay.
Terminals
Continuity B
Rear cooler switch Rear cooler relay
Yes
R103-3 R106-2 C

Yes or No D
E
16. CHECK REAR COOLER SWITCH (FRONT)
1. Connect rear cooler relay and rear cooler switch.
F
3. Turn fan control knob (front) to the desired (1 to 4 speed) posi-
tion.
G
Terminals
Voltage
Rear cooler switch
H
Approx. 12 V
M16-2 R
Continuity should exist. I

SJIA0074E
OK or NG
OK >> GO TO 17 MTC
17. CHECK CIRCUIT CONTINUITY K

Disconnect rear cooler switch and thermo control amp.
Terminals
Continuity L
Rear cooler switch Thermo control amp.
Yes
M16-2 R M6-2 R M

Yes or No
MTC-49
TROUBLE DIAGNOSIS
18. CHECK REAR COOLER SWITCH (FRONT) CONTINUITY
Terminals
Continuity
Switch position Fan switch
ON-1 M16-3
M16-2 Yes
ON-2 M16-1

Yes or No
No >> Replace rear cooler fan switch (front)

Description
Terminals
Continuity
Rear cooler switch (front) Rear cooler switch (rear)
Connectors Wire color Connectors Wire color
M16-1 L/B R103-4 L/B Yes
M16-3 L/W R103-5 L/W

Yes or No SJIA0077E
Yes >> Check the following.

Harness for open or short between blower relay and fuse block (J/B).

Magnet Clutch Circuit EJS00127
SYMPTOM:
Magnet clutch does not engage when A/C switch and fan switch are ON.
1. CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT

1. Disconnect A/C compressor harness connector.
2. Press the A/C switch ON.
Terminals
(+) Voltage
(-)
F9-1 (Gasoline
R/W
engine) Ground Approx. 12V
A10-1 (Diesel engine) R/Y
OK or NG
SJIA0078E
OK >> 1. If NG, replace magnet clutch.
2. Check magnet clutch operation.
NG >> GO TO 2
MTC-50
TROUBLE DIAGNOSIS
2. CHECK CIRCUIT CONTINUITY A

1. Disconnect A/C relay.
2. Check circuit continuity between A/C relay connector and A/C
compressor connector. B
3.
terminals
Continuity
Compressor connectors A/C relay connector C
F9-1 (Gasoline engine) R/W M128-5 R/W
Yes
A10-1 (Diesel engine) R/Y M128-5 R/Y
D
SJIA0079E
Yes or No
E
Yes >> GO TO 3
3. CHECK A/C RELAY POWER SUPPLY F
Terminals G
Voltage
(+) (-)
Connector Wire color H
Ground Approx. 12 V
M128 -1, 3 and 6 L
OK or NG
OK >> GO TO 4. I
NG >> Check power supply circuit and 10A(No.13), 15A(No.15,
16) fuse at fuse block. Refer to PG-78, "FUSE BLOCK- SJIA0080E
JUNCTION BOX(J/B)" . MTC
4. CHECK CIRCUIT CONTINUITY BETWEEN TERMINAL ON A/C RELAY

1. Disconnect A/C relay. K
2. When apply 12 volts between connector No.1 and 2, Check cir-
cuit continuity.
L
Terminals
Continuity
Connectors Wire color Connectors Wire colors
M128-5 M
R/W
(Gasoline engine)
M128-3
L M128-5 Yes
R/Y
(Diesel engine)
M128-6 M128-7 R/W
SJIA0081E

Yes or No
Yes >> GO TO 5
No >> Replace A/C relay.
MTC-51
TROUBLE DIAGNOSIS

1. Reconnect A/C relay.
Terminals
A/C relay ECM Continuity
Connector Wire color Connectors Wire color
F106-23 (Gasoline)
M128-2 B/W B/W Yes
F111-15 (Diesel)

Yes or No SJIA0082E
Yes >> GO TO 6
6. CHECK A/C ON SIGNAL IN ECM

Engine running and A/C ON.
Terminals
(+) Condition Voltage
(-)
M106-23(Gasoline) COMP:ON Approx. 0V
B/W Ground
M111-15(Diesel) COMP:OFF Approx. 12V
OK or NG
OK >> INSPECTION END. Refer to MTC-28, "How to Perform
Trouble Diagnoses for Quick and Accurate Repair" .
SJIA0083E
>> When compressor ON, do not approx. 0 V. GO TO 7
When compressor OFF, do not approx. 12 V. Refer to KA Engine (Gasoline) EC-61, "ECM
INSPECTION TABLE" ,ZD Engine (Diesel)EC-222, "ECM INSPECTION TABLE" .
7. CHECK DUAL PRESSURE SWITCH

Disconnect dual pressure switch connector.
Terminals
Continuity
Dual pressure switch
Yes
H15-2 B/R H15-1 BR/Y

Yes or No
Yes >> GO TO 8
No >> Replace dual pressure switch. SJIA0084E
MTC-52
TROUBLE DIAGNOSIS
8. CHECK COMPRESSOR ON SIGNAL IN ECM A

Engine running and A/C ON.
Terminals
B
(+) Condition Voltage
(-)
F106-46(Gassoline) COMP:ON Approx. 0V C
BR/Y Ground
F111-21(Diesel) COMP:OFF Approx. 12V
OK or NG
D
OK >> GO TO 12
>> When compressor ON, do not approx. 0V. GO TO 9
SJIA0085E
When compressor OFF, do not approx. 12 V. Refer to
E
KA Engine (Gasoline) EC-61, "ECM INSPECTION TABLE" , ZD Engine (Diesel) EC-222, "ECM
INSPECTION TABLE" .
9. CHECK POWER SUPPLY FOR THERMO CONTROL AMP. F
Disconnect thermo control amp.

Terminals G
Voltage
(+) (-)
Ground Approx. 12V H
M6- 1 and (3) L and (B/R)
OK or NG
OK >> GO TO 10 I
SJIA0086E
MTC
10. CHECK CIRCUIT CONTINUITY FOR THERMO CONTROL AMP.
Disconnect thermo control amp. connector and A/C switch connec-
tor. K
Terminals
Continuity
Thermo control amp. A/C switch L
Yes
M6-2 R M10-1 R
M
Yes or No SJIA0087E
Yes >> GO TO 11
MTC-53
TROUBLE DIAGNOSIS
11. CHECK THERMO CONTROL AMP.

1. Connect thermo control amp. and A/C switch connector.
Terminals
Voltage
(+) (-)
Ground Approx. 12V
M6- 2 R
OK or NG
OK >> GO TO 12
NG >> Replacer thermo control amp.
SJIA0088E
12. CHECK POWER SUPPLY FOR A/C SWITCH

Disconnect A/C switch connector.
Terminals
Voltage
(+) (-)
Ground Approx. 12V
M10- 1 R
OK or NG
OK >> GO TO 13
SJIA0089E

Disconnect fan switch.
Terminals
Continuity
A/C switch Fan switch
Yes
M10-2 G/Y M13-1 G/Y

Yes or No
14. CHECK FAN SWITCH GROUND
Terminals
Continuity
Fan switch
Yes
M13-6 B

Yes or No
MTC-54
TROUBLE DIAGNOSIS
15. CHECK FAN SWITCH A

Turn fan control knob to ON (any speed position except OFF).
Terminals
Continuity B
Fan switch
Yes
M13-1 G/Y M13-6 B C

Yes or No D
Yes >> Replace A/C switch. SJIA0092E
No >> Replace fan switch.
E
Intake Door Circuit EJS00128
SYMPTOM:
Intake door does not operate. F
1. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR G

Observe intake door operation when the REC switch is pushed ON
and OFF.
H
Terminals
REC switch
(+) Voltage
condition (-)
Connectors Wire color I
ON Approx. 12V
M5-2 BR
OFF Approx. 0V
Ground MTC
ON Approx. 0V
M5-4 L/W SJIA0093E
OFF Approx. 12V
OK or NG K
OK >> GO TO 3
NG >> Check power supply circuit and 10A(No.13), 15A(No.15, 16) fuse at fuse block. Refer to PG-78,
"FUSE BLOCK-JUNCTION BOX(J/B)" . L
If OK, replace intake door motor.
2. CHECK CIRCUIT CONTINUITY M

Disconnect intake door connector and REC switch.
Terminals
Continuity
Fan switch
Yes
M13-1 G/Y M13-6 B

Yes or No
Yes >> Replace REC switch. SJIA0094E
Insufficient Cooling EJS00129
SYMPTOM: Insufficient cooling
MTC-55
TROUBLE DIAGNOSIS
INSPECTION FLOW
WHA292
*1 MTC-90 *2 MTC-60 *3 MTC-57

*4 MTC-38 *5 MTC-28 *6 MTC-97
*7 KA24DE;EM-14 ,ZD30DD;EM-107 *8 KA24DE;CO-20 ,ZD30DD;CO-42
MTC-56
TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSES

A
MTC
MHA649A
*1 MTC-59 *2 MTC-59 *3 MTC-60
MTC-57
TROUBLE DIAGNOSIS
LHA260
*1 MTC-50 *2 KA24DE;EM-14 ,ZD30DD;EM-107
MTC-58
TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition A
Testing must be performed as follows:
Vehicle location Indoors or in the shade (in a well-ventilated place)
B
Doors Closed
Door windows Open
Hood Open C
TEMP. Max. COLD
Mode door (Ventilation) set
D
Intake door (Recirculation) set
(blower) speed Max. speed set

Engine speed Idle speed E
Operate the air conditioning system for 10 minutes before taking measurements.
Rear cooler ON (For rear cooler equipped model only)
F
Test Reading (Single A/C equipped model)
Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet G
Discharge air temperature at center ventilator
Relative humidity Air temperature C (F)
% C (F)
25 (77) 6.5 - 9.0 (44 - 48)
H
50 - 60 30 (86) 11.3 - 14.0 (52 - 57)

35 (95) 16.4 - 20.0 (62 - 68)
I
40 (104) 21.7 - 26.0 (71 - 79)
25 (77) 9.0 - 11.5 (48 - 53)
60 - 70 30 (86) 14.0 - 17.3 (57 - 63) MTC

35 (95) 20.0 - 23.4 (68 - 74)
40 (104) 26.0 - 29.7 (79 - 85)
K
Ambient Air Temperature-to-operating Pressure Table L

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar,kg/cm2, psi) kPa (bar,kg/cm2, psi)
% C (F) M
950 - 1160
130 - 160
25 (77) (9.5 - 11.6, 9.69 - 11.83, 137.8 -
(1.3 - 1.6, 1.33 - 1.63, 18.9 - 23.2)
168.2)
1300 - 1390
170 - 210
30 (86) (13.0 - 13.9, 13.26 - 14.18, 188.5 -
(1.7 - 2.1, 1.73 - 2.14, 24.7 - 30.5)
50 - 70 201.6)
1320 - 1620
210 - 260
35 (95) (13.2 - 16.2, 13.46 - 16.52, 191.4 -
(2.1 - 2.6, 2.14 - 2.65, 30.5 - 37.7)
234.9)
1510- 1850
250 - 300
40 (104) (15.1 - 18.5, 15.40 - 18.87, 219.0 -
(2.5 - 3.0, 2.55 - 3.06, 36.3 - 43.5)
268.3)
MTC-59
TROUBLE DIAGNOSIS
Test Reading (Dual A/C equipped model)

Recirculating-to-discharge Air Temperature Table
Front
Inside air (Recirculating air) at blower assembly inlet
% C (F)
25 (77) 12.4 - 14.9 (54- 59)
50 - 60 30 (86) 16.7 - 19.7 (62 - 67)

35 (95) 21.0 - 24.5 (70 - 76)
40 (104) 25.57 - 29.5 (78 - 85)
25 (77) 14.9 - 17.5 (59 - 64)
60 - 70 30 (86) 19.7 - 22.5 (67 - 73)

35 (95) 24.5 - 27.5 (76 - 82)
40 (104) 29.5 - 34.0 (85 - 93)
Rear
Inside air (Recirculating air) at blower assembly inlet
% C (F)
25 (77) 10.5 - 13.0 (51 - 55)
50 - 60 30 (86) 15.5 - 18.5 (60 - 65)

35 (95) 20.5 - 24.0 (69 - 75)
40 (104) 25.5 - 29.5 (78 - 85)
25 (77) 13.0 - 15.5 (55 - 60)
60 - 70 30 (86) 18.5 - 21.5 (65 - 71)

35 (95) 24.0 - 27.4 (75 - 81)
40 (104) 29.5 - 34.0 (85 - 93)
Ambient Air Temperature-to-operating Pressure Table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar,kg/cm2, psi) kPa (bar,kg/cm2, psi)
% C (F)
910 - 1010
240 - 270
25 (77) (9.1 - 10.1, 9.28 - 10.30, 132.0 -
(2.40 - 2.75, 2.45 - 2.75, 34.8 - 39.2)
146.5)
1050 - 1170
.270 - 310
30 (86) (10.5 - 11.7, 10.71 - 11.93, 152.3 -
(2.7 - 3.1, 2.75 - 3.16, 39.2 - 45.0)
50 - 70 169.7)
1240 - 1380
330 - 360
35 (95) (12.4 - 13.8, 12.65 - 14.08,179.8 -
(3.3 - 3.6, 3.37 - 3.67, 47.9 - 52.2)
200.1)
1430- 1590
360 - 400
40 (104) (14.3 - 15.9, 14.59 - 16.22, 207.4 -
(3.6 - 4.0, 3.67 - 4.08, 52.2 - 58.0)
230.6)
TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE

Whenever system's high and/or low side pressure is abnormal, diagnose using a manifold gauge. The marker
above the gauge scale in the following tables indicates the standard (normal) pressure range. Since the stan-
dard (normal) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-
to-operating pressure table).
MTC-60
TROUBLE DIAGNOSIS
Both High and Low-pressure Sides are Too High.

Gauge indication Refrigerant cycle Probable cause Corrective action
A
Pressure is reduced soon after

Excessive refrigerant charge in Reduce refrigerant until speci-
water is splashed on con-
refrigeration cycle fied pressure is obtained. B
denser.
Insufficient condenser cooling
performance
Clean condenser.
Air suction by cooling fan is C
insufficient. 1. Condenser fins are clogged. Check and repair cooling fan
as necessary.
2. Improper fan rotation of cool-
ing fan D
Low-pressure pipe is not
cold. Poor heat exchange in con-
Both high and low-pressure denser
When compressor is stopped E
sides are too high. (After compressor operation
high-pressure value quickly Evacuate repeatedly and
stops, high pressure decreases
drops by approximately 196 recharge system.
too slowly.)
kPa (2 kg/cm2, 28 psi). It
then decreases gradually Air in refrigeration cycle F
thereafter.
Engine cooling systems mal- Check and repair each engine
Engine tends to overheat.
AC359A function. cooling system. G
Excessive liquid refrigerant
on low-pressure side
Excessive refrigerant dis- H
charge flow
An area of the low-pressure
Expansion valve is open a lit-
pipe is colder than areas
tle compared with the specifi- I
near the evaporator outlet. Replace expansion valve.
cation.
Plates are sometimes cov-

ered with frost.
1. Improper thermal valve
MTC
installation
2. Improper expansion valve
adjustment
K
High-pressure Side is Too High and Low-pressure Side is Too Low.
High-pressure side is too high and L
low-pressure side is too low.
Upper side of condenser and High-pressure tube or parts Check and repair or replace
high-pressure side are hot, located between compressor malfunctioning parts. M
however, liquid tank is not so and condenser are clogged or Check lubricant for contami-
hot. crushed. nation.
AC360A
MTC-61
TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High.

Compressor pressure opera-
High-pressure side is too low and
High and low-pressure sides tion is improper.
low-pressure side is too high.
become equal soon after com- Replace compressor.
pressor operation stops. Damaged inside compressor
packings
Compressor pressure opera-
No temperature difference tion is improper.
between high and low-pres- Replace compressor.
sure sides Damaged inside compressor
AC356A
packings.
Both High- and Low-pressure Sides are Too Low.

There is a big temperature
difference between receiver
drier outlet and inlet. Outlet Replace desiccant assy.
temperature is extremely Liquid tank inside is slightly
clogged. Check lubricant for contami-
low. nation.
Liquid tank inlet and expan-
sion valve are frosted.
Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank. Check and repair malfunc-
High-pressure pipe located tioning parts.
Expansion valve inlet may between receiver drier and
be frosted. expansion valve is clogged. Check lubricant for contami-
nation.
Temperature difference
Both high- and low-pressure sides occurs somewhere in high-
are too low. pressure side
Expansion valve and liquid Low refrigerant charge
tank are warm or only cool Check refrigerant for leaks.
when touched. Leaking fittings or components
Expansion valve closes a little
compared with the specifica-
tion.
AC353A
Remove foreign particles by
There is a big temperature dif-
ference between expansion 1. Improper expansion valve using compressed air.
valve inlet and outlet while the adjustment Check lubricant for contami-
valve itself is frosted. 2. Malfunctioning thermal nation.
valve
3. Outlet and inlet may be
clogged.
Check and repair malfunc-
An area of the low-pressure tioning parts.
Low-pressure pipe is clogged
pipe is colder than areas near
or crushed. Check lubricant for contami-
the evaporator outlet.
nation.
Check thermo control amp.
Air flow volume is not enough operation.
Evaporator is frozen.
or is too low.
Replace compressor.
MTC-62
TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative.

A
Low-pressure side sometimes

Air conditioning system Refrigerant does not dis-
becomes negative.
does not function and does charge cyclically. B
not cyclically cool the com- Drain water from refrigerant
partment air. Moisture is frozen at expan- or replace refrigerant.
The system constantly func- sion valve outlet and inlet.
Replace desiccant assy. C
tions for a certain period of
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A
D
Low-pressure Side Becomes Negative.
Leave the system at rest until E
no frost is present. Start it
again to check whether or not
the problem is caused by
water or foreign particles.
F
If water is the cause, initially
cooling is okay. Then the
water freezes causing a G
Low-pressure side becomes nega-
blockage. Drain water from
tive.
refrigerant or replace refrig-
High-pressure side is closed erant.
Liquid tank or front/rear side of and refrigerant does not flow. H
expansion valve's pipe is If due to foreign particles,
frosted or dewed. Expansion valve or liquid tank remove expansion valve
is frosted. and remove the particles
with dry and compressed air I
AC362A (not shop air).
If either of the above meth-
ods cannot correct the prob- MTC
lem, replace expansion
valve.
Replace desiccant assy.
K
Check lubricant for contami-
nation.
Insufficient Heating EJS0012A L

SYMPTOM: Insufficient heating
MTC-63
TROUBLE DIAGNOSIS
INSPECTION FLOW
LHA261
*1 MTC-91 *2 MTC-38 *3 MTC-28

*4 KA24DE:CO-22, "WATER INLET *5 KA24DE:CO-9, "Changing Engine *6 MTC-77, "HEATER CORE"
AND THERMOSTAT ASSY" , Coolant" , ZD30DD: CO-32, "Chang-
ZD30DD:CO-45, "THERMOSTAT ing Engine Coolant"
AND WATER PIPING"
*7 KA24DE:CO-14, "CHECKING RADI-
ATOR CAP" ,ZD30DD:CO-37,
"CHECKING RADIATOR CAP"
MTC-64
TROUBLE DIAGNOSIS
Noise EJS0012B
A
SYMPTOM: Noise
INSPECTION FLOW
B
MTC
SHA336FA
*1 MTC-100 *2 MTC-100 *3 MTC-19

*4 KA24DE;EM-14 ,ZD30DD;EM-107
MTC-65
CONTROLLER
CONTROLLER PFP:27500
Removal and Installation EJS0017X
1. Remove cluster lid finisher C.

2. Remove air mix door, and mode door cable.
3. Remove air mix door, and mode door cable fixing clips.
ZJIA0008E
ZJIA0007E
4. Remove screws (4), and pull out controller.

5. Disconnect the connector, and remove controller.
ZJIA0009E
MTC-66
CONTROLLER
Disassembly and Assembly EJS0017Y
ZJIA0010J
1 Finisher 2 Mode control dial 3 Temperature control dial G

4 Fan control dial 5 E-ring 6 A/C panel
7 Mode door cable 8 Air mix door cable 9 Clips
H
10 REC switch knob 11 REC switch 12 Valve
13 A/C switch knob 14 A/C switch 15 Controller
16 Fan switch 17 Valve 18 Harness
I
MTC
MTC-67
BLOWER AND COOLING UNIT ASSEMBLY
BLOWER AND COOLING UNIT ASSEMBLY PFP:27210
Removal and Installation EJS0017Z
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove instrument lower assistance panel.
4. Remove headlight (LH).
ZJIA0012E
5. Disconnect high-pressure pipe 2 and low-pressure pipe 1 from

evaporator.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere.
6. Remove fixing nuts of blower and cooling unit.
ZJIA0013E
7. Remove connectors and clips.

8. Separate instrument panel at points shown in the figure at left.
9. Remove bolts and screws, and displace cover and lower duct.
ZJIA0015E
10. Remove air mix door cable fixing clip.
ZJIA0008E
MTC-68
11. Remove door lock relay, SRS air bag connector, air bag harness
clip, and keyless entry control connector. A
12. Remove instrument panel stay (LH).
13. Displace cover, and remove blower and cooling unit.
B
ZJIA0014E
D
INSTALLATION
1. Install blower and cooling unit.
Blower & cooling unit assembly mounting bolts and nuts E
Tightening torque : 4.31 - 5.78 Nm (0.44 - 0.59 kgm, 39 - 51 in-lb)
Blower & cooling unit assembly mounting screws F

2. Perform removal steps of 3 - 12 in reverse order.
G
CAUTION:
Replace O-rings on high-pressure and low-pressure pipes with new ones. Install new O-rings with
compressor oil applied.
After filling refrigerant, check system for refrigerant leak. H
Instrument panel stay mounting nuts

Tightening torque : 11 - 13 Nm (1.1 - 1.4 kgm, 98 - 115 in-lb) I
High-pressure pipe 2 mounting bolts

Tightening torque : 2.9 - 3.9 Nm (0.29 - 0.4 kgm, 26 - 34 in-lb) MTC
Low-pressure pipe 1 mounting bolts
Tightening torque : 8 - 10 Nm (0.8 - 1.1 kgm, 70 - 95 in-lb) K
3. Charge refrigerant using refrigerant recovery unit (for HFC134a).
MTC-69
Disassembly and Assembly EJS00180
ZJIA0016J
1 Support bracket (RH) 2 Support bracket (LH) 3 Screw

4 Evaporator lower case 5 Intake case 6 Intake door
7 Blower case 1 8 Blower case 2 9 Intake door lever
10 Intake door rod 11 Screw 12 Intake door actuator
13 Sub-harness 14 Seal 15 Bolt
16 Insulator 17 Piping block 18 Expansion valve
19 Evaporator 20 Thermal amplifier 21 Blower fan motor
22 Blower fan resistor 23 Screw 24 Blower fan harness
25 Coolant hose 26 Evaporator upper case 27 Drain hose
28 Clips
MTC-70
BLOWER FAN MOTOR
BLOWER FAN MOTOR PFP:27226

A
Removal and Installation EJS00181

2. Remove connectors and clips. B
3. Separate instrument panel at points shown in the figure at left.
ZJIA0015E
E
4. Disconnect coolant hose, and remove blower fan motor.
H
ZJIA0017E
MTC
MTC-71
BLOWER FAN RESISTOR
BLOWER FAN RESISTOR PFP:27150

2. Remove blower fan resistor.
CAUTION:
When thermal fuse of blower fan resistor is blown, inspect
blower fan motor and harness, and then replace blower fan
resistor with new one. Never repair thermal fuse.
ZJIA0018E
MTC-72
INTAKE DOOR ACTUATOR
INTAKE DOOR ACTUATOR PFP:27730

A

2. Remove intake door actuator. B
ZJIA0019E
MTC
MTC-73
HEATER UNIT ASSEMBLY
HEATER UNIT ASSEMBLY PFP:27100
REMOVAL
1. Drain engine coolant.
2. Loosen clamps as shown in the figure, and disconnect heater
hoses from heater & cooling unit assembly. Close coolant inlet/
outlet on heater core (2 locations) with shop cloths.
ZJIA0023E
3. Remove instrument panel assembly.

4. Remove instrument panel stay (LH).
ZJIA0020E
5. Remove instrument panel stay (RH).
ZJIA0021E
6. Dislocate lower duct, and displace cover.
ZJIA0022E
MTC-74
7. Remove heater unit assembly mounting nuts.

8. Remove heater unit assembly. A
SJIA0099E
D
INSTALLATION
1. Install heater unit assembly.
Heater unit assembly mounting nuts E
2. Perform removal steps of 2 to 6 in reverse order.
F
Instrument panel stay mounting nuts
Tightening torque : 11 - 13 Nm (1.1 - 1.4 kgm, 6 - 10 in-lb)
G
3. Fill engine coolant.
MTC
MTC-75
ZJIA0024E
MTC-76
HEATER CORE
HEATER CORE PFP:27140

A
1. Remove heater unit assembly.

2. Remove heater core support. B
3. Pull out heater core from heater case.
ZJIA0026E
MTC
MTC-77
REAR A/C UNIT ASSEMBLY
REAR A/C UNIT ASSEMBLY PFP:27400
INSTALLATION
refrigerant.
2. Remove roof headlining.
3. Disconnect drain hose (RH), and connector.
ZJIA0028E
4. Remove insulator, and disconnect high-pressure flexible hose 2

and low-pressure flexible hose 2 from rear A/C unit assembly.
CAUTION:
Seal connecting points of pipes with caps or vinyl tape, etc. to
prevent them from being exposed to atmosphere.
5. Disconnect drain hose (LH)
ZJIA0029E
6. Remove mounting bolts, and remove rear A/C unit assembly.
ZJIA0030E
INSTALLATION
1. Install rear A/C unit assembly.
Rear A/C unit assembly mounting bolts
Tightening : 4.31 - 5.78 Nm (0.44 - 0.59 kgm,
torque 39 - 51 in-lb)
2. Perform removal steps from 2 to 5 in reverse order.
CAUTION:
Replace O-rings on high-pressure and low-pressure flexible
hoses with new ones. Install new O-rings with compressor
oil applied.
ZJIA0031E
After filling refrigerant, check system for refrigerant leak.
Replace insulator on connections of rear A/C unit assembly and low-pressure flexible hose 2 with
new ones.
High-pressure flexible hose 2 union nut
Tightening : 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 -
torque 173 in-lb)
MTC-78
REAR A/C UNIT ASSEMBLY
Low-pressure flexible hose 2 union nut

A
Tightening : 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 -
torque 21 ft-lb)
3. Charge refrigerant using refrigerant recovery unit (for HFC134a). B
MTC
ZJIA0032J
K
1 Cover 2 Bolt 3 Screw
4 Rear blower fan motor 5 Rear A/C harness 6 Lower case
7 Seal 8 Bracket 1 9 Evaporator L
10 Bracket 2 11 Screw 12 Rear blower fan resistor
13 Relay 14 Upper case 15 Air duct (LH)
16 Air duct (RH) 17 Bracket 3 18 Bolt M
MTC-79
REAR BLOWER FAN MOTOR
REAR BLOWER FAN MOTOR PFP:27220
REMOVAL
2. Disconnect coolant hose and connectors.
3. Remove bracket 1.
4. Remove screws, and remove cover.
ZJIA0030E
5. Remove rear blower fan motor from rear A/C unit assembly.
ZJIA0033E
INSTALLATION
CAUTION:
Make sure that locating pins (2 locations) of rear A/C unit assembly (upper) and cover (lower) are
inserted into holes of motor side.
MTC-80
REAR BLOWER FAN RESISTOR
REAR BLOWER FAN RESISTOR PFP:27761

A
Removal and Installation EJS0018A
1. Remove rear intake grille (RH).

2. Disconnect rear A/C relay. B
ZJIA0078E
E
3. Remove connector and screws, and remove resistor.
H
ZJIA0034E
MTC
MTC-81
DRAIN HOSE
DRAIN HOSE PFP:92591
Removal and Installation EJS0018B
DRAIN HOSE (RH)

2. Disconnect drain hoses from rear A/C unit assembly.
CAUTION:
When disconnecting drain hoses, be careful to avoid spilling
water.
ZJIA0028E
3. Remove grommet, and pull out drain hoses upward.

4. Disconnect drain hose from clip.
ZJIA0035E
DRAIN HOSE (LH)

1. Disconnect drain hose (LH), high-pressure flexible hose 2, and
low-pressure flexible hose 2.
2. Remove band clip, and pull out drain hose.
ZJIA0076E
ZJIA0077E
MTC-82
REAR A/C CONTROLLER
REAR A/C CONTROLLER PFP:27571

A
Removal and Installation EJS0018C
1. Push clip side of rear A/C controller, and pull it out in the direc-
tion shown by arrow. B
ZJIA0037E
E
Disassembly and Assembly EJS0018D
MTC
ZJIA0038J
1 Finisher 2 Clips 3 Clips

4 Fan switch dial 5 Control assembly 6 Screw
7 Fan switch 8 Valve
MTC-83
REAR HEATER UNIT ASSEMBLY
REAR HEATER UNIT ASSEMBLY PFP:27300
Removal and Installation EJS0018E
BUILT-IN TYPE REAR HEATER (4 DOOR AND 5 DOOR)

CAUTION:
Be sure to drain rear heater coolant from rear heater pipe under vehicle.
2. Remove rear side finisher.
3. Disconnect connectors of blower fan and fan resistor.
RJIA0359E
4. Disconnect rear heater core hose.

CAUTION:
Some coolant may spill when the heater hoses are disconnected.
Close coolant inlet/outlet on heater core (2 locations), and air bleeding hose with shop cloths.
5. Remove rear heater mounting bolts and nuts, and remove rear heater unit.
FOOR-TYPE REAR HEATER (MICROBUS)
2. Remove third seat.
3. Disconnect rear heater unit hose.
RJIA0360E
4. Remove rear heater mounting bolts and rear heater connectors,

and remove rear heater unit.
RJIA0361E
MTC-84
Disassembly and Assembly EJS0018F
BUILT-IN TYPE REAR HEATER (4 DOOR AND 5 DOOR) A
I
RJIA0362J
1 Blower fan motor 2 Washer 3 Blower fan

MTC
4 Nut 5 Screw 6 Blower fan resistor
7 Rear heater case 1 8 Screw 9 Rear heater core (4 door)
10 Rear heater case 2 11 Rear heater cover 12 Adapter case
K
13 Heater core support 14 Screw 15 Screw (5 door)
16 Rear heater duct (5 door) 17 Screw (5 door) 18 Tube bracket (5 door)
19 Tube clip (5 door) 20 Rear heater hose (5 door) 21 Screw (5 door)
L
22 Rear heater core (5 door)
MTC-85
FOOR-TYPE REAR HEATER (MICROBUS)
RJIA0363J
1 Sub-harness 2 Nut 3 Blower fan

4 Washer 5 Blower fan motor 6 Screw
7 Screw 8 Bracket A 9 Screw
Heater pipe assembly (with water
10 Blower fan resistor 11 12 Bracket B
cock)
13 Screw 14 Screw 15 Heater case (upper)
16 Rear heater core 17 Bracket C 18 Heater case (lower)
19 Screw 20 Screw 21 Rear heater duct
22 Screw
Rear Blower Fan Motor EJS001EA
REMOVAL AND INSTALLATION

Built-in type rear heater (4 door and 5 door)
2. Remove connectors and mounting screws (3) of rear blower fan motor.
3. Remove rear blower fan motor.
RJIA0364E
MTC-86
Floor-type rear heater (microbus)

1. Drain engine coolant. A
2. Remove rear heater unit.
3. Disassemble rear heater unit, and remove rear blower fan motor. Refer to MTC-85, "Disassembly and
Assembly" in Rear Heater Unit. B
Rear Blower Fan Resistor EJS001EB

C
Built-in type rear heater (4 door and 5 door)
2. Remove connectors and mounting screws of rear blower fan D
resistor, and remove rear blower fan resistor.
RJIA0365E
G
Floor-type rear heater (microbus)
2. Remove rear heater unit, and disconnect connectors of rear blower fan resistor. H
3. Remove mounting screws of rear blower fan resistor, and remove rear blower fan resistor. Refer to MTC-
85, "Disassembly and Assembly" in Rear Heater Unit.
I
Rear Heater Duct (4 Door) EJS0018I

2. Remove rear heater unit. Refer to MTC-84, "Removal and Installation" in Rear Heater Unit. MTC
3. Remove clips, and remove rear heater duct.
M
RJIA0366E
Rear Heater Control EJS0018J

4 door, microbus
1. Pull left side of rear heater control, and remove clips (2).
2. Slide rear heater control to side (vehicle front), and remove rear
heater control.
RJIA0367E
MTC-87
5 door
2. Remove rear heater control mounting screws, and remove rear
heater control.
RJIA0368E
DISASSEMBLY AND ASSEMBLY
RJIA0369J
1 Finisher (4 door) 2 Fan switch knob 3 Clip (4 door)

4 Screw 5 Control assembly 6 Clip (4 door)
7 Screw 8 Fan switch 9 Valve
Rear Heater Hose EJS0018K

2. Remove engine undercover.
3. Remove clamp and screws (2), and disconnect heater tube. (ZD
engine)
RJIA0370E
MTC-88
4. Remove bolts (4), and bracket.

5. Remove clamp and bolts (3). A
6. Release parking brake.
CAUTION:
When releasing parking brake, be sure to prevent vehicle from B
moving by setting wheel blocks.
RJIA0371E
D
7. Remove heater hose assembly A.
G
RJIA0372E
8. Remove clamp and nut (1). (4 door) H
MTC
RJIA0373E
K
9. Disconnect heater hose from rear heater unit. (4 door)

L
10. Remove bolt (1), and remove heater hose assembly B. (4
door)
RJIA0374E
MTC-89
MODE DOOR
MODE DOOR PFP:27731
Adjustment of Cable EJS0018M
1. Remove outer cable from the clamp.

2. Set mode adjustment dial to DEF.
3. Push side link in the direction shown by arrow. Slightly pull outer
cable to controller side, and install it to clamp.
CAUTION:
When clamping the outer cable, do not move the inner
cable.
4. Operate mode adjustment dial, and check that inner cable
moves smoothly.
SJIA0100E
MTC-90
AIR MIX DOOR
AIR MIX DOOR PFP:27732

A
Adjustment of Cable EJS0018N
1. Remove outer cable from the clamp.

2. Set temperature adjustment dial to FULL COLD. B
3. Push air mix door lever in the direction shown by arrow. Slightly
pull outer cable toward controller side, and install clamp.
CAUTION: C
When clamping the outer cable, do not move the inner
cable.
4. Operate the temperature adjustment dial to insure that the inner D
cable moves smoothly.
ZJIA0039E
MTC
MTC-91
DUCT AND GRILLE
DUCT AND GRILLE PFP:27860
Removal and Installation EJS0018O
VENTILATOR DUCT, DEFROSTER NOZZLE, AND DUCT
ZJIA0040J
1 Cluster lid C 2 Central ventilator grille (LH) 3 Central ventilator grille (RH)
4 Instrument panel assembly 5 Side ventilator duct (LH) 6 Side ventilator grille (LH)
7 Central ventilator duct (LH) 8 Central ventilator duct (RH) 9 Side ventilator grille (RH)
10 Side ventilator duct (RH) 11 Central ventilator adapter 12 Side defroster duct
13 Central defroster nozzle
1. Remove instrument panel.

Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in IP Instrument Panel.
CENTRAL VENTILATOR GRILLE
1. Remove cluster lid C.
Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in IP
Instrument Panel.
2. Remove central ventilator grille.
ZJIA0041E
MTC-92
DUCT AND GRILLE
SIDE VENTILATOR GRILLE

1. Remove instrument panel. A
Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in IP
Instrument Panel.
2. Remove side ventilator grille. B
ZJIA0042E D
FOOT DUCT
1. Remove foot duct.
E
ZJIA0043E
H
REAR VENTILATOR GRILLE
1. Remove rear ventilator grille.
I
MTC
ZJIA0044E
L
REAR INTAKE GRILLE
1. Remove rear intake grille from clip.
ZJIA0045E
MTC-93
A/C CYCLE
A/C CYCLE PFP:92600
Component Parts Drawing EJS0018P
MTC-94
A/C CYCLE
WITHOUT REAR A/C

A
MTC
SJIA0097E
MTC-95
A/C CYCLE
WITH REAR A/C
SJIA0098E
MTC-96
A/C CYCLE
Compressor EJS0018Q
REMOVAL A
refrigerant. B
3. Remove cover.
4. Remove engine undercover.
5. Remove auxiliary drive belt. KA20 and KA24 engines: EM-14, C
"DRIVE BELTS" ZD engine:EM-107, "DRIVE BELTS"
D
ZJIA0048E
6. Disconnect high-pressure flexible hose 1 and low-pressure flexi- E

ble hose 1 from compressor.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl F
sphere.
7. Disconnect the connector of the compressor. G
8. Remove harness bracket fixing bolts, and clip, and remove vehi-
cle harness aside (ZD engine only).
ZJIA0049E
H
MTC
ZJIA0051E
L
9. Remove compressor mounting bolts.

M
ZJIA0050E
MTC-97
A/C CYCLE
10. Remove compressor from underbody of vehicle, in case of KA

engine, and from vehicle, in case of ZD engine.
ZJIA0052E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and low-
pressure flexible hose 1 with new ones. Install new O-rings
with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
ZJIA0053E
Compressor mounting bolt (KA engine)

Tightening : 57 - 66 Nm (5.8 - 6.7 kgm, 42 - 48
torque ft-lb)
Compressor mounting bolt (ZD engine)

torque ft-lb)
High-pressure flexible hose 1 mounting bolt

Tightening : 8 - 10 Nm (0.8 - 1.0 kgm, 70 - 95 ZJIA0054E
torque in-lb)
Low-pressure flexible hose 1 mounting bolt

torque in-lb)
MTC-98
A/C CYCLE
Overhaul EJS001FK
SHA493F
G
Removal EJS001FL
When removing center bolt, hold clutch disc with clutch disc
wrench. H
MTC
SHA792E
K
Remove the drive plate using the clutch disc puller.
Insert holder's three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Tighten the center bolt to L
remove the drive plate.
After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
M
SHA098EA
Remove the snap ring using external snap ring pliers.
SHA794E
MTC-99
A/C CYCLE
Pulley removal:
Use a commercially available pulley puller. Position the center of
the puller on the end of the drive shaft. Remove the pulley
assembly with the puller.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked under (not into) the pulley groove.
For machine latched pulleys:
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
SHA050F
Remove the snap ring using external snap ring pliers.

Remove the field coil harness clip using a screwdriver. The three
field coil fixing screws and remove the field coil.
SHA494F
Inspection EJS001FM
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 contact surface of pulley shows signs of excessive grooving,
replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable
solvent before reinstallation.
COIL
Check coil for loose connection or cracked insulation.
RHA075C
Installation EJS001FN
Install the field coil.

Be sure to align the coil pin with the hole in the compressor
front head.
SHA494F
MTC-100
A/C CYCLE
Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers. A
SHA797EA
D
Install the drive plate on the drive shaft, together with the original
shim(s). Press the drive plate down by hand.
E
G
SHA798E
Using the holder to prevent drive plate rotation, tighten the bolt H
to 12 to 14 N-m (1.2 to 1.4 kg-m, 9 to 10 ft-lb) torque.
MTC
SHA799E
K
After tightening the bolt, check that the pulley rotates smoothly.
L
Check clearance all the way around the clutch disc.
Disc-to-pulley clearance :
0.24 - 0.42 mm (0.0094 - 0.0165 in) M
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
SHA052FA
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
MTC-101
A/C CYCLE
High-Pressure Flexible Hose 1 and Low-Pressure Flexible Hose 1 EJS0018R
REMOVAL
refrigerant.
3. Remove condenser.MTC-109, "Condenser Assembly"
4. Remove cover.
ZJIA0048E
5. Disconnect low-pressure flexible hose 1 from low-pressure pipe

2.
CAUTION:
sphere.
ZJIA0056E
6. Remove fixing nuts of high-pressure flexible hose 1 and low-

pressure flexible hose 1.
ZJIA0055E
7. Remove mounting bolts of high-pressure flexible hose 1 and

low-pressure flexible hose 1, and remove hoses from vehicle.
ZJIA0049E
MTC-102
A/C CYCLE
ZJIA0051E
D
8. Remove band clip and clip. Disconnect high-pressure flexible
hose 1 and low-pressure flexible hose 1 from bracket, respec-
tively. E
G
ZJIA0075E
INSTALLATION H
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new ones.
Install new O-rings with compressor oil applied.
I
Replace band clips on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new
ones.
MTC
High-pressure flexible hose 1 mounting bolt
K
Low-pressure flexible hose 1 mounting bolt
L
Tightening torque : 14.7 - 24.5 Nm (1.5 - 2.5 kgm, 11 - 18 ft-lb)
M
Low-Pressure Pipe 1 EJS0018S
REMOVAL
refrigerant.
3. Remove condenser.
4. Remove mounting bolts of low-pressure pipe 1, and disconnect
it from blower and cooling unit.
CAUTION:
sphere. ZJIA0013E
MTC-103
A/C CYCLE
5. Disconnect low-pressure pipe 1 from low-pressure flexible hose

1.
6. Disconnect low-pressure pipe 1 from low-pressure pipe 2. (For
models with rear A/C only)
7. Remove clip fixing bolts, and remove low-pressure pipe 1.
ZJIA0056E
INSTALLATION
CAUTION:
O-rings on low-pressure pipe 1 and low-pressure flexible hose 1 must be replaced with new ones.
Install new O-rings with compressor oil applied.
Low-pressure pipe 1 union nut
Low-pressure pipe 1 mounting bolts


Low-Pressure Pipe 2 EJS0018T
REMOVAL
refrigerant.
3. Remove front LH wheel.
4. Remove condenser.
5. Remove splash board (LH).
6. Disconnect low-pressure pipe 2 from low-pressure pipe 1.
CAUTION:
tape, etc. to prevent them from being exposed to the atmo- ZJIA0056E
sphere.
7. Remove clip fixing bolts, and disconnect low-pressure pipe 2
from low-pressure flexible hose 2.
8. Disconnect high-pressure pipe 4 from clip of low-pressure pipe
2.
9. Remove clip fixing bolts and clips, and remove low-pressure
pipe 2 from wheel housing.
ZJIA0057E
INSTALLATION
CAUTION:
Replace O-rings on low-pressure pipe 1 and low-pressure flexible hose 2 with new ones. Install
new O-rings with compressor oil applied.
MTC-104
A/C CYCLE
Low-pressure pipe 1 union nut

A

B
High-Pressure Pipe 1 EJS0018U
REMOVAL C
refrigerant. D
3. Remove undercover.
4. Disconnect high-pressure pipe 1 from liquid tank.
CAUTION: E
sphere. F
ZJIA0059E
5. Disconnect high-pressure pipe 1 from the condenser. G
ZJIA0061E MTC
6. Remove connector and clip fixing bolts, and remove high-pres-

sure pipe 1. K
ZJIA0060E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipe 1 with new ones. Install new O-rings with compressor oil
applied.
High-pressure pipe 1 mounting bolt
MTC-105
A/C CYCLE
High-Pressure Pipe 2 EJS0018V
REMOVAL
refrigerant.
4. Disconnect high-pressure pipe 2 from liquid tank.
CAUTION:
sphere.
ZJIA0059E
5. Disconnect high-pressure pipe 2 from blower and cooling unit.
ZJIA0013E
6. Remove clip fixing bolts, and disconnect high-pressure pipe 2

from high-pressure pipe 3. (For models with rear A/C only)
ZJIA0060E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipes with new ones. Install new O-rings with compressor oil
applied.
High-pressure pipe 2 mounting bolts
High-pressure pipe union nut

MTC-106
A/C CYCLE
High-Pressure Pipe 3 EJS0018W
REMOVAL A
refrigerant. B
4. Disconnect high-pressure pipe 2 from high-pressure pipe 3. (For
models with rear A/C only) C
CAUTION:
tape, etc. to prevent them from being exposed to the atmo- D
sphere. ZJIA0060E
5. Disconnect high-pressure pipe 3 from high-pressure pipe 4.
6. Remove clip fixing bolts, and remove high-pressure pipe 3. E
ZJIA0061E H
INSTALLATION
CAUTION:
I
Replace O-rings on high-pressure pipes 3 and 4 with new ones. Install new O-rings with compres-
sor oil applied.
MTC
High-pressure pipe 3 unit nut
K
High-Pressure Flexible Hose 2 and Low-Pressure Flexible Hose 2 (Rear A/C
Side) EJS0018Y
REMOVAL L
refrigerant.
M
5. Remove insulator, and disconnect high-pressure flexible hose 2
and low-pressure flexible hose 2 from rear A/C unit assembly.
CAUTION:
tape, etc. to prevent them from being exposed to the atmo- ZJIA0029E
sphere.
6. Disconnect drain hose (LH).
CAUTION:
When disconnecting drain hoses, be careful to avoid spilling water.
MTC-107
A/C CYCLE
7. Disconnect high-pressure flexible hose 2 from high-pressure

pipe 4.
8. Disconnect low-pressure flexible hose 2 from low-pressure pipe
2.
ZJIA0057E
9. Remove clips and grommets. Pull out high-pressure flexible

hose 2, low-pressure flexible hose 2, and drain hose (LH) all
together in upward direction.
ZJIA0036E
INSTALLATION
CAUTION:
O-rings on high-pressure flexible hose 2 and low-pressure flexible hose 2 must be replaced with
new ones. Install new O-rings with compressor oil applied.
Replace insulator on connections of rear A/C unit assembly and low-pressure flexible hose 2 with
new ones.

High-Pressure Pipe 4 EJS0018X
REMOVAL
refrigerant.
3. Remove front LH wheel.
5. Disconnect high-pressure pipe 4 from high-pressure pipe 3.
CAUTION:
sphere. ZJIA0061E
MTC-108
A/C CYCLE
6. Disconnect high-pressure pipe 4 from high-pressure flexible

hose 2, and remove clips. A
7. Remove clip fixing bolts and clips, and remove high-pressure
pipe 4 from wheel housing.
B
ZJIA0057E
D
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipe 4 and high-pressure flexible hose 2 with new ones. Install
new O-rings with compressor oil applied. E
High-pressure pipe 4 union nut F
High-pressure flexible hose 2 union nut G

Pressure Switch EJS0018Z

H
refrigerant.
2. Remove liquid tank. I
3. Using a vise, secure liquid tank, and remove pressure switch.
CAUTION:
MTC
Wrap shop cloths around liquid tank to avoid any damage
to it.
When installing, apply compressor oil to O-rings on pres-
sure switch. K
SJIA0101E
Pressure switch
Tightening torque : 9.8 - 11.7 Nm (1.0 - 1.2 kgm, 87 - 104 in-lb) L
Condenser Assembly EJS00190

M
refrigerant.
4. Remove lower cover.
ZJIA0062E
MTC-109
A/C CYCLE
5. Disconnect high-pressure flexible hose 1 from condenser

assembly.
CAUTION:
sphere.
ZJIA0063E
6. Disconnect high-pressure pipe 1 from condenser assembly.
ZJIA0061E
7. Disconnect condenser fan connector.
ZJIA0060E
ZJIA0064E
8. Remove condenser assembly mounting bolts and clips. Remove condenser assembly from lower front of
vehicle.
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and high-pressure pipe 1 with new ones. Install
new O-rings with compressor oil applied.
MTC-110
A/C CYCLE
High-pressure pipe 1 mounting bolt

A
DISASSEMBLY AND ASSEMBLY
B
ZJIA0065J MTC
1 Bracket (RH) 2 Lower cover 3 Bolt

4 Bracket (LH) 5 Condenser 6 Bolt K
7 Air guide 8 Bolt 9 Condenser fan motor
10 Bolt 11 Bolt 12 Condenser fan
L
13 Nut 14 Fan shroud
Rear Evaporator EJS00191
REMOVAL AND INSTALLATION M

refrigerant.
4. Disconnect high-pressure flexible hose 2 and low-pressure flexi-
ble hose 2 from rear A/C assembly.
CAUTION:
sphere. ZJIA0069E
5. Remove lower case of rear A/C assembly.
6. Remove screws, and remove rear evaporator.
MTC-111
A/C CYCLE
CAUTION:
O-rings on high-pressure flexible hose 2 and low-pressure flexible hose 2 must be replaced with
new ones. Install new O-rings with compressor oil applied.

Front Expansion Valve EJS00192

1. Remove blower and cooling unit.
2. Remove insulator.
3. Remove piping block and expansion valve.
CAUTION:
Replace O-rings on piping block and evaporator with new
ones. Install new O-rings with compressor oil applied.
ZJIA0070E
Mounting bolts of piping block (expansion valve)

Rear Expansion Valve EJS00193

1. Remove rear evaporator.
2. Remove insulator, and then rear expansion valve.
CAUTION:
Replace O-rings on rear expansion valve inlet tube and
rear evaporator with new ones. Install new O-rings with
compressor oil applied.
Replace the insulator with new one.
ZJIA0071E
Rear evaporator inlet tube union nut

Rear evaporator union nut

MTC-112
A/C CYCLE
Liquid Tank EJS00194
REMOVAL AND INSTALLATION A

2. Using a refrigerant recovery unit (for HFC134a), remove refrig-
erant. B
3. Disconnect connector, and disconnect high-pressure pipes 1
and 2 from liquid tank.
CAUTION: C
sphere. D
4. Remove bracket fixing bolts, and pull out liquid tank from lower ZJIA0059E
side.
CAUTION: E
Replace O-ring on high-pressure pipe with new one. Install new O-ring with compressor oil
applied.
F
Mounting bolts of high-pressure pipes 1 and 2
G
MTC
MTC-113
A/C CYCLE
MTC-114

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MANUAL AIR CONDITIONER

IDENTIFICATION LABEL FOR VEHICLE

Precautions for Refrigerant Connection EJS0011O

O-RING AND REFRIGERANT CONNECTION

Precautions for Servicing Compressor EJS0011P

MANIFOLD GAUGE SET H

REFRIGERANT WEIGHT SCALE

CALIBRATING ACR4 WEIGHT SCALE

Wiring Diagrams and Trouble Diagnosis EJS0011T

When you read wiring diagrams, refer to the followings:

GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

Special Service Tools EJS0011U

KV99231260 Removing shaft nut and clutch disc

KV992T0001 Removing clutch disc

KV992T0002 Installing pulley

HFC-134a (R-134a) Service Tools and Equipment EJS0011V

Power supply: DC 12V (Battery

Application: For HFC-134a (R-134a)

Service hoses Hose color:

For measuring of refrigerant

Commercial Service Tool EJS0011W

Tool name Description

For checks refrigerant purity and for K

REFRIGERATION SYSTEM PFP:KA990

Refrigerant Cycle EJS0011X

DUAL PRESSURE SWITCH

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:

4. CHECK ANY PART

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

AIR CONDITIONER CONTROL PFP:27500

Control Operation EJS001ED

FAN CONTROL KNOB

REAR COOLER FAN CONTROL KNOB(FRONT)

REAR COOLER FAN SWITCH

Discharge Air Flow EJS001EE

Component Layout EJS001EF

Component Location EJS001ES

System Description EJS001ET

SWITCHES AND THEIR CONTROL FUNCTION A

TROUBLE DIAGNOSIS PFP:00004

Component Parts and Harness Connector Location EJS00121

Wiring Diagram HEATER EJS00122

Schematic A/C EJS001GQ

Wiring Diagram A/C EJS001GR

Wiring Diagram R/COOL EJS00123

Operational Check EJS00124

2. Check A/C Switch

6. Check Temperature Increase

7. Check rear cooler

Blower Motor Circuit EJS00125

Does not rotate at any speed>>GO TO 2

2. CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

3. CHECK BLOWER MOTOR GROUND CIRCUIT A

Continuity should exist. D

4. CHECK BLOWER MOTOR

5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT MTC

6. CHECK CIRCUIT CONTINUITY

Continuity should exist.

If NG, repair harness or connectors.

Harness connectors M13, M222 and M223.

No >> Repair harness or connector.

7. CHECK FAN SWITCH GROUND

Continuity should exist.