Professional Documents
Culture Documents
AIR CONDITIONER
SECTION HA
CONTENTS
PRECAUTIONS AND PREPARATION 2 Wiring Diagram - HEATER - 36
Supplemental Restraint System (SRS) "AIR Wiring Diagram - AIC - 38
BAG" (Dual Air Bag System) 2 SERVICE PROCEDURES 66
Supplemental Restraint System (SRS) "AIR HFC-134a (R-134a) Service Procedure 66
BAG", (Single Air Bag System) 2 Maintenance of Lubricant Quantity in
Precautions for Working with HFC-134a (R- Compressor 68
134a) 3 Refrigerant Lines 70
General Refrigerant Precautions 3 Compressor Mounting 75
Precautions for Refrigerant Connection 4 Belt Tension 76
Precautions for Servici ng Compressor. .. 5 Fast Idle Control Device (FICO) 76
Special Service Tools 5 Compressor - Model DKV-11D and DKV-14D
HFC-134a (R-134a) Service Tools and (ZEXEL make) 77
Equipment. 6 Compressor Clutch 77
Precautions for Service Equipment 8 Thermal Protector 80
DESCRIPTION 10 Compressor - Model CR-14 (Calsonic make) 80
Refrigeration Cycle . 10 Compressor Clutch .. 80
Component Layout 11 Thermal Protector 82
Discharge Air Flow 12 Ventilation Air Filter 83
Control Operation 13 SERVICE DATA AND SPECIFICATIONS (SDS) 84
TROUBLE DIAGNOSES 14 General Specifications 84
Contents 14 Inspection and Adjustment 84
HA-2
PRECAUTIONS AND PREPARATION
HA-3
PRECAUTIONS AND PREPARATION
O-ring
NG
NG
- Inflated portion
OK
SHA525DA
HA-4
PRECAUTIONS AND PREPARATION
NT204
NT206
~
NT207
Center pulley puller
NT208
C
HA-5
PRECAUTIONS AND PREPARATION
Special Service Tools (Cont'd)
CR-14 compressor
Tool number
Tool name Description
NT351
NT352
NT196
~~
Nissan A/C System Oil Type: Poly alkyline glycol oil (pAG), type R
Type R Application: HFC-134a (R-134a) vane rotary
(Part No.: KLHOO-PAGRO) compressors (Nissan only)
Lubricity: 40 me (1.4 Imp fI oz)
~
NT197
":' s Q"'~
==
NT195
~ t:J II
HA-6
PRECAUTIONS AND PREPARATION
HFC-134a (R-134a) Service Tools and Equipment
(Cont'd)
NT19S
NT199
NT202
NT200
NT203
HA-7
PRECAUTIONS AND PREPARATION
~
1f2"-16ACME
SHA533D
RHA272D
HA-8
PRECAUTIONS AND PREPARATION
Precautions for Service Equipment (Cont'd)
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
will not properly connect to the CFC-12 (R-12) system. However,
M14 x 1.5 fitting
optional
if an improper connection is attempted, discharging and con-
(Hose may be tamination may occur.
permanently
attached to Shut off valve rotation AIC service valve
coupler)
Clockwise Open
Counterclockwise Close
RHA273D
To manifold gauge
RHA274D
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant
may be vented into air from cylinder's top valve when filling the
cylinder with refrigerant. Also, the accuracy of the cylinder is
generally less than that of an electronic scale or of quality
recycle/recharge equipment.
HA-9
DESCRIPTION
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser,
liquid tank, evaporator and back to the compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expan-
sion valve, located inside the evaporator case.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specification, the thermo
control amplifier allows compressor operation.
Fusible plug
Open at temperature above 105C (221F), thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace liquid tank.
Compressor
s
D
t
Outside air
Blower motor
HA-10
__________ ~==D=ES=C~R~I~P~TI~O~N~~-
Component Layout
SEC. 270-271-272-273
Defroster nozzle
Cooling unit
Control assembly
. .11stration
This I u is for LH D models.
. symmetrically opp osite to this layout.
The layout for RHO models IS
RHA312F
HA-11
DESCRIPTION
@; Fool
Defroster
@ To defroster
Ventilator door
Bi-Ievel
(~ switch "OFF" )
RHA313F
HA-12
DESCRIPTION
Control Operation
HA-13
TROUBLE DIAGNOSES
Contents
How to Perform Trouble Diagnoses for Quick and Accurate Repair HA-15
Operational Check HA-16
Symptom Chart HA-18
Preliminary Check HA-20
PRELIMINARY CHECK 1
(A/C does not blow cold air.) HA-20
PRELIMINARY CHECK 2
(Air outlet does not change.) HA-21
PRELIMINARY CHECK 3
(Noise) HA-22
PRELIMINARY CHECK 4
(Insufficient heating) HA-23
Performance Test Diagnoses HA-24
INSUFFICIENT COOLI NG HA-24
Performance Chart HA-26
TEST CONDITION HA-26
TEST READING HA-26
Trouble Diagnoses for Abnormal Pressure HA-27
Harness Layout. HA-31
Circuit Diagram - Air Conditioner HA-34
Wiring Diagram - HEATER - HA-36
Wiring Diagram - AIC - HA-38
Main Power Supply and Ground Circuit Check HA-49
Diagnostic Procedure 1
(SYMPTOM: Blower motor does not rotate.) HA-50
Diagnostic Procedure 2
(SYMPTOM: Intake door does not change.) HA-52
Diagnostic Procedure 3
(SYMPTOM: Magnet clutch does not operate when A/C switch and fan switch are ON.)
- For GA and SR engines HA-54
- For CD engine HA-59
Electrical Components Inspection HA-62
Control Linkage Adjustment HA-64
System Description HA-65
HA-14
TROUBLE DIAGNOSES
.--------------,
LISTEN TO CUSTOMER COMPLAINT AND CONFIRM BY Operational check
+-
PERFORMING OPERATIONAL CHECK. (Refer to HA-16.)
Symptom Chart (Refer
to HA-18.)
CHECK MAIN POWER SUPPLY AND GROUND CIR- +- Main Power Supply and
CUITS. Ground Circuit Check
(Refer to HA-49.)
I REPAIR.
NG FINAL CHECK
CHECK OUT
HA-15
TROUBLE DIAGNOSES
Operational Check
The purpose of the operational check is to confirm that the sys-
tem operates as it should. The systems which are checked are
the blower, mode (discharge air), intake air, temperature
decrease, temperature increase.
CONDITIONS:
Engine running at normal operating temperature.
PROCEDURE:
1. Check blower
1) Turn fan control knob to 1-speed.
Blower should operate on 1-speed.
2) Then turn fan control knob to 2-speed.
3) Continue checking blower speed until all four speeds are
checked.
4) Leave blower on 4-speed.
RHA315F
RHA316F
_e - - -
II 100% - 100%
-
"J 80% 20% 14% 65% 21%
W - - 100% - - 100%
RHA317F
HA-16
TROUBLE DIAGNOSES
Operational Check (Cont'd)
3. Check recirculation
1) Pre~s recirculation switch.
2) ~.eclrculati~n indicator should light
Isten for Intake door position ch'an
blower sound change slightly). ge (you should hear
RHA318F
RHA319F
RHA320F
The
ON. indicator light should com e on when air. conditioner is
RHA321F
HA-17
TROUBLE DIAGNOSES
Symptom Chart
DIAGNOSTIC TABLE
Main Power
Preliminary Diagnostic Supply and
PROCEDURE
Check Procedure Ground Circuit
Check
REFERENCEPAGE 0
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Insufficient heating 0 ()
HA-18
TROUBLE DIAGNOSES
Symptom Chart (Cont'd)
c c
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.Q
C\J
CD
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0 0 (:: 0 ()
HA-19
TROUBLE DIAGNOSES
Preliminary Check
PRELIMINARY CHECK 1
Ale does not blow cold air.
DOES AIR FLOW FROM VENTS? IS BLOWER MOTOR OPERATING
Condition NORMALLY?
Engine running at operating tem-
perature . Yes
Ignition switch, AIC switch, and
fan switch are ON.
CHECK BLOWER
Mode control knob is in VENT
MOTOR OPERATION.
mode and temperature control
Go to Diagnostic Pro-
knob is in full cold position.
cedure 1. (HA-50)
Yes
CHECK COMPRESSOR BELT TEN- CHECK COMPRESSOR OPERA- CHECK FOR EVAPORATOR COIL
SION. TION. FREEZE UP.
Refer to "Checking Drive Belts" in Remove intake unit. Check if evap-
MA section. OK orator freezes.
NG OK
NG OK
NG
CHECK FOR REFRIG- CHECK WATER COCK OPERA- Adjust or replace water cock.
ERANT LEAKS TION.
Warm up engine before checking.
Refer to HA-64.
OK
NG
Go to Diagnostic Procedure 3. CHECK TEMPERATURE CONTROL Adjust temperature control cable.
(HA-54) CABLE.
Refer to Control Linkage Adjust-
ment. (HA-64)
OK
NG
VISUALLY INSPECT AIR MIX Replace air mix door.
DOOR.
Access by removing instrument
panel.
OK
HA-20
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
Air outlet does not change.
TURN IGNITION SWITCH AND FAN SWITCH ON. DOES AIR No Adjust mode control cable. Refer to
COME OUT NORMALLY FROM EACH DUCT WHEN EACH HA-64.
MODE SWITCH IS PUSHED?
iI 100% - - 100% - -
.
,7,./ 60% 40% - 60% 40% -
res
INSPECTION END
HA-21
TROUBLE DIAGNOSES
Preliminary Check (Coni' d)
PRELIMINARY CHECK 3
Noise
Noise is OK NG
constant.
Check blower Check disc-to- Fix the line with Fix the line
motor and fan pulley clearance. rubber or some tightly.
for wear. Refer to HA-79, vibration absorb-
82. ing material.
OK
OK
Noise is
interm ittent. Readjust belt The pulley cen-
tension. ter does not
Check air dis- Refer to MA match.
charge ducts section ("Check- Readjust the pul-
for obstruc- ing Drive Belts", ley center.
tions, foreign "ENGINE
materials or MAINTENANCE").
air leakage.
HA-22
TROUBLE DIAGNOSES
Preliminary Check (Cont'd)
PRELIMINARY CHECK 4
Insufficient heating
OK
OK
to LC section
OK
("Thermostat", "ENGINE
COOLING SYSTEM").
ant. Retest.
Hot inlet
OK
Both hoses
Warm outlet warm
HA-23
TROUBLE DIAGNOSES
INSUFFICIENT COOLING
OK OK
@
CHECK COMPRESSOR OPERATION. Clogged blower inlet!
(Go to
Clogged duct/Loose duct
OK next
connection/Air leakage, etc.
page.)
<ID
(Go to
next page.)
OK
CHECK HIGH AND LOW SIDE PRESSURE. USE
PERFORMANCE CHART. (Refer to HA-26.)
NG
Note
NG
CHECK HIGH AND LOW SIDE PRESSURE.
PERFORMANCE CHART. (Refer to HA-26.)
USE
BOTH HIGH AND LOW m
PRESSURE SIDES ARE
OK TOO HIGH.
Note: Fa-Ii correspond to those in TROUBLE DIAGNOSES FOR LOW PRESSURE SIDE
BECOMES NEGATIVE. Ii
ABNORMAL PRESSURE.
(Refer to HA-27.)
HA-24
TROUBLE DIAGNOSES
Performance Test Diagnoses (Cont'd)
@
Malfunctioning blower motor fan Malfunctioning electrical circuit Malfunctioning blower motor
internal circuit
Magnet clutch does not engage. Magnet clutch slipping Belt slipping
HA-25
TROUBLE DIAGNOSES
Performance Chart
TEST CONDITION
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well-venti-
lated place)
Doors: Closed
Door window: Open
Hood: Open
TEMP.: Max. COLD
Discharge Air: Face Vent
REC switch: (Recirculation) set
FAN speed: High speed
Engine speed: Idle speed
Operate the air conditioning system for 10 minutes before
taking measurements.
TEST READING
Recirculating-to-discharge air temperature 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)
.
892 - 1,138
25 (77) 118 - 226 (1.18 - 2.26,1.2 - 2.3,17 - 33)
(8.92 - 11.38, 9.1 - 11.6,129 - 165)
1,108 - 1,393
30 (86) 137 - 265 (1.37 - 2.65,1.4 - 2.7,20 - 38)
(11.08 - 13.93, 11.3 - 14.2, 161 - 202)
50 - 70
1,344 - 1,677
35 (95) 177 - 314 (1.77 - 3.14,1.8 - 3.2, 26 - 46)
(1344 - 16.77,13.7 - 17.1, 195 - 243)
1,589 - 1,971
40 (104) 226 - 373 (2.26 - 3.73, 2.3 - 3.8, 33 - 54)
(15.89 - 19.71,16.2 - 20.1, 230 - 286)
HA-26
TROUBLE DIAGNOSES
Both high and low-pressure Pressure is reduced soon Excessive refrigerant charge Reduce refrigerant until spec-
sides are too high. after water is splashed on in refrigeration cycle ified pressure is obtained.
m condenser.
HA-27
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont'd)
High-pressure side is too Upper side of condenser and High-pressure tube or parts Check and repair or
high and low-pressure side is high-pressure side are hot, located between compressor replace malfunctioning
too low. however, liquid tank is not so and condenser are clogged parts .
hot. or crushed. Check lubricant for contam-
ination.
AC360A
High-pressure side is too low High and low-pressure sides Compressor pressure opera- Replace compressor.
and low-pressure side is too become equal soon after tion is improper.
high. compressor operation stops. 1
[;J Damaged inside compressor
packings
AC356A
80th high- and low-pressure There is a big temperature Liquid tank inside is clogged Replace liquid tank.
sides are too low. difference between liquid a lillie. Check lubricant for contam-
I!] tank outlet and inlel. Outlet ination.
temperature is extremely
low .
Liquid tank inlet and expan-
sion valve are frosted.
Temperature of expansion High-pressure pipe located Check and repair malfunc-
valve inlet is extremely low between liquid tank and tioning parts.
as compared with areas expansion valve is clogged. Check lubricant for contam-
near liquid tank. ination.
Expansion valve inlet may
be frosted .
Temperature difference
AC353A occurs somewhere in high-
pressure side
HA-28
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Cont'd)
Both high- and low-pressure There is a big temperature Expansion valve closes a lit- Remove foreign particles
sides are too low. difference between expansion tle compared with the specifi- by using compressed air.
l!] valve inlet and outlet while cation. Check lubricant for contam-
the valve itself is frosted. 1 ination.
CD Improper expansion valve
adjustment
@ Malfunctioning thermal
valve
@ Outlet and inlet may be
clogged.
An area of the low-pressure Low-pressure pipe is clogged Check and repair malfunc-
@ pipe is colder than preas or crushed. tioning parts.
near the evaporator outlet. Check lubricant for contam-
ination.
Air flow volume is not Compressor pressure opera- Replace compressor.
AC353A enough or is too low. tion is improper.
1
Damaged inside compressor
packings
Low-pressure side some- Air conditioning system Refrigerant does not dis- Drain water from refriger-
times becomes negative. does not function and does charge cyclically. ant or replace refrigerant.
Ii not cyclically cool the com- 1 Replace liqUid tank.
partment air. Moisture is frozen at expan-
The system constantly func- sion valve outlet and inlet.
tions for a certain period of 1
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A
HA-29
TROUBLE DIAGNOSES
Trouble Diagnoses for Abnormal Pressure
(Conl'd)
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side becomes liquid tank or front/rear side High-pressure side is closed Leave the system at rest until
negative. of expansion valve's pipe is and refrigerant does not flow. no frost is present. Start it
Ii frosted or dewed. L again to check whether or
Expansion valve or liquid not the problem is caused by
tank is frosted. water or foreign particles .
If water is the cause, ini-
tially cooling is okay. Then
the water freezes, causing
a blockage. Drain water
from refrigerant or replace
refrigerant.
If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed
AC362A air (not shop air).
If either of the above meth-
ods cannot correct the
problem, replace expansion
valve .
Replace liquid tank .
Check lubricant for contam-
ination.
HA-30
TROUBLE DIAGNOSES
Harness Layout
ENGINE COMPARTMENT
RHA322F
HA-31
HA-32
TROUBLE DIAGNOSES
Harness Layout (Co nt' d)
LHD models
,-.....
I \
I
l~'
I \
RHA324F
HA-33
TROUBLE DIAGNOSES
AIR
CONDITIONER
RELAY
M BLOWER
MOTOR IT
o
f-
U1 THERMO
H
~
IT
CONTROL
AMP.
DUAL-
AIC W PRESSURE
SWITCH I SWITCH
f-
FAN
RESISTOR
GE C
FAN SWITCH
OFF1234 GA D
IT
o
..JI-
u
~w
IT I-
wo
To illumination IIT
f-(L
system
RECIRCULA nON IT
SWITCH o o
U1 uo
U1 HH
W [LO
IT IZW
(L >w>
~ U..J....J
1
o 404
u HUJ>
@: AIT models
@: MIT models
@: For Europe and Israel
@: Except @
@: GA engine models
@: Except f or Europe, I srae 1 and Austra 1i a
@: GA eng ine f or Europe, Israe 1 and Austra 1 ia and SR eng Ine
@: Except @
<Q:>: LHD AIT models for Europe without daytIme light system
@: Except <Q:>
*1 @ 41. @ 44
HHA001
HA-34
TROUBLE DIAGNOSES
Circuit Diagram - Air Conditioner (Cont'd)
---------,
I
I
I
(!) ~ (!) [\J
Z I Z I I
H >- H >- COOLING
-I <l: -I <l: FAN I
OZ-I OZ-I I
O<l:W O<l:W RELAY-l
ULLCI: I
ULLCI:
I
I
I
A
I
I
A
I
Z Z I
<t <t
LL LL B I
I
(!)[\J
ZI I
HCI: I
-10
01- I
00 I
U::E
<{ I
-' M I
I
,
Z Z Z I
<l: <l: <t I
LL LL LL
I COOLING COOLING
(!)(Tl
(!) ....
ZI
(!)(\J
ZI ZI I FAN FAN
H>-
-I<t
0-1
H>-
-I<t
0-1
H>-
-I<t
0-1
,
I RELAY-l RELAY-2
@
ow ow
UCI:
ow
ucr
I
UCI: I
I
I
I
I
I
A A
I
I
I
Z Z
<l: <t I
LL LL I COOLING COOLING
(!)~ (!)(\J I FAN FAN
B ZI ZI I
o MOTOR-l MOTOR-2 M
HCI: HCI:
-10
01-
-10
OI-
I @ @ COOLING
00 00 I
U::E U::E I
FAN
I MOTOR-2
I @
I
I
I
31 B 9 10 I 35 21 15 13 14
I
ECM(ENGINE I
ECMIECCS
CONTROL MODULE) CONTROL MODULE)
I
I
L J
HHA014
HA-35
TROUBLE DIAGNOSES
HA-HEATER-01
1
I
L/W .,--I-~r=t
t
:4
r
L/W
I
L/Y L!R
I I:31 12~1 Ii2'nJ
LIB RIG
n1=iI
RIG. To EL-m
BLOWER
M MOTOR
~ FAN
~I!.j.JJ SWITCH
@
LIB ILL. ~
~ ~
B B
~ol __ 1 I
II < ------.~o--l
<I> JOINT
B CONNECTOR-4
\~ ~/ \~ ~ ~/
<0 <B>
~--------------------, Refer to last page
(Foldout page) .
i~@~~:
I~W
I
2 Wi
I
l1IillIITillIil ~
~P
~
L ~
I I
HHA012
HA-36
TROUBLE DIAGNOSES
Wiring Diagram - HEATER - (Conl'd)
IGNITION SWITCH
HA-HEATER-02
ON
EE
Refer to EL-POWER.
7.5A FUSE
BLOCK
III (JIB)
~
IN21
LG/R
LG/R
ffi
RECIRCULATION
SWITCH
INDICATOR ~
~
B
Preceding ~ B
I
page ~ ~O L
1~ ~~)1
~~
~W
:
L (b) @ :
~
HHA013
HA-37
TROUBLE DIAGNOSES
HA-A/C-01
IGNITION SWITCH
ON Q: LHO models
15A
IT] m
15A
FUSE
BLOCK
(JIB)
~
t ~~~~::OR -(0 Gty LGtS
@
IN31
-
.,__LI~I_;~fr-
L/W L/W ~
L/W
I .. RIG ~ To EL-ILL
~ lbi=ll
B B
rro::::::-.--::::;8::-- --o:::: L
1
__ 1
...
<I>
B
JOINT
CONNECTOR-4
1 ~:<ED
~ {} B .--- B f> Next page
IW'ia\
\~ ~I
~
\~
~
~ ~I ~
fiI-
~
B =~ B .JC'-.- To
~-06
HA-A/C
Q <ED
r--------------------, Refer to last page
(Foldout page) .
I 0 I
I
1~@1~1 ~ I
m:ITillIillIill @ ~
I~W 2 Wi ~P
I I
I I
~--------------------~
HHA002
HA-38
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Conl'd)
HA-A/C-02
Refer to EL-POWER.
FUSE
BLOCK
(JIB)
<fill)
(HOB)
LG/R ~ To HA-A/C-04
LIB -@>}
..J?-....... Next page
LG/RV
INTAKE
DOOR
MOTOR <D: LHO mode Is
~ <ID: RHO models
@: For Europe and Israel
@: Except@
*2 ... (0 G/B , @ Y/B
*3"'(0 G/Y , @ Y/R
LG/R
m
RECIRCULATION
SWITCH
~
INDICATOR
~
B
Preceding -4 B
I
page ~ ~O L
~~
:~ ~W:
I~ ~~I
~ , (~i9B)
~W
: (0 @ :
~-------------------~
HHA003
HA-39
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
HA-A/C-03
Refer to EL-POWER.
Preceding~ ~
page LIB' I
L/Y
<I>:
<ID:
@:
@:
@:
LHO models
RHO models
GA engine
GA engine for
and Australia
Except@
Europe. Israel
and SR engine
IT ]1,rR
LIB L/Y
*1"'(0 G/Y , <ID LG/B
n CONOITIONAER *4"'(0 G/B , <ID GY
U RELAY *5... @Y , @L
1bi=Jl1!:l=Jlm>
*5 L/R
....
I I .... L/R -@> To
*5 ~Next
HA-A/C-06
page
-4-
Preceding~LG/R"""""'1 *4 -(t> Next page
page ~
LG/R
I
u=tru
A!C
SWITCH
~
.:., INDICATOR ~
To HA-A/C-01 ~ *1
I *1 ~ -4- *1 -e> To HA-A/C-05
O~I-O-eb:>-
0~O~
G/Yi8J
G/Y
~
(j
JUNCTION
BOX No.2
(~g~~~CTORS)
1
_IIIIIIC~::. G/Y (j ~ :(0
HHA004
HA.40
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
Preceding
page
To HA-AlC-02
~
~
*5
<e}-lG/R...,
---------O~
+ ..-----I GX l
HA-A/C-04
lG/R ~
THERMISTOR IFti
THERMO
CONTROL
~--:t>
Y
r.!" ~ ~~
Y
LOW HIGH
... ...,.. -.
NORMAL
OUAl-
PRESSURE
SWITCH
m:@
A~~FIER "JICHID"~AIICHID lUll
y y =r'
I6j:JJ
*6
<;> @ I
o 0--1,-0
~ <I>
_loJt t
G
I$I~II~I~
CMID '"T'
G
CBID
~
S8
<I>S8
GX .~
G
@
G
I$I
CBID
1r$J1CMID o~o--l
*__
S8m
S8
1>
S8m
(b):
<iD:
....
lHO modeIs
RHO models
*7
m + R
@: Except@
@: Except for Europe, Israel
~ OUAl- 'j/ ~ and Australia
Preceding
page
-<!}- *4 - -------:~ 0
~O ...... -.-_. G*8 ~}
y
~
Next page
(Foldout page) .
2
~~ W cftID~
1 2 8
(~) ,~
3
HHA005
HA-41
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
HA-A/C-05
-
I _
preCeding{:;t ::
page ~
<@- GY
To HA-A/C-03~ *1
1 ~f CDr~+
*1 GY R/L G *7 R/L G
CVl (Ij) m
1iTm~ 4.QJ -- rn
~ -- ~
IIIi21 -- ffilill
31
111
~A/C m
COMP ECM
(ENGINE
*1 GY R/L G *7 CONTROL
It
*1
It It It I~
GY R/L G *7
MODULE)
@:@)
HHAO06
HA-42
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
-. HA-A/C-06
To HA-A/C-03 ~ L/R ---'. o~o 1
ES
L/R
I ~
<C>
(EIOt)
~
~(@t)
rI!. o~14) I~I 116,.B II
~Cill> ~CHID L/R CHID
iemp
O
- Hi-
temp
THERMAL
PROTECTOR
L/R
I L/R ~, .... @
o ~m~-"!_I J
0-,
------ (E207)-1
SOLENOID
t
VALVE
SR I!:i=!l ~
a @ <I> <0>
------. ~@ ~~
JR ~(Blu)
L/R
[4J
L/R
(ffi)
ocr rn irh
iemp
O- Hi-
temp
THERMAL
PROTECTOR
IACV-
~6E~NOIO
VALVE
..,
VALVE
IACV-
~ ~6E~NOIO
t67i\i\
W Mg~- SOLENOID
VALVE
------ (~)-1
~ (~). !1i=!J \!ill!!I Ill~61 m:@
J,~ 1 1 a @w a CEID:@
COMPRESSOR T'C..!.S'
IWIIE"f"\' ~?) @J) r=!=(Qill)
I~I @
<I>
(E20j) -2 a GA
~
To HA-A/C-01 ~ B
..- ._1::::::::::::::1~0
~ 'I
<D: LHO models @: Except@ To ECM
@:
@:
@:
RHO models
GA engine
GA engine for Europe
@:
@:
CD engine
CD engine RHO models
and GA engine
RHO mOdels
In
(ECCS
a/y ~ control
module)
and Israel
~SZR :. GA engine
~
@:
SR engine
Except@
excePt@*15
*14 .. @ E24 ,@ E27
.. @E202,@E201
*16 .. @ 2, @ 5
t
IJ l B/Y B B
~--------------------~
~U?J
~ GY
HHA007
HA-43
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Conl'd)
COOLING FAN CONTROL
SR20DE engine MfT models, GA engine MfT models, GA engine AfT models - except for
Australia
HA-A/C-07
BATTERY (Via
fusible link)
I
<0:LHO mode Is
@: RHO models
GY SR @: GA engine for Australia
'X (OCLING
@: Except@
In
U~I
FAN
RELAY-1
*17"@9 @14
1bi=JJ1'=iJI<rn>
G/B LG/R
~ OotS)
I I O-eDoLG/RoI!jJoLG/Ri
G/B
T'---I
COOLING
G/B
COOLING
~LG/R~
~@
LGIR-eJD-O
I
LG/R~
1 FAN
M MOTOR-1
rn
~1 FAN
M MOTOR-2
m
rn
........
LG/R
@
IbiJl
I,
~ IbjJJ
B B
1_--1 LG/R
I nilln EeN
" 2
RFRL (ECCS
B B
-:!:-
mffi
-:!:-
I em
CONTROL
MOOULE)
+
2
5
1
<rn>
L
;Q..~~
~GY'GY
(MS), <ill])
~
em
HHA006
HA-44
TROUBLE DIAGNOSES
Wiring Diagram A/C (Cont'd)
GA engine AIT models for Australia
HA-A/C-08
BATTERY (Via
fusible link)
.II_~.-----
BA
I------...l n I
I
~
I!' J11~'1
BA GY LG/B
~ ~ COOLING
3 BA GY COOLING ~ ~ ~~~AY-2
n FAN 1/ 2 1/ tEi7\
t
. U AELAY-1 '"'iF Ibi=H ~ 'I::.!v
IbjJI Ibi=ll ~ LG G!Y B
!I
~
LGI/A G~B
--,-I -
G/B G/Y
I
LG/A
r=!:::.~ LG 1/db1 II r.:::!::"
1/ 2 II
COOLING COOLING
113.JIt-c~)-- - -- - - - - ~I~" ~) ~) FAN FAN
La MOTOA-1 MOTOA-2
LGfR LG m Hi
H
La
H ~
~4=H
LG/R
It=!:J ~~9Z________
LG/A @ -
I~t!J1
LG
LG/B
-1
B
I
r=!:::. LG
1IT4l1
AFAL
~
1[I3]1
RFAL Il~~CS
f,
B B
CONTROL ..... .....
(
____ --J em
MODULE)
<Ul> CE51)
~<rn>~
\]1Y GY , GY
2
57
36
~
BR
Refer to last
(Foldout page)~age
CHID,
~
(ill
(Ei0t)
"
HHA009
HA-45
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
GA engine AfT models - for Europe LHD without daytime light system (with dealer installed
towing kit)
HA-A/C-09
BATTERY (Via
fusible link)
-
BLOCK 30A
(JIB) r-e-t
(El06) ~
IQ;OI GY
SR GY LG/S
BR _ 1_
f-p:=_e:::::- ~ ~ RELAY-2
BR GY
~~~rn> t
1:Jt1 :lJIICOOLING
n
U
IbjJJ ILi=U <ill>
LG/R G/B
FAN
RELAY-1 -T-.
GIS
LG
i
G/Y
G/Y@
I '
I
S
GIS
I G/Y ID
I
LG/R~ LG
IciJ~- t~J1@D
GIS
mm
La
1+)
G/Y
Hi
(+) COOLING
$-$@g)
mrn
La
1+)
G/Y
GIS
Hi
1+)COOLING
Li~ I
~\EJQ!I ~ FAN FAN
~M8----------~ Hi La
MOTOR-1
~ Hi La
MOTOR-2
H H~ H H ~
IkjJJ ~ ~ ~
LG/S S @D LG/S S ~
IrjJ~- $ 66 IrjJ~- i$/ 6
LG/S S @ LG/S S ID
I-I
LG/R~ LG
Iqp~-~~---------~qpl
LG/RCEID LG &-_I!__ ~.,
2 m
RFRL
ffiJl
RFRL
ECM
(ECCS
I emCONTROL
MODULE)
S
~
~~
~
S
2 CHID, <rnD
2
@
1 L
rffi\ @ID, @?), (f303), ~ 57 @
5
t:]JY GY GY GY GY 36 SR (El06)
em
"
@
W
HHA047
HA-46
TROUBLE DIAGNOSES
Wiring Diagram - Ale - (Cont'd)
SR20DE engine AIT models
HA-A/C-10
IGNITION SWITCH
ON or START
~J9~~~.j;l
Refer to EL-POWER.
10A FUSE
125 I 30A 30A
(El06) IT] [B]
GY G/W
I I
----,-I-F.~= BR GY G/W BR GY LG/B BR
I I
G/W LG/R
r:r- ~r=!-JI
I$~
---~$I G/B G/R
1- -
1--& t t
LG CHIDLG/R m m
I I
LG ~LG/R
[+) COOLING
FAN
MOTOR-1
[+) COOLING
FAN
MOTOR-2
1c!J~ ~c!J1
-F~: Lo rn
Hi
(-)
lLjJJ
~
tt
CEID
LG
rl.
LG/R
LG/R B
IJ I f
~
LG
RFRH
LG/R
m
RFRL
ECM
(ECCS
___ I-_!,
CONTROL B B
MODULE) -!- -!-
(ED <rn>~
~
IIDm
m>,<UZ>,(E18)
BR BR BR
~
\MJ
m,(ffi)
GY GY
Refer to last page
(Foldout
CHID , (El01)
(lliID
(IT)
page) .
HHA010
HA-47
TROUBLE DIAGNOSES
Wiring Diagram - A/C - (Cont'd)
CD20 engine models
HA-A/C-11
IGNITION SWITCH
r1!Jj;1]
ON or START
1---1
_ ....
-,-I-F. BR GY G/W
,-1=BR GY LG/B
I
BR
I
G/W LG/R
~:r
~-M-a-~
LG
O~I.
I
CHID LG/R
"1rlt-M-a-iI3.r1l
LG CHID LG/R
(+)
Hi
ijl
M
(+) ~
Hi
ijl
r'
R
t t
LI
0 LG/B B LG/R B
LG t
IFffill
R/FAN2
mt
L:/R
R/FAN1
ECM
(ENGINE
_,
L...I1.____ ...,
CONTROL B B
MODULE) -!- -!-
@ <rnlffi
Refer to last page
(Foldout page) .
~ llli>,@,((@ ~@,~
CHID , (EiOt)
~BR BR BR ~ GY GY <lliID
~
HHA011
HA-48
TROUBLE DIAGNOSES
Voltmeter terminal
Voltage
EB e
CD Body ground Approx. 12V
RHA341F
Turn AIC and fan switches ON. Check body ground circuit for
~Iv~
Thermo control amp.
thermo control amp.
1. Disconnect thermo control amp. harness connector.
2. Connect ohmmeter from harness side.
connector @
LHD
models: GIS
RHD
;Uw-i
2
[][]
~~.
\...~
3. Check for continuity between terminal No. @ and body
ground.
EB
Ohmmeter terminal
e
Continuity
models: GY
@ Body ground Yes
Continuity exists: OK '=" RHA342F
HA-49
TROUBLE DIAGNOSES
Flow chart
Diagnostic Procedure 1
INCIDENT
No.
SYMPTOM: Blower motor does not rotate.
1 Fan fails to rotate.
Fan does not rotate at
rn Perform PRELIMINARY CHECK 1 before referring to the fol-
2 [2J lowing flow chart.
1-speed.
Fan does not rotate at
3
2-speed. ~ CD
Check if blower motor rotates prop-
Fan does not rotate at erly at each fan speed. @
4 [1J
3-speed. Conduct checks as per flow chart at
Fan does not rotate at [2] left. @
5
4-speed.
@
Blower motor CHECK POWER SUPPL V FOR BLOWER No Check 15A (No. rnand
connector @) MOTOR. No. [2J ) fuses at fuse
m LlW
Disconnect blower motor harness con-
nector.
Do approx. 12 volts exist between
blower motor harness terminal No. CD
block.
(Refer to "POWER SUP-
PLY ROUTING" in EL sec-
tion and Wiring Diagram.)
and body ground?
Ves
RHA343F
Check circuit continuity between blower Reconnect blower motor
~ DISCONNECT motor harness terminal No. @ and harness connector.
IV@a
Blower motor
body ground.
~OK
connector @)
CHECK BLOWER MOTOR.
(Refer to Electrical Components Inspec-
~ ~ tion.) (HA-62)
LIB NG
RHA344F
@J
CHECK BLOWER MOTOR CIRCUIT No Disconnect blower motor
BETWEEN BLOWER MOTOR AND and resistor harness con-
RESISTOR nectors.
Resistor
Do approx. 12 volts exist between resis-
connector@
tor harness terminal No. CD and body
[Qli1JJ ground?
Ves
LIB
LIB LIB If the result is NG after checking circuit continuity, repair harness or connec-
tor.
RHA346F
HA-50
TROUBLE DIAGNOSES
Diagnostic Procedure 1 (Cont'd)
@
Fan switch
connector @ 1
Check circuit continuity between fan switch
Note
. I Replace resistor.
@
ITJ ~ ~ @] ~
Ii
.". RHA348F CHECK FAN SWITCH CIRCUIT.
Do approx. 12 volts exist between each fan switch
harness terminal and body ground?
Terminal No.
Conti-
Fan Resistor nuity
switch
@ CD
@
@
@
~
CID
@
CHECK FAN SWITCH AFTER DIS-
CONNECTING IT.
'-NG
H Replace fan switch.
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.
HA-51
TROUBLE DIAGNOSES
Diagnostic Procedure 2
SYMPTOM: Intake door does not change.
Intake door motor
connector @ m
CHECK POWER SUPPLY FOR INTAKE No Check 7.5A (No. ~ )
~ f-----.-
~JJ 1
DOOR MOTOR. fuse at fuse block.
Disconnect intake door motor harness (Refer to "POWER SUP-
LGIRt connector. PLY ROUTING" in EL sec-
Do approx. 12 volts exist between intake tion and Wiring Diagram.)
door motor harness terminal No. G)
RHA350F
and body ground?
Yes
~i5@a~
Intake door motor
(;J
connector@ CHECK BODY GROUND CIRCUIT FOR No Disconnect recirculation
~
INTAKE DOOR MOTOR. switch harness connector.
~ LHD models Turn recirculation switch ON. Does con-
tinuity exist between intake door motor
harness terminal @ and body ground? @J Note
GIS
Turn recirculation switch OFF. Does
Check continuity between
continuity exist between intake door
recirculation switch har-
motor harness terminal @ and body
ness terminal G) (@)
ground?
and intake door motor
Yes harness terminal @
(@).
Continuity should exist.
If OK, check harness for
short.
~15
Recirculation switch
OK
~ Note:
GIS: LHO models
Y/S: RHO mOdels'
1- GIY: LHO models
VIR: RHO models
If the result is NG after checking circuit continuity, repair harness or connec-
tor.
I
I
I
'"
.-
I
I
I
Y/S t Y/R G/Y t GIS
HA-52
TROUBLE DIAGNOSES
Diagnostic Procedure 2 (Cont'd)
@
~15
Recirculation switch
1 Note
~OK
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor ..
HA-53
TROUBLE DIAGNOSES
Diagnostic Procedure 3
SYMPTOM: Magnet clutch does not engage when Ale
Compressor switch and fan switch are ON. - For GA and SR
connector @QD-2
engines
~ Perform PRELIMINARY CHECK 1 before referring to the fol-
lowing flow chart.
s
m Yes
CHECK POWER SUPPLY FOR COMPRES- Check magnet clutch coil.
SOR.
RHA354F Disconnect compressor harness connec-
NG
tor.
Do approx. 12 volts exist between com-
pressor harness terminal ill and body Replace magnet clutch.
ground? Refer to HA-77, HA-80.
Thermal protector
No
connector @QD-1
[;) [;J
~ CHECK POWER SUPPLY FOR THERMAL Yes CHECK THERMAL PRO-
PROTECTOR. TECTOR.
lIR Disconnect thermal protector harness Check circuit continuity
connector. between thermal protector
Do approx. 12V exist between thermal harness terminal ill and
protector harness terminal ill and body compressor harness termi-
RHA355F
ground? nal ill.
Continuity should exist.
No
If OK, check harness for
shorl.
~ ~
~ i5@a
Thermal
If OK, check harness for shorl.
,"R~~t
RELAY. CIRCUIT AND 7.5A (No.
Disconnect AIC relay. [Q] and ~ ) FUSES AT
Do approx. 12 volts exist !)etween AIC FUSE BLOCK.
[1[] lIR relay harness terminals ill, @ and Refer to EL section ("Wir-
body ground? ing Diagram", "POWER
SUPPLY ROUTING").
Yes
RHA357F
NG
CHECK AIC RELAY AFTER DISCON- Replace AIC relay.
NECTING IT.
~15~
AlC relay
Refer to HA-64.
OK
connector (ill)
@: GA engine (for Europe, Israel and
~lIY Australia) and SR engine
@: Except above
Note:
If the result is NG after checking circuit continuity, repair harness or connec-
tor.
RHA358F
HA-54
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Conl'd)
@
Ii ~i)@a~ ~
EGM (EGGS control
module) connector @
I Reconnect AIC relay. _
II EGM ]gCONNECTOR II Ii !
CHECK COIL SIDE CIRCUIT OF AIC
No
Disconnect A/C relay.
~
RELAY. Disconnect ECM (ECCS
Do approx. 12 volts exist between ECM control module) harness
(ECCS control module) harness terminal connector.
: GA engine for @ or @ and body ground?
l
Australia: 15 (Y)
Others : 11 (G) RHA359F Yes ~ Note
~&)
AlG relay
~Io
EGM (EGGS control
NUITY BETWEEN AIC
RELAY HARNESS TERMI-
NAL @ AND ECM (ECCS
CONTROL MODULE) HAR-
ci
connector@
II
module) connector@
EGM ]gCONNECTOR II
(I)
. NESS TERMINAL @ or
@.
Continuity should exist.
If OK, check harness for
Y short.
CHECK VOLTAGE FOR ECM (ECCS con-
tral module) .
: GA engine for Do approx. 12 volts exist between ECM
Australia : 15 (Y) No
Others : 11 (G)
RHA360F
(ECCS control module) harness terminal
@, or @ and body ground?
-.. CHECK ECM (ECCS con-
trol module). Refer to EC
section.
Yes
o Dual-
If OK, check harness for short.
~15@a
EGM (EGGS control
pressure
switch
connector@
OK
NG
CHECK DUAL-PRESSURE SWITCH. Replace dual-pressure
module) connec1or@
Refer to HA-64. switch.
~.
II EGM E[CONNECTORII
OK
.
41 or 21 G
Disconnect thermo control amp. har-
ness connector.
21: GA engine for
Australia (G)
41: Others (GY)
RHA362F II Note Note:
If the result is NG after
CHECK CIRCUIT CONTINUITY BETWEEN checking circuit continuity,
DUAL.PRESSURE SWITCH HARNESS repair harness or connector.
TERMINAL @ AND THERMO CONTROL
AMP. HARNESS TERMINAL @.
Thermo Continuity should exist.
Dual-
control amp. If OK, check harness for short.
pressure
tm
switch
connector @ OOD @
OK
S8
S8
@ (Go to m .)
RHA363F
HA-55
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Co nt' d)
~ CONNECT ~ (gl ~
l41E) ~ @ ~
EGM (EGGS control
module) connector @ I Reconnect AIC relay_. _... _
II EGM J9"CONNECTORII
11 II !
CHECK COIL SIDE CIRCUIT OF AIC Disconnect ECM (ECCS
G RELAY. control module) harness
Do approx. 12 volts exist between ECM connector.
(ECCS control module) harness termi. Disconnect dual-pressure
nal @ and body ground? switch harness connector.
SHA734E
Yes
II Note
II CHECK CIRCUIT CONTINU-
ITY BETWEEN ECM (ECCS
CONTROL MODULE) HAR-
EGM (EGGS control Dual-pressure NESS TERMINAL @ AND
module) connector @ switch connector @ DUAL-PRESSURE SWITCH
HARNESS TERMINAL CD.
II ECM Ej'coNNEcTORII ~ Continuity should exist.
11 If OK, check harness for
G short.
G
~OK
NG
CHECK --+ Replace
RHA446F DUAL- dual-
PRES- pressure
SURE switch.
SWITCH.
Refer to
HA-64.
Dual-pressure switch NC relay
connector@ connector@
Note
CHECK CIRCUIT CONTINU-
L ITY BETWEEN AIC RELAY
L HARNESS TERMINAL @
AND DUAL-PRESSURE
SWITCH HARNESS TERMI-
NAL @.
RHA414F
Continuity should exist.
If OK, check harness for
~i)~@ short.
Yes
@
Note:
If the result is NG after checking circuil continuity, repair harness or connec-
tor.
HA-56
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)
@
Thermo control
amp. connector ~
EGM (EGGS control
module) connector@ CHECK CIRCUIT CONTINUITY
t
BETWEEN
Note
~OK
Reconnect thermo control amp. harness
connector.
Thermo control
,mp;""",,, @ ~
CHECK POWER SUPPLY FOR THERMO
Note
CONTROL AMP.
Refer to HA-49.
LHD:
RHD:
G/S'~L-.D--J
GY
rrIDl rJ.1
CHECK BODY GROUND CIRCUIT FOR Replace thermo control
RHA364F THERMO CONTROL AMP. amp.
Disconnect thermo control amp. harness
connector.
Does continuity exist between thermo
control amp. harness terminal @ and
Thermo control A/G switch body ground?
amp. connector @) connector @
No
i55lJ Disconnect
tor.
AIC switch harness connec-
~
LHD: GIS LHD: GIS Note
RHD: GY RHD: GY
CHECK CIRCUIT CONTINUITY BETWEEN
RHA365F THERMO CONTROL AMP. HARNESS
TERMINAL @ AND AIC SWITCH HAR-
NESS TERMINAL @.
Continuity should exist.
If OK. check harness for short.
OK
NG switch Fan switch
connector@ connector@ Replace AIC switch.
CHECK AIC SWITCH.
62J ~
Refer to HA-63.
OK
LHD: G/Y
RHD: LG/S
LHD: G/Y
RHD: LG/B
RHA366F
Disconnect
tor.
fan switch
BETWEEN
AIC SWITCH HARNESS TERMINAL @
connec-
Note
AND FAN SWITCH HARNESS TERMINAL
@.
OK
Note:
If the result is NG or No alter checking circuit continuity, repair harness or
connector.
HA-57
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)
~iv@a CID
Fan switch
connector@ 1
CHECK BODY GROUND CIRCUIT FOR
Note
~ FAN SWITCH.
Does continuity exist between fan switch
B harness terminal @ and body ground?
Yes
NG
CHECK FAN SWITCH. Replace fan switch.
'="RHA367F
Refer to HA-62.
Note:
If the result is No after checking circuit continuity, repair harness or connec-
tor.
HA-58
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)
SYMPTOM: Magnet clutch does not engage when Ale
switch and fan switch are ON. - For CD engine
Perform PRELIMINARY CHECK 1 before referring to the fol-
Compressor
connector @Q7>-2 lowing flow chart.
m Yes
~ CHECK POWER SUPPLY FOR COMPRES- Check magnet clutch coil.
SOR.
B OK
Disconnect compressor harness connec-
tor.
Do approx. 12 volts exist between com-
Replace magnet clutch.
RHA354F
pressor harness terminal CD and body
Refer to HA-77.
ground?
No
(;J [!]
Thermal protector CHECK POWER SUPPLY FOR THERMAL Yes CHECK THERMAL PRO-
connector @Q7>-1 PROTECTOR. TECTOR.
Disconnect thermal protector harness Check circuit continuity
connector. between thermal protector
~ Do approx. 12V exist between thermal harness terminal G) and
LlR protector harness terminal G) and body compressor harness termi-
ground? nal CD.
Continuity should exist.
No
If OK. check harness for
RHA355F short.
NG
j. ~~1-
AIC RELAY HARNESS TERMINAL @)
AND THERMAL PROTECTOR HARNESS
TERMINAL G).
I1iJ Continuity should exist.
If OK. check harness for short.
RHA356F
OK
~ ciP
1
relay harness terminals
body ground?
CD. @ and Refer to EL section ("Wir-
ing Diagram", "POWER
SUPPLY ROUTING").
Yes
~/R ~
NG
~L1R Replace AIC relay.
CHECK AIC RELAY AFTER DISCON-
NECTING IT.
RHA357F Refer to HA-64.
OK
@
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.
RHA358F
HA-59
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)
Ii ~i)~@ @
+
ECM (Engine control
I
r---
module) connector @ Reconnect AIC relay.
II ECM E[CONNECTORII Ii
8
CHECK COIL SIDE CIRCUIT OF AIC No Disconnect ECM (Engine
G RELAY. control module) harness
Do approx. 12 Yolts exist between ECM connector.
(Engine control module) harness termi- Disconnect dual-pressure
nal @ and body ground? switch harness connector .
....RHA370F
Yes
[iJ Note
CHECK CIRCUIT CONTINU-
ITY BETWEEN ECM
(ENGINE CONTROL MOD-
ECM (Engine control Dual-pressure ULE) HARNESS TERMINAL
module) connector ~ switch connector @) @ AND DUAL-PRESSURE
SWITCH HARNESS TERMI-
II ECM HCONNECTORII ~ NAL G).
8 Continuity should exist.
G If OK, check harness for
G
short.
OK
RHA368F
NG
CHECK Replace
DUAL- dual-
PRES- pressure
SURE switch.
SWITCH.
Refer to
Dual-pressure switch AlC relay
HA-64.
connector@ connector@
Note
~i5~~ o
short.
II ECM 11
31
CONNECTOR II CHECK VOLTAGE FOR ECM (Engine
No
CHECK ECM (Engine con-
ECM control unit). trol module). (Refer to EC
(Engine control AIL
Do approx. 12 YOIts exist between ECM section.)
module)@ (Engine control module) Ilarness termi-
nal No. @ and body ground?
Yes
@
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.
HA-60
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Conl'd)
II (!)
II ~ Note
Thermo control ECM (Engine control
CHECK CIRCUIT CONTINUITY BETWEEN
amp. connector@) module) connector @
ECM (ENGINE CONTROL MODULE)
~ II ECM ?,CONNECTOOII
HARNESS TERMINAL @ AND THERMO
CONTROL AMP. HARNESS TERMINAL
IAIL ~_tR/L
@.
Continuity should exist.
If OK, check harness for short.
OK
Note
CHECK POWER SUPPLY FOR THERMO
Co"NTROL AMP.
:~~~~~;;:~:@) ~ Refer to HA-49.
'L-.D--J 1
LHO: THERMO CONTROL AMP. amp.
RHO: GY Disconnect thermo control amp. harness
connector.
RHA364F
Does continuity exist between thermo
control amp. harness terminal @ and
II body ground?
No
Thermo control A/C switch
amp. connector @) connector @ Disconnect AIC switch harness connec-
tor.
~
~
II Note
CHECK CIRCUIT CONTINUITY BETWEEN
LHO: GIS LHO: GIS THERMO CONTROL AMP. HARNESS
RHO: GY RHO: GY TERMINAL @ AND AIC SWITCH HAR-
NESS TERMINAL @.
RHA365F
Continuity should exist.
If OK, check harness for short.
OK
[ij ~
Disconnect fan switch harness connec-
tor.
LHO: G/Y
RHO: LG/S
LHO: G/Y
RHO: LG/S
@.
Continuity should exist.
BETWEEN
AIC SWITCH HARNESS TERMINAL @
AND FAN SWITCH HARNESS TERMINAL
Note
If OK, check harness for short.
OK
@
(Go to next page.)
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.
HA-61
TROUBLE DIAGNOSES
Diagnostic Procedure 3 (Cont'd)
~15@a @
Fan switch
connector@
1
CHECK BODY GROUND CIRCUIT FOR
Note
~ FAN SWITCH.
B Does continuity exist between fan switch
harness terminal @ and body ground?
Yes
'="RHA367F NG
CHECK FAN SWITCH. Replace fan switch.
Refer to HA-62.
Note:
If the result is NG or No after checking circuit continuity, repair harness or
connector.
OFF
1 @-@-@
2 @----@-@
3 @ -------@ - @
RHA325F
4 @ ----------@ - @
BLOWER MOTOR
Confirm smooth rotation of the blower motor.
Ensure that there are no foreign particles inside the intake
unit.
HA-62
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
BLOWER RESISTOR
Check resistance between terminals.
Circuit check
Terminal No.
Resistance
EB 8
@ Approx. 1.4 - 1.6Q
AIC SWITCH
Check continuity between terminals at each switch position.
RECIRCULATION SWITCH
Check continuity between terminals at each switch position.
I
ON Yes
I
(1) @
I OFF No
I
I ON No
'- @ @
OFF Yes
SHA732E
THERMAL PROTECTOR
Temperature of compressor
Compressor operation
C (OF)
HA-63
TROUBLE DIAGNOSES
Electrical Components Inspection (Cont'd)
AIC RELAY
Check continuity between terminals <ID and CID.
Conditions Continuity
12V direct current supply between terminals G)
Yes
and @
No current supply No
AHA233
DUAL-PRESSURE SWITCH
Dual-pressure ON OFF
switch connector kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
Increasing to Decreasing to
Low-pressure
157 - 216 (1.57 - 2.16, 157 -196 (1.57 - 1.96,
side
1.6 - 2.2,23 - 31) 1.6 - 2.0,23 - 28)
Decreasing to Increasing to
High-pressure
1,863 - 2,256 (18.6 - 22.6, 2,452 - 2,844 (24.5 - 28.4,
side
19 - 23, 270 - 327) 25 - 29, 356 - 412)
HA-64
TROUBLE DIAGNOSES
Control Linkage Adjustment (Cont'd)
TEMPERATURE CONTROL CABLE
1. For RHO models, move the temperature control knob to the
full cold position.
For LHO models, move the temperature control knob to the
full hot position.
2. For RHO models, set the air mix door lever in the full cold
position.
For LHO models, set the air mix door lever in the full hot
position.
3. Pull on the cable cover in the direction of the arrow, then
clamp it.
After positioning control cable, check that it operates properly.
ZHA178A
System Description
INTAKE DOOR MOTOR
The intake door motor is installed on the intake unit. Using a
link it opens and closes the intake door.
When RECIRCULATION switch is ON, the ground line of the
motor is switched from terminal @ to @. This starts the motor
because the position switch contacts built into it make current
flow. When RECIRCULATION switch is OFF, the ground line is
switched from terminal @ to @. The contacts turn along with
the motor. When they reach the non-current flow position, the
LHD: u:Eh!.IJ motor will stop. The motor always turns in the same direction.
o::EhhJ
---I
RHD:
I
~----j
Intake door
molar
RHA331F
HA-65
SERVICE PROCEDURES
I -,
I~
V ~I~e service
~ .._----~
Recovery/Recycling/Recharging equipment
SHA539DC
SHA540DC
HA-66
SERVICE PROCEDURES
HFC-134a (R-134a) Service Procedure (Cont'd)
Set the recoverylrecycling equip-
ment.
I
Partial charging
'-1
, -1
Complete charging [specified
amount - 200 g (7.05 oz)J.
--H'-2
--r.---~.
'---.
---
---C-h-e-c-k-f-o-r-re-f-r-ig-e-r-a-nt-Ie-a-k-s-. Repair.
HA-67
SERVICE PROCEDURES
START
~
Yes
Can lubricant return operation be per- -+ Perform lubricant return operation, proceeding as follows:
formed?
AIC system works properly. 1. Start engine, and set the following conditions:
There is no evidence of a large amount Test condition
of lubricant leakage. Engine speed: Idling to 1,200 rpm
AlC or AUTO switch: ON
No Blower speed: Max. position
Temp. control: Optional [Set so that Intake air temperature is
25 to 30C (77 to 86F).]
2. Next item is for V-5 or V-6 compressor. Connect the manifold
gauge, and check that the high pressure side pressure is 588 kPa
(5.9 bar, 6 kg/cm2, 85 psi) or higher,
If less than the reference level, attach a cover to the front face of
the condenser to raise the pressure.
Should the compressor be replaced? 3. Perform lubricant return operation for about 10 minutes.
~ 4. Stop engine.
No Yes CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant
return operation.
@
(Go to next page.)
Yes
Is there any part to be replaced?
(Evaporator, condenser, liquid tank or in
-.. After replacing any of .the following major components, add the cor-
rect amount of lubricant to the system.
case there is evidence of a large amount Amount of lubricant to be added
of lubricant leakage.) Lubricant to be added to
system
No Part replaced
Amount of lubricant
Remarks
mf (Imp II oz)
Evaporator 75 (2.6) -
Condenser 75 (2.6) -
Add if compressor is not
Liquid tank 5 (0.2)
replaced. '1
30 (11) Large leak
Carry out the AIC performance test. In case of refrigerant leak
~ - Small leak'2
.
HA-68
SERVICE PROCEDURES
Maintenance of Lubricant Quantity in
Compressor (Cont'd)
@
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the
recovery/ recycling equipment.
2. Remove the drain plug of the "old" (removed) compressor (applicable only to V-5, V-6 or DKS-16H compressor).
Drain the lubricant into a graduated container and record the amount of drained lubricant.
3. Remove the drain plug and drain the lubricant from the "new" compressor into a separate, clean container.
4. Measure an amount of new lubricant installed equal to amount drained from "old" compressor. Add this lubricant to
"new" compressor through the suction port opening.
5. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to "new"
compressor through the suction port opening.
6. Torque the drain plug.
V.5 or V-6 compressor: 18 - 19 N'm (1.8 - 1.9 kg-m, 13 - 14 ft-Ib)
DKS.16H compressor: 14 - 16 N'm (1.4 - 1.6 kg-in, 10 - 12 ft-Ib)
7. If the liquid tank also needs to be replaced, add an additional 5 mC (0.2 Imp II oz) of lubricant at this time.
Do not add this 5 m C(0.2 Imp II oz) of lubricant if only replacing the compressor.
DO DO
Reinstall
"X"m Q + "Y"m Q
New
of new lubricant
New
-.------- lubricant
fAdda;-addition;; "I
15m Q (0.2 US fl Ol,
I 0.2 Imp fl Ol) of I
I new lubricant when I
! replacing liquid I
, tank. I
1- - __I
RHA065DD
HA-69
SERVICE PROCEDURES
Refrigerant Lines
Refer to page HA-4 regarding "Precautions for Refrigerant
Connection" .
o (Tightening torque)
o0 (Wrench size)
o (O-ring size)
RHA332F
HA-70
S~~~~:~::--_~S~ER ~V~1~C~E~P;.R;O~CE,D~U~fo;;r.:i)
R ENGINE RHD MO DEL
_ Ref ngerant
" L" RES
EC. 271.274 '276 mes (Cont' d)
5
Cooling unit
Dual-pressure switch
Liquid tank
Condenser
oo
o
~:
o
IiiiI
(Tightening
(Wrench size)
(D-ring size)
t orque)
r.:.1 :
25 - 34 ( 2.5 - 3.5 18
~ : N.m ( ,- 25)
kg-m, in-Ib)
RHA371F
HA-71
SERVICE
R f PROCE DURES
e ngerant L.mes (Cont'd)
CD ENGINE RHO MO DEL
SEC. 271'274-276
iii 810mm
- 20 (1.0 - 2
dia. .0, 87 - 174)
Expansion valve
[O.J 15
12 -mm
25 d'
(1.5 - 2.5, 11 - 18)
la. Hi~h-pressure
[SJ (Discharge)
service valve
\~
il!1d
Low-pressure (
service valve Suction)
I
I
D
DO (Tightening t
orque)
(Wrench size)
o (O-ring size)
Compressor [O.J : N'm (kg-m, ft-Ib)
iiia::N'm
20 - 29 (20
. - 3.0, 14 - 22)
(kg-m, in-Ib)
Condenser [SJ :: 810- 11 (0.8 - 1.1, 69 - 95)
ICl
- 20 (1.0 2
[Q] : 3 _4 .0, 87 - 174)
Liquid tank
(0.3 - 04
., 26 35)
RHA333F
HA-72
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
GA ENGINE lHD MODEL
~
."""\
~t;, 12 mm (0.47 in) dia.
Expansion valve
(Discharge) service valve
High-pressure
(Discharge) service valve
~ 10 - 20 (1.0 - 2.0, 87 - 174)
6 mm (0.24 in) dia.
Thermo control amp.
Dual-pressure switch
~ Liquid tank
o
DD
D
~
~
(Tightening
(Wrench size)
(O-ring size)
torque)
RHA334F
HA-73
SERVICE PROCEDURES
Refrigerant Lines (Co nt' d)
CD ENGINE LHD MODEL
Cooling unit
o (Tightening torque)
o0 (Wrench size)
o (O-ring size)
RHA335F
HA-74
SERVICE PROCEDURES
Compressor Mounting
GA engine models
SEC. 274.275
CD engine models
SEC. 274.275
HA-75
SERVICE PROCEDURES
Compressor Mounting (Cont'd)
SR20DE engine models
SEC. 274.275 ~ 16 19 (1.6 1.9, 12 14)
AHA387
Belt Tension
Refer to MA section.
HA-76
SERVICE PROCEDURES
SEC. 274
~4 -6
(0.4 - 0.6, 35 52)
Thermal protector
Clutch disc ~ 15 - 18 (1.5 - 1.8, 11 13)
Compressor Clutch
REMOVAL
When removing center bolt, hold clutch disc with clutch disc
wrench.
Drive plate
Remove the drive plate using Tool KV99232340.
Insert holder's three pins into the drive plate. Rotate the
holder clockwise to hook it onto the plate. Then, tighten the
center bolt to remove the drive plate.
When tightening the center bolt, insert a round bar
(screwdriver, etc.) between two of the pins (as shown in the
left-hand figure) to prevent drive plate rotation. After remov-
Shim ing the drive plate, remove the shims from either the drive
shaft or the drive plate.
SHA098EA
HA-77
SERVICE PROCEDURES
Compressor Clutch (Cont'd)
Remove the snap ring using external snap ring pliers.
External snap
ring pliers
Snap ring
RHA072C
Pulley removal
Use any commercially available pulley puller. Position the
center of it on the end of the drive shaft, and remove the
KV99233130 pulley assembly.
For pressed pulleys
To prevent deformation of the pulley groove, the puller
claws should be hooked into (not under) the pulley groove.
For machine latched pulleys
ulley puller Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
SHA099EA Remove the field coil harness clip using a screwdriver.
Remove the three field coil fixing screws and remove the
field coil.
~/S"'wd""'"
g- Field coil
1J
RHA074C
INSPECTION
Shim Snap ring
Clutch disc: If the contact surface shows signs of damage due
BOll\
JJ _ ~crew to excessive heat, replace clutch disc and pulley.
Pulley: Check the appearance of the pulley assembly. Check
the contact surface of the pulley for any sign of excessive groov-
ing due to slippage. If any sign is found, replace both the pul-
~ ley and clutch disc. !he contact surfaces of the pulley assem-
~ bly should be cleaned with a suitable solvent before reinstalla-
L Clutch disc tion.
Coil: Check coil for loose connection or cracked insulation.
RHA075C
INSTAllATION
Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head.
Install the field coil harness clip using a screwdriver.
RHA076C
HA-78
SERVICE PROCEDURES
Compressor Clutch (Cont'd)
Install the pulley assembly using the installer and a hand
Pulley assembly press, and then install the snap ring using snap ring pliers.
SHA100EA
Install the drive plate on the drive shaft, together with the
original shim(s). Press the drive plate down by hand.
Drive plate
-Shim
RHA07BC
Drive plate
holder
SHA101EA
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct
the break-in operation. This is done by engaging and disengag- i
/
Feeler gauge -.I ing the clutch about thirty times. Break-in operation raises the
level of transmitted torque.
-~~
'Spark plug gap gauge
( ~
Unit: mm (in)
RHAOBOC
HA-79
SERVICE PROCEDURES
Thermal Protector
INSPECTION
When servicing, do not allow foreign matter to get into com-
pressor.
Check continuity between two terminals.
Pulley assembly
Snap ring
Clutch disc
Compressor Clutch
REMOVAL
When removing center bolt, hold clutch disc with clutch disc
wrench.
Take off clutch disc.
HA-80
SERVICE PROCEDURES
Compressor Clutch (Co nt' d)
Pulley removal
Position the center pulley puller on the end of the drive
shaft, and remove the pulley assembly using any commer-
cially available pulley puller.
To prevent the pulley groove from being deformed, the
puller claws should be positioned onto the edge of the pul-
ley assembly.
RHA317E
INSPECTION
Clutch disc
If the contact surface shows signs of damage due to excessive
heat, the clutch disc and pulley should be replaced.
Pulley
~~
\t PUlley assembly
Check the appearance of the pulley assembly. If the contact
surface of the pulley shows signs of excessive grooving due to
-Shim RHA319E slippage, both the pulley and clutch disc should be replaced.
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 .
INSTALLATION
Position the field coil.
Be sure to align the coil's pin with the hole in compressor's
front head.
Install snap ring (which secures field coil) by using external
snap ring pliers.
RHA320E
HA-81
SERVICE PROCEDURES
Compressor Clutch (Cont'd)
Position and install pulley assembly securely by using plas-
tic hammer.
Install snap ring (which secures rotor pulley) by using exter-
nal snap ring pliers.
KV991 06800
~ RHA321EA
Install the clutch disc on the drive shaft, together with the
original shim(s). Press the disc down by hand.
~
s~ ~ Clutch disc
RHA323E
BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget
break-in operation, accomplished by engaging and disengaging
the clutch about thirty times. Break-in operation raises the level
of transmitted torque.
Thermal Protector
INSPECTION
When servicing, do not allow foreign matter to get into com-
pressor.
Check continuity between two terminals.
SHA055B
HA-82
SERVICE PROCEDURES
Evaporator
RHA336F
REPLACEMENT TIMING
Replace ventilation air filter every 2 years or 24,000 km (15,000
miles).
C-aution label is fixed inside the glove box.
REPLACEMENT PROCEDURES
Remove glove box which is secured with two clips.
Remove instrument reinforcement from instrument panel.
Take out ventilation air filter which is secured with one clip,
from cooling unit.
Replace with new one and reinstall instrument reinforce-
ment on instrument panel.
Reinstall glove box.
RHA340F
HA-83
SERVICE DATA AND SPECIFICATIONS (50S)
General Specifications
COMPRESSOR LUBRICANT
GA15DE, ZEXEL make
CALSONIC make
SR20DE GA14DE GA16DE Model DKV-11D
CR-14
engine engine and CD20 DKV-14D
Model engines
Nissan A/C System Oil
Name
CALSONIC ZEXEL ZEXEL Type R
make make make
Part number KLHOO-PAGRO
CR-14 DKV-14D DKV-11D
CapacitymC (Imp fl oz)
Type Vane rotary
Total in system 200 (7.0) 180 (6.3)
Displacement
144 (8.79) 140 (8.54) 110 (6.71)
cm3 (cu in)/Rev Compressor (Ser-
vice parts) 200 (7.0) 180 (6.3)
Clockwise
Direction of rotation charging amount
(Viewed from drive end)
Capacity kg (Ib)
HA-84