Automatic Air Conditioner: Section

AUTOMATIC AIR CONDITIONER
J AIR CONDITIONER
SECTION
AUTOMATIC AIR CONDITIONER
ATC B
E
CONTENTS
PRECAUTIONS .......................................................... 4 GASOLINE ENGINE: CWV-615M COMPRES- F
Precautions for Supplemental Restraint System SOR) ................................................................... 17
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- DUAL-PRESSURE SWITCH (WITH DIESEL
SIONER” .................................................................. 4 ENGINE: DKV-11G COMPRESSOR) .................. 17 G
Precautions for Working with HFC-134a (R-134a)..... 4 PRESSURE RELIEF VALVE (WITH GASOLINE
General Refrigerant Precautions .............................. 4 ENGINE: CWV-615M COMPRESSOR) .............. 17
Lubricant Precautions .............................................. 5 V-6 Variable Displacement Compressor (With Gas-
H
Precautions for Refrigerant Connection ................... 5 oline Engine: CWV-615M Compressor) .................. 18
FEATURES OF NEW TYPE REFRIGERANT GENERAL INFORMATION ................................. 18
CONNECTION ...................................................... 5 DESCRIPTION .................................................... 19
O-RING AND REFRIGERANT CONNECTION..... 6 Component Layout ................................................. 22 I
Precautions for Servicing Compressor ..................... 9 LUBRICANT .............................................................. 23
Precautions for Service Equipment .......................... 9 Maintenance of Lubricant Quantity in Compressor... 23
RECOVERY/RECYCLING EQUIPMENT .............. 9 LUBRICANT ........................................................ 23 ATC
ELECTRONIC LEAK DETECTOR ........................ 9 LUBRICANT RETURN OPERATION .................. 23
VACUUM PUMP ................................................... 9 LUBRICANT ADJUSTING PROCEDURE FOR
MANIFOLD GAUGE SET ...................................... 9 COMPONENTS REPLACEMENT EXCEPT
K
SERVICE HOSES ............................................... 10 COMPRESSOR .................................................. 24
SERVICE COUPLERS ........................................ 10 LUBRICANT ADJUSTING PROCEDURE FOR
REFRIGERANT WEIGHT SCALE ...................... 10 COMPRESSOR REPLACEMENT ....................... 24
CALIBRATING ACR4 WEIGHT SCALE .............. 10 AIR CONDITIONER CONTROL ............................... 26 L
CHARGING CYLINDER .......................................11 Overview Air Conditioner LAN Control System ...... 26
Precautions for Leak Detection Dye ........................11 System Construction .............................................. 26
IDENTIFICATION ................................................ 12 OPERATION ........................................................ 26 M
IDENTIFICATION LABEL FOR VEHICLE ........... 12 TRANSMISSION DATA AND TRANSMISSION
Wiring Diagrams and Trouble Diagnosis ................ 12 ORDER ............................................................... 27
PREPARATION ......................................................... 13 AIR MIX DOOR CONTROL (AUTOMATIC TEM-
Special Service Tools ............................................. 13 PERATURE CONTROL) ..................................... 28
WITH GASOLINE ENGINE (CWV-615M COM- FAN SPEED CONTROL ...................................... 28
PRESSOR) ......................................................... 13 INTAKE DOOR CONTROL ................................. 28
WITH DIESEL ENGINE (DKV-11G COMPRES- OUTLET DOOR CONTROL ................................ 28
SOR) ................................................................... 13 MAGNET CLUTCH CONTROL ........................... 28
HFC-134a (R-134a) Service Tools and Equipment... 14 SELF-DIAGNOSTIC SYSTEM ............................ 28
REFRIGERATION SYSTEM ..................................... 17 Overview of Control System ................................... 29
Refrigerant Cycle ................................................... 17 Control Operation ................................................... 30
REFRIGERANT FLOW ....................................... 17 MODE CONTROL DIAL ...................................... 30
FREEZE PROTECTION (WITH GASOLINE TEMPERATURE CONTROL DIAL (POTENTIO
ENGINE: CWV-615M COMPRESSOR) .............. 17 TEMPERATURE CONTROL) .............................. 30
Refrigerant System Protection ............................... 17 FAN CONTROL DIAL .......................................... 30
REFRIGERANT PRESSURE SENSOR (WITH REAR WINDOW DEFOGGER SWITCH ............. 30
ATC-1
INTAKE SWITCH ................................................. 30 DOOR MOTOR ....................................................76
A/C SWITCH ....................................................... 30 Intake Door Motor Circuit ........................................77
Discharge Air Flow ................................................. 31 INSPECTION FLOW ............................................77
System Description ................................................. 32 SYSTEM DESCRIPTION .....................................78
SWITCHES AND THEIR CONTROL FUNCTION... 32 COMPONENT DESCRIPTION ............................78
TROUBLE DIAGNOSIS ............................................ 33 DIAGNOSTIC PROCEDURE FOR INTAKE
How to Perform Trouble Diagnoses for Quick and DOOR MOTOR ....................................................79
Accurate Repair ...................................................... 33 Blower Motor Circuit ................................................80
WORK FLOW ...................................................... 33 INSPECTION FLOW ............................................80
SYMPTOM TABLE .............................................. 33 SYSTEM DESCRIPTION .....................................81
Component Parts and Harness Connector Location... 34 COMPONENT DESCRIPTION ............................82
ENGINE COMPARTMENT .................................. 34 DIAGNOSTIC PROCEDURE FOR BLOWER
PASSENGER COMPARTMENT .......................... 35 MOTOR ................................................................82
Schematic — A/C, A — .......................................... 36 COMPONENT INSPECTION ...............................85
WITH GASOLINE ENGINE ................................. 36 Magnet Clutch Circuit ..............................................86
WITH DIESEL ENGINE ....................................... 37 INSPECTION FLOW ............................................86
Wiring Diagram — A/C, A — .................................. 38 SYSTEM DESCRIPTION .....................................87
WITH GASOLINE ENGINE / LHD MODELS ....... 38 DIAGNOSTIC PROCEDURE FOR MAGNET
WITH GASOLINE ENGINE / RHD MODELS ...... 42 CLUTCH ..............................................................87
WITH DIESEL ENGINE / LHD MODELS ............ 46 COMPONENT INSPECTION ...............................92
WITH DIESEL ENGINE / RHD MODELS ............ 50 Insufficient Cooling ..................................................94
Auto Amp. Terminals and Reference Value ............ 54 INSPECTION FLOW ............................................94
PIN CONNECTOR TERMINAL LAYOUT ............ 54 PERFORMANCE TEST DIAGNOSIS ..................96
TERMINALS AND REFERENCE VALUE FOR PERFORMANCE CHART ....................................98
AUTO AMP. ......................................................... 54 TROUBLE DIAGNOSES FOR UNUSUAL PRES-
Self-diagnosis Function .......................................... 56 SURE ................................................................. 100
DESCRIPTION .................................................... 56 Insufficient Heating ............................................... 103
FUNCTION CONFIRMATION PROCEDURE ...... 58 INSPECTION FLOW .......................................... 103
AUXILIARY MECHANISM: TEMPERATURE Noise ..................................................................... 104
SETTING TRIMMER ........................................... 62 INSPECTION FLOW .......................................... 104
AUXILIARY MECHANISM: FOOT POSITION Self-diagnosis ....................................................... 105
SETTING TRIMMER ........................................... 63 INSPECTION FLOW .......................................... 105
AUXILIARY MECHANISM: INLET PORT MEM- Ambient Sensor Circuit ......................................... 106
ORY FUNCTION ................................................. 63 COMPONENT DESCRIPTION .......................... 106
Operational Check .................................................. 64 AMBIENT TEMPERATURE INPUT PROCESS .106
CHECKING BLOWER ......................................... 64 DIAGNOSTIC PROCEDURE FOR AMBIENT
CHECKING DISCHARGE AIR ............................ 64 SENSOR ............................................................ 106
CHECKING INTAKE DOOR ................................ 64 COMPONENT INSPECTION ............................. 108
CHECKING TEMPERATURE DECREASE ......... 65 In-vehicle Sensor Circuit ....................................... 108
CHECKING TEMPERATURE INCREASE .......... 65 COMPONENT DESCRIPTION .......................... 108
CHECKING A/C SWITCH ................................... 65 DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
Power Supply and Ground Circuit for Auto Amp. ... 66 SENSOR ............................................................ 109
INSPECTION FLOW ........................................... 66 COMPONENT INSPECTION ............................. 110
COMPONENT DESCRIPTION ............................ 66 Sunload Sensor Circuit ......................................... 111
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 67 COMPONENT DESCRIPTION .......................... 111
LAN System Circuit ................................................ 68 SUNLOAD INPUT PROCESS ........................... 111
DIAGNOSTIC PROCEDURE FOR LAN CIR- DIAGNOSTIC PROCEDURE FOR SUNLOAD
CUIT .................................................................... 68 SENSOR ............................................................ 111
Mode Door Motor Circuit ........................................ 71 COMPONENT INSPECTION ............................. 113
INSPECTION FLOW ........................................... 71 Intake Sensor Circuit ............................................. 114
SYSTEM DESCRIPTION .................................... 72 COMPONENT DESCRIPTION .......................... 114
COMPONENT DESCRIPTION ............................ 73 DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
DIAGNOSTIC PROCEDURE FOR MODE SOR ................................................................... 114
DOOR MOTOR ................................................... 73 COMPONENT INSPECTION ............................. 116
Air Mix Door Motor Circuit ...................................... 74 CONTROLLER ........................................................ 117
INSPECTION FLOW ........................................... 74 Removal and Installation ....................................... 117
SYSTEM DESCRIPTION .................................... 75 REMOVAL .......................................................... 117
COMPONENT DESCRIPTION ............................ 76 INSTALLATION .................................................. 117
DIAGNOSTIC PROCEDURE FOR AIR MIX
ATC-2
AMBIENT SENSOR .................................................118 REFRIGERANT LINES ........................................... 138
Removal and Installation .......................................118 HFC-134a (R-134a) Service Procedure ............... 138 A
REMOVAL ..........................................................118 SETTING OF SERVICE TOOLS AND EQUIP-
INSTALLATION ..................................................118 MENT ................................................................ 138
IN-VEHICLE SENSOR .............................................119 Components ......................................................... 140 B
Removal and Installation .......................................119 WITH GASOLINE ENGINE ............................... 140
REMOVAL ..........................................................119 WITH DIESEL ENGINE ..................................... 141
INSTALLATION ..................................................119 Removal and Installation for Compressor ............ 141
SUNLOAD SENSOR .............................................. 120 REMOVAL ......................................................... 141 C
Removal and Installation ...................................... 120 INSTALLATION ................................................. 143
REMOVAL ......................................................... 120 Removal and Installation for Compressor Clutch . 144
INSTALLATION ................................................. 120 REMOVAL ......................................................... 144 D
INTAKE SENSOR ................................................... 121 INSTALLATION ................................................. 147
Removal and Installation ...................................... 121 Removal and Installation for Low-pressure Flexible
REMOVAL ......................................................... 121 Hose ..................................................................... 150 E
INSTALLATION ................................................. 121 REMOVAL ......................................................... 150
BLOWER UNIT ....................................................... 122 INSTALLATION ................................................. 151
Removal and Installation ...................................... 122 Removal and Installation for High-pressure Flexible
REMOVAL ......................................................... 122 Hose ..................................................................... 151 F
Disassembly and Assembly ................................. 123 INSTALLATION ................................................. 151
BLOWER MOTOR .................................................. 124 Removal and Installation for High-pressure Pipe . 151 G
Removal and Installation ...................................... 124 REMOVAL ......................................................... 151
REMOVAL ......................................................... 124 INSTALLATION ................................................. 152
INSTALLATION ................................................. 124 Removal and Installation for Condenser .............. 152 H
INTAKE DOOR MOTOR ......................................... 125 REMOVAL ......................................................... 152
REMOVAL ......................................................... 125 Removal and Installation for Liquid Tank .............. 153
I
FAN CONTROL AMPLIFIER .................................. 126 INSTALLATION ................................................. 154
Removal and Installation ...................................... 126 Removal and Installation for Refrigerant Pressure
REMOVAL ......................................................... 126 Sensor .................................................................. 154 ATC
AIR CONDITIONER FILTER ................................... 127 INSTALLATION ................................................. 154
Removal and Installation ...................................... 127 Removal and Installation for Dual-pressure Switch. 154 K
FUNCTION ........................................................ 127 REMOVAL ......................................................... 154
REPLACEMENT TIMING .................................. 127 INSTALLATION ................................................. 154
REPLACEMENT PROCEDURES ..................... 127 Removal and Installation for Evaporator .............. 155 L
HEATER & COOLING UNIT ASSEMBLY .............. 128 REMOVAL ......................................................... 155
REMOVAL ......................................................... 128 Removal and Installation for Expansion Valve ...... 156
INSTALLATION ................................................. 129 REMOVAL ......................................................... 156 M
Disassembly and Assembly ................................. 130 INSTALLATION ................................................. 156
MODE DOOR MOTOR ........................................... 131 Checking for Refrigerant Leaks ............................ 156
Removal and Installation ...................................... 131 Checking System for Leaks Using the Fluorescent
REMOVAL ......................................................... 131 Leak Detector ....................................................... 157
INSTALLATION ................................................. 131 Dye Injection ......................................................... 157
AIR MIX DOOR MOTOR ......................................... 132 Electronic Refrigerant Leak Detector .................... 157
Removal and Installation ...................................... 132 PRECAUTIONS FOR HANDLING LEAK
REMOVAL ......................................................... 132 DETECTOR ....................................................... 157
INSTALLATION ................................................. 132 CHECKING PROCEDURE ............................... 158
HEATER CORE ...................................................... 133 SERVICE DATA AND SPECIFICATIONS (SDS) .... 160
Removal and Installation ...................................... 133 COMPRESSOR .................................................... 160
REMOVAL ......................................................... 133 LUBRICANT ......................................................... 160
INSTALLATION ................................................. 133 REFRIGERANT .................................................... 160
DUCTS AND GRILLES .......................................... 134 ENGINE IDLING SPEED ...................................... 160
Removal and Installation ...................................... 134 BELT TENSION .................................................... 160
REMOVAL ......................................................... 134
INSTALLATION ................................................. 137
ATC-3
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EJS001OH
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 and/or orange harnesses or
harness connectors.
Precautions for Working with HFC-134a (R-134a) EJS001JU
WARNING:
● 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 malfunction 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. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refriger-
ant. If accidental system discharge occurs, ventilate work area before resuming service. Addi-
tional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
– Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam
parts. Damage may result.
General Refrigerant Precautions EJS001JV
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 52°C (125°F).
● 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.
● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
● 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 HFC-134a (R-134a)
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
ATC-4
PRECAUTIONS
injury or property damage. Additional health and safety information may be obtained from refriger-
ant manufacturers. A
Lubricant Precautions EJS001JW
● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. B
If lubricant other than that specified is used, compressor malfunction is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following
handling precautions must be observed:
C
– 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 con-
D
necting the components. Connect all refrigerant loop components as quickly as possible to minimize the
entry of moisture into system.
– 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. E
● Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If acciden-
tal system discharge occurs, ventilate work area before resuming service. Additional health and safety F
information may be obtained from refrigerant and lubricant manufacturers.
● Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam parts. Dam-
age may result. G
Precautions for Refrigerant Connection EJS001JX
A new type refrigerant connection has been introduced to all refrigerant lines except the following location. H
● Expansion valve to cooling unit
● Refrigerant pressure sensor (or dual-pressure switch) to liquid tank
FEATURES OF NEW TYPE REFRIGERANT CONNECTION I
● The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing ATC
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. K
SHA815E
ATC-5
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION

With Gasoline Engine
RJIA2817E
NOTE:
This illustration is for RHD models. The blower and heater & cooling unit layouts for LHD models are symmet-
rically opposite.
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
ATC-6
PRECAUTIONS
With Diesel Engine

A
ATC
RJIA2818E
NOTE:
This illustration is for RHD models. The blower and heater & cooling unit layouts for LHD models are symmet-
K
rically opposite.
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or L
around, the connection.
O-Ring Part Numbers and Specifications
M
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)
8
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
New 92472 N8210 10.9 (0.429) 2.43 (0.0957)
12
Former 92475 71L00 11.0 (0.433) 2.4 (0.094)
New 92473 N8210 13.6 (0.535) 2.43 (0.0957)
16
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
SHA814E New 92474 N8210 16.5 (0.650) 2.43 (0.0957)

19
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
ATC-7
PRECAUTIONS
CAUTION:
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.
Malfunction to do so will cause lubricant to enter the low-pressure chamber.
● 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-
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
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.
● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
With gasoline engine With diesel engine
(CWV-615M compressor) (DKV-11G compressor)
Lubricant name: Nissan A/C System Oil Type S Nissan A/C System Oil Type R
Part number: KLH00-PAGS0 KLH00-PAGR0
● 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.
● 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
ATC-8
PRECAUTIONS
Precautions for Servicing Compressor EJS001JY
A
● 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- B
sor” exactly. Refer to ATC-23, "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.
C
● 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.
D
● After replacing the compressor magnet clutch, apply voltage to the new one and check for usual
operation.
Precautions for Service Equipment EJS001JZ E
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. F
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer′s instructions for tester operation and tester maintenance.
G
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
H
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it. I
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows.
● Usually vacuum pumps have a manual isolator valve as part of ATC
the pump. Close this valve to isolate the service hose from the
pump.
● For pumps without an isolator, use a hose equipped with a man- K
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.
● 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 L
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump′s M
ability to pull a deep vacuum and are not recommended.
RHA270DA
MANIFOLD GAUGE SET

Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.
SHA533D
ATC-9
PRECAUTIONS
SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shut-
off devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.
RHA272D
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:
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.
ATC-10
PRECAUTIONS
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder′s top valve A
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.
B
Precautions for Leak Detection Dye EJS001K0
● 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.
C
● Always wear fluorescence enhancing UV safety goggles 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- D
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
E
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).
● Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis F
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 G
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. H
● Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C systems or A/C system damage may result. I
● The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.
ATC
ATC-11
PRECAUTIONS
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
RJIA2721E
SHA867F
Wiring Diagrams and Trouble Diagnosis EJS001K1
When you read wiring diagrams, refer to the following:

● GI-15, "How to Read Wiring Diagrams" in GI section.
● PG-3, "Wiring Diagram — POWER —" in PG section.
When you perform trouble diagnosis, refer to the following:
● GI-11, "How to Follow Trouble Diagnoses" in GI section.
● GI-24, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.
ATC-12
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools EJS001K2
WITH GASOLINE ENGINE (CWV-615M COMPRESSOR)

Tool number
Description
B
Tool name
D
KV99106100 S-NT232
Removing shaft nut and clutch disc
Clutch disc wrench
E
RJIA0194E
G
KV99232340
or
Removing clutch disc
KV992T0001 H
Clutch disc puller
S-NT376
KV99106200 ATC
Installing pulley
Pulley installer
S-NT235 K
WITH DIESEL ENGINE (DKV-11G COMPRESSOR)
Tool number L
Description
Tool name
M
KV99231260
Removing shaft nut and clutch disc
Clutch disc wrench
RJIA0475E
KV992T0001
Removing clutch disc
Clutch disc puller
RJIA0476E
ATC-13
PREPARATION
Tool number
Description
Tool name
KV992T0002
Installing pulley
Pulley installer
RJIA0477E
KV99233130
Removing pulley
Pulley puller
RJIA0478E
HFC-134a (R-134a) Service Tools and Equipment EJS001K3
Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or
its lubricant.
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 malfunction will result.
Tool number
Description
Tool name
Container color: Light blue

Container marking: HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size: Thread size
● Large container 1/2″ -16 ACME
S-NT196
Gasoline engine (CWV-615M):

Type: Poly alkylene glycol oil (PAG),
Gasoline engine (CWV-615M):
type S
KLH00-PAGS0
Application: HFC-134a (R-134a)
Nissan A/C System Oil Type S
wobble (swash) plate compressors
(DH-PS)
(Nissan only)
Diesel engine (DKV-11G):
Diesel engine (DKV-11G):
Type: Poly alkylene glycol oil (PAG),
KLH00-PAGR0
type R
Nissan A/C System Oil Type R
S-NT197 Application: HFC-134a (R-134a) vane
(DH-PR)
rotary compressors (Nissan only)
Lubricity: 40 m (1.4 Imp fl oz)
ATC-14
PREPARATION
Tool number
Description A
Tool name
Recovery/Recycling Function: Refrigerant Recovery and C

Recharging equipment Recycling and Recharging
RJIA0195E
F
Power supply:
Electrical leak detector
● DC 12V (Cigarette lighter)
G
SHA705EB H
(J-43926)
Refrigerant dye leak detection kit
Kit includes: I
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector ATC
Power supply:
Use with J-41447, 1/4 ounce
DC 12V (Battery terminal)
bottle
(J-41447)
HFC-134a (R-134a) fluorescent K
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872) ZHA200H
L
Refrigerant dye cleaner
Power supply: DC 12V (Battery

terminal) M
For checking refrigerant leak when
(J-42220)
fluorescent dye is installed in A/C
UV lamp and UV safety goggles
system.
Includes: UV lamp and UV safety
goggles
SHA438F
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
ATC-15
PREPARATION
Tool number
Description
Tool name
(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.
Refrigerant dye cleaner
SHA441F
Identification:
● The gauge face indicates HFC-134a
Manifold gauge set (with hoses
(R-134a).
and couplers)
● 1/2″ -16 ACME
RJIA0196E
Hose color:
● Low hose: Blue with black stripe
Service hoses
● High-pressure side hose ● High hose: Red with black stripe
● Low-pressure side hose ● Utility hose: Yellow with black stripe

or green with black stripe
● Utility hose Hose fitting to gauge:
S-NT201 ● 1/2″ -16 ACME
Service couplers Hose fitting to service hose:

● High-pressure side coupler ● M14 × 1.5 fitting is optional or
● Low-pressure side coupler permanently attached.
S-NT202
For measuring of refrigerant

Refrigerant weight scale Fitting size: Thread size
● 1/2″ -16 ACME
S-NT200
Capacity:
● Air displacement: 4 CFM
Vacuum pump ● Micron rating: 20 microns
(Including the isolator valve) ● Oil capacity: 482 g (17 oz)
S-NT203
● 1/2″ -16 ACME
ATC-16
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM PFP:KA990

A
Refrigerant Cycle EJS001K4
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, B
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.
FREEZE PROTECTION (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR) C
Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the V-6 variable displacement compressor to
prevent freeze up.
D
Refrigerant System Protection EJS001K5
REFRIGERANT PRESSURE SENSOR (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR)

The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sen- E
sor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refriger-
ant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.
ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side F
detected by refrigerant pressure sensor is over about 2,746 kPa (27.46 bar, 28 kg/cm2 , 398 psi), or below
about 134 kPa (1.34 bar, 1.4 kg/cm2 , 20 psi).
DUAL-PRESSURE SWITCH (WITH DIESEL ENGINE: DKV-11G COMPRESSOR) G
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 opens to interrupt the compressor operation. H
PRESSURE RELIEF VALVE (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR)
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 unusual level [more than 3,727 kPa (37.27 bar, I
38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refriger-
ant into the atmosphere.
ATC
ATC-17
RJIA0676E
V-6 Variable Displacement Compressor (With Gasoline Engine: CWV-615M

Compressor) EJS001K6
GENERAL INFORMATION
1. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable com-
pressor do not drop too far below 5°C (41°F) when:
Evaporator intake air temperature is less than 20°C (68°F).
Engine is running at speeds less than 1,500 rpm.
This is because the V-6 compressor provides a means of “capacity” control.
2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it
may not produce high refrigerant pressure discharge (compared to previous units) when used with air
conditioning systems.
3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt
angle of the wobble (swash) plate has changed and is not a malfunction.
4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system
main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or
when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.
5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It
normally ranges from 147 to 177 kPa (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm2 , 21 to 26 psi) under varying con-
ditions.
In previous compressors, however, suction pressure was reduced with increases in engine speed.
ATC-18
DESCRIPTION
General A
The variable compressor is basically a swash plate type that changes piston stroke in response to the required
cooling capacity.
The tilt of the wobble (swash) plate allows the piston′s stroke to change so that refrigerant discharge can be B
continuously changed from 14.5 to 146 cm3 (0.885 to 8.91 cu in).
ATC
RJIA1346E
ATC-19
Operation
1. Operation Control Valve
Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response
to changes in refrigerant suction pressure.
Operation of the valve controls the internal pressure of the crankcase.
The angle of the wobble (swash) plate is controlled between the crankcase′s internal pressure and the
piston cylinder pressure.
2. Maximum Cooling
Refrigerant pressure on the low-pressure side increases with an increase in heat loads.
When this occurs, the control valve′s bellows compress to open the low-pressure side valve and close the
high-pressure side valve.
This causes the following pressure changes:
● The crankcase′s internal pressure to equal the pressure on the low-pressure side;
● The cylinder′s internal pressure to be greater than the crankcase′s internal pressure.
Under this condition, the wobble (swash) plate is set to the maximum stroke position.
RHA473C
3. Capacity Control
● Refrigerant pressure on suction side is low during high speed driving or when ambient or interior tem-
perature is low.
● The bellows expands when refrigerant pressure on the suction pressure side drops below approxi
mately 177 kPa (1.77 bar, 1.8 kg/cm2 , 26 psi).
Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crank-
case pressure becomes high as high-pressure enters the crankcase.
● The force acts around the journal pin near the wobble (swash) plate, and is generated by the pressure
difference before and behind the piston.
The drive lug and journal pin are located where the piston generates the highest pressure. Piston pres-
sure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If
crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the wobble
(swash) plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure
increase triggers pressure difference between the piston and the crankcase. The pressure difference
changes the angle of the wobble (swash) plate.
ATC-20
F
RHA474C
ATC
ATC-21
Component Layout EJS001K7
NOTE:
This illustration is for RHD models. The layout for LHD models is symmetrically opposite.
RJIA2819E
ATC-22
LUBRICANT
LUBRICANT PFP:KLG00
A
Maintenance of Lubricant Quantity in Compressor EJS001K8
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
(CWV-615M Compressor) (DKV-11G Compressor)
Name: Nissan A/C System Oil Type S Nissan A/C System Oil Type R E
Part number: KLH00-PAGS0 KLH00-PAGR0
LUBRICANT RETURN OPERATION
F
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed? G
● A/C system works properly.
● There is no evidence of a large amount of lubricant leakage.
H
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
YES or NO I
YES >> GO TO 2.
NO >> GO TO 3.
2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS: ATC
1. Start engine, and set the following conditions:

– Test condition K
Engine speed: Idling to 1,200 rpm
A/C switch: ON
Blower speed: Max. position L
Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).]
Intake position: Recirculation (REC)
2. Perform lubricant return operation for about 10 minutes.
M
3. Stop engine.
>> GO TO 3.
3. CHECK REPLACEMENT PART
Should the compressor be replaced?

YES >> GO TO ATC-24, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
NO >> GO TO ATC-24, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACE-
MENT EXCEPT COMPRESSOR" .
ATC-23
LUBRICANT
LUBRICANT ADJUSTING 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
m (Imp fl oz)
Evaporator 75 (2.6) -
Condenser 75 (2.6) -
Liquid tank 10 (0.4) -
30 (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 m (0.2 Imp fl oz) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz) of lubricant if only replacing the compressor.
ATC-24
LUBRICANT
RHA065DI
I
ATC
ATC-25
AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL PFP:27500
Overview Air Conditioner LAN Control System EJS001K9
The LAN (Local Area Network) system consists of auto amp., mode door motor, air mix door motor and intake
door motor.
A configuration of these components is shown in the diagram below.
RJIA0480E
System Construction EJS001KA
A small network is constructed between the auto amplifier, air mix door motor, mode door motor and intake
door motor. The auto amplifier and motors are connected by data transmission lines and motor power supply
lines. The LAN network is built through the ground circuits of each door motor.
Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted
through the data transmission lines connecting the auto amplifier and each door motor.
The following functions are contained in LCUs built into air mix door motor, mode door motor and intake door
motor.
● Address
● Motor opening angle signals
● Data transmission
● Motor stop and drive decision
● Opening angle sensor (PBR function)
● Comparison
● Decision (Auto amplifier indicated value and motor opening angle comparison)
RHA350H
OPERATION
The auto amplifier receives data from each of the sensors. The amplifier sends mode door, air mix door and
intake door opening angle data to the mode door motor LCU, air mix door motor LCU and intake door motor
LCU.
The mode door motor, air mix door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amplifier and each of the motor posi-
tion sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subse-
quently, HOT/COLD, DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection
data is returned to the auto amplifier.
ATC-26
RHA351H
D
TRANSMISSION DATA AND TRANSMISSION ORDER
Amplifier data is transmitted consecutively to each of the door motors following the form shown in figure below.
Start: Initial compulsory signal sent to each of the door motors.
E
Address: Data sent from the auto amplifier is selected according to data-based decisions made by the air mix
door motor, mode door motor and intake door motor.
If the addresses are identical, the opening angle data and error check signals are received by the door motor
LCUs. The LCUs then make the appropriate error decision. If the opening angle data is usual, door control F
begins.
If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon
the corrected opening angle data.
G
Opening angle:
Data that shows the indicated door opening angle of each door motor.
Error check:
Procedure by which sent and received data is checked for errors. Error data is then compiled. The error check H
prevents corrupted data from being used by the air mix door motor, mode door motor and intake door motor.
Error data can be related to the following symptoms.
● Malfunction electrical frequency I
● Poor electrical connections
● Signal leakage from transmission lines
● Signal level fluctuation ATC
Stop signal:
At the end of each transmission, a stop operation, in-operation, or internal malfunction message is delivered to
the auto amplifier. This completes one data transmission and control cycle. K
RHA352H
ATC-27
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)

The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.
FAN SPEED CONTROL
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature, amount of sunload and air mix door position.
With FAN control dial set to AUTO, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing.
INTAKE DOOR CONTROL
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor.
OUTLET DOOR CONTROL
The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature and amount of sunload.
MAGNET CLUTCH CONTROL
The ECM controls compressor operation using input signals from the throttle position sensor, refrigerant pres-
sure sensor (or dual-pressure switch) and auto amplifier.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the auto amplifier to quickly locate the cause of symptoms.
ATC-28
Overview of Control System EJS001KB
A
The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs.
The relationship of these components is shown in the diagram below:
ATC
RJIA2820E K
ATC-29
Control Operation EJS004O7
SJIA0386E
MODE CONTROL DIAL

Controls the air discharge outlets.
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.
When shifting mode control dial to DEF under the following conditions, compressor is turned ON. (A/C LED
ON)
● FAN: ON
● A/C: OFF
TEMPERATURE CONTROL DIAL (POTENTIO TEMPERATURE CONTROL)
Increase or decrease the set temperature.
FAN CONTROL DIAL
Automatically or Manually control the blower speed. Twenty five speeds are available for manual control. Shift-
ing fan control dial to AUTO, compressor is turned ON automatically.
REAR WINDOW DEFOGGER SWITCH
When illumination is ON, rear window is defogged.
INTAKE SWITCH
● When intake switch is ON, REC indicator turns ON, and air inlet is fixed to REC.
● Press intake switch again, FRE indicator turns ON, and air inlet is fixed to FRE.
● When intake switch is pressed for approximately 1.5 seconds or longer, REC and FRE indicators blink
twice. Then, automatic control mode is entered. Inlet status is displayed even during automatic control.
● When DEF switch or FRE indicator is turned ON, or when compressor is turned from ON to OFF, REC
switch is automatically turned OFF (fixed to FRE mode).
REC mode can be re-entered by pressing intake switch again. (Except DEF position)
A/C SWITCH
The compressor is ON or OFF.
(Pressing the A/C switch when the fan control dial is ON will turn off the A/C switch and compressor.)
ATC-30
Discharge Air Flow EJS001KD
ATC
SJIA0441E
ATC-31
System Description EJS001KE
SWITCHES AND THEIR CONTROL FUNCTION
SJIA0448E
RJIA2822E
ATC-32
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS PFP:00004

A
How to Perform Trouble Diagnoses for Quick and Accurate Repair EJS004OD
WORK FLOW
B
SHA900E
E
*1 ATC-64, "Operational Check"
SYMPTOM TABLE
Symptom Reference Page
F
ATC-66, "Power
Supply and
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System. G
Ground Circuit for
Auto Amp."
Air outlet does not change. ATC-71, "Mode
Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN) Door Motor Cir- H
Mode door motor does not operate normally. cuit"
Discharge air temperature does not change. ATC-74, "Air Mix
Air mix door motor does not operate nor- Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN) Door Motor Cir- I
mally. cuit"
Intake door does not change. ATC-77, "Intake

Go to Trouble Diagnosis Procedure for Intake Door Motor. (LAN) Door Motor Cir- ATC
Intake door motor does not operate normally. cuit"
Blower motor operation is malfunctioning.
ATC-80, "Blower
Blower motor operation is malfunctioning Go to Trouble Diagnosis Procedure for Blower Motor. K
Motor Circuit"
under out of starting fan speed control.
ATC-86, "Magnet
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch.
Clutch Circuit" L
ATC-94, "Insuffi-
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling.
cient Cooling"
ATC-103, "Insuffi- M
Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating.
cient Heating"
Noise Go to Trouble Diagnosis Procedure for Noise. ATC-104, "Noise"
ATC-105, "Self-
Self-diagnosis can not be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis.
diagnosis"
ATC-33
TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location EJS004OE
ENGINE COMPARTMENT
RJIA0677E
ATC-34
TROUBLE DIAGNOSIS
PASSENGER COMPARTMENT
A
ATC
RJIA2855E
ATC-35
TROUBLE DIAGNOSIS
Schematic — A/C, A — EJS004OF
WITH GASOLINE ENGINE
TJWA0077E
ATC-36
TROUBLE DIAGNOSIS
WITH DIESEL ENGINE

A
ATC
TJWB0035E
ATC-37
TROUBLE DIAGNOSIS
Wiring Diagram — A/C, A — EJS004OG
WITH GASOLINE ENGINE / LHD MODELS
TJWB0001E
ATC-38
TROUBLE DIAGNOSIS
ATC
TJWA0079E
ATC-39
TROUBLE DIAGNOSIS
TJWB0002E
ATC-40
TROUBLE DIAGNOSIS
ATC
TJWB0003E
ATC-41
TROUBLE DIAGNOSIS
WITH GASOLINE ENGINE / RHD MODELS
TJWB0004E
ATC-42
TROUBLE DIAGNOSIS
ATC
TJWB0005E
ATC-43
TROUBLE DIAGNOSIS
TJWB0006E
ATC-44
TROUBLE DIAGNOSIS
ATC
TJWB0007E
ATC-45
TROUBLE DIAGNOSIS
WITH DIESEL ENGINE / LHD MODELS
TJWA0087E
ATC-46
TROUBLE DIAGNOSIS
ATC
TJWB0008E
ATC-47
TROUBLE DIAGNOSIS
TJWB0009E
ATC-48
TROUBLE DIAGNOSIS
ATC
TJWB0010E
ATC-49
TROUBLE DIAGNOSIS
WITH DIESEL ENGINE / RHD MODELS
TJWB0011E
ATC-50
TROUBLE DIAGNOSIS
ATC
TJWB0012E
ATC-51
TROUBLE DIAGNOSIS
TJWB0013E
ATC-52
TROUBLE DIAGNOSIS
ATC
TJWB0014E
ATC-53
TROUBLE DIAGNOSIS
Auto Amp. Terminals and Reference Value EJS004OH
Measure voltage between each terminal and ground by following ter-

minals and reference value for auto amp.
RJIA2824E
PIN CONNECTOR TERMINAL LAYOUT
RJIA0489E
TERMINALS AND REFERENCE VALUE FOR AUTO AMP.

Termi- Wire Ignition Voltage
Item Condition
nal No. color switch (V)
1 BR/Y Power supply for IGN ON - Battery voltage
2 L Power supply for BAT OFF - Battery voltage
3 B Ground ON - Approx. 0
Compressor: ON Approx. 0
4 L/R A/C (Compressor ON) signal ON
Compressor: OFF Approx. 5
Power supply for each door
5 W ON - Battery voltage
motor
8 P In-vehicle sensor - - -
9 R/B Ambient sensor - - -
10 OR Sunload sensor - - -
11 B Illumination ground ON Light switch: ON Approx. 0
12 R/L Power supply for illumination ON Light switch: ON Approx. 12
Approx. 5.5
15 G LAN signal ON -
HAK0652D
Fan control amp. control sig- Fan speed: 1st - 24th Approx. 2.5 - 3.5
17 L/Y ON
nal Fan speed: 25th Approx. 9.0
18 R Blower motor feed back ON Fan speed: 1st Approx. 8.0
Fan ON signal (With gaso- Blower fan: ON Approx. 0

19 LG/B ON
line engine) Blower fan: OFF Approx. 5
ATC-54
TROUBLE DIAGNOSIS
Termi- Wire Ignition Voltage

Item Condition
nal No. color switch (V) A
20 L/W Power supply for ACC ON - Battery voltage
B
At idle (after warming up, approx.
80°C)
21 GY Water temperature sensor ON CAUTION:
The waveforms vary depend- C
ing on coolant temperature
SKIA0056J
D
Rear window defogger ON Rear window defogger: ON Approx. 0
22 LG/B ON
signal Rear window defogger: OFF Approx. 12
Rear window defogger feed Rear window defogger: ON Approx. 12 E

23 BR ON
back signal Rear window defogger: OFF Approx. 0
24 B/Y Sensor ground ON - Approx. 0
25 BR/Y Intake sensor - - -
F
Power supply for ambient

28 Y ON - Approx. 5
temperature display
G
- Approx. 0
Compressor feed back signal
30 PU ON Disconnect the refrigerant pres-
(With gasoline engine) Approx. 5
sure sensor connector
H
ATC
ATC-55
TROUBLE DIAGNOSIS
Self-diagnosis Function EJS004OI
DESCRIPTION
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line.
Self-diagnosis is step-1 to 7. There are two ways of changing method during self-diagnosis.
● Switching to self-diagnosis step-1 to 4.
Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing A/C switch for at least 5 seconds. The A/C switch must
be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be
canceled by either pressing intake switch or turning the ignition switch OFF. Shifting from one step to
another is accomplished be means of turning fan control dial, as required.
● Switching to self-diagnosis step-5 to 7 (Auxiliary mechanism).
Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing intake switch for at least 5 seconds. The intake switch
must be pressed within 10 seconds after starting the engine (ignition switch is tuned ON). This system will
be canceled by either pressing A/C switch or turning the ignition switch OFF. Shifting from one step to
another is accomplished by means of turning fan control dial, as required.
ATC-56
TROUBLE DIAGNOSIS
ATC
RJIA2106E
ATC-57
TROUBLE DIAGNOSIS
FUNCTION CONFIRMATION PROCEDURE

1. SET IN SELF-DIAGNOSTIC MODE (STEP-1 TO 4)
1. Set the fan control dial to OFF position.
2. Turn ignition switch ON.
3. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press A/C switch for at least 5 seconds.
CAUTION:
If battery voltage drops below 12V during diagnosis step-3, actuator speed becomes slower and as a
result, the system may generate an error even when operation is usual. To avoid this, start engine
before performing this diagnosis.
>> GO TO 2.
2. STEP-1: LEDS ARE CHECKED

Check intake and A/C switch LEDs illumination.
OK or NG
OK >> GO TO 3.
NG >> Refer to ATC-105, "Self-diagnosis" .
SJIA0389E
3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP-2

1. Turn fan control dial to AUTO position.
CAUTION:
When switched to STEP-2, LED of REC position blinks for
approximately 25 seconds.
2. Advance to self-diagnosis STEP-2?
Check A/C switch LED illumination.
YES >> GO TO 4.
NO >> Replace controller.
SJIA0390E
4. CHECK TO RETURN SELF-DIAGNOSIS STEP-1

Turn fan control dial to OFF position.
Return to self-diagnosis STEP-1?
YES >> GO TO 5.
NO >> Replace controller.
ATC-58
TROUBLE DIAGNOSIS
5. STEP-2: SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT A

2. Turn mode control dial to AUTO position.
CAUTION: B
3. Check A/C switch LED is illuminate. C
OK or NG
OK >> GO TO 6.
NG >> GO TO 9. D
SJIA0391E
6. STEP-3: MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED E
1. Turn fan control dial to 1st–12th speed.

2. Check A/C switch LED is illuminate.
F
OK or NG
OK >> GO TO 7.
NG >> GO TO 10. G
SJIA0392E
7. STEP-4: OPERATION OF EACH ACTUATOR IS CHECKED I
1. Turn fan control dial to 13th–25th speed.

2. Change operation status of air conditioner by changing mode control dial position. ATC
>> GO TO 8.
K
ATC-59
TROUBLE DIAGNOSIS
8. CHECK ACTUATORS
Refer to the following chart and confirm discharge air flow, air tem-
perature, blower motor voltage and compressor operation.
RJIA0492E
Mode control dial position
STEP No.*1 STEP-41 STEP-42 STEP-43 STEP-44 STEP-45 STEP-46

Mode control dial FOOT or
AUTO VENT B/L D/F or D/F2 DEF
position FOOT2
Mode door position VENT VENT B/L FOOT*2 D/F DEF
Intake door position REC REC REC FRE FRE FRE
Air mix door position FULL COLD FULL COLD FULL COLD FULL HOT FULL HOT FULL HOT
Blower motor voltage Approx. 4.5V Approx. 10.5V Approx. 8.5V Approx. 8.5V Approx. 8.5V Approx. 12V
Compressor ON ON OFF OFF ON ON
Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for
improper operation.
*1: Step No. 41 to 46 are for differentiation and will not be displayed.
*2: FOOT position during automatic control. Refer to ATC-63, "AUXILIARY MECHANISM: FOOT POSITION
SETTING TRIMMER" .
OK or NG
OK >> 1. Turn ignition switch OFF or intake switch ON.
2. INSPECTION END
NG >> ● Air outlet does not change.
Go to Mode Door Motor Circuit. Refer to ATC-71, "Mode Door Motor Circuit" .
● Intake door does not change.
Go to Intake Door Motor Circuit. Refer to ATC-77, "Intake Door Motor Circuit" .
● Blower motor operation is malfunctioning.
Go to Blower Motor Circuit. Refer to ATC-80, "Blower Motor Circuit" .
● Magnet clutch does not engage.
Go to Magnet Clutch Circuit. Refer to ATC-86, "Magnet Clutch Circuit" .
● Discharge air temperature does not change.
Go to Air Mix Door Motor Circuit. Refer to ATC-74, "Air Mix Door Motor Circuit"
ATC-60
TROUBLE DIAGNOSIS
9. CHECK MALFUNCTIONING SENSOR A

Refer to the following chart.
*1: Perform self-diagnosis STEP-2 under sunshine.
When performing indoors, aim a light (more than 60W) at sunload B
sensor, otherwise LED of A/C switch will not indicate despite that
sunload sensor is functioning properly.
CAUTION: C
D
SJIA0393E
E
Mode control dial position Unusual Malfunctioning sensor (Including circuits) Reference page
VENT Ambient sensor *2
B/L In-vehicle sensor *3 F
FOOT or FOOT2 A/C LED: OFF Sunload sensor*1 *4
D/F or D/F2 Intake sensor *5 G
DEF Air mix door motor (LCU) PBR *6
*2: ATC-106, "DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR" .

*3: ATC-109, "DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR" . H
*4: ATC-111, "DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR" .
*5: ATC-114, "DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR" .
*6: ATC-76, "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR" . I
>> INSPECTION END

ATC
10. CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH
Mode or (and) intake door motor position switch (es) is (are) mal-
functioning. K
CAUTION:
approximately 25 seconds. L
Unusual Mode or intake door position Reference page

REC LED: ON Mode door motor *1 M
FRE LED: ON Intake door motor *2
*1: ATC-73, "DIAGNOSTIC PROCEDURE FOR MODE DOOR SJIA0394E
MOTOR" .
*2: ATC-79, "DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR" .
>> INSPECTION END
ATC-61
TROUBLE DIAGNOSIS
AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER

The trimmer compensates for differences in range of ±3°C between temperature setting (Temperature control
dial position) and temperature felt by driver.
Operating procedures for this trimmer are as follows:
1. Set temperature at 25°C.
2. Set fan control dial to OFF.
ON.), press intake switch for at least 5 seconds.
5. Turn temperature control dial as desired. Temperature will change at a rate of 1°C each time a dial is
turned.
LED status of each switch
Setting temperature
FRE REC A/C
−3°C ON ON ON
−2°C ON ON OFF
−1°C ON OFF ON
0°C (Initial setting) OFF OFF OFF
1°C OFF OFF ON
2°C OFF ON OFF
3°C OFF ON ON
When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial
condition, i.e. 0°C.
ATC-62
TROUBLE DIAGNOSIS
AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER

Wind distribution ratio in FOOT mode can be set. A
1. Set temperature at 25°C.
B
2. Set fan control dial to AUTO.
4. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned C
5. Turn temperature control dial as desired.
D
I
RJIA2825E
LED status of each switch

ATC
Type
FRE REC A/C
Type-A (initial setting) OFF OFF ON
K
Type-B OFF ON OFF
Type-C OFF ON ON
Type-D ON OFF OFF L
AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION

When ignition key is turned from OFF to ON, inlet port can be set to AUTO or manual. M
1. Set fan control dial to 1st–25th speed.
4. Press intake switch as desired.
LED status of LED status of Setting status Setting changeover

FRE position REC position FRE REC method
OFF OFF AUTO control AUTO control.

Manual REC status is memorized.
OFF ON AUTO control (Initial setting)
(Initial setting) Intake SW: ON
ON OFF Manual FRE status is memorized. AUTO control
ON ON Manual FRE status is memorized. Manual REC status is memorized.
ATC-63
TROUBLE DIAGNOSIS
Operational Check EJS004OJ
The purpose of the operational check is to confirm that the system operates properly.
Conditions : Engine running and at usual operating temperature
CHECKING BLOWER
1. Turn fan control dial to 1st speed. Blower should operate on low
speed.
2. Turn fan control dial to 2nd speed, and continue checking
blower speed until all speeds are checked.
3. Leave blower on Max. speed.
If NG, go to trouble diagnosis procedure for ATC-80, "Blower Motor
Circuit" .
If OK, continue with next check.
SJIA0395E
CHECKING DISCHARGE AIR

1. Turn mode control dial to each position.
SJIA0396E
2. Confirm that discharge air comes out according to the air distri-
bution table. Refer to ATC-31, "Discharge Air Flow" .
Mode door position is checked in the next step.
If NG, go to trouble diagnosis procedure for ATC-71, "Mode Door
Motor Circuit" .
NOTE:
Confirm that the compressor clutch is engaged (sound or visual
inspection) and intake door position is at FRESH when the D/F, D/F2
or DEF position are selected.
RJIA0492E
CHECKING INTAKE DOOR

1. Press intake switch. Recirculation indicator should illuminate.
2. Press intake switch again. Fresh indicator should illuminate.
3. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for ATC-77, "Intake Door
Motor Circuit" .
SJIA0397E
ATC-64
TROUBLE DIAGNOSIS
CHECKING TEMPERATURE DECREASE

1. Turn temperature control dial until 18°C. A
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for ATC-94, "Insufficient
Cooling" . B
SJIA0398E
D
CHECKING TEMPERATURE INCREASE

1. Turn temperature control dial until 32°C.
E
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for ATC-103, "Insufficient
Heating" .
F
SJIA0399E
H
CHECKING A/C SWITCH
2. Press A/C switch. I
● Confirm that the compressor clutch engages (sound or visual
inspection). (Discharge air and blower speed will depend on
ambient, in-vehicle, and set temperatures.) ATC
If NG, go to ATC-66, "Power Supply and Ground Circuit for Auto
Amp." , then if necessary, trouble diagnosis procedure for ATC-86,
"Magnet Clutch Circuit" . K
If all operational check are OK (symptom cannot be duplicated), go
to Incident Simulation Tests in GI-24, "How to Perform Efficient Diag-
nosis for an Electrical Incident" and perform tests as outlined to sim- SJIA0400E
ulate driving conditions environment. If symptom appears, refer to L

ATC-33, "SYMPTOM TABLE" and perform applicable trouble diagnosis procedures.
ATC-65
TROUBLE DIAGNOSIS
Power Supply and Ground Circuit for Auto Amp. EJS004OK
SYMPTOM: A/C system does not come on.

INSPECTION FLOW
RJIA2826E
*1 ATC-64, "Operational Check". *2 ATC-67, "DIAGNOSTIC PROCE-

DURE FOR A/C SYSTEM".
COMPONENT DESCRIPTION
Auto Amp. (Automatic Amplifier)
The auto amplifier has a built-in microcomputer which processes
information sent from various sensors needed for air conditioner
operation. The air mix door motor, mode door motor, intake door
motor, blower motor and compressor are then controlled.
The auto amplifier is unitized with control mechanisms. Signals from
various switches and Potentio Temperature Control (PTC) are
directly entered into auto amplifier.
Self-diagnostic functions are also built into auto amplifier to provide
quick check of malfunctions in the auto air conditioner system.
RJIA2824E
Potentio Temperature Control (PTC)

The PTC is built into the A/C auto amp. It can be set at an interval of
1°C in the 18°C to 32°C temperature range by turning the tempera-
ture control dial.
SJIA0402E
ATC-66
TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM

SYMPTOM: A/C system does not come on. A
RJIA0504E
D
1. CHECK POWER SUPPLY CIRCUIT FOR AUTO AMP.

1. Disconnect auto amp. connector. E
2. Check voltage between auto amp. harness connector M52 ter-
minal 1 (BR/Y), 2 (L), 20 (L/W) and ground.
F
Terminals Ignition switch position
(+)
Auto amp. Terminal (-) OFF ACC ON G
connector (wire color)
Approx. Approx. Battery
M52 1 (BR/Y)
0V 0V voltage RJIA2856E
H
Battery Battery Battery
M52 2 (L) Ground
voltage voltage voltage
Approx. Battery Battery I
M52 20 (L/W)
0V voltage voltage
OK or NG
OK >> GO TO 2. ATC
NG >> Check 10A fuses (Nos. 15 and 28) and 15A fuses (Nos. 19 and 24), located in the fuse block (J/
B). Refer to PG-77, "FUSE BLOCK - JUNCTION BOX (J/B)" .
● If fuses are OK, check for open circuit in wiring harness. Repair or replace as necessary. K
● If fuses are NG, replace fuse and check wiring harness for short circuit. Repair or replace as
necessary.
L
2. CHECK GROUND CIRCUIT FOR AUTO AMP.
Check continuity between auto amp. harness connector M52 termi-

nal 3 (B) and ground. M
3 – Ground : Continuity should exist.

OK or NG
OK >> Replace auto amp.
NG >> Repair or replace harness.
RJIA2857E
ATC-67
TROUBLE DIAGNOSIS
LAN System Circuit EJS004OL
SYMPTOM: Mode door motor, intake door motor and/or air mix door motor does not operate normally.
RJIA0507E
DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT

1. CHECK POWER SUPPLY FOR AUTO AMP.
minal 5 (W) and ground.
5 – Ground : Battery voltage
OK or NG
OK >> GO TO 2.
NG >> Replace auto amp.
RJIA2858E
2. CHECK SIGNAL FOR AUTO AMP.

Check voltage between auto amp. harness connector M52 terminal
15 (G) and ground.
15 – Ground : Approx. 5.5V
OK or NG
OK >> GO TO 3.
NG >> Replace auto amp.
RJIA2859E
ATC-68
TROUBLE DIAGNOSIS
3. CHECK POWER SUPPLY FOR EACH DOOR MOTOR A

Check voltage between mode door motor harness connector M37
terminal 1 (W), air mix door motor harness connector M38 terminal 1
(W) or intake door motor harness connector M47 terminal 1 (W) and B
ground.
OK or NG C
OK >> GO TO 4.
NG >> Replace harness or connector.
D
RJIA0509E
4. CHECK SIGNAL FOR EACH DOOR MOTOR E
Check voltage between mode door motor harness connector M37

terminal 3 (G), air mix door motor harness connector M38 terminal 3
(G) or intake door motor harness connector M47 terminal 3 (G) and F
ground.
3 – Ground : Approx. 5.5V
G
OK or NG
OK >> GO TO 5.
NG >> Replace harness or connector. H
RJIA0510E
5. CHECK MOTOR GROUND CIRCUIT I
1. Turn ignition switch OFF.

2. Disconnect each door motor connector. ATC
3. Check continuity between mode door motor harness connector
M37 terminal 2 (B), air mix door motor harness connector M38
terminal 2 (B) or intake door motor harness connector M47 ter- K
minal 2 (B) and ground.
L
OK or NG
OK >> GO TO 6.
RJIA0511E
NG >> Replace harness or connector.
M
6. CHECK MOTOR OPERATION
2. Disconnect each door motor connector.
3. Reconnect each door motor connector.
5. Confirm each door motor operation.
OK or NG
OK >> (Return to operate normally.)
● Poor contact in motor connector.
NG >> (Does not operate normally.)

● GO TO 7.
ATC-69
TROUBLE DIAGNOSIS
7. CHECK AIR MIX AND INTAKE DOOR MOTORS OPERATION

2. Disconnect mode, air mix, and intake door motor connectors.
3. Reconnect air mix and intake door motor connectors.
5. Confirm air mix and intake door motors operation.
OK or NG
OK >> (Air mix and intake door motors operate normally.)
● Replace mode door motor.
NG >> (Air mix and intake door motors does not operate normally.)
● GO TO 8.
8. CHECK MODE AND INTAKE DOOR MOTORS OPERATION

2. Disconnect air mix door motor connector.
3. Reconnect mode door motor connector.
5. Confirm mode and intake door motors operation.
OK or NG
OK >> (Mode and intake door motors operate normally.)
● Replace air mix door motor.
NG >> (Mode and intake door motors does not operate normally.)
● GO TO 9.
9. CHECK MODE AND AIR MIX DOOR MOTORS OPERATION

2. Disconnect intake door motor connector.
3. Reconnect air mix door motor connector.
5. Confirm mode and air mix door motors operation.
OK or NG
OK >> (Mode and air mix door motors operate normally.)
● Replace intake door motor.
NG >> (Mode and air mix door motors does not operate normally.)
● Replace auto amp.
ATC-70
TROUBLE DIAGNOSIS
Mode Door Motor Circuit EJS004OM
A
SYMPTOM:
● Air outlet does not change.
● Mode door motor does not operate normally. B
INSPECTION FLOW
ATC
RJIA2827E
*1 ATC-31, "Discharge Air Flow". *2 ATC-64, "Operational Check". *3 ATC-58, "FUNCTION CONFIRMA-
TION PROCEDURE", see No. 1.
*4 ATC-58, "FUNCTION CONFIRMA- *5 ATC-106, "Ambient Sensor Circuit". *6 ATC-108, "In-vehicle Sensor Cir-
TION PROCEDURE", see No. 5 to cuit".
7.
*7 ATC-111, "Sunload Sensor Circuit". *8 ATC-114, "Intake Sensor Circuit". *9 ATC-74, "Air Mix Door Motor Cir-
cuit".
ATC-71
TROUBLE DIAGNOSIS
*10 ATC-58, "FUNCTION CONFIRMA- *11 ATC-68, "LAN System Circuit". *12 ATC-73, "Mode Door Motor".
*13 ATC-33, "SYMPTOM TABLE".
SYSTEM DESCRIPTION
Component Parts
Mode door control system components are:
● Auto amp.
● Mode door motor (LCU)
● A/C LAN system (PBR built-in air mix door motor, mode door motor and intake door motor)
● In-vehicle sensor
● Ambient sensor
● Sunload sensor
● Intake sensor
System Operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door, mode door and
intake door opening angle data to the air mix door motor LCU, mode door motor LCU and intake door motor
LCU.
The air mix door motor, mode door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amplifier and each of the motor posi-
quently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new
selection data is returned to the auto amplifier.
RJIA2828E
Mode Door Control Specification
RHA384HA
ATC-72
TROUBLE DIAGNOSIS
Mode Door Motor A
The mode door motor is attached to the heater & cooling unit. It
rotates so that air is discharged from the outlet set by the auto ampli-
fier. Motor rotation is conveyed to a link which activates the mode B
door.
D
RJIA0513E
H
RJIA0514E
DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR

I
SYMPTOM: Mode door motor does not operate normally.
Perform diagnostic procedure for ATC-68, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .
ATC
ATC-73
TROUBLE DIAGNOSIS
Air Mix Door Motor Circuit EJS004ON
SYMPTOM:
● Discharge air temperature does not change.
● Air mix door motor does not operate.
INSPECTION FLOW
RJIA2829E
*1 ATC-64, "Operational Check". *2 ATC-58, "FUNCTION CONFIRMA- *3 ATC-58, "FUNCTION CONFIRMA-

TION PROCEDURE", see No. 1. TION PROCEDURE", see No. 5 to 7.
*4 ATC-106, "Ambient Sensor Circuit". *5 ATC-108, "In-vehicle Sensor Circuit" *6 ATC-111, "Sunload Sensor Circuit".
*7 ATC-114, "Intake Sensor Circuit" *8 ATC-76, "DIAGNOSTIC PROCE- *9 ATC-33, "SYMPTOM TABLE".
DURE FOR AIR MIX DOOR
MOTOR".
*10 ATC-58, "FUNCTION CONFIRMA- *11 ATC-68, "LAN System Circuit". *12 ATC-76, "Air Mix Door Motor".
ATC-74
TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts A
Air mix door control system components are:
● Auto amp.
B
● Air mix door motor (LCU)
● In-vehicle sensor C
● Ambient sensor
● Sunload sensor
● Intake sensor D
System Operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door, mode door and
intake door motor opening angle data to the air mix door motor LCU, mode door motor LCU and intake door E
motor LCU.
The air mix door motor, mode door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amplifier and each of the motor posi- F
quently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new
selection data is returned to the auto amplifier.
G
ATC
RHA424GB
M
Air Mix Door Control Specification
RHA457H
ATC-75
TROUBLE DIAGNOSIS
Air Mix Door Motor
The air mix door motor is attached to the heater & cooling unit. It
rotates so that the air mix door is opened or closed to a position set
by the auto amplifier. The air mix door position is then fed back to the
auto amplifier by PBR built-in air mix door motor.
RJIA0516E
RJIA0517E
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR

SYMPTOM: Discharge air temperature does not change.
Perform diagnostic procedure for ATC-68, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .
ATC-76
TROUBLE DIAGNOSIS
Intake Door Motor Circuit EJS004OO
A
SYMPTOM:
● Intake door does not change.
● Intake door motor does not operate normally. B
INSPECTION FLOW
ATC
RJIA2830E

*4 ATC-106, "Ambient Sensor Circuit". *5 ATC-108, "In-vehicle Sensor Circuit". *6 ATC-111, "Sunload Sensor Circuit".
*7 ATC-114, "Intake Sensor Circuit". *8 ATC-74, "Air Mix Door Motor Circuit". *9 ATC-33, "SYMPTOM TABLE".
*10 ATC-58, "FUNCTION CONFIRMA- *11 ATC-68, "LAN System Circuit". *12 ATC-78, "Intake Door Motor".
ATC-77
TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Component Parts
Intake door control system components are:
● Auto amp.
● Intake door motor (LCU)
● Ambient sensor
● Sunload sensor
● Intake sensor
System Operation
The intake door control determines intake door position based on the ambient temperature, the intake air tem-
perature and the in-vehicle temperature. When set mode control dial to D/F, D/F2 or DEF position, or OFF
switch is pushed, the auto amp. sets the intake door at the FRESH position.
RJIA2831E
Intake Door Motor
The intake door motor is attached to the intake unit. It rotates so that
air is drawn from inlets set by the auto amplifier. Motor rotation is
conveyed to a lever which activates the intake door.
RJIA0519E
ATC-78
TROUBLE DIAGNOSIS
RJIA0520E
D
DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR
SYMPTOM: Intake door motor does not operate normally.
Perform diagnostic procedure for ATC-68, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . E
ATC
ATC-79
TROUBLE DIAGNOSIS
Blower Motor Circuit EJS004OP
SYMPTOM:
● Blower motor operation is malfunctioning.
● Blower motor operation is malfunctioning under out of starting fan speed control.
INSPECTION FLOW
RJIA2832E

TION PROCEDURE", see No. 1. TION PROCEDURE", see No. 5.
*4 ATC-58, "FUNCTION CONFIRMA- *5 ATC-106, "Ambient Sensor Circuit". *6 ATC-108, "In-vehicle Sensor Circuit".
ATC-80
TROUBLE DIAGNOSIS
*7 ATC-111, "Sunload Sensor Circuit". *8 ATC-114, "Intake Sensor Circuit". *9 ATC-33, "SYMPTOM TABLE".
*10 ATC-58, "FUNCTION CONFIRMA- *11 ATC-82, "DIAGNOSTIC PROCE- *12 EC-154, "DTC P0117, P0118 ECT A
TION PROCEDURE", see No. 9. DURE FOR BLOWER MOTOR". SENSOR" (With QR engine: For
Hong Kong), EC-577, "DTC P0117,
P0118 ECT SENSOR" (With QR
engine: Except Hong Kong) or EC-
B
990, "DTC P0117, P0118 ECT SEN-
SOR" (With YD engine).
C
SYSTEM DESCRIPTION
Component Parts
Fan speed control system components are: D
● Auto amp.
● Fan control amp. E
● Ambient sensor
● Sunload sensor F
● Intake sensor
System Operation G
ATC
RJIA2833E
M
Automatic Mode
In the automatic mode, the blower motor speed is calculated by the automatic amplifier based on input from
the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor.
The blower motor applied voltage ranges from approximately 4 volts (lowest speed) to 12 volts (highest
speed).
The control blower speed (in the range of 4 to 12V), the automatic amplifier supplies a gate voltage to the fan
control amplifier. Based on this voltage, the fan control amplifier controls the voltage supplied to the blower
motor.
ATC-81
TROUBLE DIAGNOSIS
Starting Fan Speed Control

Start Up From COLD SOAK Condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 56°C (133°F), the blower will not
operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the
ambient and engine coolant temperature.
In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described
above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above
56°C (133°F), at which time the blower speed will increase to the objective speed.
Start Up From Usual or HOT SOAK Condition (Automatic mode)

The blower will begin operation momentarily after the A/C switch is pushed. The blower speed will gradually
rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective
blower speed).
Blower Speed Compensation
Sunload
When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low
speed. The low speed will vary depending on the sunload. During conditions of low or no sunload, the blower
low speed is usual low speed (approx. 4V). During high sunload conditions, the auto amp causes the blower
fan speed to increase. (Approx. 7V)
Fan Speed Control Specification
RJIA0522E
Fan Control Amplifier
The fan control amplifier is located on the intake unit. The fan control
amp. receives a gate voltage from the auto amp. to steplessly main-
tain the blower fan motor voltage in the 4 to 12 volt range.
RJIA0523E
DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR

SYMPTOM: Blower motor operation is malfunctioning under starting
fan speed control.
RHA467GA
ATC-82
TROUBLE DIAGNOSIS
1. CHECK POWER SUPPLY FOR BLOWER MOTOR A

1. Disconnect blower motor connector.
3. Check voltage between blower motor harness connector M65 B
terminal 1 (L/W) and ground.
C
OK or NG
OK >> GO TO 2.
NG >> Check power supply circuit and 15A fuses [Nos. 19 and D
24, located in the fuse block (J/B)]. Refer to PG-77,
RJIA2860E
"FUSE BLOCK - JUNCTION BOX (J/B)" .
● If OK, check for open circuit in wiring harness. Repair or replace as necessary. E
● If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.
2. CHECK FAN FEED BACK CIRCUIT F

1. Reconnect blower motor connector.
minal 18 (L/W) and ground. G

OK or NG H
OK >> GO TO 3.
NG >> GO TO 9.
I
RJIA2861E
3. CHECK BLOWER MOTOR ATC
Refer to ATC-85, "Blower Motor" .

OK or NG K
OK >> GO TO 4.
NG >> Replace blower motor.
4. CHECK POWER SUPPLY FOR FAN CONTROL AMP. L

2. Check voltage between fan control amp. harness connector M
M67 terminal 3 (R) and ground.
Terminals
(+)
Condition Voltage
Fan control Terminal (wire (-)
amp. connector color)
M67 3 (R) Ground Fan speed: 1 Approx. 8V
OK or NG RJIA2862E
OK >> GO TO 5.
NG >> Repair harness or connector.
ATC-83
TROUBLE DIAGNOSIS
5. CHECK GROUND CIRCUIT FOR FAN CONTROL AMP.

2. Disconnect fan control amp. connector.
3. Check continuity between fan control amp. harness connector
M67 terminal 1 (B) and ground.
OK or NG
OK >> GO TO 6.
RJIA2863E
6. CHECK FOR AUTO AMP. OUTPUT SIGNAL

1. Reconnect the fan control amp. connector.
3. Check voltage between fan control amp. harness connector
M67 terminal 2 (L/Y) and ground.
Terminals
(+)
Condition Voltage
Fan control (-)
Terminal (wire
amp. connec-
color)
tor
RJIA2864E
Fan speed: 1st Approx. 2.5 -

- 24th 3.5V
M67 2 (L/Y) Ground
Fan speed:
Approx. 9.0V
25th
OK or NG
OK >> GO TO 9.
NG >> ● If the voltage is less than 2.5V: GO TO 7.
● If the voltage is more than 9.0V: GO TO 8.
7. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND FAN CONTROL AMP.
2. Disconnect the auto amp. connector and fan control amp. con-
nector.
3. Check continuity between auto amp. harness connector M52
terminal 17 (L/Y) and fan control amp. harness connector M67
terminal 2 (L/Y).
17 – 2 : Continuity should exist.
OK or NG
OK >> Replace fan control amp.
RJIA2865E
ATC-84
TROUBLE DIAGNOSIS
8. CHECK FAN CONTROL AMP. A

2. Disconnect the fan control amp. connector.
3. Check continuity between fan control amp. connector M67 ter- B
minal 2 and 1.
2 (-) – 1 (+) : Continuity should exist.
C
OK or NG
OK >> GO TO 9.
NG >> Replace fan control amp. D
RJIA2866E
9. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND FAN CONTROL AMP. E
1. Disconnect auto amp. connector.

F
terminal 18 (R) and fan control amp. harness connector M67 ter-
minal 3 (R).
18 – 3 : Continuity should exist. G
OK or NG
NG >> Repair harness or connector. H
RJIA2867E
COMPONENT INSPECTION I
Blower Motor
Confirm smooth rotation of the blower motor.
● Ensure that there are no foreign particles inside the intake unit. ATC
RJIA0532E
M
ATC-85
TROUBLE DIAGNOSIS
Magnet Clutch Circuit EJS004OQ
SYMPTOM: Magnet clutch does not engage.

INSPECTION FLOW
RJIA2834E

*4 ATC-106, "Ambient Sensor Circuit". *5 ATC-114, "Intake Sensor Circuit". *6 ATC-33, "SYMPTOM TABLE".
*7 ATC-58, "FUNCTION CONFIRMA- *8 ATC-87, "DIAGNOSTIC PROCE- *9 ATC-100, "TROUBLE DIAGNOSES
TION PROCEDURE", see No. 9. DURE FOR MAGNET CLUTCH". FOR UNUSUAL PRESSURE".
ATC-86
TROUBLE DIAGNOSIS
SYSTEM DESCRIPTION
Auto amplifier controls compressor operation by ambient temperature and signal from ECM. A
Low Temperature Protection Control (With Gasoline Engine)

Auto amplifier will turn the compressor ON or OFF as determined by B
a signal detected by ambient sensor.
When ambient temperatures are higher than −2°C (28°F), the com-
pressor turns ON. The compressor turns OFF when ambient temper-
atures are lower than −5°C (23°F). C
RHA094GB
E
Evaporator Freeze Protection Control (With Diesel Engine)
Auto amplifier will turn the compressor ON or OFF as determined by
a signal detected by intake sensor. F
When intake air temperatures are higher than 4°C (39°F), the com-
pressor turns ON. The compressor turns OFF when intake air tem-
peratures are lower than 2.5°C (37°F). G
RHA094GD
I
DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH
SYMPTOM: Magnet clutch does not engage when A/C switch is ON.
ATC
RJIA2868E
ATC-87
TROUBLE DIAGNOSIS
1. CHECK POWER SUPPLY FOR COMPRESSOR

1. Disconnect compressor connector.
2. Start the engine.
4. Press A/C switch.
5. Check voltage between compressor harness connector E34 ter-
minal 1 (L/R) and ground.
OK or NG
OK >> GO TO 2. RJIA2869E
NG >> GO TO 3.
2. CHECK MAGNET CLUTCH CIRCUIT

Check for operation sound when applying battery voltage direct cur-
rent to terminal.
OK or NG
OK >> 1. Repair harness or connector.
2. Go to self-diagnosis procedure ATC-58, "FUNCTION
CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-4. Confirm that magnet clutch opera-
tion is usual.
NG >> 1. Replace magnet clutch. Refer to ATC-144, "Removal
and Installation for Compressor Clutch" . RJIA2005E
2. Go to self-diagnosis procedure ATC-58, "FUNCTION
CONFIRMATION PROCEDURE" and perform self-diagnosis STEP-4. Confirm that magnet
clutch operation is usual.
3. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR

2. Disconnect A/C relay connector.
3. Check continuity between A/C relay harness connector E5 ter-
minal 5 (L/R) and compressor harness connector E34 terminal 1
(L/R).
5–1 : Continuity should exist.
OK or NG
OK >> GO TO 4.
RJIA2870E
ATC-88
TROUBLE DIAGNOSIS
4. CHECK POWER SUPPLY FOR A/C RELAY A

2. Check voltage between A/C relay harness connector E5 termi-
nal 1 (BR/Y), 3 (BR/Y) and ground. B

3 – Ground : Battery voltage C
OK or NG
OK >> GO TO 5.
NG >> Check power supply circuit and 10A fuse No. 15 D
[located in the fuse block (J/B)]. Refer to PG-77, "FUSE RJIA2871E
BLOCK - JUNCTION BOX (J/B)" .
● If OK, check for open circuit in wiring harness. Repair or replace as necessary. E
● If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.
5. CHECK A/C RELAY AFTER DISCONNECTING IT F

Refer to ATC-92, "A/C Relay" .
OK or NG
G
OK >> GO TO 6.
NG >> 1. Replace A/C relay.
2. Go to self-diagnosis procedure ATC-58, "FUNCTION CONFIRMATION PROCEDURE" and
perform self-diagnosis STEP-4. Confirm that magnet clutch operation is usual. H
6. CHECK COIL SIDE CIRCUIT OF A/C RELAY

I
2. Reconnect A/C relay connector.
3. Turn ignition switch ON. ATC
4. Check voltage between ECM harness connector F43 terminal
105 (BR/W) or ECM harness connector F43 terminal 19 (L) and
ground. K
105 – Ground (Gasoline engine) : Battery voltage
19 – Ground (Diesel engine) : Battery voltage
L
OK or NG RJIA2872E
OK >> GO TO 7.
M
7. CHECK AMBIENT SENSOR
Refer to ATC-106, "Ambient Sensor Circuit" .
OK or NG
OK >> ● With gasoline engine: GO TO 8.
● With diesel engine: GO TO 13.
NG >> Repair or replace the malfunctioning part (s).
8. CHECK REFRIGERANT PRESSURE SENSOR (QR ENGINE)

Refer to ATC-92, "Refrigerant Pressure Sensor (With Gasoline Engine)" .
OK or NG
OK >> GO TO 9.
NG >> Repair or replace the malfunctioning part (s).
ATC-89
TROUBLE DIAGNOSIS
9. CHECK VOLTAGE FOR AUTO AMP. (COMPRESSOR ON SIGNAL)

minal 4 (L/R) and ground.
Terminals
(+)
Condition Voltage
Auto amp. Terminal (wire (-)
connector color)
A/C SW: ON Approx. 0V
M52 4 (L/R) Ground
A/C SW: OFF Approx. 5V RJIA2873E
OK or NG
OK >> GO TO 10.
NG >> ● If the voltage is approx. 5V when the A/C switch is ON: Replace the auto amp.
● If the voltage is approx. 0V when the A/C switch is OFF: GO TO 12.
10. CHECK VOLTAGE FOR AUTO AMP. (FAN ON SIGNAL)

Check voltage between auto amp. harness connector M52 terminal
19 (LG/B) and ground.
Terminals
(+)
Condition Voltage
Auto amp. Terminal (-)
connector (wire color)
Fan control dial:
ON (Blower Approx. 0V
M52 19 (LG/B) Ground motor operates)
RJIA2874E
Fan control dial:
Approx. 5V
OFF
OK or NG
NG >> ● If the voltage is approx. 5V when the blower motor is ON: Replace the auto amp.
● If the voltage is approx. 0V when the blower motor is OFF: GO TO 11.
11. CHECK CIRCUIT CONTINUITY BETWEEN ECM AND AUTO AMP. (QR ENGINE)
2. Disconnect ECM connector and auto amp. connector.
3. Check continuity between ECM harness connector F43 terminal
96 (LG/B) and auto amp. harness connector M52 terminal 19
(LG/B).
OK or NG
OK >> INSPECTION END
RJIA2837E
ATC-90
TROUBLE DIAGNOSIS
12. CHECK CIRCUIT CONTINUITY BETWEEN ECM AND AUTO AMP. (QR ENGINE) A
2. Disconnect ECM connector and auto amp. connector.
3. Check continuity between ECM harness connector F43 terminal B
110 (L/R) and auto amp. harness connector M52 terminal 4 (L/
R).
C
OK or NG
OK >> Check EC-429, "REFRIGERANT PRESSURE SEN- D
SOR" (For Hong Kong) or EC-845, "REFRIGERANT
RJIA2838E
PRESSURE SENSOR" (Except Hong Kong).
E
13. CHECK VOLTAGE FOR AUTO AMP. (COMPRESSOR ON SIGNAL)
Check voltage between auto amp. harness connector M52 terminal F
4 (L/R) and ground.
Terminals
G
(+)
Condition Voltage
Auto amp. Terminal (wire (-)
connector color)
H
A/C SW: ON Approx. 0V
M52 4 (L/R) Ground
A/C SW: OFF Approx. 5V
OK or NG RJIA2873E I
OK >> INSPECTION END
NG >> GO TO 14.
ATC
14. CHECK DUAL- PRESSURE SWITCH (YD ENGINE)
Refer to ATC-93, "Dual-Pressure Switch (With Diesel Engine)" .
K
OK or NG
OK >> GO TO 15.
NG >> Replace the dual-pressure switch.
L
15. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND DUAL-PRESSURE SWITCH
1. Turn ignition switch OFF. M
2. Disconnect the auto amp. connector.
terminal 4 (L/R) and dual-pressure switch harness connector
E40 terminal 2 (L/R).
OK or NG
OK >> GO TO 16.
RJIA2875E
ATC-91
TROUBLE DIAGNOSIS
16. CHECK CIRCUIT CONTINUITY BETWEEN DUAL-PRESSURE SWITCH AND COMBINATION

METER
1. Disconnect the combination meter connector.
2. Check continuity between dual-pressure switch harness con-
nector E40 terminal 1 (PU/W) and combination meter harness
connector M44 terminal 7 (SB).
OK or NG
OK >> Check DI-25, "Trouble Diagnosis Chart by Symptom" .
SJIA0432E
COMPONENT INSPECTION
A/C Relay
Check continuity between terminal Nos. 3 and 5.
Conditions Continuity
12V direct current supply between terminal Nos. 1 and 2 Yes
No current supply No
If NG, replace relay.
RHA638H
Refrigerant Pressure Sensor (With Gasoline Engine)

The refrigerant pressure sensor is attached to the liquid tank (con-
denser).
Make sure that the A/C refrigerant pressure and the sensor output
voltage are within the specified range as shown in the A/C operating
condition figure. Refer to EC-429, "REFRIGERANT PRESSURE
SENSOR" (For Hong Kong) or EC-845, "REFRIGERANT PRES-
SURE SENSOR" (Except Hong Kong).
RJIA0690E
RJIA2954E
ATC-92
TROUBLE DIAGNOSIS
Dual-Pressure Switch (With Diesel Engine)

The dual-pressure switch is attached to the liquid tank (condenser). A
If the system pressure rises above or falls below the specifications,
the dual-pressure switch opens to interrupt the compressor opera-
tion. B
Compressor: ON Compressor: OFF
kPa (bar, kg/cm2 , psi) kPa (bar, kg/cm2 , psi)
C
Low-pressure side 186 (1.86, 1.9, 27) 177 (1.77, 1.8, 26)
High-pressure side 1,569 (15.7, 16, 228) 2,746 (27.5, 28, 398)
RJIA0691E
D
Thermal Protector (With Diesel Engine)

Check continuity between compressor harness terminal and field E
coil.
RHA671H H
ATC
ATC-93
TROUBLE DIAGNOSIS
Insufficient Cooling EJS004OR
SYMPTOM: Insufficient cooling

INSPECTION FLOW
SJIA0408E

TION PROCEDURE", see No. 1. TION PROCEDURE", see No. 5 to
7.
*4 EM-13, "Checking Drive Belts" (With *5 ATC-74, "Air Mix Door Motor Cir- *6 ATC-98, "Test Reading (With QR
QR engine) or EM-142, "Checking cuit". Engine)" or ATC-99, "Test Reading
Drive Belts" (With YD engine). (With YD Engine)" .
*7 ATC-62, "AUXILIARY MECHA- *8 ATC-58, "FUNCTION CONFIRMA- *9 ATC-68, "LAN System Circuit".
NISM: TEMPERATURE SETTING TION PROCEDURE", see No. 9.
TRIMMER".
ATC-94
TROUBLE DIAGNOSIS
*10 ATC-80, "Blower Motor Circuit". *11 ATC-86, "Magnet Clutch Circuit". *12 EC-330, "System Description"
(With QR engine: For Hong Kong), A
EC-679, "System Description"
(With QR engine: Except Hong
Kong) or EC-1021, "System
Description" (With YD engine). B
*13 ATC-96, "PERFORMANCE TEST
DIAGNOSIS".
C
ATC
ATC-95
TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSIS
RJIA1601E
*1 ATC-98, "PERFORMANCE *2 ATC-98, "PERFORMANCE *3 ATC-100, "TROUBLE DIAGNOSES

CHART". CHART". FOR UNUSUAL PRESSURE".
*4 ATC-74, "Air Mix Door Motor Circuit".
ATC-96
TROUBLE DIAGNOSIS
ATC
RJIA1595E
*1 ATC-144, "Removal and Installation *2 ATC-80, "Blower Motor Circuit". *3 EM-13, "Checking Drive Belts" (With
for Compressor Clutch". QR engine) or EM-142, "Checking
Drive Belts" (With YD engine).
ATC-97
TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition
Testing must be performed as follows:
Vehicle location Indoors or in the shade (in a well-ventilated place)
Doors Closed
Door windows Open
Hood Open
TEMP. Max. COLD
Mode control dial (Ventilation) set
Intake switch (Recirculation) set
Fan (blower) speed Max. speed set

Engine speed Idle speed
Operate the air conditioning system for 10 minutes before taking measurements.
Test Reading (With QR Engine)

Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature °C (°F)
% °C (°F)
25 (77) 10.0 - 11.6 (50 - 53)
50 - 60 30 (86) 13.9 - 16.2 (57 - 61)
35 (95) 17.8 - 21.4 (64 - 71)
25 (77) 11.6 - 13.9 (53 - 57)
60 - 70 30 (86) 16.2 - 18.9 (61 - 66)
35 (95) 21.4 - 24.5 (71 - 76)
Ambient Air Temperature-to-operating Pressure Table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature 2
kPa (bar, kg/cm , psi) kPa (bar, kg/cm2 , psi)
% °C (°F)
980 - 1,180 230 - 270
30 (86)
(9.8 - 11.8, 9.99 - 12.04, 142 - 171) (2.3 - 2.7, 2.35 - 2.75, 33 - 39)
1,180 - 1,390 260 - 310
50 - 70 35 (95)
(11.8 - 13.9, 12.04 - 14.18, 171 - 202) (2.6 - 3.1, 2.65 - 3.16, 38 - 45)
1,400 - 1,580 300 - 350
40 (104)
(14.0 - 15.8, 14.28 - 16.12, 203 - 229) (3.0 - 3.5, 3.06 - 3.57, 44 - 51)
ATC-98
TROUBLE DIAGNOSIS
Test Reading (With YD Engine)

Recirculating-to-discharge Air Temperature Table A
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature °C (°F) B
% °C (°F)
20 (68) 6.5 - 9.0 (44 - 48)
25 (77) 12 - 14 (54 - 57) C
50 - 60
30 (86) 15.5 - 18.8 (60 - 66)
35 (95) 20.4 - 24.0 (69 - 75)
20 (68) 9.0 - 11.0 (48 - 52) D
25 (77) 14.0 - 16.5 (57 - 62)
60 - 70
30 (86) 18.8 - 21.5 (66 - 71)
E
35 (95) 24 - 27 (75 - 81)
Ambient Air Temperature-to-operating Pressure Table

F
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)
G
765 - 922 177 - 226
20 (68)
(7.65 - 9.22, 7.8 - 9.4, 111 - 134) (1.77 - 2.26, 1.8 - 2.3, 26 - 33)
922 - 1,020 196 - 245
25 (77)
(9.22 - 10.20, 9.4 - 10.4, 134 - 148) (1.96 - 2.45, 2.0 - 2.5, 28 - 36)
H
1,177 - 1,451 235 - 284

50 - 70 30 (86)
(11.77 - 14.51, 12.0 - 14.8, 171 - 210) (2.35 - 2.84, 2.4 - 2.9, 34 - 41)
I
1,373 - 1,667 275 - 333
35 (95)
(13.73 - 16.67, 14 - 17, 199 - 242) (2.75 - 3.33, 2.8 - 3.4, 40 - 48)
1,618 - 1,961 333 - 392
40 (104) ATC
(16.18 - 19.61, 16.5 - 20.0, 235 - 284) (3.33 - 3.92, 3.4 - 4.0, 48 - 57)
ATC-99
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE

Whenever system′s high and/or low side pressure is unusual, diagnose using a manifold gauge. The marker
above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the stan-
dard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-
to-operating pressure table).
Both High- and Low-pressure Sides are Too High
Gauge indication Refrigerant cycle Probable cause Corrective action
Pressure is reduced soon after
Excessive refrigerant charge in Reduce refrigerant until speci-
water is splashed on con-
refrigeration cycle fied pressure is obtained.
denser.
Insufficient condenser cooling
performance
↓ ● Clean condenser.
Air suction by cooling fan is
insufficient. 1. Condenser fins are clogged. ● Check and repair cooling fan
as necessary.
2. Improper fan rotation of cool-
ing fan
● Low-pressure pipe is not
cold. Poor heat exchange in con-
Both high- and low-pressure denser
● When compressor is stopped
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 (1.96 bar, 2 kg/cm2 , 28 ↓
psi). It then decreases gradu- Air in refrigeration cycle
ally thereafter.
Engine cooling systems mal- Check and repair each engine
Engine tends to overheat.
AC359A
function. cooling system.
● Excessive liquid refrigerant
on low-pressure side
● Excessive refrigerant dis-
charge flow
● An area of the low-pressure
● Expansion valve is open a lit-
pipe is colder than areas
tle compared with the specifi-
near the evaporator outlet. Replace expansion valve.
cation.
● Plates are sometimes cov-
↓
ered with frost.
1. Improper expansion valve
installation
2. Improper expansion valve
adjustment
High-pressure Side is Too High and Low-pressure Side is Too Low

High-pressure side is too high and
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.
however, liquid tank is not so and condenser are clogged or ● Check lubricant for contami-
hot. crushed. nation.
AC360A
ATC-100
TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High

A
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. B
pressor operation stops. Damaged inside compressor
packings
Compressor pressure opera- C
No temperature difference tion is improper.
between high- and low-pres- ↓ Replace compressor.
sure sides Damaged inside compressor
AC356A
packings. D
Both High- and Low-pressure Sides are Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action E
● There is a big temperature
difference between receiver
drier outlet and inlet. Outlet ● Replace liquid tank.
temperature is extremely Liquid tank inside is slightly F
clogged. ● Check lubricant for contami-
low. nation.
● Liquid tank inlet and expan-
sion valve are frosted. G
● Temperature of expansion
valve inlet is extremely low
as compared with areas H
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. I
● Temperature difference
occurs somewhere in high-
Both high- and low-pressure sides pressure side
are too low.
ATC
Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
tank are warm or only cool ↓ Refer to ATC-156, "Checking
when touched. Leaking fittings or components for Refrigerant Leaks" .
Expansion valve closes a little
K
compared with the specifica-
tion.
↓ ● Remove foreign particles by L
AC353A 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 expansion nation. M
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 intake sensor circuit.
Refer to ATC-114, "Intake
Air flow volume is not enough Sensor Circuit" (With die-
Evaporator is frozen.
or is too low. sel engine)
● Replace compressor.
ATC-101
TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative

Low-pressure side sometimes
● Air conditioning system Refrigerant does not dis-
becomes negative.
does not function and does charge cyclically.
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 liquid tank.
tions for a certain period of
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A
Low-pressure Side Becomes Negative

Leave the system at rest until
no frost is present. Start it
again to check whether or not
the malfunction is caused by
water or foreign particles.
● If water is the cause, initially
cooling is okay. Then the
water freezes causing a
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.
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
AC362A
(not shop air).
● If either of the above meth-
ods cannot correct the mal-
function, replace expansion
valve.
● Replace liquid tank.
● Check lubricant for contami-
nation.
ATC-102
TROUBLE DIAGNOSIS
Insufficient Heating EJS004OS
A
SYMPTOM: Insufficient heating
INSPECTION FLOW
B
ATC
SJIA0409E

*4 CO-10, "Changing Engine Coolant" *5 CO-14, "Checking Radiator Cap" *6 EC-154, "DTC P0117, P0118 ECT
(With QR engine) or CO-32, "Chang- (With QR engine) or CO-36, "Check- SENSOR" (With QR engine: For
ing Engine Coolant" (With YD ing Radiator Cap" (With YD engine). Hong Kong), EC-577, "DTC P0117,
engine). P0118 ECT SENSOR" (With QR
engine: Except Hong Kong) or EC-
990, "DTC P0117, P0118 ECT SEN-
SOR" (With YD engine).
ATC-103
TROUBLE DIAGNOSIS
*7 ATC-58, "FUNCTION CONFIRMA- *8 ATC-68, "LAN System Circuit". *9 ATC-80, "Blower Motor Circuit".
*10 ATC-74, "Air Mix Door Motor Circuit".
Noise EJS004OT
SYMPTOM: Noise
INSPECTION FLOW
RJIA1596E
ATC-104
TROUBLE DIAGNOSIS
*1 Compressor clutch, ATC-144, *2 Compressor clutch, ATC-147, *3 ATC-23, "Maintenance of Lubricant

"REMOVAL" . "INSTALLATION" . Quantity in Compressor". A
*4 ATC-64, "Operational Check". *5 EM-13, "Checking Drive Belts" (With
QR engine) or EM-142, "Checking
Drive Belts" (With YD engine). B
Self-diagnosis EJS004OU
Symptom: Self-diagnosis cannot be performed.

C
INSPECTION FLOW
ATC
RJIA2840E
M
*1 ATC-64, "Operational Check". *2 ATC-66, "Power Supply and Ground *3 ATC-33, "SYMPTOM TABLE".
Circuit for Auto Amp.".
ATC-105
TROUBLE DIAGNOSIS
Ambient Sensor Circuit EJS004OV
Ambient Sensor
The ambient sensor is attached on the hood lock stay. It detects
ambient temperature and converts it into a resistance value which is
then input into the auto amplifier.
RJIA0048E
AMBIENT TEMPERATURE INPUT PROCESS

The auto amplifier includes a processing circuit for the ambient sensor input. However, when the temperature
detected by the ambient sensor increases quickly, the processing circuit retards the auto amp. function. It only
allows the auto amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds.
As an example, consider stopping for a few minutes after high speed driving. Although the actual ambient tem-
perature has not changed, the temperature detected by the ambient sensor will increase. This is because the
heat from the engine compartment can radiate to the front grille area, location of the ambient sensor.
DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR
SYMPTOM: Ambient sensor circuit is open or shorted.
LED of A/C switch does not illuminate as a result of performing self-
diahnosis STEP-2.
RHA051GD
1. CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND

1. Disconnect ambient sensor harness connector.
3. Check voltage between ambient sensor harness connector E38
terminal 1 (R/B) and ground.
1 – Ground : Approx. 5V
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
RJIA2017E
ATC-106
TROUBLE DIAGNOSIS
2. CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. A
3. Check continuity between ambient sensor harness connector B
E38 terminal 2 (B/Y) and auto amp. harness connector M53 ter-
minal 24 (B/Y).
C
OK or NG
OK >> GO TO 3. D
RJIA2876E
3. CHECK AMBIENT SENSOR E
Refer to ATC-108, "Ambient Sensor" .

OK or NG
F
OK >> 1. Replace auto amp.
2. Go to self-diagnosis ATC-58, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2. G
NG >> 1. Replace ambient sensor.
diagnosis STEP-2. H
4. CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP.
1. Turn ignition switch OFF. I
3. Check continuity between ambient sensor harness connector
E38 terminal 1 (R/B) and auto amp. harness connector M52 ter- ATC
minal 9 (R/B).
K
4. Check continuity between ambient sensor harness connector
E38 terminal 1 (R/B) and ground.
1 – Ground : Continuity should not exist. RJIA2877E
L
OK or NG
M
diagnosis STEP-2.
ATC-107
TROUBLE DIAGNOSIS
Ambient Sensor
After disconnecting ambient sensor connector E38, measure resis-
tance between terminals 2 and 1 at sensor side, using the table
below.
Temperature °C (°F) Resistance kΩ
−15 (5) 12.73
−10 (14) 9.92
−5 (23) 7.80
0 (32) 6.19
5 (41) 4.95
10 (50) 3.99
15 (59) 3.24
20 (68) 2.65
25 (77) 2.19
30 (86) 1.81
35 (95) 1.51
40 (104) 1.27
45 (113) 1.07
SJIA0433E
If NG, replace ambient sensor.
In-vehicle Sensor Circuit EJS004OW
In-vehicle sensor
The in-vehicle sensor is located on instrument driver lower panel. It
converts variations in temperature of compartment air drawn from
the aspirator into a resistance value. It is then input into the auto
amplifier.
RJIA2841E
Aspirator
The aspirator is located on front side of heater & cooling unit. It pro-
duces vacuum pressure due to air discharged from the heater &
cooling unit, continuously taking compartment air in the aspirator.
RJIA0557E
ATC-108
TROUBLE DIAGNOSIS
RJIA1402E
D
DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR
SYMPTOM: In-vehicle sensor circuit is open or shorted.
diagnosis STEP-2. E
RJIA0745E
H
1. CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND
1. Disconnect in-vehicle sensor connector.
I
3. Check voltage between in-vehicle sensor harness connector
M34 terminal 1 (P) and ground.
ATC
OK or NG
OK >> GO TO 2. K
NG >> GO TO 4.
RJIA2022E
L
2. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND AUTO AMP.
1. Turn ignition switch OFF. M
3. Check continuity between in-vehicle sensor harness connector
M34 terminal 2 (B/Y) and auto amp. harness connector M53 ter-
minal 24 (B/Y).
OK or NG
OK >> GO TO 3.
SJIA0434E
ATC-109
TROUBLE DIAGNOSIS
3. CHECK IN-VEHICLE SENSOR

Refer to ATC-110, "In-vehicle Sensor" .
OK or NG
diagnosis STEP-2.
NG >> 1. Replace in-vehicle sensor.
diagnosis STEP-2.
4. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND AUTO AMP.

M34 terminal 1 (P) and auto amp. harness connector M52 termi-
nal 8 (P).
M34 terminal 1 (P) and ground.
1 – Ground : Continuity should not exist. SJIA0456E
OK or NG
diagnosis STEP-2.
In-vehicle Sensor
After disconnecting in-vehicle sensor connector M34, measure resis-
tance between terminals 1 and 2 at sensor side, using the table
below.
Temperature °C (°F) Resistance kΩ
−15 (5) 12.73
−10 (14) 9.92
−5 (23) 7.80
0 (32) 6.19
5 (41) 4.95
10 (50) 3.99
15 (59) 3.24
20 (68) 2.65
25 (77) 2.19
30 (86) 1.81
35 (95) 1.51
40 (104) 1.27
45 (113) 1.07
SJIA0436E
If NG, replace in-vehicle sensor.
ATC-110
TROUBLE DIAGNOSIS
Sunload Sensor Circuit EJS004OX
COMPONENT DESCRIPTION A
The sunload sensor is located on the defroster grille (passenger
side). It detects sunload entering through windshield by means of a
photo diode. The sensor converts the sunload into a current value B
which is then input into the auto amplifier.
D
RJIA0050E
SUNLOAD INPUT PROCESS E

The auto amp. also includes a processing circuit which averages the variations in detected sunload over a
period of time. This prevents drastic swings in the ATC system operation due to small or quick variations in
detected sunload.
For example, consider driving along a road bordered by an occasional group of large trees. The sunload F
detected by the sunload sensor will vary whenever the trees obstruct the sunlight. The processing circuit aver-
ages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily
obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly G
after entering a long tunnel, the system will recognize the change in sunload, and the system will react accord-
ingly.
DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR H
SYMPTOM: Sunload sensor circuit is open or shorted.
diagnosis STEP-2. I
ATC
K
SHA601F
L
1. CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND
1. Disconnect sunload sensor connector.
M
3. Check voltage between sunload sensor harness connector M74
terminal 1 (OR) and ground.
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
RJIA2027E
ATC-111
TROUBLE DIAGNOSIS
2. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND AUTO AMP.

3. Check continuity between sunload sensor harness connector
M74 terminal 2 (B/Y) and auto amp. harness connector M53 ter-
minal 24 (B/Y).
OK or NG
OK >> GO TO 3.
SJIA0437E
3. CHECK SUNLOAD SENSOR.

1. Reconnect sunload sensor connector and AUTO amp. connector.
2. Refer to ATC-113, "Sunload Sensor" .
OK or NG
diagnosis STEP-2.
NG >> 1. Replace sunload sensor.
diagnosis STEP-2.
4. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND AUTO AMP.

M74 terminal 1 (OR) and auto amp. harness connector M52 ter-
minal 10 (OR).
M74 terminal 1 (OR) and ground.
1 – Ground : Continuity should not exist. RJIA2882E
OK or NG
diagnosis STEP-2.
ATC-112
TROUBLE DIAGNOSIS
Sunload Sensor A
Measure voltage between auto amp. harness connector M52 termi-
nal 10 (OR) and ground.
If NG, replace sunload sensor. B
RJIA2883E H
● When checking sunload sensor, select a place where sun shines directly on it.
I
ATC
SHA930E
ATC-113
TROUBLE DIAGNOSIS
Intake Sensor Circuit EJS004OY
Intake Sensor
The intake sensor is located on the heater & cooling unit. It converts
temperature of air after it passes through the evaporator into a resis-
tance value which is then input to the auto amp.
RJIA0051E
DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR

SYMPTOM: Intake sensor circuit is open or shorted.
diagnosis STEP-2.
RJIA0567E
1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND

1. Disconnect intake sensor connector.
3. Check voltage between intake sensor harness connector M68 (With Gasoline engine) or M69 (With Diesel
engine) terminal 1 (BR/Y) and ground.
RJIA2884E
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
ATC-114
TROUBLE DIAGNOSIS
2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND AUTO AMP. A

3. Check continuity between intake sensor harness connector M68 (With Gasoline engine) or M69 (With B
Diesel engine) terminal 2 (B/Y) and auto amp. harness connector M53 terminal 24 (B/Y).
RJIA2885E
F
OK or NG
OK >> GO TO 3. G
3. CHECK INTAKE SENSOR H

Refer to ATC-116, "Intake sensor" .
OK or NG
I
diagnosis STEP-2.
ATC
NG >> 1. Replace intake sensor.
diagnosis STEP-2.
K
ATC-115
TROUBLE DIAGNOSIS
4. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND AUTO AMP.

3. Check continuity between intake sensor harness connector M68 (With Gasoline engine) or M69 (With
Diesel engine) terminal 1 (BR/Y) and auto amp. harness connector M53 terminal 25 (BR/Y).
RJIA2886E

4. Check continuity between intake sensor harness connector M68 (With Gasoline engine) or M69 (With
Diesel engine) terminal 1 (BR/Y) and ground.
1 – Ground : Continuity should not exist.
OK or NG
diagnosis STEP-2.
Intake sensor
After disconnecting intake sensor connector M68 (With Gasoline
engine) or M69 (With Diesel engine), measure resistance between
terminals 1 and 2 at sensor side, using the table below.
Resistance kΩ
Temperature °C (°F)
−15 (5) 12.34 18.63
−10 (14) 9.62 14.15
−5 (23) 7.56 10.86
0 (32) 6.00 8.41
5 (41) 4.80 6.58
10 (50) 3.87 5.19
15 (59) 3.15 4.12
20 (68) 2.57 3.30
25 (77) 2.12 2.67
30 (86) 1.76 2.17
35 (95) 1.47 1.78
40 (104) 1.23 1.46
45 (113) 1.04 1.21 SJIA0439E
If NG, replace intake sensor.
ATC-116
CONTROLLER
CONTROLLER PFP:27500
A
Removal and Installation EJS004O8
REMOVAL
1. Remove cluster lid C. Refer to ATC-117, "Removal and Installation" .
B
2. Remove the controller.
E
RJIA2402E
INSTALLATION
Installation is basically the reverse order of removal. F
ATC
ATC-117
AMBIENT SENSOR
AMBIENT SENSOR PFP:27722
Removal and Installation EJS004O9
REMOVAL
1. Remove the front grille. Refer to EI-19, "FRONT GRILLE" .
2. Remove the ambient sensor.
RJIA0048E
INSTALLATION
Installation is basically the reverse order of removal.
ATC-118
IN-VEHICLE SENSOR
IN-VEHICLE SENSOR PFP:27720

A
Removal and Installation EJS004OB
REMOVAL
1. Remove instrument driver lower panel. Refer to IP-11, "Removal and Installation" .
B
2. Remove in-vehicle sensor.
E
RJIA2842E
INSTALLATION
ATC
ATC-119
SUNLOAD SENSOR
SUNLOAD SENSOR PFP:27721
Removal and Installation EJS004OA
REMOVAL
1. Remove sunload sensor garnish.
2. Remove sunload sensor.
RJIA0050E
INSTALLATION
ATC-120
INTAKE SENSOR
INTAKE SENSOR PFP:27723

A
Removal and Installation EJS004OC
REMOVAL
1. Remove the evaporator. Refer to ATC-155, "Removal and Installation for Evaporator" .
B
2. Remove the intake sensor.
E
RJIA0051E
INSTALLATION
CAUTION:
● Replace O-rings for A/C piping with new ones. Before installing, apply compressor oil to them.
● When recharging refrigerant, check for leaks. G
ATC
ATC-121
BLOWER UNIT
BLOWER UNIT PFP:27200
Removal and Installation EJS001L8
REMOVAL
1. Remove the glove box assembly.
2. Remove the glove box cover, the instrument passenger lower panel and instrument reinforcement. Refer
to IP-11, "Removal and Installation" .
3. Remove the ECM with ECM bracket attached.
4. Remove the instrument panel fixing screw.
5. Remove the blower unit fixing bolt and screws.
6. Disconnect the blower motor connector and fan control amp.
connector.
7. Remove the blower unit.
RJIA0052E
8. Disconnect the intake door motor connector and harness clip.

CAUTION:
Slide the blower unit toward the right, remove location pins (2
pieces), then move it downwards.
RJIA0098E
INSTALLATION
CAUTION:
● Make sure the location pins (2 pieces) are securely installed.
ATC-122
BLOWER UNIT
Disassembly and Assembly EJS001L9
A
NOTE:
RJIA2888E
ATC
1. Filter cover 2. Air conditioner filter 3. Upper case 1
4. Screw 5. Intake door link 6. Intake door motor
7. Nut 8. Blower fan 9. Fan control amp.
K
10. Cooling hose 11. Blower fan motor assembly 12. Bell mouth
13. Upper case 2 14. Intake door 1 15. Intake door 2
16. Intake door lever 1 17. Intake door lever 2 18. Washer
L
CAUTION:
If retaining tabs are damaged while disassembling blower unit,
use 9 screws (27111-2Y000) to assemble blower unit. M
RJIA0097E
ATC-123
BLOWER MOTOR
BLOWER MOTOR PFP:27226
Removal and Installation EJS004OZ
REMOVAL
1. Remove the blower unit. Refer to ATC-122, "BLOWER UNIT" .
2. Separate the blower unit.
RJIA0054E
3. Remove the cooling hose, fan control amp. and blower fan.
RJIA0055E
INSTALLATION
CAUTION:
If retaining tabs are damaged while disassembling blower unit,
use 9 screws (27111-2Y000) to assemble blower unit.
RJIA0097E
ATC-124
INTAKE DOOR MOTOR
INTAKE DOOR MOTOR PFP:27730

A
Removal and Installation EJS004P1
REMOVAL
B
2. Remove the intake door motor from the blower unit.
E
RJIA0056E
RJIA0571E I
INSTALLATION
Installation is basically the reverse order of removal. ATC
ATC-125
FAN CONTROL AMPLIFIER
FAN CONTROL AMPLIFIER PFP:27761
REMOVAL
2. Remove the fan control amp.
RJIA0572E
INSTALLATION
ATC-126
AIR CONDITIONER FILTER
AIR CONDITIONER FILTER PFP:27277

A
Removal and Installation EJS004SP
FUNCTION
Air inside passenger compartment is kept clean at either recircula- B
tion or fresh mode by installing air conditioner filter into blower unit.
SJIA0446E
E
REPLACEMENT TIMING
Refer to MA-32, "CHASSIS AND BODY MAINTENANCE" .
F
Caution label is fixed inside the glove box.Refer to IP-11, "Removal and Installation" .
REPLACEMENT PROCEDURES
1. Remove the glove box. G
2. Remove the filter cover.
3. Take out the air conditioner filter from blower unit.
H
4. Replace with new one and reinstall on blower unit.
5. Reinstall the glove box.
I
ATC
SJIA0447E
ATC-127
HEATER & COOLING UNIT ASSEMBLY
HEATER & COOLING UNIT ASSEMBLY PFP:27110
Removal and Installation EJS001LE
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Drain coolant from cooling system. Refer to CO-10, "Changing Engine Coolant" for QR engine or CO-32,
"Changing Engine Coolant" for YD engine.
3. Disconnect two heater hoses from heater core pipe.
4. Remove the instrument panel. Refer to IP-11, "Removal and
Installation" .
6. Remove clips of vehicle harness from steering member.
RJIA0060E
7. Remove the instrument stay.
RJIA0061E
8. Remove the bolts from heater & cooling unit.
RJIA2889E
ATC-128
9. Remove the steering member.

A
RJIA2890E
10. Remove the heater & cooling unit. G

INSTALLATION
H
CAUTION:
● Replace the O-ring of the low-pressure flexible hose and the high-pressure pipe with a new one,
then apply compressor oil to it when installing it.
● When recharging refrigerant, check for leaks. I
NOTE:
When filling radiator with coolant, refer to CO-10, "Changing Engine Coolant" for QR engine or CO-32,
"Changing Engine Coolant" for YD engine. ATC
ATC-129
Disassembly and Assembly EJS001LF
NOTE:
RJIA2891E
1. Defroster door 2. Heater & cooling unit case (right 3. Aspirator

side)
4. Screw 5. Rod holder 6. Rod
7. Mode door motor 8. Air mix door motor 9. Insulator
10. Heater pipe support 11. Cooler grommet 12. Expansion valve cover
13. Bolt 14. Expansion valve 15. Evaporator
16. Evaporator cover 17. Intake sensor 18. Foot duct (left side)
19. Heater core cover 20. Heater & cooling unit case (left side) 21. Ventilator door
22. Max. cool door 23. Defroster door lever 24. Foot duct (right side)
25. Ventilator door lever 26. Ventilator door link 1 27. Ventilator door link 2
28. Slide door unit (Air mix door) 29. Intake sensor bracket 30. Heater core
31. Max. cool door lever 32. Main link
ATC-130
MODE DOOR MOTOR
MODE DOOR MOTOR PFP:27731

A
REMOVAL
1. Remove rod from rod holder.
B
2. Remove the mode door motor.
3. Disconnect the mode door motor connector.
C
RJIA0065E
E
RJIA0574E
INSTALLATION I
1. Install rod to mode door.
2. Reconnect mode door motor connector.
3. Install mode door motor. ATC
5. Turn mode control dial to VENT position.
K
6. Turn side link clockwise, then install rod to rod holder.
ATC-131
AIR MIX DOOR MOTOR
AIR MIX DOOR MOTOR PFP:27732
REMOVAL
1. Set the temperature control dial at 18°C.
2. Disconnect the battery negative cable.
3. Disconnect the air mix door motor connector.
4. Remove the air mix door motor.
RJIA0066E
RJIA0575E
INSTALLATION
ATC-132
HEATER CORE
HEATER CORE PFP:27140

A
REMOVAL
1. Remove the heater & cooling unit. Refer to ATC-128, "HEATER & COOLING UNIT ASSEMBLY" .
B
2. Remove the heater pipe support.
3. Remove the foot duct and heater core cover.
4. Remove the heater core from the heater & cooling unit. C
E
RJIA0069E
INSTALLATION
ATC
ATC-133
DUCTS AND GRILLES
DUCTS AND GRILLES PFP:27860
REMOVAL
RJIA2892E
1. Side defroster duct (right) 2. Defroster nozzle 3. Side defroster duct (left)
4. Side ventilator duct (left) 5. Front speaker grille (left) 6. Cup holder (left)
7. Side ventilator grille (left) 8. Multi-box (Instrument center lower 9. Side ventilator grille (right)
panel)
10. Cup holder (right) 11. Front speaker grille (right) 12. Side ventilator duct (right)
13. Adaptor 14. Center ventilator grille (left) 15. Multi-box duct
16. Center ventilator grille (right) 17. Driver ventilator grille 18. Instrument panel
NOTE:
ATC-134
DUCTS AND GRILLES
Removal of Center Ventilator Grille

1. Remove the cluster lid C. Refer to IP-11, "Removal and Installation" . A
2. Remove center ventilator grille.
D
RJIA2407E
Removal of Side Ventilator Grille E

1. Remove the instrument panel. Refer to IP-11, "Removal and Installation" .
2. Remove side ventilator ducts. Refer to ATC-136, "Removal of Defroster Nozzle, Duct and Side Ventilator
Duct" .
F
3. Remove side ventilator grille.
I
RJIA2408E
Removal of Driver Ventilator Grille

1. Remove instrument finisher. Refer to IP-11, "Removal and Installation" . ATC
2. Remove driver ventilator grille.
M
RJIA2409E
ATC-135
DUCTS AND GRILLES
Removal of Defroster Nozzle, Duct and Side Ventilator Duct

1. Remove instrument panel. Refer to IP-11, "Removal and Installation" .
2. Remove side defroster ducts with defroster nozzle.
RJIA2410E
3. Remove side ventilator ducts.

Removal of Adaptor
1. Remove heater & cooling unit. Refer to ATC-128, "HEATER & COOLING UNIT ASSEMBLY" .
2. Remove mounting screw and clip.
3. Slide adaptor backward, then remove adaptor.
RJIA2411E
Removal of Multi-box Duct

1. Remove instrument panel. Refer to IP-11, "Removal and Installation" .
2. Remove mounting screw, then disconnect multi-box duct from
heater & cooling unit.
3. Remove heater & cooling unit bracket.
4. Remove multi-box duct from left side.
RJIA2412E
ATC-136
DUCTS AND GRILLES
Removal of Foot Duct

1. Remove multi-box duct. A
2. Remove foot duct.
D
RJIA0069E
Removal of Floor Duct E

1. Remove the front seats. Refer to SE-25, "FRONT SEAT" .
2. Remove multi-box (Instrument center lower panel). Refer to IP-11, "Removal and Installation" .
3. Peel back the floor trim to a point where the floor duct is visible. F
4. Remove rear floor duct.
ATC
L
RJIA0071E
5. Remove front floor duct.

M
RJIA0070E
INSTALLATION
ATC-137
REFRIGERANT LINES
REFRIGERANT LINES PFP:92600
HFC-134a (R-134a) Service Procedure EJS001LK
SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
SHA539DE
Evacuating System and Charging Refrigerant
SHA540DC
ATC-138
REFRIGERANT LINES
ATC
RJIA1940E
*1 ATC-23, "LUBRICANT RETURN *2 ATC-156, "Checking for Refrigerant *3 ATC-158, "CHECKING PROCE-
OPERATION". Leaks". DURE".
*4 ATC-96, "PERFORMANCE TEST
DIAGNOSIS".
ATC-139
REFRIGERANT LINES
Components EJS001LL
Refer to ATC-5, "Precautions for Refrigerant Connection" .

WITH GASOLINE ENGINE
RJIA2843E
NOTE:
This illustration is for RHD models. The blower unit and heater & cooling unit layouts for LHD models are sym-
metrically opposite.
ATC-140
REFRIGERANT LINES
WITH DIESEL ENGINE

A
ATC
RJIA2844E
NOTE:
This illustration is for RHD models. The blower unit and heater & cooling unit layouts for LHD models are sym-
K
metrically opposite.
Removal and Installation for Compressor EJS001LM
REMOVAL L
With Gasoline Engine
RJIA2893E
ATC-141
REFRIGERANT LINES
With Diesel Engine
RJIA2894E
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.

2. Remove the engine undercover.
3. Remove the compressor-alternator belt.
Refer to EM-13, "Removal and Installation" or EM-14, "Removal and Installation of Drive Belt Auto-Ten-
sioner" with gasoline engine, EM-143, "Removal and Installation" with diesel engine.
4. Remove the mounting nuts (bolts) from the high-pressure flexi-
ble hose and low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Disconnect the compressor connector.
RJIA0073E
RJIA0579E
ATC-142
REFRIGERANT LINES
6. Remove the mounting bolts from compressor.

7. Remove the compressor from the lower side of the vehicle. A
RJIA0021E
G
RJIA0580E
INSTALLATION H
CAUTION:
● Replace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new I
one, then apply compressor oil to it when installing it.
● When recharging refrigerant, check for leaks.
ATC
ATC-143
REFRIGERANT LINES
Removal and Installation for Compressor Clutch EJS001LN
REMOVAL
Overhaul (With Gasoline Engine: CWV-615M Compressor)
1. When removing center bolt, hold clutch disc with wrench.
RHA136EB
RHA399F
2. Remove the clutch disc using the clutch disc puller.
RHA124F
3. Remove the snap ring using external snap ring pliers.
RHA138E
ATC-144
REFRIGERANT LINES
4. Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail- A
able pulley puller.
To prevent the pulley groove from being deformed, the puller
claws should be positioned into the edge of the pulley assembly.
B
RHA139E
D
5. Remove the field coil harness clip using a pair of pliers.
G
RHA125F
6. Remove the snap ring using external snap ring pliers. H
ATC
K
RHA145E
Overhaul (With Diesel Engine: DKV-11G Compressor)

1. Remove the two screws holding the connector bracket, thermal L
protector to the compressor.
RHA669H
ATC-145
REFRIGERANT LINES
2. When removing center bolt, hold clutch disc with clutch disc
wrench.
SHA097EA
3. Remove the drive plate using the clutch disc puller.

4. Insert holder′s three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate.
5. Tighten the center bolt to remove the drive plate.
6. While tightening the center bolt, insert a screwdriver between
two of the pins (as shown in the figure) to prevent rotation.
7. After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
ZHA093H
8. Remove the snap ring using external snap ring pliers.
RHA072C
9. Remove the pulley assembly with the puller using a commer-

cially available pulley puller. (Position the center of the puller on
the end of the drive shaft)
For pressed pulleys:
To prevent deformation of the pulley groove, the puller claws
should be hooked under (not into) the pulley groove.
For machine lathed pulleys:
Align the pulley puller groove with the pulley groove, and then
remove the pulley assembly.
SHA099EA
ATC-146
REFRIGERANT LINES
10. Remove the field coil harness clip using a screwdriver.

11. Then remove the three field coil fixing screws and remove the A
field coil.
RHA074C
D
Inspection
Clutch disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley. E
RJIA0582E
H
Pulley
Check the appearance of the pulley assembly. If the contact surface
of pulley sows signs of excessive grooving, replace clutch disc and
pulley. The contact surfaces of the pulley assembly should be I
cleaned with a suitable solvent before reinstallation.
ATC
K
RJIA0583E
Coil
Check coil for loose connection or cracked insulation. L
INSTALLATION
M
With Gasoline Engine (CWV-615M Compressor)
1. Install the field coil.
Be sure to align the coil′s pin with the hole in the compressor′s
front head.
2. Install the field coil harness clip using a screwdriver.
RHA142E
ATC-147
REFRIGERANT LINES
3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
RHA143EA
4. Install the clutch disc on the drive shaft, together with the original
shim (s). Press the clutch disc down by hand.
RHA127F
5. Using the holder to prevent clutch disc rotation.

Tightening torque : 14 N·m (1.4 kg-m, 10 ft-lb)
After tightening the bolt, check that the pulley rotates smoothly.
RHA086E
6. Check clearance around the entire periphery of clutch disc.

Disc to pulley clear- : 0.3 - 0.6 mm (0.012 - 0.024 in)
ance
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
RHA087E
ATC-148
REFRIGERANT LINES
With Diesel Engine (DKV-11G Compressor)

1. Install the field coil. A
Be sure to align the coil′s pin with the hole in the compressor′s
front head.
2. Install the field coil harness clip using a screwdriver. B
RHA076C
D
3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers. E
ZHA094H
H
4. Install the drive plate on the drive shaft, together with the original
shim (s). Press the clutch disc down by hand.
I
ATC
K
RHA078C
L
5. Using the holder to prevent clutch disc rotation.
Tightening torque : 14 N·m (1.4 kg-m, 10 ft-lb)
After tightening the bolt, check that the pulley rotates smoothly. M
SHA101EA
ATC-149
REFRIGERANT LINES
6. Check clearance around the entire periphery of clutch disc.

Disc to pulley clear- : 0.2 - 0.5 mm (0.008 - 0.020 in)
ance
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
RHA080CA
Break-In Operation
When replacing compressor clutch assembly, always carry out 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.
Removal and Installation for Low-pressure Flexible Hose EJS001LO
REMOVAL
2. Remove cowl top. Refer to EI-20, "COWL TOP" .
3. Remove the clips from the low-pressure flexible hose.
4. Remove the mounting bolts from the low-pressure flexible hose
bracket.
5. Remove the clip from the vacuum hose.
RJIA0074E
RJIA0584E
ATC-150
REFRIGERANT LINES
6. Remove the mounting bolts (nut) from the low-pressure flexible

hose. A
CAUTION:
as vinyl tape to avoid the entry of air. B
7. Remove the low-pressure flexible hose.
RJIA0075E
D
INSTALLATION
CAUTION: E
● Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
F
Removal and Installation for High-pressure Flexible Hose EJS001LP
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. G
2. Remove high-pressure flexible hose mounting clip.
3. Remove the mounting bolt and nut from the high-pressure flexi-
ble hose, then remove it. H
CAUTION:
as vinyl tape to avoid the entry of air. I
ATC
RJIA0076E
INSTALLATION
K
CAUTION:
● Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
L
Removal and Installation for High-pressure Pipe EJS004P6 M
REMOVAL
2. Remove the low-pressure flexible hose. Refer to ATC-150, "Removal and Installation for Low-pressure
Flexible Hose" .
3. Remove the high-pressure pipe from the clip.
RJIA0077E
ATC-151
REFRIGERANT LINES
4. Remove the mounting bolt from the high-pressure pipe.

CAUTION:
5. Remove the high-pressure pipe.
RJIA2419E
INSTALLATION
CAUTION:
● Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
Removal and Installation for Condenser EJS001LT
REMOVAL
2. Disconnect the high-pressure flexible hose and the high-pres-
sure pipe from the condenser.
CAUTION:
3. Remove air duct (inlet). Refer to EM-15, "AIR CLEANER AND
AIR DUCT" . (With gasoline engine)
4. Remove the battery and battery tray.
RJIA2419E
5. Disconnect the refrigerant pressure sensor connector (With gas-

oline engine) or dual-pressure switch connector (With diesel
engine).
RJIA0690E
RJIA0691E
ATC-152
REFRIGERANT LINES
6. Remove the front grille and radiator mounting bracket.

7. Remove the mounting nuts from the condenser. A
8. Remove the radiator from the lower mount, move it to the engine
side, then remove the condenser between the radiator and the
radiator core support. B
CAUTION:
Be careful not to damage the core surface of the condenser
and the radiator. C
RJIA0081E
D
INSTALLATION
CAUTION: E
● Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
F
Condenser mounting bolts
Tightening torque : 4.2 N·m (0.43 kg-m, 37 in-lb)
G
Removal and Installation for Liquid Tank EJS004P7
REMOVAL
1. Remove the condenser. Refer to ATC-152, "Removal and Installation for Condenser" . H
2. Clean liquid tank and its surrounding area, and remove dirt and rust from liquid tank.
CAUTION:
Be sure to clean carefully. I
3. Remove mounting bolt for liquid tank.
CAUTION:
Cap or wrap the joint of the condenser pipe with a suitable ATC
tool such as a vinyl tape to avoid the entry of air.
L
RJIA2895E
4. Lift liquid tank upward. Remove bracket from protruding part of M

condenser.
5. Slide liquid tank upward, then remove liquid tank.
RJIA1440E
ATC-153
REFRIGERANT LINES
INSTALLATION
CAUTION:
● Replace the O-rings of the condenser pipe with new ones,
then apply compressor oil to them after installing them.
RJIA1441E
Removal and Installation for Refrigerant Pressure Sensor EJS004P8
REMOVAL
2. Remove liquid tank. Refer to ATC-153, "Removal and Installation for Liquid Tank" .
3. Using a vise, secure liquid tank, and remove refrigerant pres-
sure sensor.
RJIA2148E
INSTALLATION
CAUTION:
● Replace the O-ring of the refrigerant pressure sensor with a new one, then apply compressor oil to
Removal and Installation for Dual-pressure Switch EJS004P9
REMOVAL
2. Remove liquid tank. Refer to ATC-153, "Removal and Installation for Liquid Tank" .
3. Using a vise, secure liquid tank, and remove dual-pressure
switch.
RJIA2896E
INSTALLATION
CAUTION:
● Replace the O-ring of the dual pressure switch with a new one, then apply compressor oil to it
when installing it.
ATC-154
REFRIGERANT LINES
Removal and Installation for Evaporator EJS001LU
REMOVAL A
3. Disconnect the low-pressure flexible hose and the high-pressure B
pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and C
the high-pressure pipe with a suitable tool such as a vinyl
tape to avoid the entry of air.
D
E
RJIA0082E
4. Remove the expansion valve cover and expansion valve.

F
RJIA2423E
I
6. Remove foot duct (passenger side).

7. Remove evaporator cover. ATC
8. Slide the evaporator, then remove it from the heater & cooling
unit.
K
RJIA0084E
M
9. Remove the intake sensor from the evaporator, then remove the
evaporator.
RJIA0051E
INSTALLATION
CAUTION:
● Replace the O-rings of the low-pressure flexible hose and the high-pressure pipe with new ones,
then apply compressor oil to them when installing them.
ATC-155
REFRIGERANT LINES
● Mark the mounting position of the intake sensor bracket.

Removal and Installation for Expansion Valve EJS004PA
REMOVAL
3. Disconnect the low-pressure flexible hose and high-pressure pipe from the evaporator.
CAUTION:
Cap or wrap the joint of the low-pressure flexible hose and the high-pressure pipe with a suitable
tool such as a vinyl tape to avoid the entry of air.
4. Remove the expansion valve cover.
5. Remove the expansion valve.
RJIA2423E
INSTALLATION
CAUTION:
● Replace the O-rings of expansion valve and piping with new ones, then apply compressor oil to
them when installing them.
Checking for Refrigerant Leaks EJS001LX
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
ATC-156
REFRIGERANT LINES
Checking System for Leaks Using the Fluorescent Leak Detector EJS001LY
A
1. Check A/C system for leaks using the UV lamp and safety goggles (J-42220) in a low sunlight area (area
without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright
green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak. B
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag- C
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector. D
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be E
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector. F
Dye Injection EJS001LZ
(This procedure is only necessary when recharging the system or when the compressor has seized and was G
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50
psi). H
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW-PRESSURE side service fitting.
4. Start engine and switch A/C ON. I
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture′s operat-
ing instructions). ATC
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con- K
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to L
penetrate a leak and become visible.
Electronic Refrigerant Leak Detector EJS001M0
PRECAUTIONS FOR HANDLING LEAK DETECTOR M

When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
SHA705EB
ATC-157
REFRIGERANT LINES
1. Position probe approximately 5 mm (3/16 in) away from point to

be checked.
SHA707EA
2. When testing, circle each fitting completely with probe.
SHA706E
3. Move probe along component approximately 25 to 50 mm (1 to

2 in)/sec.
SHA708EA
CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C
(61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of
refrigerant.
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm2 , 50 psi).
4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet g) to the low side
(evaporator drain hose h to shaft seal k). Refer to ATC-140, "Components" . Perform a leak check for the
following areas carefully. Clean the component to be checked and move the leak detected probe com-
pletely around the connection/component.
Compressor
Check the fitting of high- and low-pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
ATC-158
REFRIGERANT LINES
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks). A
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector. B
Cooling unit (Evaporator)

With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the C
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer′s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose. D
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. E
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows; F
a. A/C switch: ON
b. Mode control dial: VENT (Ventilation)
G
c. Intake position: Recirculation
d. Max. cold temperature
e. Fan speed: High H
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4 through 6 above.
I
Refrigerant leaks should be checked immediately after stopping the
engine. Begin with the leak detector at the compressor. The pres-
sure on the high-pressure side will gradually drop after refrigerant
circulation stops and pressure on the low-pressure side will gradually ATC
rise, as shown in the graph. Some leaks are more easily detected
when pressure is high.
K
L
SHA839E
11. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com- M
ponent as necessary.
12. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
13. Conduct A/C performance test to ensure system works properly.
ATC-159
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
COMPRESSOR EJS001QO

Model ZEXEL VALEO CLIMATE CONTROL make
Calsonic Kansei make CWV-615M
DKV-11G
Type V-6 variable displacement Vane rotary
Displacement Max. 146 (8.91)
3 110 (6.71)
cm (cu in)/rev Min. 14.5 (0.885)
Cylinder bore × stroke
37 (1.46) × [2.3 - 25.0 (0.091 - 0.984)] -
mm (in)
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V
LUBRICANT EJS001QP

Model ZEXEL VALEO CLIMATE CON-
Calsonic Kansei make CWV-615M
TROL make DKV-11G
Name Nissan A/C System Oil Type S Nissan A/C System Oil Type R
Part number KLH00-PAGS0 KLH00-PAGR0
Total in system 180 (6.3)
Capacity
m (lmp fl oz) Compressor (Service part) charg-
180 (6.3)
ing amount
REFRIGERANT EJS001QQ
Type HFC-134a (R-134a)

Capacity
0.55 (1.21)
kg (lb)
ENGINE IDLING SPEED EJS001QR
Refer to EC-35, "Idle Speed and Ignition Timing Check" (With QR engine: For Hong Kong), EC-478, "Idle
Speed and Ignition Timing Check" (With QR engine: Except Hong Kong) or EC-921, "Basic Inspection" (With
YD engine).
BELT TENSION EJS001QS
Refer to EM-13, "DRIVE BELTS" (With QR engine) or EM-142, "DRIVE BELTS" (With YD engine).
ATC-160

Automatic Air Conditioner: Section

Uploaded by

Copyright:

Available Formats

Automatic Air Conditioner: Section

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Automatic Air Conditioner: Section

Uploaded by

Copyright:

Available Formats

AUTOMATIC AIR CONDITIONER

O-RING AND REFRIGERANT CONNECTION

With Diesel Engine

SHA814E New 92474 N8210 16.5 (0.650) 2.43 (0.0957)

Precautions for Servicing Compressor EJS001JY

MANIFOLD GAUGE SET

REFRIGERANT WEIGHT SCALE

CALIBRATING ACR4 WEIGHT SCALE

Wiring Diagrams and Trouble Diagnosis EJS001K1

When you read wiring diagrams, refer to the following:

WITH GASOLINE ENGINE (CWV-615M COMPRESSOR)

HFC-134a (R-134a) Service Tools and Equipment EJS001K3

Container color: Light blue

Gasoline engine (CWV-615M):

Recovery/Recycling Function: Refrigerant Recovery and C

Power supply: DC 12V (Battery

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

● Low-pressure side hose ● Utility hose: Yellow with black stripe

Service couplers Hose fitting to service hose:

For measuring of refrigerant

REFRIGERATION SYSTEM PFP:KA990

REFRIGERANT PRESSURE SENSOR (WITH GASOLINE ENGINE: CWV-615M COMPRESSOR)

V-6 Variable Displacement Compressor (With Gasoline Engine: CWV-615M

Component Layout EJS001K7

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS: ATC

1. Start engine, and set the following conditions:

3. CHECK REPLACEMENT PART

Should the compressor be replaced?

LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

AIR CONDITIONER CONTROL PFP:27500

Overview Air Conditioner LAN Control System EJS001K9

System Construction EJS001KA

AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)

Overview of Control System EJS001KB

Control Operation EJS004O7

MODE CONTROL DIAL

Discharge Air Flow EJS001KD

System Description EJS001KE

SWITCHES AND THEIR CONTROL FUNCTION

TROUBLE DIAGNOSIS PFP:00004

Intake door does not change. ATC-77, "Intake

Component Parts and Harness Connector Location EJS004OE

Schematic — A/C, A — EJS004OF

WITH GASOLINE ENGINE

WITH DIESEL ENGINE

Wiring Diagram — A/C, A — EJS004OG

WITH GASOLINE ENGINE / LHD MODELS

WITH GASOLINE ENGINE / RHD MODELS

WITH DIESEL ENGINE / LHD MODELS

WITH DIESEL ENGINE / RHD MODELS

Auto Amp. Terminals and Reference Value EJS004OH

Measure voltage between each terminal and ground by following ter-

PIN CONNECTOR TERMINAL LAYOUT

TERMINALS AND REFERENCE VALUE FOR AUTO AMP.

Fan ON signal (With gaso- Blower fan: ON Approx. 0

Termi- Wire Ignition Voltage

Rear window defogger feed Rear window defogger: ON Approx. 12 E

Power supply for ambient

1 ATC-64, "Operational Check". 2 ATC-67, "DIAGNOSTIC PROCE-

1 ATC-64, "Operational Check". 2 ATC-58, "FUNCTION CONFIRMA- *3 ATC-58, "FUNCTION CONFIRMA-

1 ATC-64, "Operational Check". 2 ATC-58, "FUNCTION CONFIRMA- *3 ATC-58, "FUNCTION CONFIRMA-

1 ATC-64, "Operational Check". 2 ATC-58, "FUNCTION CONFIRMA- *3 ATC-58, "FUNCTION CONFIRMA-