Manual Air Conditioner: Section

MANUAL AIR CONDITIONER
J AIR CONDITIONER
SECTION
MANUAL AIR CONDITIONER
MTC 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 ..................... 8 LUBRICANT .............................................................. 23
Precautions for Service Equipment .......................... 9 Maintenance of Lubricant Quantity in Compressor... 23
RECOVERY/RECYCLING EQUIPMENT .............. 9 LUBRICANT ........................................................ 23 MTC
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 Control Operation ................................................... 26
Precautions for Leak Detection Dye ........................11 FAN CONTROL DIAL .......................................... 26
IDENTIFICATION .................................................11 MODE CONTROL DIAL ...................................... 26 M
IDENTIFICATION LABEL FOR VEHICLE ........... 12 TEMPERATURE CONTROL DIAL ...................... 26
Wiring Diagrams and Trouble Diagnosis ................ 12 A/C SWITCH ....................................................... 26
PREPARATION ......................................................... 13 RECIRCULATION (REC) SWITCH ..................... 26
Special Service Tools ............................................. 13 Discharge Air Flow ................................................. 27
WITH GASOLINE ENGINE (CWV-615M COM- System Description ................................................. 28
PRESSOR) ......................................................... 13 SWITCHES AND THEIR CONTROL FUNCTION... 28
WITH DIESEL ENGINE (DKV-11G COMPRES- TROUBLE DIAGNOSIS ............................................ 29
SOR) ................................................................... 13 How to Perform Trouble Diagnoses for Quick and
HFC-134a (R-134a) Service Tools and Equipment... 14 Accurate Repair ...................................................... 29
REFRIGERATION SYSTEM ..................................... 17 WORK FLOW ...................................................... 29
Refrigerant Cycle ................................................... 17 SYMPTOM TABLE .............................................. 29
REFRIGERANT FLOW ....................................... 17 Component Parts and Harness Connector Location... 30
FREEZE PROTECTION (WITH GASOLINE ENGINE COMPARTMENT .................................. 30
ENGINE: CWV-615M COMPRESSOR) .............. 17 PASSENGER COMPARTMENT ......................... 31
Refrigerant System Protection ............................... 17 Circuit Diagram - A/C, M - ...................................... 32
REFRIGERANT PRESSURE SENSOR (WITH Wiring Diagram - A/C, M - ...................................... 33
MTC-1
WITH GASOLINE ENGINE ................................. 33 VENTILATION AIR FILTER .......................................81
WITH DIESEL ENGINE ....................................... 36 Removal and Installation .........................................81
Operational Check .................................................. 39 FUNCTION ..........................................................81
CHECKING BLOWER ......................................... 39 REPLACEMENT TIMING ....................................81
CHECKING DISCHARGE AIR ............................ 39 REPLACEMENT AND PROCEDURES ...............81
CHECKING RECIRCULATION ............................ 40 CLEANING ...........................................................81
CHECKING TEMPERATURE DECREASE ......... 41 HEATER & COOLING UNIT ASSEMBLY .................82
CHECKING TEMPERATURE INCREASE .......... 41 Removal and Installation .........................................82
CHECKING A/C SWITCH ................................... 42 REMOVAL ............................................................82
Mode Door .............................................................. 43 INSTALLATION ....................................................83
INSPECTION FLOW ........................................... 43 Disassembly and Assembly ....................................83
Air Mix Door ............................................................ 44 HEATER CORE .........................................................84
INSPECTION FLOW ........................................... 44 Removal and Installation .........................................84
Intake Door Motor Circuit ........................................ 44 MODE DOOR ............................................................85
INSPECTION FLOW ........................................... 45 Control Linkage Adjustment ....................................85
COMPONENT DESCRIPTION ............................ 45 MODE DOOR CONTROL CABLE .......................85
DIAGNOSTIC PROCEDURE .............................. 46 AIR MIX DOOR ..........................................................86
Blower Motor Circuit ............................................... 48 Control Linkage Adjustment ....................................86
INSPECTION FLOW ........................................... 48 AIR MIX DOOR CONTROL CABLE ....................86
DIAGNOSTIC PROCEDURE .............................. 48 DUCTS AND GRILLES .............................................87
COMPONENT INSPECTION .............................. 51 Removal and Installation .........................................87
Magnet Clutch Circuit ............................................. 51 VENTILATOR DUCT, DEFROXTER NOZZLE
INSPECTION FLOW ........................................... 52 AND DEFROSTER DUCTS .................................87
DIAGNOSTIC PROCEDURE (FOR GASOLINE CENTER VENTILATOR GRILLE .........................87
ENGINE) .............................................................. 53 SIDE VENTILATOR GRILLE ...............................87
DIAGNOSTIC PROCEDURE (FOR DIESEL FOOT DUCT ........................................................88
ENGINE) .............................................................. 57 FLOOR DUCT ......................................................88
ELECTRICAL COMPONENT INSPECTION ....... 61 REFRIGERANT LINES .............................................89
Insufficient Cooling ................................................. 63 HFC-134a (R-134a) Service Procedure ..................89
INSPECTION FLOW ........................................... 63 SETTING OF SERVICE TOOLS AND EQUIP-
PERFORMANCE TEST DIAGNOSES ................ 64 MENT ...................................................................89
PERFORMANCE CHART ................................... 66 Components ............................................................91
TROUBLE DIAGNOSES FOR UNUSUAL PRES- WITH GASOLINE ENGINE ..................................91
SURE ................................................................... 68 WITH DIESEL ENGINE .......................................92
Insufficient Heating ................................................. 71 Removal and Installation for Compressor ...............92
INSPECTION FLOW ........................................... 71 REMOVAL ............................................................92
Noise ...................................................................... 73 INSTALLATION ....................................................94
TROUBLE DIAGNOSIS PROCEDURE FOR Removal and Installation for Compressor Clutch ...95
NOISE ................................................................. 73 REMOVAL ............................................................95
INSPECTION FLOW ........................................... 73 INSTALLATION ....................................................98
CONTROLLER .......................................................... 75 Removal and Installation for Low-pressure Flexible
Removal and Installation ........................................ 75 Hose ...................................................................... 101
Disassembly and Assembly .................................... 75 REMOVAL .......................................................... 101
BLOWER UNIT ......................................................... 76 INSTALLATION .................................................. 101
Removal and Installation ........................................ 76 Removal and Installation for High-pressure Flexible
REMOVAL ........................................................... 76 Hose ...................................................................... 102
INSTALLATION .................................................... 76 REMOVAL .......................................................... 102
Disassembly and Assembly .................................... 77 INSTALLATION .................................................. 102
BLOWER MOTOR .................................................... 78 Removal and Installation for High-pressure Pipe . 102
Removal and Installation ........................................ 78 REMOVAL .......................................................... 102
BLOWER FAN RESISTOR ....................................... 79 INSTALLATION .................................................. 102
Removal and Installation ........................................ 79 Removal and Installation for Refrigerant Pressure
INTAKE DOOR MOTOR ........................................... 80 Sensor ................................................................... 103
Removal and Installation ........................................ 80 Removal and Installation for Dual-pressure Switch.103
Removal and Installation for Condenser ............... 103
REMOVAL .......................................................... 103
INSTALLATION .................................................. 104
Removal and Installation for Evaporator ............... 104
REMOVAL .......................................................... 104
MTC-2
INSTALLATION ................................................. 105 DETECTOR ....................................................... 107
Removal and Installation for Expansion Valve ..... 105 CHECKING PROCEDURE ............................... 108 A
Removal and Installation for liquid tank ................ 106 SERVICE DATA AND SPECIFICATIONS (SDS) .... 110
REMOVAL ......................................................... 106 COMPRESSOR .................................................... 110
INSTALLATION ................................................. 106 LUBRICANT ......................................................... 110 B
Checking for Refrigerant Leaks ............................ 106 REFRIGERANT .................................................... 110
Checking System for Leaks Using the Fluorescent ENGINE IDLING SPEED ...................................... 110
Leak Detector ....................................................... 106 BELT TENSION .................................................... 110
Dye Injection ........................................................ 107 C
Electronic Refrigerant Leak Detector ................... 107
PRECAUTIONS FOR HANDLING LEAK
D
MTC
MTC-3
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EJS0023S
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) EJS001M3
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. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meet-
ing requirements of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-
134a) recovery equipment. If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be obtained from refrigerant and
lubricant manufacturers.
– Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam
parts. Damage may result.
General Refrigerant Precautions EJS001M4
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)
MTC-4
PRECAUTIONS
have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause
injury or property damage. Additional health and safety information may be obtained from refriger- A
ant manufacturers.
Lubricant Precautions EJS001M5
B
● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
If lubricant other than that specified is used, compressor malfunction is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following
C
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.
D
– When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before con-
necting the components. Connect all refrigerant loop components as quickly as possible to minimize the
entry of moisture into system.
– Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. With- E
out proper sealing, lubricant will become moisture saturated and should not be used.
● Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting require- F
ments of SAE J2210 HFC-134a (R-134a) recycling equipment, or J2209 HFC-134a (R-134a) recovery
equipment. If accidental system discharge occurs, ventilate work area before resuming service. Additional
health and safety information may be obtained from refrigerant and lubricant manufacturers. G
● Do not allow lubricant (Nissan A/C System Oil Type S or R) to come in contact with styrofoam parts. Dam-
age may result.
Precautions for Refrigerant Connection EJS001M6
H
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
● Expansion valve to cooling unit
I
● Refrigerant pressure sensor to liquid tank
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
● The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi- MTC
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics. K
● 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.
L
SHA815E
MTC-5
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION

With Gasoline Engine
RJIA0674E
NOTE:
This illustration is for RHD models. The blower unit and heater & cooling unit layouts for LHD models are sym-
metrically opposite.
MTC-6
PRECAUTIONS
With Diesel Engine

A
MTC
RJIA0742E
NOTE:
This illustration is for LHD models. The blower unit and heater & cooling unit layouts for RHD models are sym-
K
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.
MTC-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
Precautions for Servicing Compressor EJS001M7
● Plug all openings to prevent moisture and foreign matter from entering.
● When the compressor is removed, store it in the same position as it is when mounted on the car.
● When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to MTC-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.
MTC-8
PRECAUTIONS
● 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 A
is installed, let the engine idle and operate the compressor for one hour.
● After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation. B
Precautions for Service Equipment EJS001M8
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never C
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
D
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible E
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
F
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows. G
● Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump. H
● For pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump. I
● If the hose has an automatic shut off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate. MTC
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
K
RHA270DA
MANIFOLD GAUGE SET L

Be certain that the gauge face indicates HFC-134a (R-134a) or
134a. Be sure the gauge set has 1/2″-16 ACME threaded connec-
tions for service hoses. Confirm the set has been used only with M
refrigerant HFC-134a (R-134a) and specified lubricants.
SHA533D
MTC-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.
MTC-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 EJS001M9
● 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 glasses to protect your eyes and enhance the visibility of
the fluorescent dye.
● The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo- 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 (R12) 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 (R12) 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.
MTC
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label. K
MTC-11
PRECAUTIONS
IDENTIFICATION LABEL FOR VEHICLE

Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
SHA436FA
RJIA0675E
Wiring Diagrams and Trouble Diagnosis EJS001MA
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.
MTC-12
PREPARATION
PREPARATION PFP:00002
A
Special Service Tools EJS001MB
WITH GASOLINE ENGINE (CWV-615M COMPRESSOR)

Tool number
Description
B
Tool name
KV99106100 S-NT232
Removing shaft nut and clutch disc
Clutch disc wrench E
RJIA0194E
G
KV99232340
H
or
Removing clutch disc
KV992T0001
Clutch disc puller
I
S-NT376
MTC
KV99106200
Installing pulley
Pulley installer
K
S-NT235
WITH DIESEL ENGINE (DKV-11G COMPRESSOR) L

Tool number
Description
Tool name
M
KV99231260
Removing shaft nut and clutch disc
Clutch disc wrench
RJIA0475E
KV992T0001
Removing clutch disc
Clutch disc puller
RJIA0476E
MTC-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 EJS001MC
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),
type S
Gasoline engine (CWV-615M):
Application: HFC-134a (R-134a)
KLH00-PAGS0
swash plate compressors (Nissan
Nissan A/C System Oil Type S
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
rotary compressors (Nissan only)
Lubricity: 40 m (1.4 Imp fl oz)
MTC-14
PREPARATION
Tool number
Description A
Tool name
Recovery/Recycling Function: Refrigerant Recovery and C

Recharging equipment (ACR4) 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 MTC
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
MTC-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
and couplers) (R-134a).
● 1/2″-16 ACME
RJIA0196E
Hose color:
Service hoses ● Low hose: Blue with black stripe
● High side hose ● High hose: Red with black stripe
● Low 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 side coupler ● M14 x 1.5 fitting is optional or
● Low 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
MTC-16
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM PFP:KA990

A
Refrigerant Cycle EJS001MD
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 EJS001ME
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 (28 kg/cm2 , 398 psi), or below about 134 kPa
(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.
I
When the pressure of refrigerant in the system increases to an unusual level [more than 3,727 kPa (38 kg/cm2
, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the
atmosphere.
MTC
MTC-17
RJIA0676E
V-6 Variable Displacement Compressor (With Gasoline Engine: CWV-615M

Compressor) EJS001MF
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 swash plate has changed and is not a problem.
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 (1.5 to 1.8 kg/cm2 , 21 to 26 psi) under varying conditions.
In previous compressors, however, suction pressure was reduced with increases in engine speed.
MTC-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 swash plate allows the piston's stroke to change so that refrigerant discharge can be continu- B
ously changed from 14.5 to 146 cm3 (0.885 to 8.91 cu in).
MTC
RJIA0744E
MTC-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 swash plate is controlled between the crankcase's internal pressure and the piston cylin-
der 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 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 (1.8 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 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 swash
plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase
MTC-20
triggers pressure difference between the piston and the crankcase. The pressure difference changes the
angle of the swash plate. A
RHA474C
G
MTC
MTC-21
Component Layout EJS001MG
NOTE:
This illustration is for RHD models. The layout for LHD models is symmetrically opposite.
RJIA0479E
MTC-22
LUBRICANT
LUBRICANT PFP:KLG00
A
Maintenance of Lubricant Quantity in Compressor EJS001MH
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
YES or NO
YES >> GO TO 2.
NO >> GO TO 3. I
2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:
1. Start engine, and set the following conditions: MTC
– Test condition
Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON K
Blower speed: Max. position
Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).]
Intake position: Recirculation (REC)
L
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
CAUTION: M
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
>> GO TO 3.
3. CHECK COMPRESSOR
Should the compressor be replaced?
YES or NO
YES >> Go to MTC-24, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
NO >> GO TO 4.
MTC-23
LUBRICANT
4. CHECK ANY PART

Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large
amount of lubricant leakage.)
YES or NO
YES >> Go to MTC-24, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT
EXCEPT COMPRESSOR" .
NO >> Carry out the A/C performance test.
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.
MTC-24
LUBRICANT
RHA065DI
I
MTC
MTC-25
AIR CONDITIONER CONTROL
AIR CONDITIONER CONTROL PFP:27500
Control Operation EJS001ML
RJIA0700E
RJIA0740E
FAN CONTROL DIAL

This dial turns the fan ON and OFF, and controls fan speed.
MODE CONTROL DIAL
This dial controls the outlet air flow.
TEMPERATURE CONTROL DIAL
This dial allows you to adjust the temperature of the discharge air.
A/C SWITCH
The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the com-
pressor will turn ON. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running.
RECIRCULATION (REC) SWITCH
Recirculation (REC) position: Interior air is recirculated inside the vehicle. (The indicator lamp will light.)
MTC-26
Fresh (FRE) position: Outlet air is drawn into the passenger compartment. (The indicator lamp will not light.)
A
Discharge Air Flow EJS001MM
MTC
RJIA0483E
MTC-27
System Description EJS001MN
SWITCHES AND THEIR CONTROL FUNCTION
RJIA0484E
RJIA0701E
MTC-28
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS PFP:00004

A
How to Perform Trouble Diagnoses for Quick and Accurate Repair EJS001MO
WORK FLOW
B
SHA900E
E
*1 MTC-39, "Operational Check"
SYMPTOM TABLE
Symptom Reference Page
F
Air outlet does not change. Go to Trouble Diagnosis Procedure for Mode Door. MTC-43, "Mode Door"
MTC-44, "Air Mix G
Discharge air temperature does not change. Go to Trouble Diagnosis Procedure Air Mix Door.
Door"
Intake door does not change. MTC-44, "Intake Door
Go to Trouble Diagnosis Procedure for Intake Door Motor.
Intake door motor does not operate normally. Motor Circuit" H
MTC-48, "Blower
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor.
Motor Circuit"
Magnet clutch does not operate when A/C MTC-51, "Magnet I
Go to Trouble Diagnosis Procedure for Magnet clutch.
switch and fan switch are ON. Clutch Circuit"
MTC-63, "Insufficient
Insufficient cooling. Go to Trouble Diagnosis Procedure for Insufficient cooling.
Cooling" MTC
MTC-71, "Insufficient
Insufficient heating. Go to Trouble Diagnosis Procedure for Insufficient Heating.
Heating"
Noise. Go to Trouble Diagnosis Procedure for Noise. MTC-73, "Noise" K
MTC-29
TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location EJS001MP
ENGINE COMPARTMENT
RJIA0702E
MTC-30
TROUBLE DIAGNOSIS
PASSENGER COMPARTMENT
A
MTC
RJIA0739E
MTC-31
TROUBLE DIAGNOSIS
Circuit Diagram - A/C, M - EJS001OC
TJWA0021E
MTC-32
TROUBLE DIAGNOSIS
Wiring Diagram - A/C, M - EJS001O6
WITH GASOLINE ENGINE A
MTC
TJWA0022E
MTC-33
TROUBLE DIAGNOSIS
TJWA0023E
MTC-34
TROUBLE DIAGNOSIS
MTC
TJWA0024E
MTC-35
TROUBLE DIAGNOSIS
WITH DIESEL ENGINE
TJWA0025E
MTC-36
TROUBLE DIAGNOSIS
MTC
TJWA0026E
MTC-37
TROUBLE DIAGNOSIS
TJWA0027E
MTC-38
TROUBLE DIAGNOSIS
Operational Check EJS001MS
A
The purpose of the operational check is to confirm that the system operates properly.
Conditions: Engine running and at normal
operating temperature B
CHECKING BLOWER
1. Turn fan switch to 1-speed. Blower should operate on low
speed. C
2. Then turn fan switch to 2-speed, and continue checking blower
speed until all speeds are checked.
3. Leave blower on 4-speed. D
If NG, go to trouble diagnosis procedure for blower motor MTC-48,
"Blower Motor Circuit" .
If OK, continue with next check. E
RJIA0703E
F
I
RJIA0704E
CHECKING DISCHARGE AIR MTC

1. Set the mode control dial to each position.
M
RJIA0705E
RJIA0706E
MTC-39
TROUBLE DIAGNOSIS
2. Confirm that discharge air comes out according to the air distri-
bution table.Refer to Discharge Air Flow MTC-27, "Discharge Air
Flow" .
Intake door position is checked in the next step.
If NG, go to trouble diagnosis procedure for mode door motor.
If OK, continue with next check.
RJIA0492E
CHECKING RECIRCULATION
1. Press REC switch one time. Recirculation indicator should illu-
minate.
2. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for intake door MTC-44,
"Intake Door Motor Circuit" .
RJIA0707E
RJIA0708E
MTC-40
TROUBLE DIAGNOSIS
CHECKING TEMPERATURE DECREASE

1. Turn the temperature dial to full cold position. A
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for air mix doorMTC-44, "Air
Mix Door" . B
RJIA0709E
D
RJIA0710E
H
CHECKING TEMPERATURE INCREASE
1. Turn the temperature dial to full hot position.
2. Check for hot air at discharge air outlets. I
If NG, go to trouble diagnosis procedure for insufficient heating MTC-
71, "Insufficient Heating" .
MTC
RJIA0711E
RJIA0712E
MTC-41
TROUBLE DIAGNOSIS
CHECKING A/C SWITCH

1. Turn the fan control switch to the desired (1 to 4 speed) position
and push the A/C switch to turn ON the air conditioner.
2. The indicator lamp should come on when air conditioner is ON.
If NG, go to trouble diagnosis procedure for magnet clutch MTC-51,
"Magnet Clutch Circuit" .
If all operational check are OK (symptom can not 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
simulate driving conditions environment. If symptom appears, refer
to MTC-29, "SYMPTOM TABLE" and perform applicable trouble
diagnosis procedures. RJIA0713E
RJIA0714E
MTC-42
TROUBLE DIAGNOSIS
Mode Door EJS001O7
A
SYMPTOM: Air outlet does not change.
INSPECTION FLOW
B
MTC
RJIA0715E
*1 MTC-27, "Discharge Air Flow" *2 MTC-39, "Operational Check" *3 MTC-85, "Control Linkage Adjust-
ment"
*4 MTC-29, "SYMPTOM TABLE"
MTC-43
TROUBLE DIAGNOSIS
Air Mix Door EJS001O8
SYMPTOM: Air mix door does not change.

INSPECTION FLOW
RJIA0716E
*1 MTC-86, "Control Linkage Adjust- *2 MTC-29, "SYMPTOM TABLE" *3 MTC-39, "Operational Check"
ment"
Intake Door Motor Circuit EJS001MV
SYMPTOM:
● Intake door does not change.
● Intake door motor does not operate normally.
MTC-44
TROUBLE DIAGNOSIS
INSPECTION FLOW
A
RJIA0717E
I
*1 MTC-44, "Intake Door Motor Circuit" *2 MTC-39, "Operational Check" *3 MTC-29, "SYMPTOM TABLE"
COMPONENT DESCRIPTION MTC

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 heater control panel. Motor rotation K
is conveyed to a lever which activates the intake door.
RJIA0519E
RJIA0520E
MTC-45
TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE
SYMPTOM: Intake door does not change.
RJIA0595E
1. CHECK POWER SUPPLY FOR HEATER CONTROL PANEL

Disconnect heater control panel harness connector.
Terminals
(+)
Voltage
Terminal (Wire (-)
Connector
color)
M55 1 (BR/Y) Body ground Approx. 12V
OK or NG
OK >> GO TO 2.
NG >> Check power supply circuit and 10 A fuse [No. 15, RJIA0596E
located in the fuse block (J/B)]. Refer toPG-3, "BAT-

TERY POWER SUPPLY — IGNITION SW. IN ANY POSITION" .
● If OK, check for open circuit in wiring harness. Repair or replace as necessary.
● If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.
2. CHECK BODY GROUND CIRCUIT FOR HEATER CONTROL PANEL
Terminals
(+)
Continuity
Terminal (Wire (-)
Connector
color)
M55 5 (B) Body ground Yes
OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector. RJIA0597E
3. CHECK RECIRCULATION SWITCH CIRCUIT
Terminals
(+) (-)
Continuity
Terminal (Wire Terminal (Wire
Connector Connector
color) color)
M55 5 (B) M55 1 (BR/Y) Yes
OK or NG
OK >> GO TO 4.
NG >> Replace heater control panel. RJIA0598E
MTC-46
TROUBLE DIAGNOSIS
4. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR A

Reconnect heater control panel connector.
RJIA0718E
E
Terminals
(+) (-)
Condition Voltage
Terminal (Wire Terminal (Wire
F
Connector Connector
color color)
M48 2 (R/W) M48 1(Y/R) REC SW: ON
Approx. 12V G
M48 1 (Y/R) M48 2(R/W) REC SW: OFF
OK or NG
OK >> Replace intake door motor. H
NG >> GO TO 5.
5. CHECK CIRCUIT CONTINUITY BETWEEN HEATER CONTROL PANEL AND INTAKE DOOR MOTOR I
Disconnect the heater control panel connector and intake door motor connector.
MTC
RJIA0719E
M
Terminals
Heater control panel connector Intake door motor connector
Continuity
Terminal Terminal (Wire
Connector Connector
(Wire color) color)
M55 10 (R/W) M48 2 (R/W)
Yes
M55 11 (Y/R) M48 1 (Y/R)
OK or NG
OK >> Replace heater control panel.
NG >> Repair harness or connector.
MTC-47
TROUBLE DIAGNOSIS
Blower Motor Circuit EJS001MW
SYMPTOM: Blower motor operation is malfunctioning.

INSPECTION FLOW
RJIA0720E
*1 MTC-48, "Blower Motor Circuit" *2 MTC-39, "Operational Check" *3 MTC-29, "SYMPTOM TABLE"
*4 MTC-39, "Operational Check"
DIAGNOSTIC PROCEDURE
SYMPTOM: Blower motor operation is malfunctioning.
RJIA0602E
MTC-48
TROUBLE DIAGNOSIS
1. CHECK POWER SUPPLY FOR BLOWER MOTOR A

Disconnect blower motor harness connector.
Terminals
B
(+) (-)
Voltage
Terminal
Connector -
(Wire color) C
M65 1 (L/W) Ground Approx. 12V
OK or NG
OK >> GO TO 2. D
NG >> Check power supply circuit and 15A fuses [Nos. 19 and SJIA0188E
24, located in the fuse block (J/B)]. Refer toPG-3, "BAT-

TERY POWER SUPPLY — IGNITION SW. IN ANY POSITION" . E
● If OK, check for open circuit in wiring harness. Repair or replace as necessary.
● If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.
F
2. CHECK BODY GROUND CIRCUIT FOR BLOWER MOTOR
G
Terminals Condition
Terminal Continuity
Connector - -
(Wire color) H
M65 2 (L/B) Ground FAN SW: ON Yes
OK or NG
I
OK >> GO TO 3.
NG >> GO TO 4.
SJIA0189E
MTC
3. CHECK BLOWER MOTOR
Refer to MTC-51, "COMPONENT INSPECTION" . K
OK or NG
OK >> INSPECTION END
NG >> Replace blower motor. L
4. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND FAN RESISTOR

Disconnect fan resistor connector. M
Terminals
Fan resistor connector Blower motor connector
Continuity
Terminal Terminal
Connector Connector
(Wire color) (Wire color)
M66 1 (L/B) M65 2 (L/B) Yes
OK or NG
OK >> GO TO 4.
5. CHECK FAN RESISTOR

Refer to MTC-51, "Blower Fan Resistor" .
OK or NG
OK >> GO TO 6.
NG >> Replace fan resistor.
MTC-49
TROUBLE DIAGNOSIS
6. CHECK CIRCUIT CONTINUITY BETWEEN FAN RESISTOR AND HEATER CONTROL PANEL
Disconnect heater control panel connector.
Terminals
Fan resistor connector Heater control panel connector
Continuity
Terminal Terminal
Connector Connector
(Wire color) (Wire color)
M66 2 (L/R) M54 16 (L/R)
M66 3 (L/Y) M54 15 (L/Y) Yes
M66 4 (L/W) M54 14 (L/W)
RJIA0606E
OK or NG
OK >> GO TO 7.
7. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND HEATER CONTROL PANEL
Terminals
Blower motor connector Heater control panel connector
Continuity
Terminal Terminal (Wire
Connector Connector
(Wire color) color)
M65 2 (L/B) M54 17 (L/B) Yes
OK or NG
OK >> GO TO 8.
8. CHECK FAN SWITCH

Refer to MTC-51, "Fan Switch" .
OK or NG
OK >> GO TO 9.
NG >> Replace fan switch.
9. CHECK GROUND CIRCUIT
Terminals
Terminal Continuity
Connector -
(Wire color)
M54 13 (B) Ground Yes
OK or NG
RJIA0608E
MTC-50
TROUBLE DIAGNOSIS
COMPONENT INSPECTION
Blower Motor A
Confirm smooth rotation of the blower motor.
● Ensure that there are no foreign particles inside the intake unit.
B
D
RJIA0609E
Fan Switch E
Check continuity between terminals at each switch position.
Switch position Connector Terminals Continuity
F
OFF 13 - 14, 15, 16, 17 No
1 13 - 14
2 M54 13 - 15 G
Yes
3 13 - 16
4 13 - 17
H
RJIA0610E
Blower Fan Resistor

Check resistance between terminals. I
Resistance (Ω)
Terminals
LHD models RHD models MTC
M66 - 2 0.25 - 0.31 0.28 - 0.34
M66 - 1 M66 - 3 0.58 - 0.70 0.79 - 0.97
K
M66 - 4 1.33 - 1.63 1.84 - 2.24
L
RJIA0611E
Magnet Clutch Circuit EJS001O9
SYMPTOM: Magnet clutch does not operate when A/C switch and fan switch are ON. M
MTC-51
TROUBLE DIAGNOSIS
INSPECTION FLOW
RJIA0721E
*1 MTC-106, "Checking for Refrigerant *2 MTC-51, "Magnet Clutch Circuit" *3 MTC-39, "Operational Check"
Leaks"
*4 MTC-29, "SYMPTOM TABLE" *5 QR engine; EM-12, "Checking Drive
Belts"
YD engine; EM-121, "Checking Drive
Belts"
MTC-52
TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE (FOR GASOLINE ENGINE)

SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON. A
1. CHECK POWER SUPPLY FOR COMPRESSOR
Disconnect compressor harness connector. B
(+)
Compressor connector (-) Voltage C
Connector Terminal
E34 1 (L/R) Body ground Approx. 12
D
OK or NG
OK >> Go to 2.
NG >> Disconnect A/C relay. Go to 3.
RJIA0295E
E
2. CHECK MAGNET CLUTCH COIL

F
Check for operation sound when applying battery voltage direct cur-
rent tot terminal.
OK or NG
G
NG >> Replace magnet clutch. Refer to MTC-95, "Removal and
Installation for Compressor Clutch" .
H
I
SJIA0197E
3. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR

MTC
A/C relay connector Compressor connector

Continuity K
Connector Terminal Connector Terminal
E5 5 (L/R) E34 1 (L/R) Yes
OK or NG L
OK >> Go to 4.
M
RJIA0536E
4. CHECK POWER SUPPLY FOR A/C RELAY
(+)
A/C relay connector (-) Voltage
Connector Terminals
1 (BR/Y)
E5 Body ground Approx. 12
3 (BR/Y)
OK or NG
OK >> Go to 5.
RJIA0537E
NG >> Check power supply circuit and 10A (No.15) fuse at fuse
block. Refer to PG-3, "Wiring Diagram — POWER —" .
MTC-53
TROUBLE DIAGNOSIS
5. CHECK A/C RELAY AFTER DISCONNECTING IT

Refer to MTC-61, "A/C Relay" .
OK or NG
OK >> Reconnect A/C relay. Go to 6.
NG >> Replace A/C relay.
6. CHECK COIL SIDE CIRCUIT OF A/C RELAY
(+)
ECM connector (-) Voltage
Connector Terminal
F43 26 (L) Body ground Approx. 12
OK or NG
OK >> Go to 8.
NG >> Disconnect A/C relay. Disconnect ECM harness connec-
tor. Go to 7. SJIA0287E
7. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND ECM
A/C relay connector ECM connector

Continuity
E5 2 (L) F43 26 (L) Yes
OK or NG
OK >> Check ECM. Refer to EC-64, "ECM Terminals and Ref-
erence Value" for QR25 engine,EC-439, "ECM Termi-
nals and Reference Value" for QR20 engine.
NG >> Repair harness or connector. SJIA0286E
8. CHECK COMPRESSOR ON SIGNAL

Reconnect ECM harness connector.
Terminals
Connector Condition Voltage
(+) (-)
A/C: ON Approx. 0V
M55 7 (L/R) Body ground
A/C: OFF Approx. 4.6V
OK or NG
OK >> Go to 9.
NG >> Go to 15.
RJIA0724E
MTC-54
TROUBLE DIAGNOSIS
9. CHECK COMPRESSOR FEED BACK SIGNAL A
Terminals
Connector Condition Voltage B
(+) (-)
M55 12 (PU/W) Body ground A/C: ON Approx. 0V
OK or NG C
OK >> Go to 10.
NG >> Go to 16.
D
RJIA0725E
10. CHECK REFRIGERANT PRESSURE SENSOR E
Refer to MTC-62, "Refrigerant Pressure Sensor (With Gasoline Engine)" .

OK or NG
F
OK >> Go to 11.
NG >> Replace refrigerant pressure sensor.
11. CHECK A/C SWITCH G

H
Heater control panel connector
Condition Continuity
Connector Terminals
M55 7 8 A/C SW: ON Yes I
OK or NG
OK >> Go to 12.
NG >> Replace heater control panel. MTC
RJIA0726E
K
12. CHECK HEATER CONTROL PANEL CIRCUIT
L
Heater control panel
Continuity
M55 8 (LG/B) M54 18 (LG/B) Yes M
OK or NG
OK >> Go to 13.
RJIA0727E
MTC-55
TROUBLE DIAGNOSIS
13. CHECK FAN SWITCH

Connector Terminals
FAN: ON Yes
M54 18 13
FAN: OFF No
OK or NG
OK >> Go to 14.
RJIA0728E
14. CHECK BODY GROUND CIRCUIT

Body ground Continuity
Connector Terminal
M54 13 (B) - Yes
OK or NG
RJIA0729E
15. CHECK CIRCUIT CONTINUITY BETWEEN ECM AND HEATER CONTROL PANEL
Disconnect ECM and heater control panel connector.
ECM connector Heater control panel connector
Continuity
F43 44 (L/R) M55 7 (L/R) Yes
OK or NG
OK >> Check ECM.
RJIA0730E
16. CHECK CIRCUIT CONTINUITY BETWEEN ECM AND HEATER CONTROL PANEL
Disconnect ECM and heater control panel connector.
Heater control panel connec-
ECM connector
tor Continuity
F43 30 (PU/W) M55 12 (PU/W) Yes
OK or NG
OK >> Check ECM.
RJIA0731E
MTC-56
TROUBLE DIAGNOSIS
DIAGNOSTIC PROCEDURE (FOR DIESEL ENGINE)

SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON. A
1. CHECK POWER SUPPLY FOR COMPRESSOR
Disconnect compressor harness connector. B
(+)
Compressor connector (-) Voltage C
Connector Terminal
E34 1 (L/R) Body ground Approx. 12
D
OK or NG
OK >> Go to 2.
NG >> Disconnect A/C relay. Go to 3.
RJIA0295E
E
2. CHECK MAGNET CLUTCH COIL

F
Check for operation sound when applying battery voltage direct cur-
rent to terminal.
OK or NG
G
NG >> Refer to MTC-95, "Removal and Installation for Com-
pressor Clutch" .
H
I
SJIA0197E
3. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR

MTC
A/C relay connector Compressor connector

Continuity K
E5 5 (L/R) E34 1 (L/R) Yes
OK or NG L
OK >> Go to 4.
M
RJIA0536E
4. CHECK POWER SUPPLY FOR A/C RELAY
(+)
A/C relay connector (-) Voltage
Connector Terminal
1 (BR/Y)
E5 Body ground Approx. 12
3 (BR/Y)
OK or NG
OK >> Go to 5.
RJIA0537E
block (J/B). Refer to PG-3, "Wiring Diagram — POWER —" .
MTC-57
TROUBLE DIAGNOSIS
5. CHECK A/C RELAY AFTER DISCONNECTING IT

Refer to MTC-61, "A/C Relay" .
OK or NG
OK >> Reconnect A/C relay. Go to 6.
NG >> Replace A/C relay.
6. CHECK COIL SIDE CIRCUIT A/C RELAY
(+)
ECM connector (-) Voltage
Connector Terminal
F34 D11 (L) Body ground Approx. 12
OK or NG
OK >> Go to 8.
NG >> Disconnect A/C relay. Disconnect ECM harness connec-
tor. Go to 7. RJIA0538E
7. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND ECM
ECM connector A/C relay connector

Continuity
F34 D11 (L) E5 2 (L) Yes
OK or NG
OK >> Check ECM. Refer to EC-691, "ECM Terminals And
Reference Value"
RJIA0723E
8. CHECK POWER SUPPLY FOR THERMO CONTROL AMP.
(+)
Thermo control amp. connector (-) Voltage
Connector Terminal
M83 1 (BR/Y) Body ground Approx. 12V
OK or NG
OK >> Go to 9.
block. Refer to PG-3, "Wiring Diagram — POWER —" . RJIA0746E
MTC-58
TROUBLE DIAGNOSIS
9. CHECK POWER SUPPLY FOR THERMO CONTROL AMP. A
(+)
B
Thermo control amp. connector (-) Voltage
Connector Terminal
M83 3 (R) Body ground Approx. 12V C
OK or NG
OK >> Go to 10.
NG >> Go to 16. D
RJIA0732E
10. CHECK BODY GROUND CIRCUIT E
1. Disconnect thermo control amp. connector.

2. Set the fan switch and A/C switch to ON position.
F
Thermo control amp. connector
Body ground Continuity
Connector Terminals
G
M83 2 (L/R) - Yes
OK or NG
OK >> Replace thermo control amp. H
NG >> Go to 11.
RJIA0733E
I
11. CHECK CIRCUIT CONTINUITY BETWEEN THERMO CONTROL AMP. AND HEATER CONTROL
PANEL
MTC
Thermo control amp. Heater control panel
Continuity K
M83 2 (L/R) M55 7 (L/R) Yes
OK or NG L
OK >> Go to 12.
M
RJIA0734E
12. CHECK A/C SWITCH

Connector Terminals
M55 7 8 A/C SW: ON Yes
OK or NG
OK >> Go to 13.
NG >> Replace heater control panel.
RJIA0726E
MTC-59
TROUBLE DIAGNOSIS
13. CHECK HEATER CONTROL PANEL CIRCUIT

Continuity
M55 8 (LG/B) M54 18 (LG/B) Yes
OK or NG
OK >> Go to 14.
RJIA0727E
14. CHECK FAN SWITCH

Connector Terminals
FAN: ON Yes
M54 18 13
FAN: OFF No
OK or NG
OK >> Go to 15.
RJIA0728E
15. CHECK BODY GROUND CIRCUIT
Terminals
Continuity
Heater control panel Body ground
M54 - 13 (B) - Yes
OK or NG
RJIA0729E
16. CHECK CIRCUIT CONTINUITY BETWEEN THERMO CONTROL AMP. AND DUAL-PRESSURE
SWITCH
Disconnect dual-pressure switch connector.
Thermo control amp. Dual-pressure switch
Continuity
M83 3 (R) E40 1 (R) Yes
OK or NG
OK >> Go to 17.
RJIA0735E
MTC-60
TROUBLE DIAGNOSIS
17. CHECK DUAL-PRESSURE SWITCH A

Refer to MTC-62, "Dual-pressure Switch" .
OK or NG
OK >> Go to 18. B
NG >> Replace dual-pressure switch.
18. CHECK CIRCUIT CONTINUITY BETWEEN DUAL-PRESSURE SWITCH AND ECM C

Disconnect ECM connector.
Dual-pressure switch ECM D
Continuity
E40 2 (PU/W) F34 D23 (PU/W) Yes
E
OK or NG
OK >> Replace ECM.
F
SJIA0191E
ELECTRICAL COMPONENT INSPECTION G

A/C Relay
Check circuit continuity between terminal Nos. 3 and 5.
H
Conditions Continuity
12V direct current supply between terminal Nos. 1
Yes
and 2.
I
No current supply. No
If NG, replace A/C relay.

MTC
RHA638H
MTC-61
TROUBLE DIAGNOSIS
Refrigerant Pressure Sensor (With Gasoline Engine)

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-357, "REFRIGERANT PRESSURE SENSOR" for
QR25 engine,EC-640, "REFRIGERANT PRESSURE SENSOR" for
QR20 engine.
RJIA0690E
SHA315F
Dual-pressure Switch
ON OFF
kPa (bar, kg/cm2 , psi) kPa (bar, kg/cm2 , psi)
Decreasing to 157 - 196
Increasing to 157 - 216 (1.57
Low-pressure side (1.57 - 1.96, 1.6 - 2.0, 23 -
- 2.16, 1.6 - 2.2, 23 - 31)
28)
Decreasing to 1,863 - 2,256 Increasing to 2,452 - 2,844
High-pressure side (18.6 - 22.6, 19 - 23, 270 - (24.5 - 28.4, 25 - 29, 356 -
327) 412)
RJIA0691E
MTC-62
TROUBLE DIAGNOSIS
Insufficient Cooling EJS001OA
A
SYMPTOM: Insufficient cooling
INSPECTION FLOW
B
MTC
SJIA0283E
*1 MTC-44, "Air Mix Door" *2 MTC-68, "TROUBLE DIAGNOSES *3 MTC-66, "PERFORMANCE CHART"
FOR UNUSUAL PRESSURE"
*4 MTC-39, "Operational Check" *5 MTC-29, "SYMPTOM TABLE" *6 QR engine; EM-12, "Checking Drive
Belts"
Belts"
*7 QR25 engine; EC-247, "System
Description"
QR20 engine;EC-554, "System
Description"
YD engine; EC-768, "SYSTEM
DESCRIPTION"
MTC-63
TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSES
RJIA1601E
*1 MTC-66, "PERFORMANCE CHART" *2 MTC-66, "PERFORMANCE CHART" *3 MTC-68, "TROUBLE DIAGNOSES

FOR UNUSUAL PRESSURE"
*4 MTC-44, "Air Mix Door"
MTC-64
TROUBLE DIAGNOSIS
MTC
RJIA1595E
*1 MTC-95, "Removal and Installation *2 MTC-48, "Blower Motor Circuit" *3 QR engine; EM-12, "Checking Drive
for Compressor Clutch" Belts"
Belts"
MTC-65
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 switch (Ventilation) set
Intake switch (Recirculation) set
(blower) speed Max. speed set

Engine speed Idle speed
Operate the air conditioning system for 10 minutes before taking measurements.
Test Reading (Gasoline 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 (kg/cm , psi) kPa (kg/cm2 , psi)
% °C (°F)
980 - 1,180
30 (86) 230 - 270 (2.35 - 2.75, 33 - 39)
(9.99 - 12.04, 142 - 171)
1,180 - 1,390
50 - 70 35 (95) 260 - 310 (2.65 - 3.16, 38 - 45)
(12.04 - 14.18, 171 - 202)
1,400 - 1,580
40 (104) 300 - 350 (3.06 - 3.57, 44 - 51)
(14.28 - 16.12, 203 - 229)
Test Reading (Diesel Engine)

Recirculating-to-discharge Air Temperature Table
Discharge air temperature at center ventilator
% °C (°F)
20 (68) 6.5 - 9.0 (44 - 48)
25(77) 12 - 14(54 - 57)
50 - 60
30 (86) 15.5 - 18.8 (60 - 66)
35 (95) 20.4 - 24.0 (69 - 75)
MTC-66
TROUBLE DIAGNOSIS

Discharge air temperature at center ventilator A
% °C (°F)
20 (68) 9.0 - 11.0 (48 - 52)
B
25(77) 14.0 - 16.5 (57 - 62)
60 - 70
30 (86) 18.8 - 21.5 (66 - 71)
35 (95) 24 - 27 (75 - 81) C
Ambient Air Temperature-to-operating Pressure Table
Ambient air
High-pressure (Discharge side) Low-pressure (Suction side) D
Relative humidity Air temperature kPa (kg/cm2 , psi) kPa (kg/cm2 , psi)
% °C (°F)
20 (68) 765 - 922 (7.8 - 9.4, 111 - 134) 177 - 226 (1.8 - 2.3, 26 - 33) E
25 (77) 922 - 1,020 (9.4 - 10.4, 134 - 148) 196 - 245 (2.0 - 2.5, 28 - 36)
50 - 70 30 (86) 1,177 - 1,451 (12.0 - 14.8, 171 - 210) 235 - 284 (2.4 - 2.9, 34 - 41)
35 (95) 1,373 - 1,667 (14 - 17, 199 - 242) 275 - 333 (2.8 - 3.4, 40 - 48) F
40 (104) 1,618 - 1,961 (16.5 - 20.0, 235 - 284) 333 - 392 (3.4 - 4.0, 48 - 57)
MTC
MTC-67
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 (2 kg/cm2 , 28 psi). It ↓
then decreases gradually Air in refrigeration cycle
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 thermal 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
MTC-68
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. MTC
Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
tank are warm or only cool ↓ Refer to MTC-106, "Checking
when touched. Leaking fittings or components for Refrigerant Leaks" .
Expansion valve closes a little
K
compared with the specifica-
tion.
AC353A
↓ ● Remove foreign particles by L
There is a big temperature dif-
ference between expansion 1. Improper expansion valve using compressed air.
valve inlet and outlet while the adjustment ● Check lubricant for contami-
valve itself is frosted. 2. Malfunctioning thermal nation. 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 thermo amp. Refer
Air flow volume is not enough toMTC-51, "Magnet Clutch
Evaporator is frozen. Circuit"
or is too low.
● Replace compressor.
MTC-69
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 problem 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 prob-
lem, replace expansion
valve.
● Replace liquid tank.
● Check lubricant for contami-
nation.
MTC-70
TROUBLE DIAGNOSIS
Insufficient Heating EJS001MX
A
SYMPTOM: Insufficient heating
INSPECTION FLOW
B
MTC
RJIA0738E
MTC-71
TROUBLE DIAGNOSIS
*1 QR engine; CO-9, "Changing Engine *2 QR engine; CO-12, "Checking Radi- *3 QR25 engine;EC-121, "ENGINE
Coolant" ator Cap" COOLANT TEMPERATURE SEN-
YD engine; CO-28, "Changing YD engine; CO-32, "Checking Radi- SOR" ,CO-20, "THERMOSTAT AND
Engine Coolant" ator Cap" WATER CONTROL VALVE"
QR20 engine; CO-20, "THERMO-
STAT AND WATER CONTROL
VALVE" ,EC-482, "ENGINE COOL-
ANT TEMPERATURE SENSOR"
YD engine;:CO-40, "THERMOSTAT
AND WATER PIPING" ,EC-721,
"ENGINE COOLANT TEMPERA-
TURE SENSOR"
*4 QR engine;CO-9, "Changing Engine *5 MTC-39, "Operational Check" *6 MTC-29, "SYMPTOM TABLE"
Coolant"
YD engine; CO-28, "Changing
Engine Coolant"
MTC-72
TROUBLE DIAGNOSIS
Noise EJS001OB
TROUBLE DIAGNOSIS PROCEDURE FOR NOISE A

SYMPTOM: Noise
INSPECTION FLOW B
MTC
RJIA1596E
MTC-73
TROUBLE DIAGNOSIS
*1 MTC-95, "Removal and Installation *2 MTC-92, "Removal and Installation *3 MTC-23, "LUBRICANT"
for Compressor Clutch" for Compressor"
*4 QR engine; EM-12, "Checking Drive *5 QR engine; CO-9, "Changing Engine

Belts" Coolant"
YD engine; EM-121, "Checking Drive YD engine; CO-28, "Changing
Belts" Engine Coolant"
MTC-74
CONTROLLER
CONTROLLER PFP:27500
A
Removal and Installation EJS001MY
1. Remove the mode control cable and air mix control cable from
heater unit. B
2. Remove the cluster lid finisher.
3. Remove the fixing screw from heater control panel.
4. Remove the heater control panel, then remove the heater con- C
trol panel connector.
RJIA0089E
E
Disassembly and Assembly EJS001MZ
MTC
RJIA0090E K
MTC-75
BLOWER UNIT
BLOWER UNIT PFP:27200
Removal and Installation EJS001N0
REMOVAL
1. Remove the glove box assembly.
2. Remove the glove box cover, the instrument lower assist panel
and instrument reinforcement.
3. Remove the ECM with ECM bracket.
4. Remove the instrument panel fixing screw.
5. Remove the blower unit fixing bolt and screw.
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.
MTC-76
BLOWER UNIT
Disassembly and Assembly EJS001N1
A
NOTE:
RJIA0053J
MTC
1. Fan control amplifier 2. Screw 3. Cooling hose
4. Blower fan motor assembly 5. Washer 6. Blower fan
7. Nut 8. Screw 9. Bell mouth
K
10. Intake door lever 2 11. Intake door lever 1 12. Intake door link
13. Intake door motor 14. Screw 15. Upper case 2
16. Intake door 2 17. Intake door 1 18. Upper case 1
L
19. Screw 20. Ventilation air filter 21. Filter cover
CAUTION:
If retaining tabs are damaged while disassembling blower unit, M
use 9 screws (27111-2Y000) to assemble blower unit.
RJIA0097E
MTC-77
BLOWER MOTOR
BLOWER MOTOR PFP:27226
1. Remove the blower unit. Refer to MTC-76, "Removal and Instal-

lation" .
2. Separate the blower unit.
RJIA0054E
3. Remove the cooling hose, blower fan resistor and blower fan.
RJIA0092E
MTC-78
BLOWER FAN RESISTOR
BLOWER FAN RESISTOR PFP:27150

A
1. Remove the glove box cover.

2. Remove the blower fan resistor. B
CAUTION:
Do not repair the thermal fuse of the fan resistor.
C
RJIA0093E
MTC
MTC-79
INTAKE DOOR MOTOR
INTAKE DOOR MOTOR PFP:27730

2. Remove the intake door motor from blower unit.
RJIA0056E
RJIA0571E
MTC-80
VENTILATION AIR FILTER
VENTILATION AIR FILTER PFP:27277

A
FUNCTION
Air inside passenger compartment is kept clean at either recircula- B
tion or fresh mode by installing ventilation air filter into blower unit.
RHA680H
E
REPLACEMENT TIMING
Replace ventilation air filter.
Refer to MA-30, "CHASSIS AND BODY MAINTENANCE" in SCHEDULE 1 and 2. F
Caution label is fixed inside the glove box.

REPLACEMENT AND PROCEDURES G
1. Remove the glove box.
2. Remove the ventilation air filter cover.
H
3. Take out the ventilation air filter from blower unit.
4. Replace with new one and reinstall on blower unit.
5. Reinstall the glove box.
I
MTC
RJIA0058E
CLEANING K
1. Soak the filter in a solution of a mild strength detergent cleaner
& water.
2. Move the filter lightly through the solution to clean. L
3. Rinse with tap water.
4. Drain the filter water into a can etc., and dry.
CAUTION: M
● The filter could become moldy or smell if it is left in a moist
state.
● Once cleaned, the filter can only be used 1-2 more times.
● Replace the filter if, after cleaning, should the filter not RJIA0747E
function correctly.
MTC-81
HEATER & COOLING UNIT ASSEMBLY
HEATER & COOLING UNIT ASSEMBLY PFP:27110
REMOVAL
1. Discharge refrigerant from A/C system.
2. Drain coolant from cooling system. Refer to CO-9, "Changing
Engine Coolant" for QR engine, CO-28, "Changing Engine
Coolant" for YD engine.
3. Disconnect two heater hoses from heater core pipe.
4. Remove the instrument panel.
6. Remove clips of vehicle harness from steering member.
RJIA0060E
7. Remove the instrument stay.
RJIA0061E
RJIA0062E
8. Remove the bolts from heater & cooling unit.

9. Remove the steering member.
10. Remove the heater & cooling unit.
RJIA0063E
MTC-82
HEATER & COOLING UNIT ASSEMBLY
INSTALLATION
Installation is basically the reverse order of removal. A
NOTE:
When filling radiator with coolant, refer to CO-9, "Changing Engine Coolant" for QR engine, CO-28, "Chang-
ing Engine Coolant" for YD engine. B
Disassembly and Assembly EJS001N7
NOTE: C
MTC
RJIA0064J
M
1. Cooler grommet 2. Screw 3. Heater pipe support
4. Screw 5. Expansion valve cover 6. Bolt
7. Expansion valve 8. Insulator 9. Evaporator
10. Slide door unit (Air mix door) 11. Evaporator cover 12. Screw
13. Screw 14. Air mix door motor 15. mode door motor
16. Screw 17. Ventilator door link 1 18. Ventilator door link 2
19. Ventilator door lever 20. Rod 21. Rod holder
22. Main link 23. Max cool door lever 24. Defroster door lever
25. Screw 26. Foot duct (right side) 27. Heater core
28. Heater core cover 29. Foot duct (left side) 30. Intake sensor bracket
31. Intake sensor 32. Screw 33. Aspirator
34. Screw 35. Heater & cooling unit case (right side) 36. Defroster door
37. Ventilator door 38. Max cool door 39. Heater & cooling unit case (left side)
MTC-83
HEATER CORE
HEATER CORE PFP:27140
1. Remove the heater & cooling unit. Refer to MTC-82, "HEATER

& COOLING UNIT ASSEMBLY" .
2. Remove the heater pipe support.
3. Remove the foot duct and heater core cover.
4. Remove the heater core from the heater unit.
RJIA0069E
MTC-84
MODE DOOR
MODE DOOR PFP:27181

A
Control Linkage Adjustment EJS001N9
MODE DOOR CONTROL CABLE

1. Turn the mode control dial to VENT position.
B
2. Move side link by hand and hold mode door in VENT position.
3. Pull on the cable cover in the direction of the arrow, then clamp
it.
C
NOTE:
After positioning control cable, check that it operates properly.
D
RJIA0095E
E
H
RJIA0614E
MTC
MTC-85
AIR MIX DOOR
AIR MIX DOOR PFP:27180
Control Linkage Adjustment EJS001NA
AIR MIX DOOR CONTROL CABLE

1. Turn the temperature control dial to full cold position.
2. Move air mix door lever by hand and hold it at the full cold posi-
tion.
3. Pull on the cable cover in the direction of the arrow, then clamp
it.
NOTE:
After positioning control cable, check that it operates properly.
RJIA0085E
RJIA0615E
MTC-86
DUCTS AND GRILLES
DUCTS AND GRILLES PFP:27860

A
Removal and Installation EJS001NB
VENTILATOR DUCT, DEFROXTER NOZZLE AND DEFROSTER DUCTS

1. Remove the instrument panel.
B
MTC
RJIA0067E
NOTE:
K
CENTER VENTILATOR GRILLE
1. Remove the cluster lid C. Refer to IP-11, "Removal and Installation" .
L
SIDE VENTILATOR GRILLE
1. Remove the instrument panel. Refer to IP-11, "Removal and
Installation" .
2. Remove the side ventilator grille. M
RJIA0068E
MTC-87
DUCTS AND GRILLES
FOOT DUCT
1. Remove the heater and cooling unit. Refer to MTC-82,
"Removal and Installation" .
2. Remove the foot duct.
RJIA0069E
FLOOR DUCT
1. Remove the front seats.
2. Remove the instrument lower center panel. Refer to IP-11,
"Removal and Installation" .
3. Remove the front floor duct.
4. Peel back the floor trim to a point where the floor duct is visible.
5. Remove the mounting screw and clip from the rear floor duct.
6. Remove the rear floor duct.
RJIA0070E
RJIA0071E
MTC-88
REFRIGERANT LINES
REFRIGERANT LINES PFP:92600

A
HFC-134a (R-134a) Service Procedure EJS001NH
SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant B
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 C
and safety information may be obtained from refrigerant and lubricant manufacturers.
I
SHA539DE
Evacuating System and Charging Refrigerant

MTC
SHA540DC
MTC-89
REFRIGERANT LINES
SHA383F
*1 MTC-23, "LUBRICANT RETURN *2 MTC-106, "Checking for Refrigerant *3 MTC-108, "CHECKING PROCE-
OPERATION" Leaks" DURE"
*4 ATC-92, "PERFORMANCE TEST
DIAGNOSES"
MTC-90
REFRIGERANT LINES
Components EJS001NI
A
Refer to page MTC-5, "Precautions for Refrigerant Connection" .
WITH GASOLINE ENGINE
B
MTC
K
RJIA0696E
NOTE:
This illustration is for RHD models. The blower unit and heater & cooling unit layouts for LHD models are sym-
metrically opposite. L
MTC-91
REFRIGERANT LINES
WITH DIESEL ENGINE
RJIA0697E
NOTE:
This illustration is for LHD models. The blower unit and heater & cooling unit layouts for RHD models are sym-
Removal and Installation for Compressor EJS001NJ
REMOVAL
WITH GASOLINE ENGINE
RJIA0578E
MTC-92
REFRIGERANT LINES
WITH DIESEL ENGINE

A
RHA667H
G
1. Using recycling and recovery equipment (for HFC-134a), discharge the refrigerant.
2. Remove the engine under cover.
3. Remove the compressor-alternator belt. H
Refer to,EM-12, "Removal and Installation"EM-13, "Removal and Installation of Drive Belt Auto-Ten-
sioner" for QR engine,EM-122, "Removal and Installation" for YD engine.
4. Remove the mounting nuts (bolts) from the high-pressure flexi-
I
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. MTC
5. Disconnect the compressor connector.
RJIA0073E
L
RJIA0579E
MTC-93
REFRIGERANT LINES
6. Remove the mounting bolts from compressor.

7. Remove the compressor from the lower side of the vehicle
RJIA0021E
RJIA0580E
INSTALLATION
CAUTION:
● Replace the O-ring of the low-pressure flexible hose and
high-pressure flexible hose with a new one, then apply
compressor oil to it when installing it.
● When pouring refrigerant, check for leaks.
RJIA0023E
RJIA0581E
Bolts mounting the compressor (With gasoline engine)

Tightening torque : 28.4 - 33.3 N-m (2.9 - 3.4 kg-m, 21 - 24 ft- lb)
Bolts mounting the compressor (With diesel engine)
Tightening torque : 60 - 69 N-m (6.1 - 7.1 kg-m, 45 - 51 ft- lb)
Nut (bolt) mounting the high-pressure flexible hose
Tightening torque : 8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164 in-lb)
Nut (bolt) mounting the low-pressure flexible hose
Tightening torque : 8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164 in-lb)
MTC-94
REFRIGERANT LINES
Removal and Installation for Compressor Clutch EJS001NK
REMOVAL A
Overhaul (With Gasoline Engine: CWV-615M Compressor)
1. When removing center bolt, hold clutch disc with wrench.
B
RHA136EB
E
H
RHA399F
2. Remove the clutch disc using the clutch disc puller. I
MTC
RHA124F L
3. Remove the snap ring using external snap ring pliers.
M
RHA138E
MTC-95
REFRIGERANT LINES
4. Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail-
able pulley puller.
To prevent the pulley groove from being deformed, the puller
claws should be positioned into the edge of the pulley assembly.
RHA139E
5. Remove the field coil harness clip using a pair of pliers.
RHA125F
6. Remove the snap ring using external snap ring pliers.
RHA145E
Overhaul (With Diesel Engine: DKV-11G Compressor)

1. Remove the two screws holding the connector bracket, thermal
protector to the compressor.
RHA669H
MTC-96
REFRIGERANT LINES
2. When removing center bolt, hold clutch disc with clutch disc
wrench. A
SHA097EA
D
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. E
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. F
7. After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
G
ZHA093H
8. Remove the snap ring using external snap ring pliers. H
MTC
RHA072C
K
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) L
For pressed pulleys:
To prevent deformation of the pulley groove, the puller claws
should be hooked under (not into) the pulley groove. M
For machine lathed pulleys:
Align the pulley puller groove with the pulley groove, and then
remove the pulley assembly.
SHA099EA
10. Remove the field coil harness clip using a screwdriver.

11. Then remove the three field coil fixing screws and remove the
field coil.
RHA074C
MTC-97
REFRIGERANT LINES
Inspection
Clutch disc
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.
RJIA0582E
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
cleaned with a suitable solvent before reinstallation.
RJIA0583E
Coil
Check coil for loose connection or cracked insulation.
INSTALLATION
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
3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
RHA143EA
MTC-98
REFRIGERANT LINES
4. Install the clutch disc on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand. A
RHA127F
D
5. Using the holder to prevent clutch disc rotation.
Tightening torque : 14 N·m (1.4 kg·m, 10 ft-lb)
E
After tightening the bolt, check that the pulley rotates smoothly.
G
RHA086E
6. Check clearance around the entire periphery of clutch disc. H

Disc to pulley clear- : 0.3 - 0.6 mm (0.012 - 0.024 in)
ance
If the specified clearance is not obtained, replace adjusting I
spacer and readjust.
MTC
RHA087E
K
With Diesel Engine (DKV-11G Compressor)
1. Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's L
front head.
2. Install the field coil harness clip using a screwdriver.
M
RHA076C
MTC-99
REFRIGERANT LINES
3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
ZHA094H
4. Install the drive plate on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.
RHA078C
5. Using the holder to prevent clutch disc rotation.

Tightening torque : 12 - 15 N·m (1.2 - 1.5 kg·m,
9 - 10 ft-lb)
After tightening the bolt, check that the pulley rotates smoothly.
SHA101EA
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
MTC-100
REFRIGERANT LINES
Break-In Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag- A
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 EJS001NL
B
REMOVAL
1. Use the refrigerant collecting equipment (for HFC-134a) to dis-
charge the refrigerant from A/C system.
C
2. Remove the clips from the low-pressure flexible hose.
3. Remove the mounting bolts from the low-pressure flexible hose
bracket.
D
4. Remove the clip from the vacuum hose.
RJIA0074E
RJIA0584E I
5. Remove the mounting bolts from the low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as MTC
vinyl tape to avoid the entry of air.
6. Remove the low-pressure flexible hose.
K
L
RJIA0075E
INSTALLATION M
CAUTION:
● Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
Low-pressure flexible hose and bolts mounting the high-pressure pipe (evaporator side)
Tightening torque :3.4 - 5.9 N·m (0.35 - 0.60 kg·m, 30 - 52 in-lb)
Nut (Bolt) mounting the low-pressure flexible hose (compressor side)
Tightening torque :8 - 18 N·m (0.8 - 1.9 kg·m, 70 - 164 in-lb)
MTC-101
REFRIGERANT LINES
Removal and Installation for High-pressure Flexible Hose EJS001NM
REMOVAL
1. Using the recycling and recovery equipment (for HFC-134a),
discharge the refrigerant from A/C system.
2. Remove the mounting bolt and nut from the high-pressure flexi-
ble hose, then remove it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as
RJIA0076E
INSTALLATION
CAUTION:
● Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
Bolt and nut mounting the high-pressure flexible hose
Removal and Installation for High-pressure Pipe EJS001NN
REMOVAL
2. Remove the low-pressure flexible hose. Refer to MTC-101,
"Removal and Installation for Low-pressure Flexible Hose" .
3. Remove the high-pressure pipe from the clip.
RJIA0077E
4. Remove the mounting bolt from the high-pressure pipe.

5. Remove the high-pressure pipe.
CAUTION:
RJIA0078E
INSTALLATION
CAUTION:
● Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
Bolts mounting the high-pressure pipe (condenser side, evaporator side)
MTC-102
REFRIGERANT LINES
Removal and Installation for Refrigerant Pressure Sensor EJS001NO
A
1. Use refrigerant collecting equipment (for HFC-134a) to dis-
charge refrigerant.
2. Remove the condenser, and then remove the liquid tank. Refer
to MTC-103, "Removal and Installation for Condenser" . B
3. Using a vise, secure liquid tank, and remove refrigerant pres-
sure sensor.
CAUTION: C
● When working, be careful not to damage the compressor
fan.
● Apply compressor oil to the O-ring of the refrigerant pres- D
RJIA0698E
sure sensor when installing it.
Tightening torque :9.8 - 11.0 N·m (1.0 - 1.2kg·m, 7.3 -
E
8.6 ft-lb)
Removal and Installation for Dual-pressure Switch EJS001NP
1. Use the refrigerant collecting equipment (for HFC-134a) to dis- F

charge refrigerant.
2. Remove the condenser, and then remove the liquid tank. Refer
to MTC-103, "Removal and Installation for Condenser" . G
3. Using a vise, secure liquid tank, and remove pressure switch.
CAUTION:
● When working, be careful not to damage the compressor H
fan.
● Apply compressor oil to the O-ring of the refrigerant pres-
sure sensor when installing it. RJIA0699E
I
Tightening torque :9.8 - 11.0 N·m (1.0 - 1.2kg·m, 7.3 -
8.6 ft-lb)
MTC
Removal and Installation for Condenser EJS001NQ
REMOVAL
1. Use the refrigerant collecting equipment (for HFC-134a) to dis- K
2. Disconnect the high-pressure flexible hose and the high-pres-
sure pipe from the condenser. L
CAUTION:
M
3. Remove the battery and battery tray.
RJIA0080E
4. Disconnect the refrigerant pressure sensor connector (For QR

engine) or dual-pressure switch connector (For YD engine).
RJIA0690E
MTC-103
REFRIGERANT LINES
RJIA0691E
5. Remove the front grille and radiator mounting bracket.

6. Remove the mounting nuts from the condenser.
7. 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.
CAUTION:
Be careful not to damage the core surface of the condenser
and the radiator.
RJIA0081E
INSTALLATION
CAUTION:
● 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.
High-pressure flexible hose mounting bolts
High-pressure pipe mounting bolts
Condenser mounting bolts
Tightening torque :3.82 - 4.51 N·m (0.39 - 0.46 kg·m 34 - 39 in-lb)
Removal and Installation for Evaporator EJS001NR
REMOVAL
2. Disconnect the low-pressure flexible hose and the 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.
3. Remove the cooler grommet cover and cooler grommet.
RJIA0082E
MTC-104
REFRIGERANT LINES
4. Remove the expansion valve cover and expansion valve.

A
RJIA0083E
D
5. Remove the blower unit. Refer to MTC-76, "Removal and Instal-
lation" .
6. Remove the evaporator cover. E
7. Slide the evaporator, then remove it from the heater & cooling
unit.
F
G
RJIA0084E
8. Remove the intake sensor from the evaporator, then remove the H
evaporator.
MTC
RJIA0051E
K
INSTALLATION
CAUTION:
● Replace the O-rings of the low-pressure flexible hose and the high-pressure pipe with new ones, L
then apply compressor oil to them when installing them.
● Mark the mounting position of the intake sensor bracket.
M
Removal and Installation for Expansion Valve EJS001NS

2. 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.
3. Remove the expansion valve cover.
4. Remove the expansion valve. RJIA0083E
Expansion valve mounting bolts

MTC-105
REFRIGERANT LINES
Removal and Installation for liquid tank EJS001O5
REMOVAL
1. Remove the condenser. Refer to MTC-103, "Removal and
Installation for Condenser" .
2. Remove the liquid tank.
CAUTION:
● Cap or wrap the joint of the liquid tank and the condenser
pipe with a suitable tool such as a vinyl tape to avoid the
entry of air.
RJIA0743E
INSTALLATION
CAUTION:
● Replace the O-rings of the condenser pipe with new ones, then apply compressor oil to them
when installing them.
Condenser pipe mounting bolt
Checking for Refrigerant Leaks EJS001NU
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.
Checking System for Leaks Using the Fluorescent Leak Detector EJS001NV
1. Check A/C system for leaks using the UV lamp and safety glasses (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.
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-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
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
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.
MTC-106
REFRIGERANT LINES
Dye Injection EJS001NW
A
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (50 psi).
B
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. C
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).
D
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 E
connection 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
penetrate a leak and become visible. F
Electronic Refrigerant Leak Detector EJS001NX
PRECAUTIONS FOR HANDLING LEAK DETECTOR G

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.
H
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.
I
MTC
SHA705EB
1. Position probe approximately 5 mm (3/16 in) away from point to K

be checked.
SHA707EA
2. When testing, circle each fitting completely with probe.
SHA706E
MTC-107
REFRIGERANT LINES
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 (3.52 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
(3.54 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 MTC-91, "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 or dual-pressure switch.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)

With engine OFF, turn blower fan on "High" for at least 15 seconds to dissipate any refrigerant trace in the
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.
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.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Face mode
c. Intake position: Recirculation
d. Max cold temperature
e. Fan speed: High
MTC-108
REFRIGERANT LINES
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. A
Refrigerant leaks should be checked immediately after stopping

the engine. Begin with the leak detector at the compressor. The B
pressure on the high pressure side will gradually drop after
refrigerant circulation stops and pressure on the low pressure
side will gradually rise, as shown in the graph. Some leaks are C
more easily detected when pressure is high.
SHA839E
E
11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity.
12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com- F
ponent as necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Conduct A/C performance test to ensure system works properly. G
MTC
MTC-109
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
COMPRESSOR EJS001QT

Model ZEXEL VALEO CLIMATE CONTROL make
Calsonic Kansei make V-6
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 EJS001QU

Model ZEXEL VALEO CLIMATE CON-
Calsonic Kansei make V-6
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 EJS001QV
Type HFC-134a (R-134a)

Capacity
0.50 (1.10)
kg (lb)
ENGINE IDLING SPEED EJS001QW
Refer to EC-30, "Idle Speed and Ignition Timing Check" for QR25 engine, EC-408, "Idle Speed and Ignition
Timing Check" for QR20 engineEC-678, "Basic Inspection" ,see No.3 for YD engine.
BELT TENSION EJS001QX
Refer to EM-12, "DRIVE BELTS" for QR engine,EM-121, "DRIVE BELTS" for YD engine.
MTC-110

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MANUAL 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 EJS001M7

MANIFOLD GAUGE SET L

REFRIGERANT WEIGHT SCALE

CALIBRATING ACR4 WEIGHT SCALE

IDENTIFICATION LABEL FOR VEHICLE

Wiring Diagrams and Trouble Diagnosis EJS001MA

When you read wiring diagrams, refer to the following:

WITH GASOLINE ENGINE (CWV-615M COMPRESSOR)

WITH DIESEL ENGINE (DKV-11G COMPRESSOR) L

HFC-134a (R-134a) Service Tools and Equipment EJS001MC

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)

● High side hose ● High hose: Red with black stripe

● Low 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

mately 177 kPa (1.8 kg/cm2 , 26 psi).

Component Layout EJS001MG

4. CHECK ANY PART

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

AIR CONDITIONER CONTROL PFP:27500

Control Operation EJS001ML

FAN CONTROL DIAL

System Description EJS001MN

SWITCHES AND THEIR CONTROL FUNCTION

TROUBLE DIAGNOSIS PFP:00004

Component Parts and Harness Connector Location EJS001MP

Circuit Diagram - A/C, M - EJS001OC

Wiring Diagram - A/C, M - EJS001O6

WITH GASOLINE ENGINE A

WITH DIESEL ENGINE

Operational Check EJS001MS

CHECKING DISCHARGE AIR MTC

CHECKING TEMPERATURE DECREASE

CHECKING A/C SWITCH

Mode Door EJS001O7

Air Mix Door EJS001O8

SYMPTOM: Air mix door does not change.

Intake Door Motor Circuit EJS001MV

COMPONENT DESCRIPTION MTC

1. CHECK POWER SUPPLY FOR HEATER CONTROL PANEL

located in the fuse block (J/B)]. Refer toPG-3, "BAT-

2. CHECK BODY GROUND CIRCUIT FOR HEATER CONTROL PANEL

3. CHECK RECIRCULATION SWITCH CIRCUIT

4. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR A

Blower Motor Circuit EJS001MW

SYMPTOM: Blower motor operation is malfunctioning.

1. CHECK POWER SUPPLY FOR BLOWER MOTOR A

24, located in the fuse block (J/B)]. Refer toPG-3, "BAT-

1 MTC-66, "PERFORMANCE CHART" 2 MTC-66, "PERFORMANCE CHART" *3 MTC-68, "TROUBLE DIAGNOSES

4 QR engine; EM-12, "Checking Drive 5 QR engine; CO-9, "Changing Engine