HEATER & AIR CONDITIONERSECTION HACONTENTSPRECAUTIONS AND PREPARATION............................2Supplemental Restraint System (SRS)AIR BAG ...................................................................2Precautions for Working with R-134a..........................2Contaminated Refrigerant .......................................3General Refrigerant Precautions.................................3Precautions for Refrigerant Connection ......................4Precautions for Servicing Compressor........................7R-134a Service Tools and Equipment .........................8Special Service Tools ................................................10Commercial Service Tools.........................................10Precautions for Service Equipment ........................... 11DESCRIPTION...............................................................13Refrigeration Cycle ....................................................13Control Operation ......................................................14Component Layout ....................................................15Discharge Air Flow.....................................................16Component Location..................................................17Circuit Diagram..........................................................19Wiring Diagram HEATER ......................................20Wiring Diagram A/C...............................................21Operational Check.....................................................23TROUBLE DIAGNOSES ...............................................25How to Perform Trouble Diagnoses for Quickand Accurate Repair ..................................................25Blower Motor Circuit ..................................................26Air Outlet....................................................................30Intake Door ................................................................32Magnet Clutch Circuit ................................................33Trouble Diagnosis Procedure For InsufficientCooling.......................................................................39 ...39Performance Test Diagnoses ....................................41Performance Chart ....................................................43Trouble Diagnoses for Abnormal Pressure ...............44Trouble Diagnosis for Insufficient Heating.................47Trouble Diagnosis for Noise......................................49SERVICE PROCEDURES.............................................50Refrigerant Lines .......................................................50Checking Refrigerant Leaks ......................................51R-134a Service Procedure ........................................54Compressor Lubricant Quantity.................................56Compressor Mounting ...............................................58Belt Tension ...............................................................58Fast Idle Control Device (FICD) ................................58Condenser .................................................................58Compressor ...............................................................59Compressor Clutch....................................................59Thermal Protector ......................................................62Heater Unit (Heater Core) .........................................63Cooling Unit (A/C Evaporator)...................................64Blower Case and Motor.............................................65Fan Lever and Illumination Bulbs..............................66SERVICE DATA AND SPECIFICATIONS (SDS) ..........67General Specifications...............................................67Inspection and Adjustment ........................................67When you read wiring diagrams:GRead GI section, HOW TO READ WIRING DIAGRAMS.GSee EL section, POWER SUPPLY ROUTING for power distribution circuit.Whenyouperformtroublediagnoses, readGI section, HOWTOFOLLOWFLOWCHART IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSISFOR AN ELECTRICAL INCIDENT.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSupplemental Restraint System (SRS)AIR BAGTheSupplemental Restraint SystemAIRBAG, usedalongwithaseat belt, helpstoreducetheriskorseverity of injury to the driver and front passenger in a frontal collision. The Supplemental Restraint Systemconsists of air bag modules (located in the center of the steering wheel and in the instrument panel on thepassenger side), a diagnosis sensor unit, a crash zone sensor (4WD models), warning lamp, wiring harnessand spiral cable.The vehicle is equipped with a passenger air bag deactivation switch. Because no rear seat exists where arear-facing child restraint can be placed, the switch is designed to turn off the passenger air bag so that arear-facing child restraint can be used in the front passenger seat. The switch is located in the center of theinstrument panel, near the ashtray. When the switch is turned to the ON position, the passenger air bag isenabled and could inflate in a frontal collision. When the switch is turned to the OFF position, the passengerair bag is disabled and will not inflate in a frontal collision. A passenger air bag OFF indicator on the instru-ment panel lights up when the passenger air bag is switched OFF. The driver air bag always remains enabledand is not affected by the passenger air bag deactivation switch.Information necessary to service the system safely is included in the RS section of this Service Manual.WARNING:GTo avoid rendering the SRS inoperative, which could increase the risk of personal injury or death inthe event of a collision which would result in air bag inflation, all maintenance should be performedby an authorized NISSAN dealer.GImproper maintenance, including incorrect removal and installation of the SRS, can lead to personalinjury caused by unintentional activation of the system.GDo not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. SRS wiring harnesses are covered with yellow insulation either just before the har-ness connectors or on the complete harness, for easy identification.GThe vehicle is equipped with a passenger air bag deactivation switch which can be operated by thecustomer. When the passenger air bag is switched OFF, the passenger air bag is disabled and willnot inflate in a frontal collision. When the passenger air bag is switched ON, the passenger air bagis enabled and could inflate in a frontal collision. After SRS maintenance or repair, make sure thepassenger air bag deactivation switch is in the same position (ON or OFF) as when the vehiclearrived for service.Precautions for Working with R-134aWARNING:GCFC-12 (R-12) refrigerant and R-134a refrigerant are not compatible. If the refrigerants are mixed,compressor malfunction is likely to occur, refer to Contaminated Refrigerant. To determine thepurity of HFC-134a (R-134a) inthe vehicle andrecovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500-NI) and Refrigerant Identifier.GUse only specified lubricant for the R-134a A/C system and R-134a components. If lubricant otherthan that specified is used, compressor malfunction is likely.G The specified R-134a lubricant rapidly absorbs moisture from the atmosphere. The followinghandling precautions must be observed:a: When removing refrigerant components from a vehicle, immediately cap (seal) the componentto minimize the entry of moisture from the atmosphere.b: When installing refrigerant components to a vehicle, do not remove the caps (unseal) untiljust before connecting the components. Connect all refrigerant loop components as quicklyas possible to minimize the entry of moisture into the system.c: Only use the specified lubricant from a sealed container. Immediately reseal containers oflubricant. Without proper sealing, lubricant will become moisture saturated and should notbe used.d: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, noseand throat. Remove R-134a from the A/C system using certified service equipment meetingrequirements of SAE J2210 (R-134a recycling equipment) or J2209 (R-134a recovery equip-ment). If accidental system discharge occurs, ventilate work area before resuming service.Additional healthandsafetyinformationmaybeobtainedfromrefrigerant andlubricantmanufacturers.e: Do not allow lubricant to contact styrofoam parts. Damage may result.PRECAUTIONS AND PREPARATIONHA-2Contaminated RefrigerantIf a refrigerant other than pure R-134a is identified in a vehicle, your options are:GExplain to the customer that environmental regulations prohibit the release of contaminated refrigerant intothe atmosphere.GExplain that recovery of the contaminated refrigerant could damage your service equipment and refriger-ant supply.GSuggest the customer return the vehicle to the location of previous service where the contamination mayhave occured.GIf you choose to perform the repair, recover the refrigerant using only dedicated equipment and contain-ers. Do not recover contaminated refrigerant into your existing service equipment. If your facilitydoesnot havededicatedrecoveryequipment, youmaycontact alocal refrigerant product retailerforavailable service. This refrigerant must be disposed of in accordance with all federal and local regulations.In addition, replacement of all refrigerant system components on the vehicle is recommended.GIf the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NissanCustomer Affairs for further assistance.General Refrigerant PrecautionsWARNING:GDo not release refrigerant into the air. Use approved recovery/recycling equipment to capture therefrigerant every time an air conditioner system is discharged. Always follow the manufacturersrecommendations for use of the recovery/recycling equipment.GAlways wear eye and hand protection (goggles and gloves) when working with any refrigerant orair conditioner system.GDo not store or heat refrigerant containers above 52C (125F).GDo not heat a refrigerant container with an open flame; if container warming is required, place thebottom of the container in a pail of warm water.GDo not intentionally drop, puncture, or incinerate refrigerant containers.GKeep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.GRefrigerant will displace oxygen, therefore be certain to work in well ventilated areas to preventsuffocation.GDo not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-tioning systems with compressed air during repair. Some mixtures of air and R-134a have beenshown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury orproperty damage. Additional health and safety information may be obtained from refrigerant manu-facturers.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND PREPARATIONPrecautions for Working with R-134a (Contd)HA-3Precautions for Refrigerant ConnectionA new type refrigerant connection has been introduced to all refrigerant lines except the following location:G Expansion valve to cooling unit.FEATURES OF NEW TYPE REFRIGERANT CONNECTIONG The O-ring is relocated in a groove for proper installation. This eliminates the chance of the O-ring beingcaught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in rela-tion to the contacting surface of the mating part to improve sealing characteristics.G The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, therebyfacilitating piping connections.AHA022APRECAUTIONS AND PREPARATIONHA-4O-RING AND REFRIGERANT CONNECTIONAHA474ACAUTION:Refrigerant connections in some systems use different O-ring configuration. Do not confuse O-ringssince they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around,the connection.AHA049AO-ring part numbers and specificationsConnectiontypeO-ringsizePart numberDmm (in) Wmm (in)New 92471 N82106.8 (0.268)1.85 (0.0728)Former92470 N82006.07 (0.2390)1.78 (0.0701)New 92472 N821010.9 (0.429)2.43 (0.0957)Former92475 71L0011.0 (0.433)2.4 (0.094)New 92473 N821013.6 (0.535)2.43 (0.0957)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND PREPARATIONPrecautions for Refrigerant Connection(Contd)HA-5WARNING:Make sure all refrigerant is discharged into the recycling equipment and the pressure in the systemis less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and removeit.CAUTION:When replacing or cleaning refrigerant cycle components, observe the following.GDo not leave compressor on its side or upside down for more than 10 minutes. Compressor lubri-cant will enter low pressure chamber.GWhen connecting tubes, always use a torque wrench and a back-up wrench.GAfter disconnecting tubes, plug all openings immediately to prevent entry of dirt and moisture.GWhen installing an air conditioner unit in the vehicle, connect the pipes as the final stage of theoperation. Do not remove seal caps from pipes and other components until just before connec-tion.GAllow components stored in cool areas to warm to working area temperature before removing sealcaps. This prevents condensation from forming inside A/C components.GThoroughly remove moisture from the refrigeration system before charging the refrigerant.GAlways replace used O-rings.GWhen connecting tube, apply lubricant to portions shown in illustration. Be careful not to applylubricant to threaded portion.Name: Nissan A/C System Lubricant Type RPart No.: KLH00-PAGR0GO-ring must be closely attached to inflated portion of tube.GAfter inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.GAfter connecting line, conduct leak test and make sure that there is no leakage. When the gasleaking point is found, disconnect that line and replace the O-ring. Then tighten connections of sealseat to the specified torque.AHA025APRECAUTIONS AND PREPARATIONPrecautions for Refrigerant Connection(Contd)HA-6Precautions for Servicing CompressorG Plug all openings to prevent moisture and foreign matter from entering.G Do not keep the compressor in the upside down position or laid on its side for more than 10 min-utes.G When replacing or repairing compressor, be sure to remove lubricant from the compressor andcheck the lubricant quantity extracted.G Whenreplacingor repairingcompressor, followlubricant checkingandadjustingprocedureexactly. Refer to Compressor Lubricant Quantity, SERVICE PROCEDURES, HA-56.G Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with oil, wipeit off by using a clean waste cloth moistened with thinner.G After compressor service operation, turn the compressor shaft by hand more than five turns inboth directions. This will equally distribute lubricant inside the compressor. After the compressoris installed, let the engine idle and operate the compressor for one hour.G After replacing the compressor magnet clutch, apply voltage to the new one and check for normaloperation.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND PREPARATIONHA-7R-134a Service Tools and EquipmentNever mix 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 each type of refrigerant/lubricant.Refrigerant container fittings, service hose fittings, and service equipment fittings (equipment which handlesrefrigerant and/or lubricant) are different between CFC-12 (R-12) and R-134a. This is to avoid mixed use ofthe refrigerants/lubricants.Adapters to convert from one size fitting to the other must never be used: refrigerant/lubricant contaminationwill occur and compressor failure will result.Tool number(Kent-Moore No.)Tool nameDescription NoteR-134a refrigerantNT196Container color: Light blueContainer marking: R-134aFitting size: Thread sizeG large container 1/2-16 ACMEKLH00-PAGR0( )Nissan A/C SystemLubri-cant Type RNT197Type: Polyalkylene glycol oil (PAG), type RApplication: R-134a vane rotary compres-sors (Nissan only)Lubricity: 40 ml (1.4 US fl oz, 1.4 Imp fl oz)(J-39500-NI)Recovery/Recycling equip-ment (ACR4)NT195Function: Refrigerant Recovery and Recy-cling and Recharging(J-41955)A/C leak detectorAHA281APower supply:G DC 12 V (Cigarette lighter)(J-39183)Manifold gauge set (withhoses and couplers)NT199Identification:G The gauge face indicates R-134a.Fitting size: Thread sizeG 1/2-16 ACMEPRECAUTIONS AND PREPARATIONHA-8Tool number(Kent-Moore No.)Tool nameDescription NoteService hosesG High-side hose(J-39501-72)G Low-side hose(J-39502-72)G Utility hose(J-39476-72)NT201Hose color:G Low hose: Blue with black stripeG High hose: Red with black stripeG Utility hose: Yellow with black stripe orgreen with black stripeHose fitting to gauge:G 1/2-16 ACMEService couplersG High-side coupler(J-39500-20)G Low-side coupler(J-39500-24)NT202Hose fitting to service hose:G M14 x 1.5 fitting (optional) orpermanently attached(J-39650)Refrigerant weight scaleNT200For measuring of refrigerantFitting size: Thread sizeG 1/2-16 ACME(J-39649)Vacuum pump(Including the isolator valve)NT203Capacity:G Air displacement: 4 CFMG Micron rating: 20 micronsG Oil capacity: 482 g (17 oz)Fitting size: Thread sizeG 1/2-16 ACMEGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND PREPARATIONR-134a Service Tools and Equipment (Contd)HA-9Special Service ToolsThe actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.Tool number(Kent-Moore No.)Tool nameDescription NoteKV99231260(J-38874)Clutch disc wrenchNT204Removing shaft nut and clutch discKV99232340(J-38874)Clutch disc pullerNT206Removing clutch discKV99234330(J-39024)Pulley installerNT207Installing pulleyKV99233130(J-39023)Pulley pullerNT208Removing pulleyCommercial Service ToolsTool name Description NoteReferigerant identifier equip-mentNT765Function: Checksreferigerant purityandfor system contaminationPRECAUTIONS AND PREPARATIONHA-10Precautions for Service EquipmentRECOVERY/RECYCLING EQUIPMENTFollow the manufacturers instructions for machine operation andmachine maintenance. Never introduce any refrigerant other thanthat specified into the machine.ELECTRONIC LEAK DETECTORFollowthemanufacturersinstructionsfor tester operationandtester maintenance.RHA270DVACUUM PUMPThe lubricating oil contained inside the vacuum pump is not com-patible with the specified lubricant for R-134a A/C systems. Thevent side of the vacuum pump is exposed to atmospheric pressure.Therefore, if the pump is switched off after evacuation the lubricat-ing oil may migrate into the hose. To prevent this, isolate the pumpfrom the hose after evacuation (vacuuming).This migration is avoided by placing a manual shut-off valve nearthe hose-to-pump connection, as follows:G Usually vacuum pumps have a manual isolator valve as partof the pump. Close this valve to isolate the service hose fromthe pump.G For pumps without an isolator valve, use a hose equipped witha manual shut-off valve near the pump end. Close the valve toisolate the hose from the pump.G If thehosehasanautomaticshut-off valve, disconnect thehose from the pump. As long as the hose is connected, thevalve is open and lubricating oil may migrate.Someone-wayvalvesopenwhenvacuumisappliedandcloseunder a no vacuum condition. Such valves may restrict the pumpsability to pull a deep vacuum and are not recommended.SHA533DMANIFOLD GAUGE SETBe sure the gauge set has 1/2-16 ACME threaded connections forservice hoses. Confirm the set has been used only with refrigerantR-134a along with specified lubricants.RHA272DSERVICE HOSESBe certain that the service hoses display the markings described(colored hose with black stripe). Be certain that all hoses includepositive shut-off devices (either manual or automatic) near the endof the hoses opposite the manifold gauge.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXPRECAUTIONS AND PREPARATIONHA-11RHA273DSERVICE COUPLERSNever attempt to connect R-134a service couplers to a CFC-12(R-12) A/C system. The R-134a couplers will not properly connectto the CFC-12 (R-12) system. However, if an improper connectionis attempted, discharging and contamination can occur.Shut-off valve rotation A/C service valveClockwise OpenCounterclockwise CloseAHA211REFRIGERANT WEIGHT SCALEWhen using a scale which controls refrigerant flow electronically,assure the following:G Hose fitting size is 1/2-16 ACMEG No refrigerant other than R-134a (along with specified lubri-cant) has been used with the scale.CalibrationCalibrate the scale every 3 months.To calibrate the weight scale on the ACR4 (J-39500):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 andchange to A2.5. Place a known weight (dumbbell or similar weight), between 10and 19 lbs., on the center of the weight scale.6. Enter theknownweight using4digits. (Example10lbs=10.00, 10.5 lbs = 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 dis-played.11. Press Shift/Reset to return the ACR4 to the program mode.CHARGING CYLINDERUsing a charging cylinder is not recommended. Refrigerant may bevented into the air through the cylinders top valve when filling thecylinder.PRECAUTIONS AND PREPARATIONPrecautions for Service Equipment (Contd)HA-12Refrigeration CycleREFRIGERANT FLOWThe refrigerant flow is in the standard pattern. Refrigerant flows through the compressor, condenser, liquidtank, evaporator, and back to the compressor.The refrigerant evaporation through the evaporator coilis controlled by an externally equalized expansionvalve, located inside the evaporator case.FREEZE PROTECTIONThe compressor cycles on and off to maintain the evaporator temperature within a specified range. When theevaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the compres-sor operation. When the evaporator coil temperature rises above the specification, the thermo control ampli-fier allows compressor operation.REFRIGERANT SYSTEM PROTECTIONDual-pressure switchThe refrigerant system is protected against excessively high or low pressure. The protection is effected by thedual-pressure switch located on the liquid tank. If the pressure rises or falls out of specifications, the switchopens to interrupt the compressor operation.Pressure relief valveThe refrigerant system is protected by a pressure relief valve. The valve is located on the end of the flexiblehigh pressure hose near the compressor. When refrigerant system pressure increases abnormally [over 3,727kPa (38 kg/cm2, 540 psi)], the relief valves port opens. The valve then releases refrigerant into the atmo-sphere.RHA258DGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDESCRIPTIONHA-13Control OperationAHA109AFAN CONTROL LEVERThis lever turns the fan ON and OFF, and controls fan speed.MODE CONTROL SWITCHThis switch controls the outlet air flow.TEMPERATURE CONTROL SWITCHThis switch allows adjustment of the temperature of the outlet air.RECIRCULATION (REC) CONTROL LEVERFRESH position:Outside air is drawn into the passenger compartment.Recirculation REC position:Interior air is recirculated inside the vehicle.AIR CONDITIONER SWITCHThe 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.DESCRIPTIONHA-14Component LayoutAHA123AGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDESCRIPTIONHA-15Discharge Air FlowAHA290ADESCRIPTIONHA-16Component LocationEngine compartmentAHA133AGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDESCRIPTIONHA-17Passenger compartmentAHA148ADESCRIPTIONComponent Location (Contd)HA-18Circuit DiagramAHA442AGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDESCRIPTIONHA-19Wiring Diagram HEATERAHA042ADESCRIPTIONHA-20Wiring Diagram A/CAHA043AGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDESCRIPTIONHA-21AHA443ADESCRIPTIONWiring Diagram A/C (Contd)HA-22Operational CheckThe purpose of the operational check is to confirm that the systemoperates properly.After operational check is completed, go to SYMPTOM TABLE inHow to Perform Trouble Diagnoses for Quick and Accurate Repair,HA-25.CONDITIONS:G Engine running and at normal operating temperature.AHA103APROCEDURE:1. Check blowera. Slide fan control lever to 1-speed.Blower should operate on 1-speed.b. Then slide fan control lever to 2-speed, and continue checkingblower speed until all speeds are checked.c. Leave blower on 4-speed.AHA104A2. Check discharge aira. Turn mode switch to each mode.b. Confirm that air discharge comes out each mode.AHA983NOTE:Confirm that discharge air comes out according to the air dis-tribution table at left.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXDESCRIPTIONHA-23AHA101A3. Check recirculationa. Slide REC control lever to REC position.b. Listenfor intakedoor positiontochange(youshouldhearblower sound change slightly).AHA100A4. Check temperature decreasea. Turn temperature switch to full cold.b. Check for cold air at discharge air outlets.AHA099A5. Check temperature increasea. Turn temperature control switch to full hot.b. Check for hot air at discharge air outlets.AHA102A6. Check air conditioner switchSlide the fan control lever to the desired (1 to 4 speed) posi-tion and push the A/C switch to turn ON the air conditioner.The indicator lamp should come on when air conditioner is ON.DESCRIPTIONOperational Check (Contd)HA-24How to Perform Trouble Diagnoses for Quickand Accurate RepairWORK FLOWCHECK INLISTEN TO CUSTOMER COMPLAINT(Obtain detailed information about the environmentconditions when the symptom occured.)Verify the symptom with Operational Check HA-23.Also check related service bulletins for information.Go to appropriate trouble diagnosis.(Refer to SYMPTOM TABLE below.)REPAIR/REPLACENGFINAL CHECKConfirm the repair result by Operational Check,HA-23.OKCHECK OUTSYMPTOM TABLESymptom Reference pageGBlower motor does not rotate. GGo to Blower Motor Circuit, HA-26.GAir outlet does not change. GGo to Air Outlet, HA-30.GIntake door position does not change. GGo to Trouble Diagnoses for Intake Door, HA-32.GMagnet clutch does not engage when A/Cswitch and fan switch are ON.GGo to Magnet Clutch Circuit, HA-33.GInsufficent Cooling. GGo to Trouble Diagnosis for Insufficient Cooling, HA-39.GGo to Performance Test Diagnosis, HA-41.GGo to Performance Chart, HA-43.GGo to Trouble Diagnoses for Abnormal Pressure, HA-44.GInsufficient heating. GGo to Trouble Diagnoses for Insufficient Heating, HA-47.GNoise. GGo to Trouble Diagnoses for Noise, HA-49.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESHA-25Blower Motor CircuitSYMPTOM: Blower motor does not rotate.INSPECTION FLOW1. Confirm symptom by performing BLOWER MOTOR OPERATION CHECK shownbelow.If OK (symptom cannot be duplicated), perform complete Operational Check, HA-23.If NG (symptom is confirmed), continue with STEP 2 below.2. Check for any service bulletins.OK3. Go to Diagnostic Procedure for Blower Motor Circuit, HA-27.BLOWER MOTOR OPERATION CHECKAHA105A1. Start engine.2. Check blower motor.3. Slidefancontrol leverto1-speedandblowermotorshouldoperate on 1-speed.4. Slide fan control lever to 2-speed and continue checkingblower speed until all speeds are checked.TROUBLE DIAGNOSESHA-26DIAGNOSTIC PROCEDUREINCIDENT Flow chart1 Fan fails to rotate.2 Fan does not rotate at 1-speed.3 Fan does not rotate at 2-speed.4 Fan does not rotate at 3-speed.5 Fan does not rotate at 4-speed.AHA074AAHA075AAHA266AAHA077ACheck if blower motor rotates properly ateach fan speed.Conduct check as per flow chart at left.(Go to next page.)BCHECK POWER SUPPLY FOR BLOWERMOTOR.Disconnect blower motor harness connec-tor.Does approx. 12 volts exist betweenblower motor harness terminal1 andbody ground?YesNoCheck 15A fuses No.and , located infuse block (J/B).Refer to EL section (Wir-ing Diagram, POWERSUPPLY ROUTING).1. Slide fan control lever to 4-speed.2. Check circuit continuity between blowermotor harness terminal2 and bodyground.Continuity should exist.NGOKCheck blower motor.Refer to HA-29.NGReplace blower motor.Reconnect blower motor harness connec-tor.CHECK BLOWER MOTOR CIRCUITBETWEEN BLOWER MOTOR ANDRESISTOR.Slide fan switch to OFF position.Does approx. 12 volts exist between fanresistor harness terminal1 and bodyground?YesNoDisconnect blower motorand resistor harness con-nectors.NoteCheck circuit continuitybetween blower motor har-ness terminal2 andresistor harness terminal1.Continuity should exist.If OK, check harness forshort.A(Go to next page.)Note:If the result is NG or No after checking circuit continuity, repair harnessor connector.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESBlower Motor Circuit (Contd)HA-27AHA078AAHA079AAHA080AABNoteCHECK GROUND CIRCUIT FOR FANSWITCH.Disconnect fan switch harness connector.Check circuit continuity between fan switchharness terminal6 and body ground.OKCHECK BLOWER RESISTOR AFTER DIS-CONNECTING IT.(Refer to Electrical Components Inspection.)(HA-29).OK NGReplace resistor.Reconnect resistor harness connector. CHECK FAN SWITCH CIRCUIT.Does approx. 12 volts exist between each fan switchharness terminal and body ground?Yes NoNoteCheck circuit continuitybetween fan switch harnessterminal and resistor harnessterminal.If OK, check harness forshort.CHECK FAN SWITCH AFTER DISCON-NECTING IT.(Refer to COMPONENT INSPECTION.)(HA-29)NGReplace fan switch.Note:IftheresultisNGaftercheckingcircuitcontinuity, repairharnessorconnector.Flow chartNo.Terminal No.Voltage 5Body ground Approx. 12V432Terminal No.Continu-ityFanswitchResistor21Yes324354TROUBLE DIAGNOSESBlower Motor Circuit (Contd)HA-28AHA132ACOMPONENT INSPECTIONFan switchCheck continuity between terminals at each position.TERMINALPOSITIONOFF 1 2 3 41 2 3 4 5 6 AHA130ABlower motorConfirm smooth rotation of the blower motor.G Check that there are no foreign particles inside the intake unit.AHA117ABlower resistorCheck continuity between terminals.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESBlower Motor Circuit (Contd)HA-29Air OutletSYMPTOM: Air outlet does not change.INSPECTION FLOW1. Confirm symptom by performing AIR OUTLET CONTROL DOORS OPERATIONCHECK.If OK (symptom cannot be duplicated), perform complete Operational Check, HA-23.If NG (symptom is confirmed), continue with STEP 2 below.2. Check for any service bulletins.3. Repair/adjust control linkage, refer to CONTROL LINKAGE ADJUSTMENT, HA-31.AHA107AAIR OUTLET CONTROL DOORS OPERATION CHECK1. Start engine.2. Slide fan control lever to 4-speed.3. Check discharge air.a. Turn mode control switch to posiitonb. Confirm that all discharge air comes out of face vents.c. Turn mode control switch to position.d. Confirm that discharge air comes out of face vents and footvents.e. Turn mode control switch to position.f. Confirm that discharge air comes out of foot vents, with someair from defrost vents.g. Turn mode control switch to position.h. Confirm that discharge air comes out of foot vents with someair from defrost vents.AHA106Ai. Turn mode control switch to position.j. Confirm that all discharge air comes out of defrost vents.Note:Confirm that discharge air comes out according to the air distributiontable, HA-23.TROUBLE DIAGNOSESHA-30AHA121ACONTROL LINKAGE ADJUSTMENTMode control cableG Turn mode control switch to position.Set side link in DEF mode.Pull on outer cable in direction of arrow and then clamp it.G After positioning mode control cable, check that it oper-ates properly.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESAir Outlet (Contd)HA-31Intake DoorSYMPTOM: Intake door position does not change.INSPECTION FLOW1. Confirm symptom by performing INTAKE DOOR OPERATION CHECK, shown below.If OK (symptom cannot be duplicated), perform complete Operational Check, HA-23.If NG (symptom is confirmed), continue with STEP 2 below.2. Check for any service bulletins.3. Repair/adjust control linkage, refer to CONTROL LINKAGE ADJUSTMENT, shown below.AHA108AINTAKE DOOR OPERATION CHECK1. Start engine.2. Slide fan control switch to 4-speed.3. Check recirculation.a. Slide recirculation control lever to the REC posiiton.b. Listen for intake door position change (you should hear blowersound change slightly).AHA156ACONTROL LINKAGE ADJUSTMENTRecirculation control cableG Move recirculation lever to REC position.Set recirculation lever in REC mode.Pull on outer cable in direction of arrow and then clamp it.G After positioning recirculation control cable, check that itoperates properly.TROUBLE DIAGNOSESHA-32Magnet Clutch CircuitSYMPTOM: Magnet clutch does not engage when A/Cswitch and fan switch are ON.INSPECTION FLOW1. Confirm symptom by performing MAGNET CLUTCH OPERATION CHECK, shown below.If OK (magnet clutch can be engaged), go to Trouble Diagnosis Procedure for Insufficient Cooling,HA-39.If NG (symptom is confirmed), continue with STEP 2 below.2. Check for any service bulletins.3. Check refrigeration cycle pressure with manifold gauge corrected.Refer to Trouble Diagnoses for Abnormal Pressure, HA-44.4. Go to THERMO CONTROL AMP. CHECK, HA-34.Go to DIAGNOSES PROCEDURE, HA-35.AHA102AMAGNET CLUTCH OPERATION CHECK1. Start engine.2. Slide fan control lever to operate blower motor.3. PushA/CswitchtoON. Makesurethat magnet clutchisengaged. (You can hear magnet clutch engage sound.)4. Push A/C switch to OFF. Make sure that magnet clutch is dis-engaged.Note: If magnet clutch sticks, check magnet clutch. Refer toHA-35.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESHA-33AHA081ATHERMO CONTROL AMP. CHECKPower supply circuit checkCheck power supply circuit for thermo controlamp. with ignitionswitch ON.1. Disconnect thermo control amp. harness connector.2. Connect voltmeter from harness side.3. Measure voltage across terminal1 and body ground.Voltmeter terminalVoltage 1 Body ground Approx. 12VAHA082AGround circuit checkCheckbodygroundcircuit forthermocontrol amp. withignitionswitch ON, air conditioner switch ON and fan switch ON.1. Disconnect thermo control amp. harness connector.2. Connect ohmmeter from harness side.3. Check for continuity between terminal2 and body ground.Ohmmeter terminalContinuity 4 Body ground YesIf the ground circuit is NG, check the following.G A/C switch (Refer to HA-37.)G Fan switch (Refer to HA-29.)G Harness for open or short between thermo control amp. andA/C switchG Harness for open or short between A/C switch and fan switchG Fan switch ground circuitTROUBLE DIAGNOSESMagnet Clutch Circuit (Contd)HA-34AHA083ADIAGNOSTIC PROCEDUREAHA084AAHA085AAHA086ACHECK POWER SUPPLY FOR COM-PRESSOR.Disconnect compressor harness connec-tor.Does approx. 12 volts exist between com-pressor harness terminal1 and bodyground?NoYesCheck the thermal protec-tor.Refer to HA-37.OKCheck the magnet clutchcoil.NGNoteCheck circuit continuity between A/C relayharness terminal3 and compressor har-ness terminal1.Continuity should exist.If OK, check harness for short.OKReplace magnet clutch.Refer to HA-59.CHECK POWER SUPPLY FOR A/CRELAY.Does approx. 12 volts exist between A/Crelay harness terminal5 and bodyground?YesNoCheck power supply circuitand 7.5A fuse (No. ,located in the fuse block).(Refer to POWER SUP-PLY ROUTING in EL sec-tion and Wiring Diagram.)CHECK POWER SUPPLY FOR A/CRELAY.Does approx. 12 volts exist between A/Crelay harness terminal2 and bodyground?YesNoCheck power supply circuitand 7.5A fuse (No. ,located in the fuse block).(Refer to POWER SUP-PLY ROUTING in EL sec-tion and Wiring Diagram.)CHECK A/C RELAY AFTER DISCON-NECTING IT.Refer to HA-38.OKNGReplace A/C relay.Reconnect A/C relay.A(Go to next page.)Note:IftheresultisNGaftercheckingcircuitcontinuity, repairharnessorconnector.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESMagnet Clutch Circuit (Contd) HA-35AHA087AAHA088AAHA089AAHA267AAHA268AACHECK COIL SIDE CIRCUIT OF A/CRELAY.Does approx. 12 volts exist between ECMharness terminal No.12 and bodyground?YesNoCheck circuit continuitybetween A/C relay harnessterminal1 and ECM har-ness terminal12 .Continuity should exist.If OK, check harness forshort.CHECK POWER SUPPLY AND GROUNDCIRCUIT FOR THERMO CONTROL AMP.Refer to HA-34.OKCHECK VOLTAGE FOR THERMO CON-TROL AMP.Does approx. 5 volts exist betweenthermo control amp. harness terminal2and body ground?NoYesReplace thermo controlamp.Check circuit continuity between thermocontrol amp. harness terminal2 anddual-pressure switch harness terminal2.Continuity should exist.If OK, check harness for short.OKCHECK DUAL-PRESSURE SWITCH.Refer to HA-37.OKNGReplace thermo controlamp.Check circuit continuity between ECM har-ness terminal21 and dual-pressureswitch harness terminal1.Continuity should exist.If NG, check harness or connector.OKCHECK ECM.Refer to EC section.TROUBLE DIAGNOSESMagnet Clutch Circuit (Contd)HA-36AHA092AELECTRICAL COMPONENT INSPECTIONAir conditioner switchCheck continuity between terminals at each switch positionSwitch condition Terminal No. ContinuityON1 -2,1 -3YesOFF NoAHA128ADual pressure switchTerminalsHigh-pressure sideline pressurekPa (kg/cm2, psi)Operation ContinuityLow-pressureside1 -2Increasing to 157 - 216(1.6 - 2.2, 23 - 31)ON YesDecreasing to 157 - 196(1.6 - 2.0, 23 - 28)OFF NoHigh-pressuresideIncreasing to 2,452 - 2,844(25 - 29, 356 - 412)OFF NoDecreasing to 1,863 - 2,256(19 - 23, 270 - 327)ON YesAHA093AThermo control amp.1. Run engine, and operate A/C system.2. Connect the voltmeter from harness side.3. Check thermo control amp. operation shown in the table.Evaporator outlet air temperatureC (F)Thermo amp.operationTesterDecreasing to 2.5 - 3.5 (37 - 38) Turn OFF Approx. 12VIncreasing to 4.0 - 5.0 (39 - 41) Turn ON Approx. 0VAHA135AThermal protectorTemperature of compressorC (F)OperationIncreasing to approx. 145 - 155 (293 - 311) Turn OFFDecreasing to approx. 130 - 140 (266 - 284) Turn ONIf NG, replace thermal protector.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESMagnet Clutch Circuit (Contd)HA-37AHA233Air conditioner relayCheck circuit continuity between terminals by supplying 12 volts tocoil side terminals of air conditioner relay.TROUBLE DIAGNOSESMagnet Clutch Circuit (Contd)HA-38Trouble Diagnosis Procedure For InsufficientCoolingINSPECTION FLOW1. Confirm symptom by performing COOLING OPERATION CHECK shownbelow.If NG (symptom can be duplicated), perform complete Operational CheckHA-23.If NG (symptom is confirmed), continue with STEP-2 below.2. Check for any service bulletins.3. Check compressor belt tension. Refer to MA section (Checking DriveBelts, ENGINE MAINTENANCE).OKNGAdjust or replace compressorbelt.4. Check Temperature Control Cable, HA-48.OKNGRepair/adjust.5. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerantpressure should be displayed. If NG, Recover refrigerant from equipmentlines.OK6. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identi-fier.OKNGRefer to ContaminatedRefrigerant, HA-3.Connect ACR4 to vehicle7. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerantidentifier.OKNGRefer to ContaminatedRefrigerant, HA-3.8. Check refrigeration cycle pressure with manifold gauge connected.Refer to Trouble Diagnoses For Abnormal Pressure, HA-44.OKNGPerform Performance Test Diag-noses. Refer to HA-41.9. CHECK FOR EVAPORATOR COIL FREEZE UP.OK (Does not freeze up.)Check Compressor CircuitHA-37 (A/C relay, thermo controlamp and magnet clutch.)10. Check ducts for air leaks.Repair air leaks.INSPECTION ENDNG(Freezeup.)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESHA-39AHA102ACOOLING OPERATION CHECK1. Start engine.2. Slide fan control lever to 4-speed.3. Turn air conditioner switch ON.4. Check temperature decrease.a. Turn temperature switch to full cold.b. Check for cold air at discharge air outlets.TROUBLE DIAGNOSESTrouble Diagnosis Procedure For InsufficientCooling (Contd)HA-40Performance Test DiagnosesINSUFFICIENT COOLINGINSUFFICIENT COOLINGCHECK AIR FLOW.OKNGCHECK BLOWER MOTOR OPERATION.OK NGCHECK COMPRESSOR OPERATION.OK NGClogged blower inlet/Cloggedduct/Loose duct connection/Airleakage, etc.A(Go tonext page.)B(Go tonext page.)Before connecting ACR4 to vehicle, check ACR4gauges. No refrigerant pressure should be dis-played. If NG, Recover refrigerant from equip-ment lines.OKConfirm refrigerant purity in supply tank usingACR4 and refrigerant identifier.OKNGRefer to CONTAMINATED REFRIGERANT,HA-3.Connect ACR4 to vehicle.Confirm refrigerant purity in vehicle A/C systemusing ACR4 and refrigerant identifier.OKNGRefer to CONTAMINATED REFRIGERANT,HA-3.OKCHECK HIGH AND LOW-SIDE PRESSURE.USE PERFORMANCE CHART. Refer to HA-43.NGRECOVER REGRIGERANT USING RECOVERYRECYCLING EQUIPMENT AND CHARGESPECIFIED AMOUNT OF REFRIGERANT.CHECK HIGH AND LOW-SIDE PRESSURE.Refer to HA-43.OKNGBOTH HIGH AND LOW-PRESSURE SIDES ARETOO HIGH.HA-44NoteCHECK DISCHARGE AIR TEMPERATURE.USE PERFORMANCE CHART. Refer to HA-43.NG OKHIGH-PRESSURE SIDE ISTOO HIGH AND LOW-PRESSURE SIDE IS TOOLOW.HA-44END HIGH-PRESSURE SIDE ISTOO LOW AND LOW-PRESSURE SIDE IS TOOHIGH.HA-45Malfunctioning temperature control operation (airmix door position improperly adjusted)BOTH HIGH AND LOW-PRESSURE SIDES ARETOO LOW.HA-45LOW-PRESSURE SIDESOMETIMES BECOMESNEGATIVE.HA-46LOW-PRESSURE SIDEBECOMES NEGATIVE.HA-46Note: - correspond to those in TROUBLE DIAGNOSES FORABNORMAL PRESSURE.Refer to HA-44.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES HA-41AMalfunctioning blower motor fan Malfunctioning electrical circuit Malfunctioning blower motor internalcircuitLoose fan/Improper contact of fanand case/Deformed fanDisconnected wiring or componentcircuits or poor connection/Malfunctioning resistor, amplifier,etc./ Burned out fuse or low batteryvoltageBMagnet clutch does not engage Magnet clutch slipping Belt slippingCHECK MAGNET CLUTCH. Inspectcoil circuit, disc-to-pulley clearance.CHECK COMPRESSOR BELT ANDBELT TENSION. Refer to MA sec-tion (Checking Drive Belts,ENGINE MAINTENANCE).CHECK ELECTRICAL CIRCUIT.Inspect wiring, components circuit.Malfunctioning internal parts ofclutch, compressorCHECK ACTIVATION OF SAFETY/PROTECTION DEVICES. Inspectdevices such as pressure switch,etc.Foreign particles on clutch frictionalsurface or excessive disc clearanceMalfunctioning electrical circuit(poor connection, low batteryvoltage, etc.)TROUBLE DIAGNOSESPerformance Test Diagnoses (Contd) HA-42Performance ChartTEST CONDITIONTesting must be performed as follows:Vehicle location: Indoors or in the shade (in a well-ventilatedplace)Doors: ClosedDoor window: OpenHood: OpenTEMP. setting: Max. COLDDischarge Air: FACE VENTINTAKElever position: (Recirculation)FAN speed: 4-speedEngine speed: 1,500 rpmOperate the air conditioner system for 10 minutes before tak-ing measurements.TEST READINGRecirculating-to-discharge air temperature tableInside air (Recirculating air)at blower assembly inletDischarge air temperature at center ventilatorC (F)Relative humidity%Air temperatureC (F)50 - 6020 (68) 6.6 - 8.3 (44 - 47)25 (77) 10.4 - 12.4 (51 - 54)30 (86) 14.2 - 16.7 (58 - 62)35 (95) 18.2 - 21.0 (65 - 70)40 (104) 22.0 - 25.2 (72 - 77)60 - 7020 (68) 8.3 - 9.8 (47 - 50)25 (77) 12.4 - 14.4 (54 - 58)30 (86) 16.7 - 18.9 (62 - 66)35 (95) 21.0 - 23.6 (70 - 74)40 (104) 25.2 - 28.1 (77 - 83)Ambient air temperature-to-operating pressure tableAmbient airHigh-pressure (Discharge side)kPa (kg/cm2, psi)Low-pressure (Suction side)kPa (kg/cm2, psi)Relative humidity%Air temperatureC (F)50 - 7020 (68) 961 - 1,187 (9.8 - 12.1, 139 - 172) 108 - 157 (1.1 - 1.6, 16 - 23)25 (77) 1,295 - 1,599 (13.2 - 16.3, 188 - 232) 161.8 - 215.8 (1.65 - 2.2, 23.5 - 31.3)30 (86) 1,285 - 1,569 (13.1 - 16, 186 - 228) 167 - 216 (1.7 - 2.2, 24 - 31)35 (95) 1,520 - 1,863 (15.5 - 19, 220 - 270) 235 - 284 (2.4 - 2.9, 34 - 41)40 (104) 1,765 - 2,158 (18 - 22, 256 - 313) 289.3 - 353.1 (2.95 - 3.6, 41.9 - 51.2)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESHA-43Trouble Diagnoses for Abnormal PressureWhenever systems high or low-side pressure is abnormal, diagnose using a manifold gauge. The marker abovethe gauge scale in the following table indicates the standard (normal) pressure range. Since the standard normalpressure differs from vehicle to vehicle, refer to HA-43 (Ambient air temperature-to-operating pressure table).Pressure measurements are effective only when ambient temperature is in the range indicated underthe Performance Chart.Gauge indication Refrigerant cycle Probable cause Corrective actionBoth high and low-pressuresides are too high.AC359AG Pressure is reduced soonafter water is splashed oncondenser.Excessive refrigerant charge inrefrigeration cycle.Reduce refrigerant until speci-fied pressure is obtained.G Air suction by radiator orcooling fan is insufficient.Insufficient condenser coolingperformance.1 Condenser fins areclogged.2 Improper rotation of cool-ing fan.G Clean condenser.G Check and repair radiator orcooling fan as necessary.G Low-pressure pipe is notcold.G When compressor is stoppedhigh-pressure value quicklydrops by approximately 196kPa (2 kg/cm2, 28 psi). Itthen decreases graduallythereafter.Poor heat exchange in con-denser.(After compressor operationstops, high-pressure decreasestoo slowly.)Air in refrigeration cycle.Evacuate repeatedly andrecharge system.Engine tends to overheat. Engine cooling systems mal-function.Check and repair each enginecooling system.G An area of the low-pressurepipe is colder than near theevaporator outlet.G Plates are sometimes cov-ered with frost.G Excessive liquid refrigeranton low-pressure side.G Excessive refrigerant dis-charge flow.G Expansion valve is open alittle compared with thespecification.1 Improper thermal valveinstallation.2 Improper expansion valveadjustment.Replace expansion valve.High-pressure side is too highand low-pressure side is toolow.AC360AUpper side of condenser andhigh-pressure side are hot,however, liquid tank is not ashot.High-pressure tube or partslocated between compressorand condenser are clogged orcrushed.G Check and repair or replacemalfunctioning parts.G Check lubricant for contami-nation.TROUBLE DIAGNOSESHA-44Gauge indication Refrigerant cycle Probable cause Corrective actionHigh-pressure side is too lowand low-pressure side is toohigh.AC356AHigh and low-pressure sidesbecome equal soon after com-pressor operation stops.Compressor pressure operationis improper.Damaged inside compressorpackings.Replace compressor.No temperature differencebetween high and low-pressuresides.Compressor pressure operationis improper.Damaged inside compressorpackings.Replace compressor.Both high and low-pressuresides are too low.AC353AG There is a big temperaturedifference between liquidtank outlet and inlet. Outlettemperature is extremely low.G Liquid tank inlet and expan-sion valve are frosted.Liquid tank is partly clogged. G Replace liquid tank.G Check lubricant for contami-nation.G Temperature of expansionvalve inlet is extremely lowas compared with areas nearliquid tank.G Expansion valve inlet may befrosted.G Temperature differenceoccurs somewhere in high-pressure side.High-pressure pipe locatedbetween liquid tank and expan-sion valve is clogged.G Check and repair malfunc-tioning parts.G Check lubricant for contami-nation.G Expansion valve and liquidtank are warm or only cool tothe touch.Low refrigerant charge.Leaking fittings or components.G Check for refrigerant leaks.Refer to Checking Refriger-ant Leaks, HA-51.Both high and low-pressuresides are too low.AC353AThere is a big temperature dif-ference between expansionvalve inlet and outlet while thevalve itself is frosted.Expansion valve closes a littlecompared with the specifica-tion.1 Improper expansion valveadjustment.2 Malfunctioning thermalvalve.3 Outlet and inlet may beclogged.G Remove foreign particles byusing compressed air.G Check lubricant for contami-nation.An area of low-pressure pipe iscolder than areas near theevaporator outlet.Low-pressure pipe is cloggedor crushed.G Check and repair malfunc-tioning parts.G Check lubricant for contami-nation.Air flow volume is not enoughor is too low.Compressor pressure operationis improper.Replace compressor.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSESTrouble Diagnoses for Abnormal Pressure(Contd)HA-45Gauge indication Refrigerant cycle Probable cause Corrective actionLow-pressure side sometimesbecomes negative.AC354AG Air conditioner system doesnot function and does notcyclically cool the compart-ment air.G The system constantly func-tions for a certain period oftime after compressor isstopped and restarted.Refrigerant does not dischargecyclically.Moisture is frozen at expansionvalve outlet and inlet.Water is mixed with refrigerant.G Replace refrigerant.G Replace liquid tank.Low-pressure side becomesnegative.AC362ALiquid tank or front/rear side ofexpansion valves pipe isfrosted or dewed.High-pressure side is closedand refrigerant does not flow.Expansion valve or liquid tankis frosted.Leave the system at rest . Startit again to check whether or notthe problem is caused by wateror foreign particles.G If water is the cause, initiallycooling is okay. Then thewater freezes, causing ablockage. Drain water fromrefrigerant or replace refriger-ant.G If due to foreign particles,remove expansion valve andremove the particles with dryand compressed air.G If either of the above meth-ods cannot correct theproblem, replace expansionvalve.G Replace liquid tank.G Check lubricant for contami-nation.TROUBLE DIAGNOSESTrouble Diagnoses for Abnormal Pressure(Contd)HA-46Trouble Diagnosis for Insufficient HeatingINSPECTION FLOW1. Confirm symptom by performing HEATINGOPERATION CHECK HA-48.If OK (symptom can not be duplicated), performcomplete Operational Check, HA-23.If NG (symptom is confirmed), continue withSTEP-2 below.2. Check for any service bulletins.OK3. Check the following:GEngine coolant level (Refer to MA section).GHoses for leaks or kinks.GRadiator cap.Refer to LC section(ENGINE COOLING SYSTEM).GAir in cooling system.OKNGRepair/replace as necessary.4. Check air outlet. Refer to HA-30.OKNGRepair/replace as necessary.5. Check ducts for air leaks.OKNGRepair leaks.6. Check by feel the heater inlet and outlet hoses.Hot inlet Both hosesWarm outlet warmCheck thermostat installation.OKCheck heater hoses for proper installation.OK NGReplace thermostat. Refer to LC sec-tion (Thermostat, ENGINE COOL-ING SYSTEM). Retest.Back flush heater core, drain and refill cool-ant. Retest.Hot inlet Both hosesWarm outlet warmRepair orreplace.Hot inletWarm outletSystem OK.Replace heater core. Refill enginecoolant.(Refer to MA section) Retest.Hot inletWarm outletGIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES HA-47AHA099AHEATING OPERATION CHECK1. Start and warm up engine.2. Slide fan control lever to 4-speed.3. Turn air conditioner switch OFF.4. Check temperature increase.a. Turn temperature switch to full hot.b. Check hot air at discharge air outlets.AHA120ATEMPERATURE CONTROL LINKAGE ADJUSTMENTTemperature control cableG When adjusting ventilator door rod and defrost door rod,first disconnect mode control cable from side link. Recon-nect and readjust mode control cable.G Move temperature control lever to max. COLD position. Set airmix door lever in full hot mode. Pull on outer cable in directionof arrow and then clamp it.G After positioning temperature control cable, check that itoperates properly.TROUBLE DIAGNOSESTrouble Diagnosis for Insufficient Heating(Contd)HA-48Trouble Diagnosis for NoiseConfirm symptom by performing OperationalCheck, HA-23.If OK (symptom cannot be duplicated), per-form complete Operational Check.If NG (symptom is confirmed), continue withSTEP-2 following.Check for any service bulletins.Check where noise comes from.Blower motor Compressor Expansion valve Refrigerant line BeltCheck for noise inall modes and tem-perature settings.Noise isconstantInspect the com-pressor clutch andpulley and idler pul-ley.OK NGReplace expansionvalve.Check blowermotor for foreignparticles.Replace com-pressor clutchand pulley.Refer toHA-59.The line is fixeddirectly to thebody.The line is notfixed.Check blowermotor and fan forwear.Check disc-to-pul-ley clearance.Refer to HA-62.OKFix line with rub-ber or somevibration absorb-ing material.Fix the line tightly.Check and adjustcompressor lubri-cant.Refer to HA-56.OKReplace compres-sor and liquid tank.The belt vibra-tion is intense.Side of belt is wornout.Noise isintermittentCheck air dis-charge ducts forobstructions, for-eign materials orair leakage.Readjust belttension.Refer to MA sec-tion (CheckingDrive Belts,ENGINEMAINTE-NANCE).The pulley centerdoes not match.Readjust pulleycenter.Refer to HA-60.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXTROUBLE DIAGNOSES HA-49Refrigerant LinesG Refer to HA-5.AHA122ASERVICE PROCEDURESHA-50Checking Refrigerant LeaksPRELIMINARY CHECKPerform a visual inspection of all refrigeration parts, fittings, hoses,and components for signs of A/C lubricant leakage, damage andcorrosion. Takenoteof theareaswith A/Clubricant leakagetoallow extra time in these areas with an electronic leak detector.AHA281AAHA951PRECAUTIONS FOR HANDLING LEAK DETECTORWhen performing a refrigerant leak check, use a J41955 A/C leakdetector or equivalent. Ensure that the instrument is calibrated andset properly per the operating instructions.Theleakdetectorisadelicatedevice. Inordertousetheleakdetector properly, read the operating instructions and perform anyspecified maintenance.Other gases in the work area or substances on the A/Ccomponents, for example, anti-freeze, windshield washer fluid, sol-vents and lubricants, may falsely trigger the leak detector. Makesure the surfaces to be checked are clean. Clean with a dry clothor blow off with shop air. Do not allow the sensor tip of the detec-tor to contact any substance. This can also cause false readingsand may damage the detector.1. Position probe approximately 5 mm (3/16 in) away from pointto be checked.SHA706E2. When testing, circle each fitting completely with probe.AHA5973. Move probe along component approximately 25-50 mm/sec.(1-2 in./sec.)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESHA-51CHECKING PROCEDUREToprevent inaccurateor falsereadings, makesurethereisnorefrigerant vapor, shop chemicals or smoke in the vicinity of thevehicle. 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 serviceports.3. Check if the A/C refrigerant pressure is at least 345 kPa (50psi) above16C(60F). If lessthanspecification, recover/evacuate and recharge the system with the specified amountof refrigerant.NOTE: At temperatures below 16C (60F), leaks may not bedetected since the system may not reach 345 kPa (50psi).4. Conduct theleaktest fromthehighside(compressor dis-chargeA to evaporator inletF ) to the low side (evaporatordrain hoseGto compressor suctionK ). Refer to HA-50.Perform a leak check for the following areas carefully. Cleanthecomponent tobecheckedandmovetheleakdetectorprobe completely around the connection/component.G CompressorCheck the fittings of high and low-pressure hoses, relief valve,and shaft seal.G Liquid tankCheck the pressure switch, tube fitting, weld seams and thefusible plug mount.G Service valvesCheck all around the service valves. Ensure service valve capsare secured on the service valves (to prevent leaks).NOTE: Afterremoving A/Cmanifoldgaugeset fromservicevalves, wipe any residue from valves to prevent anyfalse readings by leak detector.G Cooling unit (Evaporator)Withengineoff, turnblowerfanon4-speedforat least 15seconds to dissipate any refrigerant trace in the cooling unit.Wait a minimum of 10 minutes accumulation time (Refer to themanufacturers recommended procedure for actual wait time.)before inserting the leak detector probe into the drain hose.(Keep the probe inserted for at least ten seconds.)Use caution not to contaminate the probe tip with water or dirtthat may be in the drain hose.5. If theleakdetector detectsaleak, verifyat least oncebyblowingcompressedair intoareaof suspectedleak, thenrepeat check as outlined above.6. Donot stopwhenoneleakisfound. Continuetocheckforadditional leaks at all system components and connections.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 ONb. Face modec. Recirculation switch ONd. Max cold temperaturee. Fan speed high9. Run engine at 1500 rpm for at least 2 minutes.10. Turn engine off and perform leak check again following steps4 - 6 above.SERVICE PROCEDURESChecking Refrigerant Leaks (Contd)HA-52AHA936Refrigerant leaks should be checked immediately after stopping theengine. Begin with the leak detector at the compressor. The pres-sure on the high pressure side will gradually drop after refrigerantcirculation stops and pressure on the low pressure side will gradu-allyrise, asshowninthegraph. Someleaksaremoreeasilydetected when pressure is high.11. Before connecting ACR4 to vehicle, check ACR4 gauges. Norefrigerant pressure should be displayed. If pressure isdisplayed, recover refrigerant from equipment lines and thencheck refrigerant purity.12. Confirm refrigerant purity in supply tank using ACR4 and refrig-erant identifier. Refer to CONTAMINATED REFRIGERANT,HA-3.13. Confirm refrigerant purity in vehicle A/C system using ACR4and refrigerant identifier. Refer to CONTAMINATEDREFRIGERANT, HA-3.14. DischargeA/Csystemusingapprovedrefrigerant recoveryequipment. Repair the leaking fitting or component as neces-sary.15. Evacuate and recharge A/C system and perform the leak testto confirm no refrigerant leaks.16. Conduct A/C performance test to ensure system works prop-erly.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESChecking Refrigerant Leaks (Contd)HA-53R-134a Service ProcedureDISCHARGING REFRIGERANTWARNING:Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose andthroat. Remove R-134a from the A/C system using certified service equipment meeting requirementsof SAE J2210 (R-134a recycling equipment) or J2209 (R-134a recovery equipment). If accidental sys-tem discharge occurs, ventilate work area before resuming service. Additional health and safety infor-mation may be obtained from refrigerant and lubricant manufacturers.AHA269AEVACUATING SYSTEM AND CHARGING REFRIGERANTAHA270ASERVICE PROCEDURESHA-54Before connecting ACR4 to vehicle, check ACR4 gauges. Norefrigerant pressure should be displayed. If NG, Recover refrig-erant from equipment lines.Confirm refrigerant purity in supply tank using ACR4 and refrig-erant identifier.OKNGRefer to CONTAMI-NATED REFRIGER-ANT. Refer to HA-3.Connect ACR4 to vehicle.Confirm refrigerant purity in vehicle A/C system using ACR4and refrigerant identifier.OKNGRefer to CONTAMI-NATED REFRIGER-ANT. Refer to HA-3.Set the recovery/recycling equipment.Recovered lubricantDischarge refrigerant into recovery/recycling equipment.Repair or replace parts.Evacuate (over 25 minutes). Check air tightness.OK*1NGRepair.Partial charging [approx. 200 g (7.05 oz)].Preliminary refrigerant leak check. PRELIMINARY CHECK.Refer to HA-51.OK1*NGComplete charging (specified amount less partial chargeamount). Refer to SDS.*2Check for refrigerant leaks CHECKING PROCEDURE. Referto HA-52.OKNGCheck for A/C operation and A/C cooling performance.Performance TestDiagnoses. Refer toHA- 41.Remove service couplers from A/C service valves.Recover refrigerant in charging hoses.Remove service tools.Reinstall service valve caps.Note: *1 Before charging refrigerant, ensure engine is off.*2 Before checking for leaks, start engine to activate air conditioning system, then turn engine OFF.Service valve caps must be installed to prevent leakage.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESR-134a Service Procedure (Contd)HA-55Compressor Lubricant QuantityThe lubricant used to lubricate the compressor circulates throughthe system with the refrigerant. Whenever any A/C component isreplaced or gas leakage occurs, lubricant must be added.If lubricant quantity is not maintained properly, the following mal-functions may result:GLack of lubricant: May lead to a seized compressorGExcessivelubricant: Inadequatecooling(thermal exchangeinterference)LUBRICANTName: Nissan A/C System Lubricant Type RPart No.: KLH00-PAGR0CHECKING AND ADJUSTINGAdjust thelubricant quantityaccordingtotheflowchart shownbelow.STARTCan lubricant return operation be performed?G A/C system works properly.G There is no evidence of a large amount oflubricant leakage.NoYesPerform lubricant return operation, proceeding as follows:1. Start engine, and set the following conditions:GTest conditionEngine speed: Idling to 1,200 rpmA/C switch: ONRECIRCULATION switch: OFFFan speed: Max. positionTemp. control: (Optional) Set so that intake air temperature is25 to 30C (77 to 86F).2. Perform lubricant return operation for 10 minutes.3. Stop engine.CAUTION:If excessive lubricant leakage is noted, do not perform the lubri-cant return operation.Should the compressor be replaced?NoYesA(Go to next page.)Is there any part to be replaced? (Evaporator,condenser, liquid tank or in case there is evi-dence of a large amount of lubricant leakage?)NoYesAfter replacing any of the following major components, add the correctamount of lubricant to the system.Amount of lubricant to be added:*1: If compressor is replaced, addition of lubricant is included in theflow chart.*2: If refrigerant leak is small, no addition of lubricant is needed.Perform the A/C Performance Test.Refer to HA-41.Part replacedLubricant to be added to sys-temRemarksAmount of lubricantml (US fl oz, Imp fl oz)Evaporator75 (2.5, 2.6)Condenser75 (2.5, 2.6)Liquid tank5 (0.2, 0.2)Add if compressor isnot replaced.*1In case of refrigerant leak30 (1.0, 1.1)Large leakSmall leak*2SERVICE PROCEDURESHA-56A1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrig-erant from equipment lines and then check refrigerant purity.2. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. Refer to CONTAMINATED REFRIGERANT,HA-3.3. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. Refer to CONTAMINATEDREFRIGERANT, HA-3.4. Discharge refrigerant into refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recyclingequipment.5. Drain the lubricant from the old (removed) compressor into a graduated container and record the amount of lubricant drained.6. Drain the lubricant from the new compressor into a separate, clean container.7. Measure an amount of new lubricant equal to amount drained from old compressor. Add this lubricant to new compressorthrough the suction port opening.8. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressorthrough the suction port opening.9. If the liquid tank also needs to be replaced, add an additional 5 ml (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time.Do not add this 5 ml (0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.Lubricant adjusting procedure for compressor replacementAHA374GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESCompressor Lubricant Quantity (Contd)HA-57Compressor MountingAHA855Belt TensionGRefertoMAsection(CheckingDriveBelts, ENGINEMAINTENANCE).Fast Idle Control Device (FICD)GRefer to EC section (IACV-FICD Solenoid Valve,TROUBLEDIAGNOSISFORNON-DETECTABLEITEMS).CondenserAHA150AAHA151AREMOVAL1.Discharge refrigerant using the recovery/recycling equipment(ACR4).2.Remove side marker lamps.3.Remove front grille (4 fasteners).4.Remove harness clip from hood lock stay, if equipped (gentlypress out).5.Remove grille apron (5 nuts).6.Remove hood lock stay brace (4 bolts). Remove hood latch (3bolts).7.Removehose(high-pressure) clampbracket fromradiatorcore support.8.Disconnect high-pressure hose at condenser.9.Disconnect dual-pressure switch harness connector.10. Disconnect high-pressure tube (liquid tank to cooling unit) atliquid tank.11. Remove liquid tank and bracket.12. Remove lower core support seal (4 bolts).13. Loosen windshield washer tank bolts.14. Remove condenser mounting bolts (2 bolts).15. Remove condenser assembly.CAUTION:Carefullylift condenserwithout damagingradiator(finandtube).SERVICE PROCEDURESHA-58CompressorRHA401DAAHA841Compressor ClutchREMOVALG When removing center bolt, hold clutch disc with clutch discwrench.AHA842GRemove the drive plate using the clutch disc puller.Insert holders three pins into the drive plate. Rotate the holderclockwise to hook it onto the plate. Then, tighten the center boltto remove the drive plate.While tightening the center bolt, insert a round bar(screwdriver, etc.) between two of the pins (as shown in thefigure) to prevent drive plate rotation. After removing the driveplate, remove the shims from either the drive shaft or the driveplate.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESHA-59AHA843GRemove the snap ring using external snap ring pliers.AHA391GFor pulley removal use pulley puller.Use a commercially available pully puller. Position the centerof the puller on the end of the drive shaft. Remove the pullyassembly with the puller.For Pressed Pulleys:Toprevent deformationof thepulleygroove, thepullerclaws should be hooked under (not into) the pulleygroove.G Remove the field coil harness clip using a screwdriver.RHA074CGRemove the three field coil fixing screws and remove the fieldcoil.RHA075CINSPECTIONClutch discIf thecontact surfaceshowssignsof damageduetoexcessiveheat, replace clutch disc and pully.PulleyCheck the appearance of the pulley assembly. If contact surface ofpulley shows signs of excessive grooving, replace clutch disc andpulley. Thecontact surfacesof thepulleyassemblyshouldbecleaned with a suitable solvent before reinstallation.CoilCheck coil for loose connection or cracked insulation.SERVICE PROCEDURESCompressor Clutch (Contd)HA-60RHA076CINSTALLATIONG Install the field coil.G Be sure to align the coils pin with the hole in the com-pressors front head.G Install the field coil harness clip using a screwdriver.AHA845GInstall thepulleyassemblyusingtheinstaller andahandpress, and then install the snap ring using snap ring pliers.RHA078CGInstall thedriveplateonthedriveshaft, together withtheoriginal shim(s). Press the drive plate down by hand.AHA847GUsing the holder to prevent drive plate rotation, tighten the boltto 12 to 15 Nm (1.2 to 1.5 kg-m, 9 to 11 ft-lb) torque.G After tighteningthebolt, checkthat thepulleyrotatessmoothly.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESCompressor Clutch (Contd)HA-61AHA848GCheck clearance all the way around the clutch disc.Disc-to-pulley clearance:0.3 - 0.6 mm (0.012 - 0.024 in)If thespecifiedclearanceisnot obtained, replaceadjustingspacer and recheck.BREAK-IN OPERATIONWhen replacing compressor clutch assembly, always conduct thebreak-in operation. This is done by engaging and disengaging theclutch about 30 times. Break-in operation raises the level of trans-mitted torque.AHA849Thermal ProtectorINSPECTIONG When servicing, do not allow foreign matter to get into com-pressor.G Check continuity between two terminals.SERVICE PROCEDURESCompressor Clutch (Contd)HA-62Heater Unit (Heater Core)AHA118AREMOVAL1. Drainthecoolingsystem. Refer toMAsection, (ChangingEngine Coolant).2. Disconnect the two heater hoses from inside the engine com-partment.3. Remove the cooling unit. Refer to HA-64.4. Remove the steering member assembly. Refer to BT section(Instrument Panel).5. Remove the heater unit.6. Remove the heater core.INSTALLATIONInstallation is basically the reverse order of removal.When filling radiator with coolant, refer to MA section(Changing Engine Coolant).GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESHA-63Cooling Unit (A/C Evaporator)AHA124AAHA125AREMOVAL1. Discharge the A/C system. Refer to HA-54.2. Disconnect the two refrigerant lines from the engine compart-ment.G Cap the A/C lines to prevent moisture from entering thesystem.3. Remove the glove box and mating trim. Refer to BT section(Instrument Panel).4. Disconnect the thermal amp. connector.5. Remove the cooling unit.6. Separate the cooling unit case, and remove the evaporator.INSTALLATIONInstallation is basically the reverse order of removal.Recharge the A/C system. Refer to HA-54.SERVICE PROCEDURESHA-64AHA130ABlower Case and MotorREMOVAL1. Remove the glove box and mating trim. Refer to BT section(Instrument Panel).2. Remove the cooling unit. Refer to HA-64.3. Disconnect the fan motor resistor.4. Disconnect the fan motor.5. Remove the blower case and motor.6. Remove the three bolts and remove the motor from the blowercase.INSTALLATIONInstallation is basically the reverse order of removal.G Recharge the A/C system. Refer to HA-54.GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE PROCEDURESHA-65Fan Lever and Illumination BulbsAHA134AAHA126AREMOVAL1. Remove A/C & Heat control. Refer to BT section (InstrumentPanel).2. Loosen illumination bulbs and wire and pull out.SERVICE PROCEDURESHA-66General SpecificationsCOMPRESSORModel DKV-14CType Vane rotaryDisplacement cm3(cu in)/Rev 140 (8.54)Direction of rotationClockwise (Viewed from driveend)Drive belt A typeLUBRICANTModelZEXEL makeDKV-14CNameNissan A/C System LubricantType RPart No. KLH00-PAGR0Capacity ml (US fl oz, Imp fl oz)Total in system 200 (6.8, 7.0)Compressor (Service part)charging amount200 (6.8, 7.0)REFRIGERANTType R-134aCapacity kg (lb)g (oz)0.60 - 0.70 (1.32 - 1.54)600 - 700 (21.16 - 24.69)Inspection and AdjustmentENGINE IDLING SPEEDWhen A/C is ONG Refer to EC section (Inspection andAdjustment, SERVICE DATAAND SPECIFI-CATIONS).BELT TENSIONG Refer to MA section (Checking Drive Belts,ENGINE MAINTENANCE).COMPRESSOR CLUTCHModel DKV-14CClutch disc-pulley clearancemm (in)0.3 - 0.6(0.012 - 0.024)GIMAEMLCECFECLMTATTFPDFARABRSTRSBTHAELIDXSERVICE DATA AND SPECIFICATIONS (SDS)HA-67NOTESHA-68