AUTOMATIC AIR CONDITIONER

J AIR CONDITIONER

B
SECTION
AUTOMATIC AIR CONDITIONER C

E
CONTENTS
PRECAUTIONS .......................................................... 4 LUBRICANT .............................................................. 22 F
Precautions for Supplemental Restraint System Maintenance of Lubricant Quantity in Compressor... 22
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- LUBRICANT ........................................................ 22
SIONER” .................................................................. 4 LUBRICANT RETURN OPERATION .................. 22 G
Precautions for Working with HFC-134a (R-134a)..... 4 LUBRICANT ADJUSTING PROCEDURE FOR
General Refrigerant Precautions .............................. 5 COMPONENTS REPLACEMENT EXCEPT
Lubricant Precautions .............................................. 5 COMPRESSOR .................................................. 23
H
Precautions for Refrigerant Connection ................... 6 LUBRICANT ADJUSTING PROCEDURE FOR
FEATURES OF NEW TYPE REFRIGERANT COMPRESSOR REPLACEMENT ....................... 23
CONNECTION ...................................................... 6 AIR CONDITIONER CONTROL ............................... 25
O-RING AND REFRIGERANT CONNECTION..... 7 Overview Air Conditioner LAN Control System ...... 25 I
Precautions for Servicing Compressor ..................... 8 System Construction .............................................. 25
Precautions for Service Equipment .......................... 9 OPERATION ........................................................ 26
RECOVERY/RECYCLING EQUIPMENT .............. 9 TRANSMISSION DATA AND TRANSMISSION ATC
ELECTRONIC LEAK DETECTOR ........................ 9 ORDER ............................................................... 26
VACUUM PUMP ................................................... 9 AIR MIX DOOR CONTROL (AUTOMATIC TEM-
MANIFOLD GAUGE SET ...................................... 9 PERATURE CONTROL) ..................................... 27
K
SERVICE HOSES ................................................. 9 FAN SPEED CONTROL ...................................... 27
SERVICE COUPLERS ........................................ 10 INTAKE DOOR CONTROL ................................. 27
REFRIGERANT WEIGHT SCALE ...................... 10 OUTLET DOOR CONTROL ................................ 27
CALIBRATING ACR4 WEIGHT SCALE .............. 10 MAGNET CLUTCH CONTROL ........................... 27 L
CHARGING CYLINDER ...................................... 10 SELF-DIAGNOSTIC SYSTEM ............................ 27
Precautions for Leak Detection Dye ........................11 Overview Of Control System .................................. 28
IDENTIFICATION .................................................11 Control Operation ................................................... 29 M
IDENTIFICATION LABEL FOR VEHICLE ............11 LHD MODELS ..................................................... 29
Wiring Diagrams and Trouble Diagnosis .................11 RHD MODELS .................................................... 30
PREPARATION ......................................................... 12 DISPLAY SCREEN .............................................. 30
Special Service Tools ............................................. 12 A/C SWITCH (DRIVER SIDE) ............................. 30
HFC-134a (R-134a) Service Tools and Equipment... 12 A/C SWITCH (PASSENGER SIDE) .................... 30
REFRIGERATION SYSTEM ..................................... 16 TEMPERATURE DIAL (POTENTIO TEMPERA-
Refrigerant Cycle ................................................... 16 TURE CONTROL) (DRIVER SIDE) ..................... 30
REFRIGERANT FLOW ....................................... 16 TEMPERATURE DIAL (POTENTIO TEMPERA-
FREEZE PROTECTION ..................................... 16 TURE CONTROL) (PASSENGER SIDE) ............ 30
Refrigerant System Protection ............................... 16 INTAKE SWITCH ................................................. 30
REFRIGERANT PRESSURE SENSOR ............. 16 DEFROSTER (DEF) SWITCH ............................. 31
PRESSURE RELIEF VALVE ............................... 16 OFF SWITCH ...................................................... 31
V-6 Variable Displacement Compressor ................. 17 MODE SWITCH (DRIVER SIDE) ........................ 31
GENERAL INFORMATION ................................. 17 MODE SWITCH (PASSENGER SIDE) ................ 31
DESCRIPTION .................................................... 17 ECON (ECONOMY) SWITCH ............................. 31
Component Layout ................................................. 21 FAN SWITCH ...................................................... 31

ATC-1
 DUAL SWITCH .................................................... 31 COMPONENT DESCRIPTION ............................88
REAR SWITCH ................................................... 31 DIAGNOSTIC PROCEDURE ...............................88
Discharge Air Flow ................................................. 32 COMPONENT INSPECTION ...............................90
System Description ................................................. 33 Magnet Clutch Circuit ..............................................91
SWITCHES AND THEIR CONTROL FUNCTION... 33 INSPECTION FLOW ............................................91
TROUBLE DIAGNOSIS ............................................ 34 SYSTEM DESCRIPTION .....................................92
How to Perform Trouble Diagnoses for Quick and DIAGNOSTIC PROCEDURE ...............................92
Accurate Repair ...................................................... 34 COMPONENT INSPECTION ...............................96
WORK FLOW ...................................................... 34 Insufficient Cooling ..................................................97
SYMPTOM TABLE .............................................. 34 INSPECTION FLOW ............................................97
Component Parts and Harness Connector Location... 35 PERFORMANCE TEST DIAGNOSES ................98
ENGINE COMPARTMENT .................................. 35 PERFORMANCE CHART .................................. 100
PASSENGER COMPARTMENT .......................... 36 TROBLE DIAGNOSES FOR ABNORMAL
Circuit Diagram ....................................................... 37 PRESSURE ....................................................... 101
Wiring Diagram —A/C— ......................................... 38 DIAGNOSTIC PROCEDURE FOR ECV CIR-
Auto Amp. Terminals and Reference Value ............ 56 CUIT (RHD MODELS) ....................................... 104
PIN CONNECTOR TERMINAL LAYOUT ............ 56 Insufficient Heating ............................................... 106
AUTO AMP. INSPECTION TABLE ...................... 56 INSPECTION FLOW .......................................... 106
Self-diagnosis Function .......................................... 59 Noise ..................................................................... 107
DESCRIPTION .................................................... 59 INSPECTION FLOW .......................................... 107
PROCEDURE ...................................................... 60 Self-diagnosis ....................................................... 108
AUXILIARY MECHANISM: TEMPERATURE INSPECTION FLOW .......................................... 108
SETTING TRIMMER ........................................... 66 Memory Function .................................................. 109
Operational Check .................................................. 67 INSPECTION FLOW .......................................... 109
CHECKING MEMORY FUNCTION ..................... 67 ECON (ECONOMY) Mode .................................... 110
CHECKING BLOWER ......................................... 67 INSPECTION FLOW .......................................... 110
CHECKING DISCHARGE AIR ............................ 67 Air Purifier Circuit .................................................. 111
CHECKING RECIRCUATION .............................. 68 DIAGNOSTIC PROCEDURE ............................. 111
CHECKING TEMPERATURE DECREASE ......... 68 A/C display is malfunctioning. ............................... 113
CHECKING TEMPERATURE INCREASE .......... 69 DIAGNOSTIC PROCEDURE ............................. 113
CHECK ECON (ECONOMY) MODE ................... 69 A/C operation is malfunctioning. ........................... 114
CHECKING AUTO MODE ................................... 69 DIAGNOSTIC PROCEDURE ............................. 114
Power Supply and Ground Circuit for Auto Amp. ... 70 Ambient Sensor Circuit ......................................... 116
INSPECTION FLOW ........................................... 70 COMPONENT DESCRIPTION .......................... 116
COMPONENT DESCRIPTION ............................ 70 AMBIENT TEMPERATURE INPUT PROCESS . 116
DIAGNOSTIC PROCEDURE .............................. 71 DIAGNOSTIC PROCEDURE ............................. 116
LAN System Circuit ................................................ 72 COMPONENT INSPECTION ............................. 118
DIAGNOSTIC PROCEDURE .............................. 72 In-vehicle Sensor Circuit ....................................... 118
Mode Door Motor Circuit ........................................ 76 COMPONENT DESCRIPTION .......................... 118
INSPECTION FLOW ........................................... 76 DIAGNOSTIC PROCEDURE ............................. 119
SYSTEM DESCRIPTION .................................... 77 COMPONENT INSPECTION ............................. 120
COMPONENT DESCRIPTION ............................ 78 Sunload Sensor Circuit ......................................... 121
DIAGNOSTIC PROCEDURE .............................. 78 COMPONENT DESCRIPTION .......................... 121
Air Mix Door Motor Circuit ...................................... 79 SUNLOAD INPUT PROCESS ........................... 121
INSPECTION FLOW ........................................... 79 DIAGNOSTIC PROCEDURE ............................. 121
SYSTEM DESCRIPTION .................................... 80 COMPONENT INSPECTION ............................. 123
COMPONENT DESCRIPTION ............................ 81 Intake Sensor Circuit ............................................. 124
DIAGNOSTIC PROCEDURE .............................. 81 COMPONENT DESCRIPTION .......................... 124
Intake Door Motor Circuit ........................................ 82 DIAGNOSTIC PROCEDURE ............................. 124
INSPECTION FLOW ........................................... 82 Multiplex Communication Circuit ........................... 125
SYSTEM DESCRIPTION .................................... 83 DIAGNOSTIC PROCEDURE ............................. 125
COMPONENT DESCRIPTION ............................ 84 CONTROL UNIT ...................................................... 128
DIAGNOSTIC PROCEDURE .............................. 84 Removal and Installation ....................................... 128
Rear Ventilator Door Motor ..................................... 84 AMBIENT SENSOR ................................................ 129
COMPONENT DESCRIPTION ............................ 84 Removal and Installation ....................................... 129
DIAGNOSTIC PROCEDURE .............................. 84 IN-VEHICLE SENSOR ............................................ 130
Blower Motor Circuit ............................................... 86 Removal and Installation ....................................... 130
INSPECTION FLOW ........................................... 86 SUNLOAD SENSOR ............................................... 131
SYSTEM DESCRIPTION .................................... 87 Removal and Installation ....................................... 131

ATC-2
INTAKE SENSOR CIRCUIT ................................... 132 REMOVAL ......................................................... 150
Removal and Installation ...................................... 132 INSTALLATION ................................................. 152 A
BLOWER UNIT ....................................................... 133 Removal and Installation for Low-pressure Flexible
Removal and Installation ...................................... 133 Hose ..................................................................... 153
REMOVAL ......................................................... 133 REMOVAL ......................................................... 153 B
INSTALLATION ................................................. 133 INSTALLATION ................................................. 153
Disassembly and Assembly ................................. 134 Removal and Installation for High-Pressure Flexible
BLOWER MOTOR .................................................. 135 Hose ..................................................................... 154
Removal and Installation ...................................... 135 REMOVAL ......................................................... 154 C
INTAKE DOOR MOTOR ......................................... 136 INSTALLATION ................................................. 154
Removal and Installation ...................................... 136 Removal and Installation for High-Pressure Pipe . 154
VENTILATION AIR FILTER .................................... 137 REMOVAL ......................................................... 154 D
Removal and Installation ...................................... 137 INSTALLATION ................................................. 155
FUNCTION ........................................................ 137 Removal and Installation for Refrigerant Pressure
REPLACEMENT TIMING .................................. 137 Sensor .................................................................. 155 E
REPLACEMENT PROCEDURES ..................... 137 Removal and Installation for Refrigerant Pressure
HEATER & COOLING UNIT ASSEMBLY .............. 138 Sensor (To be applied after the middle of June 2001.)
Removal and Installation ...................................... 138 . 155
REMOVAL ......................................................... 138 Removal and Installation for Condenser .............. 156 F
INSTALLATION ................................................. 139 REMOVAL ......................................................... 156
Disassembly and Assembly ................................. 140 INSTALLATION ................................................. 157
MODE DOOR MOTOR ........................................... 141 Removing and Installation for Liquid Tank (To be G
Removal and Installation ...................................... 141 applied after the middle of June 2001.) ................ 157
DRIVER SIDE MODE DOOR MOTOR ............. 141 REMOVAL ......................................................... 157
PASSENGER SIDE MODE DOOR MOTOR ..... 141 INSTALLATION ................................................. 158 H
AIR MIX DOOR MOTOR ......................................... 142 Removal and Installation for Evaporator .............. 158
Removal and Installation ...................................... 142 REMOVAL ......................................................... 158
DRIVER SIDE AIR MIX DOOR MOTOR ........... 142 INSTALLATION ................................................. 158
I
PASSENGER SIDE AIR MIX DOOR MOTOR . 142 Removal and Installation for Expansion Valve ...... 158
DUCTS AND GRILLES .......................................... 143 Removal and Installation for Desiccant Assembly. 159
Removal and Installation ...................................... 143 REMOVAL ......................................................... 159
VENTILATOR DUCT, DEFROSTER NOZZLE INSTALLATION ................................................. 159 ATC
AND DEFROSTER DUCTS .............................. 143 Checking for Refrigerant Leaks ............................ 159
CENTER VENTILATOR GRILLE ...................... 143 Checking System for Leaks Using the Fluorescent
SIDE VENTILATOR GRILLE ............................. 143 Leak Detector ....................................................... 160 K
REAR VENTILATOR GRILLE ........................... 144 Dye Injection ......................................................... 160
REAR VENTILATOR GRILLE ........................... 144 Electronic Refrigerant Leak Detector .................... 160
REAR VENTILATOR DUCTS ............................ 144 PRECAUTION FOR HANDLING LEAK DETEC- L
REAR VENTILATOR SIDE DUCTS .................. 145 TOR ................................................................... 160
FOOT DUCT ..................................................... 145 CHECKING PROCEDURE ............................... 161
FLOOR DUCT ................................................... 145 SERVICE DATA AND SPECIFICATIONS (SDS) .... 163
REFRIGERANT LINES ........................................... 146 COMPRESSOR .................................................... 163 M
HFC-134a (R-134a) Service Procedure ............... 146 LUBRICANT ......................................................... 163
SETTING OF SERVICE TOOLS AND EQUIP- REFRIGERANT .................................................... 163
MENT ................................................................ 146 ENGINE IDLING SPEED ...................................... 163
Components ......................................................... 148 BELT TENSION .................................................... 163
Removal and Installation for Compressor ............ 149 AIR PURIFIER ......................................................... 164
REMOVAL ......................................................... 149 Removal and Installation ...................................... 164
INSTALLATION ................................................. 149 Disassembly and Assembly .................................. 164
Removal and Installation for Compressor Clutch . 150 Replacement Procedure for Air filter .................... 164

ATC-3
 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” EJS002JN

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 harness connec-
tors.
Precautions for Working with HFC-134a (R-134a) EJS0015A

WARNING:
● CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These refrigerants
must never be mixed, even in the smallest amounts. If the refrigerants are mixed and compressor
failure is likely occur.
● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. If lubricant other than that specified is used, compressor failure is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
– When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
– When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just
before connecting the components. Connect all refrigerant loop components as quickly as possi-
ble to minimize the entry of moisture into system.
– Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-
cant. Without proper sealing, lubricant will become moisture saturated and should not be used.
– Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refriger-
ant. If accidental system discharge occurs, ventilate work area before resuming service. Addi-
tional health and safety information may be obtained from refrigerant and lubricant
manufacturers.
– Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.
Damage may result.

ATC-4
 PRECAUTIONS

General Refrigerant Precautions EJS0015B

A
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 B
air conditioning system.
● Do not store or heat refrigerant containers above 52°C (125°F).
C
● 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.
D
● 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.
E
● Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and R-134a have been
shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or
property damage. Additional health and safety information may be obtained from refrigerant man- F
ufacturers.
Lubricant Precautions EJS0015C
G
● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
If lubricant other than that specified is used, compressor failure is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following H
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.
I
– 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.
ATC
– Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. With-
out proper sealing, lubricant will become moisture saturated and should not be used.
● Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If acciden- K
tal system discharge occurs, ventilate work area before resuming service. Additional health and safety
information may be obtained from refrigerant and lubricant manufacturers.
● Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage L
may result.

ATC-5
 PRECAUTIONS

Precautions for Refrigerant Connection EJS0015D

A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
● Expansion valve to evaporator
● 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-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
● The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil-
itating piping connections.

SHA815E

ATC-6
 PRECAUTIONS

O-RING AND REFRIGERANT CONNECTION

A

ATC
RJIA0193E

CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
K
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-Ring Part Numbers and Specifications L
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) M
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)
New 92474 N8210 16.5 (0.650) 2.43 (0.0957)
SHA814E 19
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
New 24 92195 AH300 21.8 (0.858) 2.4 (0.094)
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.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.

ATC-7
 PRECAUTIONS

● When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber.
● 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.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
● O-ring must be closely attached to dented portion of tube.
● When replacing the O-ring, be careful not to damage O-ring and tube.
● Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
● 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 EJS0015E

● 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 ATC-22, "Maintenance of Lubricant Quantity in Compressor" .
● Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-
cant, wipe it off by using a clean waste cloth moistened with thinner.
● After compressor service operation, turn the compressor shaft by hand more than five turns in
both directions. This will equally distribute lubricant inside the compressor. After the compressor
is installed, let the engine idle and operate the compressor for one hour.
● After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation.

ATC-8
 PRECAUTIONS

Precautions for Service Equipment EJS0015F

RECOVERY/RECYCLING EQUIPMENT A
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
B
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
VACUUM PUMP C
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres- D
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose- E
to-pump connection, as follows.
● Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the F
pump.
● 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 G
the hose from the pump.
● If the hose has an automatic shut off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is H
open and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
I
ability to pull a deep vacuum and are not recommended.

RHA270DA
ATC
MANIFOLD GAUGE SET
Be certain that the gauge face indicates R-134a or 134a. Be sure the
gauge set has 1/2″-16 ACME threaded connections for service K
hoses. Confirm the set has been used only with refrigerant HFC-
134a (R-134a) and specified lubricants.
L

SHA533D

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

ATC-9
 PRECAUTIONS

SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to an
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. However, if an
improper connection is attempted, discharging and contamination
may occur.
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close

RHA273D

REFRIGERANT WEIGHT SCALE

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

RHA274D

CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press Shift/Reset and Enter at the same time.
2. Press 8787 . “A1 ” will be displayed.
3. Remove all weight from the scale.
4. Press 0 , then press Enter . “0.00 ” will be displayed and change to “A2 ”.
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of
the weight scale.
6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50)
7. Press Enter — the display returns to the vacuum mode.
8. Press Shift/Reset and Enter at the same time.
9. Press 6 — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00 ” will be displayed.
11. Press Shift/Reset to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.

ATC-10
 PRECAUTIONS

Precautions for Leak Detection Dye EJS0015G

A
● 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.
● Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of
the fluorescent dye. B
● 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.
C
● Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a
future service.
● Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,
clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period D
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. E
● 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 (R-12) leak detector dye
in HFC-134a (R-134a) A/C systems or A/C system damage may result. F
● The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
occurs.
G
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label. H

IDENTIFICATION LABEL FOR VEHICLE

Vehicles with factory installed fluorescent dye have this identification I
label on the under side of hood.

ATC

SHA436FA L
Wiring Diagrams and Trouble Diagnosis EJS0015I

When you read wiring diagrams, refer to the followings: M

● GI-14, "How to Read Wiring Diagrams" in GI section.
● PG-4, "Wiring Diagram — POWER —"in PG section.
When you perform trouble diagnosis, refer to the followings:
● GI-10, "How to Follow Trouble Diagnoses" in GI section.
● GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

ATC-11
 PREPARATION

PREPARATION PFP:00002

Special Service Tools EJS0015J

Tool number
Description
Tool name

KV99106100 Removing shaft nut and clutch disc

Clutch disc wrench

S-NT232

RJIA0194E

KV99232340 Removing clutch disc

or
KV992T0001
Clutch disc puller

S-NT376

KV99106200 Installing pulley

Pulley installer

S-NT235

HFC-134a (R-134a) Service Tools and Equipment EJS0015K

Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubri-
cant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubri-
cant.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will
occur and compressor failure will result.

ATC-12
 PREPARATION

Tool number
Tool name
Description A

Container color:Light blue B

Container marking:HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size:Thread size
● large container 1/22 -16 ACME C
S-NT196

Type:Poly alkylene glycol oil (PAG), D

type S
KLH00-PAGS0 Application:HFC-134a (R-134a)
Nissan A/C System Oil Type S swash plate compressors (Nissan
only) E
Lubricity:40 ml [Litre] (1.4 Imp fl oz)
S-NT197

G
Recovery/Recycling Function:Refrigerant Recovery and
Recharging equipment (ACR4) Recycling and Recharging
H

RJIA0195E
I

ATC

Power supply:
Electrical leak detector K
● DC 12V (Cigarette lighter)

SHA705EB

M
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses Power supply:
(J-41459) Refrigerant dye injector DC 12V (Battery terminal)
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleaner
SHA437F

ATC-13
 PREPARATION

Tool number
Description
Tool name

Power supply: DC 12V (Battery

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

(J-41459)
HFC-134a (R-134a) Dye injector For injecting 1/4 ounce of fluorescent
Use with J-41447, 1/4 ounce leak detection dye into A/C system.
bottle

SHA440F

(J-43872)
For cleaning dye spills.
Dye cleaner

SHA441F

Identification:
Manifold gauge set (with hoses ● The gauge face indicates R-134a.
and couplers) Fitting size:Thread size
● 1/22 -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
● 1/22 -16 ACME

ATC-14
 PREPARATION

Tool number
Description A
Tool name

Service couplers Hose fitting to service hose: B

● High side coupler ● M14 x 1.5 fitting is optional or
● Low side coupler permanently attached.
C
S-NT202

D
For measuring of refrigerant
Refrigerant weight scale Fitting size:Thread size
● 1/22 -16 ACME E

S-NT200

Capacity: F
● Air displacement:4 CFM
Vacuum pump ● Micron rating:20 microns
(Including the isolator valve)
● Oil capacity:482 g (17 oz)
G
Fitting size:Thread size
S-NT203 ● 1/22 -16 ACME
H

ATC

ATC-15
 REFRIGERATION SYSTEM

REFRIGERATION SYSTEM PFP:KA990

Refrigerant Cycle EJS0015M

REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank,
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is
controlled by an externally equalized expansion valve, located inside the evaporator case.
FREEZE PROTECTION
Under normal 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.
Refrigerant System Protection EJS0015N

REFRIGERANT PRESSURE SENSOR

The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sen-
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
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).
PRESSURE RELIEF VALVE
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (38 kg/
cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into
the atmosphere.

RJIA0198E

ATC-16
 REFRIGERATION SYSTEM

V-6 Variable Displacement Compressor EJS0015O

GENERAL INFORMATION A
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). B
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 C
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
D
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. E
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. F

DESCRIPTION
General G
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- H
ously changed from 14.5 to 184 cm3 (0.885 to 11.228 cu in).

ATC

ATC-17
 REFRIGERATION SYSTEM

RHA037DD

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.

ATC-18
 REFRIGERATION SYSTEM

Under this condition, the swash plate is set to the maximum stroke position.
A

RHA473C

3. Capacity Control G
● 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
H
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 I
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 ATC
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
triggers pressure difference between the piston and the crankcase. The pressure difference changes the
angle of the swash plate. K

RHA474C

ATC-19
 REFRIGERATION SYSTEM

Electrical Control Valve (RHD Models)

● High-pressure valve lift is determined by balance among following : low-pressure applied to diaphragm,
spring, and magnetic intensity generated at electromagnetic coil.
● Electromagnetic coil in control valve receives a 400 Hz pulse signal from auto amplifier. Then it controls
high-pressure valve lift by varying magnetic intensity with duty-controlled effective current.

RJIA0629E

ATC-20
 REFRIGERATION SYSTEM

Component Layout EJS0015P

ATC

RJIA0199E

ATC-21
 LUBRICANT

LUBRICANT PFP:KLG00

Maintenance of Lubricant Quantity in Compressor EJS0015Q

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-
fied amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
● Lack of lubricant: May lead to a seized compressor
● Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
Name :Nissan A/C System Oil Type S
Part number :KLH00-PAGS0
LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?
● A/C system works properly.
● There is no evidence of a large amount of lubricant leakage.
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:

1. Start engine, and set the following conditions:
– Test condition
Engine speed: Idling to 1,200 rpm
A/C or AUTO switch: ON
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)
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.
CAUTION:
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 ATC-23, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
No >> GO TO 4.

ATC-22
 LUBRICANT

4. CHECK ANY PART A

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 B
Yes >> Go to ATC-23, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT
EXCEPT COMPRESSOR" .
No >> Carry out the A/C performance test. C
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. D
Amount of lubricant to be added
Lubricant to be added to system
Part replaced Remarks
E
Amount of lubricant
ml [Litre] (Imp fl oz)
Evaporator 75 (2.6) -
F
Condenser 35 (1.2) -
Liquid tank 10 (0.4) -
30 (1.1) Large leak G
In case of refrigerant leak
- Small leak *1
*1:If refrigerant leak is small, no addition of lubricant is needed.
H
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. I
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 ATC
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 K
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. L
7. If the liquid tank also needs to be replaced, add an additional 5 ml [Litre] (0.2 Imp fl oz) of lubricant at this
time.
Do not add this 5 ml (0.2 Imp fl oz) of lubricant if only replacing the compressor.
M

ATC-23
LUBRICANT

RHA065DD

ATC-24
 AIR CONDITIONER CONTROL

AIR CONDITIONER CONTROL PFP:27500

A
Overview Air Conditioner LAN Control System EJS0015R

The LAN system consists of auto amp., mode door motor, air mix door motor and intake door motor.
A configuration of these components is shown in the diagram below. B

E
RHA439GA

System Construction EJS0015S

F
A small network is constructed between the auto amplifier, air mix door motor and mode door motor. The auto
amplifier and motors are connected by data transmission lines and motor power supply lines. The LAN net-
work is built through the ground circuits of the two motors.
Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted G
through the data transmission lines connecting the auto amplifier and two motors.
The following functions are contained in LCUs built into the air mix door motor and the mode door motor.
● Address H
● Motor opening angle signals
● Data transmission
● Motor stop and drive decision I
● Opening angle sensor (PBR function)
● Comparison
ATC
● Decision (Auto amplifier indicated value and motor opening angle comparison)

RJIA0200E

ATC-25
 AIR CONDITIONER CONTROL

OPERATION
The auto amplifier receives data from each of the sensors. The amplifier sends mode door, air mix door and
intake door opening angle data to the mode door motor LCU, air mix door motor LCU and intake door motor
LCU.
The mode door motor, air mix door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amplifier and each of the motor posi-
tion sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subse-
quently, HOT/COLD, DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection
data is returned to the auto amplifier.

RJIA0201E

TRANSMISSION DATA AND TRANSMISSION ORDER

Amplifier data is transmitted consecutively to each of the door motors following the form shown in figure below.
Start:
Initial compulsory signal sent to each of the door motors.
Address:
Data sent from the auto amplifier is selected according to data-based decisions made by the air mix door
motor, mode door motor and intake door motor.
If the addresses are identical, the opening angle data and error check signals are received by the door motor
LCUs. The LCUs then make the appropriate error decision. If the opening angle data is normal, door control
begins.
If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon
the corrected opening angle data.
Opening angle:
Data that shows the indicated door opening angle of each door motor.
Error check:
Procedure by which sent and received data is checked for errors. Error data is then compiled. The error check
prevents corrupted data from being used by the air mix door motor, mode door motor and intake door motor.
Error data can be related to the following problems.
● Abnormal electrical frequency
● Poor electrical connections
● Signal leakage from transmission lines
● Signal level fluctuation
Stop signal:

ATC-26
 AIR CONDITIONER CONTROL

At the end of each transmission, a stop operation, in-operation, or internal problem message is delivered to
the auto amplifier. This completes one data transmission and control cycle. A

RJIA0202E
G
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload. H
FAN SPEED CONTROL
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature, amount of sunload and air mix door position. I
With FAN switch set to AUTO, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing. ATC
INTAKE DOOR CONTROL
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor. K

OUTLET DOOR CONTROL

The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle tem- L
perature, intake temperature and amount of sunload.
MAGNET CLUTCH CONTROL
The ECM controls compressor operation using input signals from the throttle position sensor and auto ampli- M
fier.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of problems.

ATC-27
 AIR CONDITIONER CONTROL

Overview Of Control System EJS0015T

The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs.
The relationship of these components is shown in the diagram below:

RJIA0470E

ATC-28
 AIR CONDITIONER CONTROL

Control Operation EJS0015U

LHD MODELS A

ATC

RJIA0204E

ATC-29
 AIR CONDITIONER CONTROL

RHD MODELS

RJIA0630E

DISPLAY SCREEN
Displays the operational status of the system.
A/C SWITCH (DRIVER SIDE)
● The compressor, intake doors, air mix doors, outlet doors and blower speed are automatically controlled
so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the
operator.
When the A/C system is operating, if the screen is not displayed, press the A/C switch once to display the A/C
screen. (The display time is determined by the navigation system settings.) Or, when the A/C system is in
manual control, and the DUAL switch is depressed, pressing the A/C switch changes to auto-control for the
driver side only.
A/C SWITCH (PASSENGER SIDE)
The compressor, intake doors, air mix doors, outlet doors and blower speed are automatically controlled so
that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.
● When the A/C system is operating, if the screen is not displayed, press the A/C switch once to display the
A/C screen. (The display time is determined by the navigation system settings.) Or, when the A/C system
is in manual control, and the DUAL switch is depressed, pressing the A/C switch changes to auto-control
for the passenger side only.
TEMPERATURE DIAL (POTENTIO TEMPERATURE CONTROL) (DRIVER SIDE)
Increase or decrease the set temperature.
TEMPERATURE DIAL (POTENTIO TEMPERATURE CONTROL) (PASSENGER SIDE)
● Increase or decrease the set temperature.
● When the temperature adjustment dial is turned, the DUAL switch indicator will automatically illuminate.
INTAKE SWITCH
Set the inlet to automatic control or to REC-fixed. However, REC-fixed cannot be selected in DEF mode.

ATC-30
 AIR CONDITIONER CONTROL

DEFROSTER (DEF) SWITCH

Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position. A

OFF SWITCH
The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet B
doors are set to the foot (80% foot and 20% defrost) position.
MODE SWITCH (DRIVER SIDE)
● When the DUAL switch indicator is illuminated, the left and right outlets are switched together. C
● When the DUAL switch indicator is not illuminated, only the driver-side outlet is switched.
MODE SWITCH (PASSENGER SIDE)
D
When the MODE switch is pressed, the DUAL switch indicator illuminates, and only the passenger-side outlet
is switched.
ECON (ECONOMY) SWITCH E
By pressing the ECON switch, the indicator of ECON switch should illuminate and the compressor always
turns OFF. With the compressor OFF, the system will not remove heat (cool) or de-humidify. The system will
maintain the in-vehicle temperature at the set temperature when the set the temperature is above the ambient F
(outside) temperature. The system will set the intake doors to the outside air position.
FAN SWITCH
Manually controls the blower speed. Five speeds are available for manual control (as shown on the display G
screen).
● Pressing switch activates fan. Pressing it again deactivates fan.
● When fan is running, indicator is lit. H
DUAL SWITCH
● When the DUAL switch indicator is not illuminated and the DUAL switch is pressed, the driver-side outlet
I
and passenger-side outlet, as well as the setting temperature, can each be set independently.
● When the DUAL switch indicator is illuminated and the DUAL switch is pressed, the driver-side outlet and
setting temperature is applied to both sides.
ATC
REAR SWITCH
● Pressing rear switch activates rear seat switch operation screen. It allows operating rear seat air outlet
switch and air cleaner switch. K

ATC-31
 AIR CONDITIONER CONTROL

Discharge Air Flow EJS0015V

RJIA0205E

ATC-32
 AIR CONDITIONER CONTROL

System Description EJS0015W

SWITCHES AND THEIR CONTROL FUNCTION A

I
RJIA0206E

ATC

RJIA0207E

ATC-33
 TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS PFP:00004

How to Perform Trouble Diagnoses for Quick and Accurate Repair EJS001V4

WORK FLOW
*1:Operational Check ATC-67

SHA900E

SYMPTOM TABLE
Symptom Reference Page
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C system. ATC-70
Go to Trouble Diagnosis Procedure for Multiple communication
ATC-71
circuit.
A/C system cannot be controlled.
Go to No A/C Display Is Shown. ATC-70
Go to A/C Operation Is Not Possible. ATC-70
Air outlet does not change.
Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN) ATC-72
Mode door motor does not operate normally.
Discharge air temperature does not change.
Air mix door motor does not operate nor- Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN) ATC-72
mally.
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor.(LAN) ATC-82
Intake door motor does not operate normally.
Blower motor operation is malfunctioning.
Blower motor operation is malfunctioning Go to Trouble Diagnosis Procedure for Blower Motor. ATC-86
under out of starting fan speed control.
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. ATC-91
Insufficient cooling. Go to Trouble Diagnosis Procedure for Insufficient Cooling. ATC-97
Insufficient heating. Go to Trouble Diagnosis Procedure for Insufficient Heating. ATC-106
Noise. Go to Trouble Diagnosis Procedure for Noise. ATC-107
Self-diagnosis can not be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis. ATC-108
Memory function does not operate. Go to Trouble Diagnosis Procedure for Memory Function. ATC-109
Go to Trouble Diagnosis Procedure for ECON (ECONOMY) -
ECON mode does not operate. ATC-110
mode.
Air purifier does not operate. Go to Trouble Diagnosis procedure for Air Purifier. ATC-111

ATC-34
 TROUBLE DIAGNOSIS

Component Parts and Harness Connector Location EJS0015Y

ENGINE COMPARTMENT A

ATC

RJIA0631E

ATC-35
 TROUBLE DIAGNOSIS

PASSENGER COMPARTMENT

RJIA0209E

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

ATC-36
 TROUBLE DIAGNOSIS

Circuit Diagram EJS0015Z

ATC

TJWT0001E

ATC-37
 TROUBLE DIAGNOSIS

Wiring Diagram —A/C— EJS00160

TJWT0002E

ATC-38
TROUBLE DIAGNOSIS

ATC

TJWT0003E

ATC-39
TROUBLE DIAGNOSIS

TJWT0004E

ATC-40
TROUBLE DIAGNOSIS

ATC

TJWT0005E

ATC-41
TROUBLE DIAGNOSIS

TJWT0006E

ATC-42
TROUBLE DIAGNOSIS

ATC

TJWT0007E

ATC-43
TROUBLE DIAGNOSIS

TJWT0008E

ATC-44
TROUBLE DIAGNOSIS

ATC

TJWT0009E

ATC-45
TROUBLE DIAGNOSIS

TJWT0010E

ATC-46
TROUBLE DIAGNOSIS

ATC

TJWT0011E

ATC-47
TROUBLE DIAGNOSIS

TJWT0012E

ATC-48
TROUBLE DIAGNOSIS

ATC

TJWT0013E

ATC-49
TROUBLE DIAGNOSIS

TJWT0014E

ATC-50
TROUBLE DIAGNOSIS

ATC

TJWT0015E

ATC-51
TROUBLE DIAGNOSIS

TJWT0016E

ATC-52
TROUBLE DIAGNOSIS

ATC

TJWT0017E

ATC-53
TROUBLE DIAGNOSIS

TJWT0018E

ATC-54
TROUBLE DIAGNOSIS

ATC

TJWT0019E

ATC-55
 TROUBLE DIAGNOSIS

Auto Amp. Terminals and Reference Value EJS00161

Measure voltage between each terminal and body ground by follow-

ing AUTO AMP. INSPECTION TABLE.

RJIA0210E

PIN CONNECTOR TERMINAL LAYOUT

RJIA0211E

AUTO AMP. INSPECTION TABLE

TERMI- WIRE- Voltage
ITEM CONDITION
NAL NO. COLOR (V)
1 G/OR Intake sensor - -
2 G/R Ambient sensor - -
3 LG/B In-vehicle sensor - -
4 PU/W Vehicle speed sensor - -
IGN
5 G/Y A/C LAN signal - Approx. 5.7
ON

Power supply for rear vent IGN Rear vent SW: ON Approx. 0
6 LG
door motor ON Rear vent SW: OFF Approx. 12
IGN
7 GY/L Power supply for ACC - Battery voltage
ON

Multiplex communication IGN

9 W -
signal (Fr TX) ON

RJIA0212E

Multiplex communication IGN

10 R -
signal (Fr RX) ON

RJIA0213E

IGN
11 R/Y Sensor ground - Approx. 0
ON
12 SB Sunload sensor - -

ATC-56
 TROUBLE DIAGNOSIS

TERMI- WIRE- Voltage

ITEM CONDITION
NAL NO. COLOR (V) A

B
Multiplex communication IGN
15 G -
signal (Rr RX) ON

C
RJIA0214E

Power supply for rear vent IGN Rear vent switch: ON Approx. 12
16 W/B
door motor ON Rear vent switch: OFF Approx. 0 D
17 L/OR Water temperature sensor - - -
- Approx. 0
E
Compressor feed back sig- IGN Compres- Disconnect refriger-
18 OR
nal (Low-pressure cut) ON sor: ON ant pressure sensor Approx. 4.6
connector
F

Multiplex communication IGN

20 B - G
signal (Fr CLK) ON

HAK0363D H
Power supply for mode
IGN
21 GY door motor, air mix door - Approx. 12
ON
motor, intake door motor
I
IGN A/C switch: ON Approx. 0
22 Y Compressor ON signal
ON A/C switch: OFF Approx. 4.6
ATC

IGN
23 L/W ECV signal (RHD models) A/C switch: ON K
ON

RJIA0146J
L
Rear air purifier Lo signal IGN Air purifier: Lo-speed Approx. 0
24 R/L
(RHD models) ON Air purifier: Hi-speed or OFF Approx. 12
IGN M
25 B Ground - Approx. 0
ON
IGN
26 Y/G Power supply for BAT - Battery voltage
ON
IGN
27 P Power supply for IGN - Battery voltage
ON
A/C switch: ON (Blower fan motor
IGN Approx. 0
29 SB Blower fan motor ON signal operates)
ON
A/C switch: OFF Approx. 4.6

Multiplex communication IGN

30 BR/W -
signal (Rr CLK) ON

HAK0364D

ATC-57
 TROUBLE DIAGNOSIS

TERMI- WIRE- Voltage

ITEM CONDITION
NAL NO. COLOR (V)

Multiplex communication IGN

31 GY/L -
signal (Rr TX) ON

RJIA0215E

Rear air purifier Hi signal IGN Air purifier: Lo-speed or OFF Approx. 12
32 P/L
(RHD models) ON Air purifier: Hi-speed Approx. 0

Blower fan motor drive sig- IGN

35 L/OR Blower fan speed: 1 speed
nal ON

HAK0857D

ATC-58
 TROUBLE DIAGNOSIS

Self-diagnosis Function EJS00162

DESCRIPTION A
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to appli-
cable sections (items) for details. Shifting from normal control to the self-diagnostic system is accomplished
by starting the engine (turning the ignition switch from OFF to ON) and pressing OFF switch for at least 5 B
seconds. The "OFF" switch must be pressed within 10 seconds after starting the engine (ignition switch is
turned ON). This system will be canceled by either pressing A/C switch or turning the ignition switch OFF.
Shifting from one step to another is accomplished by means of turning temperature dial, as required.
C
Additionally shifting from STEP 5 to AUXILIARY MECHANISM is accomplished by means of pushing (fan)
UP switch.

ATC

RJIA0216E

ATC-59
 TROUBLE DIAGNOSIS

PROCEDURE
1. SET IN SELF-DIAGNOSTIC MODE
1. Turn ignition switch ON.
2. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press OFF switch for at least 5 seconds.

>> GO TO 2.

2. STEP 1 - LEDS AND DISPLAY ARE CHECKED

Check LEDs illuminate and display screen.

RJIA0217E

RJIA0218E

YES or NO
Yes >> GO TO 3.
No >> Malfunctioning OFF switch, LED or AV control unit.
>> Replace A/C auto amp.

3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP 2

1. Turn the temperature dial clockwise.
2. Advance to self-diagnosis STEP 2?
YES or NO
Yes >> GO TO 4.
No >> Malfunctioning temperature dial.
>> Replace A/C auto amp.

4. CHECK TO RETURN SELF-DIAGNOSIS STEP 1

1. Turn the temperature dial counterclockwise.
2. Return to self-diagnosis STEP 1?
YES or NO
Yes >> GO TO 5.
No >> Malfunctioning temperature dial.
>> Replace A/C auto amp.

ATC-60
 TROUBLE DIAGNOSIS

5. STEP 2 - SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT A

1. Turn the temperature dial clockwise.
2. Does code No.20 appear on the display?
YES or NO B
Yes >> GO TO 6.
No >> GO TO 14.
C

D
RJIA0219E

6. STEP 3 - MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED E

1. Turn the temperature dial clockwise.

2. Does code No.30 appear on the display?
F
YES or NO
Yes >> GO TO 7.
No >> GO TO 15. G

RJIA0220E

7. STEP 4 - OPERATION OF EACH ACTUATOR IS CHECKED I

1. Turn the temperature dial clockwise.

2. Engine running. ATC
3. Press DEF switch, code No. of each actuator test is indicated on
the display.
K
>> GO TO 8.

RJIA0221E

ATC-61
 TROUBLE DIAGNOSIS

8. CHECK ACTUATORS
Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage and com-
pressor operation.

RJIA0222E

41 42 43 44 45 46 47 48
VENT B/L1
Mode door position VENT B/L1
(B/L (B/L B/L2 FOOT D/F DEF
(Driver side) (B/L SHUT) (B/L SHUT)
OPEN) OPEN)
VENT B/L1
Mode door position VENT B/L1
(B/L (B/L B/L2 FOOT1 FOOT2 DEF
(Passenger side) (B/L SHUT) (B/L SHUT)
OPEN) OPEN)
Intake door position REC REC REC 20% FRE 20% FRE FRE FRE FRE
FULL FULL FULL FULL FULL FULL
Air mix door position FULL HOT FULL HOT
COLD COLD COLD HOT HOT HOT
Blower fan duty ratio 37% 37% 91% 65% 65% 65% 65% 91%
Compressor ON ON ON OFF OFF OFF ON ON
Rear vent door posi-
OPEN SHUT SHUT SHUT SHUT SHUT SHUT SHUT
tion

Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for
improper operation.
OK or NG
OK >> GO TO 9.
NG >> ● Air outlet does not change.
Go to Mode Door Motor ATC-76 .
● Intake door does not change.
Go to Intake Door Motor ATC-82 .
● Blower motor operation is malfunctioning.
Go to Blower Motor ATC-88 .
● Magnet clutch does not engage.
Go to Magnet Clutch ATC-92 .
● Discharge air temperature does not change.
Go to Air Mix Door Motor ATC-81 .

ATC-62
 TROUBLE DIAGNOSIS

9. STEP 5 - TEMPERATURE OF EACH SENSOR IS CHECKED A

1. Turn the temperature dial clockwise.
2. Code No.51 appears on the display.
B
>> GO TO 10.

10. CHECK AMBIENT SENSOR C

Press (DEF) switch one time, temperature detected by ambient

sensor is indicated on the display. D
NOTE:
If temperature shown on display greatly differs from actual tempera-
ture, check sensor circuit first, then inspect sensor.
E
OK or NG
OK >> GO TO 11.
NG >> Go to Ambient Sensor Circuit ATC-116 .
F

RJIA0455E

G
11. CHECK IN-VEHICLE SENSOR
Press (DEF) switch the second time, temperature detected by in-
vehicle sensor is indicated on the display. H
NOTE:
If temperature shown on display greatly differs from actual tempera-
ture, check sensor circuit first, then inspect sensor. I
OK or NG
OK >> GO TO 12.
NG >> Go to In-vehicle Sensor Circuit ATC-118 . ATC

RJIA0456E

K
12. CHECK INTAKE SENSOR
Press (DEF) switch the third time, temperature detected by intake L
sensor is indicated on the display.
NOTE:
If temperature shown on display greatly differs from actual tempera-
ture, check sensor circuit first, then inspect sensor. M
OK or NG
OK >> 1. GO TO 13.
2. Turn ignition switch OFF or (AUTO) switch ON.
3. END
NG >> Go to Intake Sensor Circuit ATC-124 . RJIA0457E

ATC-63
 TROUBLE DIAGNOSIS

13. CHECK MULTIPLEX COMMUNICATION ERROR

1. Press intake switch.
2. Multiplex communication error between AV control unit and auto
amp. is detected.
(If plural errors occur, the display of each error will blink two
times for 0.5 second intervals.)
OK or NG
OK >> 1. Turn ignition switch OFF or A/C switch ON.
2. END
NG >> Go to multiplex communication circuit ATC-125 .
RJIA0226E

14. CHECK MALFUNCTIONING SENSOR

Refer to the following chart for malfunctioning code No.
(If two or more sensors malfunction, corresponding code Nos. blink respectively two times.)
*1:Conduct self-diagnosis STEP 2 under sunshine.
When conducting indoors, aim a light (more than 60W) at sunload sensor, otherwise Code No.25 will indicate
despite that sunload sensor is functioning properly.
Code No. Malfunctioning sensor (Including circuits) Reference page
21 / -21 Ambient sensor *2
22 / -22 In-vehicle sensor *3
24 / -24 Intake sensor *4
25 / -25 Sun-load sensor *5
26 / -26 Air mix door motor (LCU) PBR (Driver side) *6
27 / -27 Air mix door motor (LCU) PBR (Passenger side) *7

*2: ATC-116 .
*3: ATC-119 .
*4: ATC-124 .
*5: ATC-121
*6: ATC-72
*7: ATC-72

RJIA0227E

>> INSPECTION END

ATC-64
 TROUBLE DIAGNOSIS

15. CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH A

Mode or (and) intake door motor position switch(es) is (are) malfunctioning.
Code No. *1 *2 Mode or intake door position Reference page
B
31 VENT (Driver side)
32 FOOT (Driver side)
33 DEF (Driver side) C
Mode door motor *3
34 VENT (Passenger side)
35 FOOT1 (Passenger side)
D
36 DEF (Passenger side)
37 FRE
38 20% FRE Intake door motor *4 E
39 REC

(If two or more mode or intake doors are out of order, corresponding code numbers blink respectively two
F
times.)
*1:If mode door motor harness connector is disconnected, the following display pattern will appear.
31→32→33→34→35→36→Return to 31
*2:If intake door motor harness connector is disconnected, the following display pattern will appear. G
37→38→39→Return to 37
*3:ATC-76
*4:ATC-82 H

ATC

K
RJIA0228E

>> INSPECTION END L

ATC-65
 TROUBLE DIAGNOSIS

AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER

The trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed
digitally) and temperature felt by driver.
Operating procedures for this trimmer are as follows:
● Begin Self-diagnosis STEP 5 mode.
● Press (fan) UP switch to set system in auxiliary mode.
● Display shows 61 in auxiliary mechanism.It takes approximately 3 seconds.
● Turn the temperature dial as desired. Temperature will change at a rate of 0.5°C (1.0°F) each time a dial
is turned.

RJIA0458E

When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial
condition, i.e. 0°C (0°F).

ATC-66
 TROUBLE DIAGNOSIS

Operational Check EJS00163

A
The purpose of the operational check is to confirm that the system operates properly.
Conditions :Engine running and at normal operating temperature
CHECKING MEMORY FUNCTION B
1. Set the temperature 90°F or 32°C.
2. Press OFF switch.
C
3. Turn the ignition switch OFF.
4. Turn the ignition switch ON.
5. Press the AUTO switch. D
6. Confirm that the set temperature remains at previous tempera-
ture.
7. Press OFF switch. E
If NG, go to trouble diagnosis procedure for memory function ATC-
109 . RJIA0230E

If OK, continue with next check.

F
CHECKING BLOWER
1. Press fan switch (up side) one time.Blower should operate on
low speed.The fan symbol should have one blade lit . G
2. Press fan switch (up side) one more time, and continue check-
ing blower speed and fan symbol until all speeds are checked.
3. Leave blower on MAX speed. H
If NG, go to trouble diagnosis procedure for blower motor ATC-86 .
If OK, continue with next check.
I

RJIA0231E

CHECKING DISCHARGE AIR ATC

1. Press mode switch four times and DEF button.
2. Each position indicator should change shape.
K

M
RJIA0232E

ATC-67
 TROUBLE DIAGNOSIS

3. Confirm that discharge air comes out according to the air distribution table.Refer to Discharge Air Flow
ATC-32 .

RJIA0222E

Intake door position is checked in the next step.

If NG, go to trouble diagnosis procedure for intake door motor ATC-82 .
If OK, continue with next check.
NOTE:
Confirm that the compressor clutch is engaged (visual inspection) and intake door position is at FRESH when
the DEF is selected.
CHECKING RECIRCUATION
1. Press intake 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 motor ATC-
82 .
If OK, continue with next check.

RJIA0233E

CHECKING TEMPERATURE DECREASE

1. Turn the temperature dial until 18°C (60°F) is displayed.
2. Check for cold air at discharge air outlets.

RJIA0234E

ATC-68
 TROUBLE DIAGNOSIS

CHECKING TEMPERATURE INCREASE

1. Turn the temperature dial until 32°C (90°F) is displayed. A
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for insufficient heating ATC-
106 . B
If OK, continue with next check.

RJIA0235E
D

CHECK ECON (ECONOMY) MODE

1. Set the temperature 75°F or 25°C.
E
2. Press ECON switch.
3. Display should indicate ECON (no AUTO).
● Confirm that the compressor clutch is not engaged (visual F
inspection). (Discharge air and blower speed will depend on
ambient, in-vehicle, and set temperatures.)
If NG, go to trouble diagnosis procedure for ECON (Economy) mode G
ATC-110 .
If OK, continue with next check.
RJIA0236E
H
CHECKING AUTO MODE
1. Press A/C switch.
2. Display should indicate AUTO (no ECON). I
● Confirm that the compressor clutch engages (audio or visual
inspection).(Discharge air and blower speed will depend on
ambient, in-vehicle, and set temperatures.) ATC
If NG, go to trouble diagnosis procedure for A/C system ATC-70 ,
then if necessary, trouble diagnosis procedure for magnet clutch
ATC-91 . K
If all operational check are OK (symptom can not be duplicated), go
to Incident Simulation Tests in GI-23, "How to Perform Efficient Diag-
nosis for an Electrical Incident" and perform tests as outlined to RJIA0237E

simulate driving conditions environment. If symptom appears, refer L

to ATC-34, "SYMPTOM TABLE" and perform applicable trouble diagnosis procedures.

ATC-69
 TROUBLE DIAGNOSIS

Power Supply and Ground Circuit for Auto Amp. EJS00164

SYMPTOM:A/C system does not come on.

INSPECTION FLOW

RJIA0238E

*1 Main power supply and ground cir- *2 Operational Check ATC-67 *3 Multiplex communication circuit ATC-
cuit ATC-71 125

COMPONENT DESCRIPTION
Automatic Amplifier (Auto Amp.)
The auto amplifier has a built-in microcomputer which processes
information sent from various sensors needed for air conditioner
operation. The air mix door motor, mode door motor, intake door
motor, blower motor and compressor are then controlled.
The auto amplifier is unitized with control mechanisms. When the
various switches and temperature adjustment dial are operated, data
is input to the auto amp from the AV control unit using multiplex com-
munication.

Self-diagnostic functions are also built into auto amplifier to provide

quick check of malfunctions in the auto air conditioner system.
RJIA0210E

ATC-70
 TROUBLE DIAGNOSIS

Potentio Temperature Control (PTC)

The PTC is built into the AV control unit. It can be set at an interval of A
0.5°C (1.0°F) in the 18°C (60°F) to 32°C (90°F) temperature range
by turning the temperature dial. The set temperature is displayed.
B

RJIA0459E
D

DIAGNOSTIC PROCEDURE
SYMPTOM: A/C system does not come on. E

RJIA0240E H

1. CHECK POWER SUPPLY CIRCUIT FOR AUTO AMP.

I

Terminal No.s Ignition switch position

ATC
(+)
Terminal (-) OFF ACC ON
Connector
(Wire color)
K
Approx. Approx.
M119 7(GY/L) Approx. 0V
12V 12V
Approx. Approx. Approx. L
M120 26(G/Y) Ground
12V 12V 12V
RJIA0241E
Approx.
M120 27(P) Approx. 0V Approx. 0V
12V
M
OK or NG
OK >> GO TO 2.
NG >> Check 10A fuses (Nos. 2, 6 and 21) located in the fuse block).
● If fuses are OK, check for open circuit in wiring harness. Repair or replace as necessary.

● If fuses are NG, replace fuse and check wiring harness for short circuit. Repair or replace as
necessary.

ATC-71
 TROUBLE DIAGNOSIS

2. CHECK BODY GROUND CIRCUIT FOR AUTO AMP.

Ohmmeter terminal
(+)
Continuity
Terminal (-)
Connector
(Wire color)
M120 25 (B) Ground Yes
Yes or No
Yes >> Replace auto amp. INSPECTION END
No >> Repair or replace harness. RJIA0242E

LAN System Circuit EJS00165

SYMPTOM:
Mode door motor, intake door motor and/or air mix door motor does not operate normally.
DIAGNOSTIC PROCEDURE
1. CHECK POWER SUPPLY FOR AUTO AMP. (LCU) SIDE

Terminal No.
(+)
Voltage
Terminal (Wire (-)
Connector
color)
M120 21 (GY) Ground Approx. 12V
OK or NG
OK >> GO TO 2.
NG >> Replace auto amp.(LCU). RJIA0273E

2. CHECK SIGNAL FOR AUTO AMP. (LCU) SIDE

Terminal No.
(+)
Voltage
Terminal (Wire- (-)
Connector
color
M119 5 (G/Y) Ground Approx. 5.5V
OK or NG
OK >> GO TO 3.
NG >> Replace auto amp.(LCU). RJIA0274E

ATC-72
 TROUBLE DIAGNOSIS

3. CHECK POWER SUPPLY FOR MOTOR SIDE A

Terminals
B
(+)
Door motor Voltage
Terminal (-)
Connector
(Wire color) C
Mode (Passenger side) M106 1 (G/Y)
Air mix (Passenger side) M107 1 (G/Y)
Approx. D
Intake M118 1 (G/Y) Ground
12V
RJIA0275E
Mode (Driver side) M471 3
Air mix (Driver side) M472 3
E
OK or NG
OK >> GO TO 4.
NG >> Replace harness or connector. F
4. CHECK SIGNAL FOR MOTOR SIDE
G

Terminal No.s
Door motor (+) H
Voltage
Terminal (-)
Connector
(Wire color)
Mode (Passenger side) M106 3 (G/Y) I
Air mix (Passenger
M107 3 (G/Y)
side)
Approx.
Ground ATC
Intake M118 3 (G/Y) 5.5V RJIA0276E

Mode (Driver side) M471 6

Air mix (Driver side) M472 6
K
OK or NG
OK >> GO TO 5.
NG >> Replace harness or connector. L
5. CHECK MOTOR GROUND CIRCUIT
M

Terminal No.s
(+)
Door motor Continuity
Terminal (-)
Connector
(Wire color)
Mode (Passenger side) M106 2 (B)
Air mix (Passenger side) M107 2 (B)
Intake M118 2 (BY) Ground Yes
RJIA0277E
Mode (Driver side) M471 11
Air mix (Driver side) M472 11
OK or NG
OK >> GO TO 6.
NG >> Replace harness or connector.

ATC-73
 TROUBLE DIAGNOSIS

6. CHECK MOTOR OPERATION

Disconnect and reconnect the motor connector and confirm the motor operation.
OK or NG
OK >> (Return to operate normally.)
● Poor contacting the motor connector

NG >> (Does not operate normally.)

● GO TO 7

7. CHECK MODE DOOR MOTOR OPERATION

1. Disconnect mode door motor (driver side, passenger side) and air mix door motor (driver side, passenger
side) connector.
2. Reconnect mode door motor connector (driver side, passenger side) and confirm the mode door motor
operation.
OK or NG
OK >> (Mode door motor operates normally.)
● GO TO 8

NG >> (Mode door motor does not operate normally.)

● GO TO 10

8. CHECK AIR MIX DOOR MOTOR OPERATION

1. Disconnect mode door motor connector (driver side, passenger side).
2. Reconnect air mix door motor connector (driver side, passenger side) and confirm the air mix door motor
operation.
OK or NG
OK >> (Air mix door motor operates normally.)
● GO TO 9

NG >> (Air mix door motor does not operate normally.)

● GO TO 11

9. CHECK INTAKE DOOR MOTOR OPERATION

1. Disconnect air mix door motor connector (driver side, passenger side).
2. Reconnect intake door motor connector and confirm the intake door motor operation.
OK or NG
OK >> (Intake door motor operates normally.)
● Replace auto amp.

NG >> (Intake door motor does not operate normally.)

● Replace intake door motor.

10. CHECK MODE DOOR MOTOR OPERATION

1. Disconnect mode door motor (driver side) connector.
2. Confirm the mode door motor (passenger side) operation.
OK or NG
OK >> (Mode door motor operates normally.)
● Replace driver side mode door motor.

NG >> (Mode door motor does not operate normally.)

● Replace passenger side mode door motor.

ATC-74
 TROUBLE DIAGNOSIS

11. CHECK AIR MIX DOOR MOTOR OPERATION A

1. Disconnect air mix door motor (driver side) connector.
2. Confirm the air mix door motor (passenger side) operation.
OK or NG B
OK >> (Air mix door motor operates normally.)
● Replace driver side air mix door motor.
C
NG >> (Air mix door motor does not operate normally.)
● Replace passenger side air mix door motor.

ATC

ATC-75
 TROUBLE DIAGNOSIS

Mode Door Motor Circuit EJS001V5

SYMPTOM:
● Air outlet does not change.
● Mode door motor does not operate normally.
INSPECTION FLOW

RJIA0281E

*1 Discharge air flow ATC-32 *2 Operational check ATC-67 *3 Self-diagnosis ATC-60 , see No.1
*4 Self-diagnosis ATC-60 , see No. 5 *5 Ambient sensor circuit ATC-116 *6 In-vehicle sensor circuit ATC-118
*7 Sunload sensor circuit ATC-121 *8 Air mix door motor circuit ATC-79 *9 Self-diagnosis ATC-60 , see No.14
*10 LAN system circuit ATC-72 *11 Component description for Mode *12 Operational check ATC-67
door ATC-78
*13 Symptom table ATC-34 *14 Intake sensor circuit ATC-124

ATC-76
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Component Parts A
Mode door control system components are:
● Auto amp.
B
● Mode door motor (LCU)
● In-vehicle sensor
● Ambient sensor C
● Sunload sensor
● Intake sensor
System Operation D
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door, mode door and
intake door opening angle data to the air mix door motor LCU, mode door motor LCU and intake door motor
LCU. E
The air mix door motor, mode door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amplifier and each of the motor posi-
tion sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subse- F
quently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new
selection data is returned to the auto amplifier.

ATC

L
RJIA0282E

Mode Door Control Specification

M

RHA384HA

ATC-77
 TROUBLE DIAGNOSIS

COMPONENT DESCRIPTION
Mode Door Motor
The mode door motor is attached to the heater & cooling unit. It
rotates so that air is discharged from the outlet set by the auto ampli-
fier. Motor rotation is conveyed to a link which activates the mode
door.

RJIA0283E

RJIA0284E

DIAGNOSTIC PROCEDURE
SYMPTOM: Mode door motor and/or air mix door motor does not operate normally.
Perform diagnostic procedure for LAN system circuit. Refer to ATC-72 .

ATC-78
 TROUBLE DIAGNOSIS

Air Mix Door Motor Circuit EJS001V6

A
SYMPTOM:
● Discharge air temperature does not change.
● Air mix door motor does not operate. B
INSPECTION FLOW

ATC

RJIA0285E

*1 Self-diagnosis ATC-60 , see No.1 *2 Ambient sensor circuit ATC-129 *3 In-vehicle sensor circuit ATC-130
*4 Sunload sensor circuit ATC-131 *5 Air mix door motor circuit ATC-79 *6 Self-diagnosis ATC-60 , see No. 14.
*7 LAN system circuit ATC-72 *8 Component description for Air mix *9 Component description for Air mix
door ATC-81 door ATC-81
*10 Operational check ATC-67 *12 Operational check ATC-67 *13 Symptom table ATC-34
*14 Intake sensor circuit ATC-124 *15 Self-diagnosis ATC-60 , see No.7

ATC-79
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Component Parts
Air mix door control system components are:
● Auto amp.
● Air mix door motor (LCU)
● In-vehicle sensor
● Ambient sensor
● Sunload sensor
● Intake sensor
System Operation
The auto amplifier receives data from each of the sensors. The amplifier sends air mix door, mode door and
intake door motor opening angle data to the air mix door motor LCU, mode door motor LCU and intake door
motor LCU.
The air mix door motor, mode door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the auto amplifier and each of the motor posi-
tion sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subse-
quently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new
selection data is returned to the auto amplifier.

RJIA0286E

Air Mix Door Control Specification

RHA457H

ATC-80
 TROUBLE DIAGNOSIS

COMPONENT DESCRIPTION
Air Mix Door Motor A
The air mix door motor is attached to the heater & cooling unit. It
rotates so that the air mix door is opened or closed to a position set
by the auto amplifier. Motor rotation is then conveyed through a shaft B
and the air mix door position is then fed back to the auto amplifier by
PBR built-in air mix door motor.
C

D
RJIA0287E

H
RJIA0288E

DIAGNOSTIC PROCEDURE
SYMPTOM: Discharge air temperature does not change. I
Perform diagnostic procedure for LAN system circuit. Refer to ATC-72 .

ATC

ATC-81
 TROUBLE DIAGNOSIS

Intake Door Motor Circuit EJS001V7

SYMPTOM:
● Intake door does not change.
● Intake door motor does not operate normally.
INSPECTION FLOW

RJIA0278E

*1 Self-diagnosis ATC-60 , see No.1 *2 Ambient sensor ATC-116 *3 In-vehicle sensor ATC-118
*4 Sunload sensor ATC-121 *5 Air mix door motor circuit ATC-79 *6 Self-diagnosis ATC-60 , see No. 14.
*7 LAN system circuit ATC-72 *8 Component description for intake *9 Operational check ATC-67
door motor ATC-84
*10 Self-diagnosis ATC-60 , see No.5 or *11 Operational check ATC-67 *12 Symptom table ATC-34
7
*13 Intake sensor circuit ATC-124

ATC-82
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Component Parts A
Intake door control system components are:
● Auto amp.
B
● Intake door motor
● A/C LAN system (PBR built-in mode motor and air mix door motor)
● In-vehicle sensor C
● Ambient sensor
● Sunload sensor
● Intake sensor D
System Operation
The intake door control determines intake door position based on the ambient temperature, the intake air tem-
perature and the in-vehicle temperature. When the ECON, DEFROST, or OFF switches are pushed, the auto E
amplifier sets the intake door at the Fresh position.

ATC

K
RJIA0279E

Intake Door Control Specification

L
COMPONENT DESCRIPTION
Intake door motor
M

RHA383H

The intake door motor is attached to the intake unit. It rotates so that
air is drawn from inlets set by the auto amplifier. Motor rotation is
conveyed to a lever which activates the intake door.

RJIA0280E

ATC-83
 TROUBLE DIAGNOSIS

COMPONENT DESCRIPTION
Intake door motor
The intake door motor is attached to the intake unit. It rotates so that
air is drawn from inlets set by the auto amplifier. Motor rotation is
conveyed to a lever which activates the intake door.

RJIA0280E

DIAGNOSTIC PROCEDURE
SYMPTOM: Intake door motor does not operate normally.
Perform diagnostic procedure for LAN system circuit. Refer to ATC-72 .
Rear Ventilator Door Motor EJS00169

COMPONENT DESCRIPTION
Rear ventilator door motor is attached to the rear ventilator duct
No.1.
Rear ventilator door is opened or closed by rear ventilator door
motor.

RJIA0289E

DIAGNOSTIC PROCEDURE
SYMPTOM: Rear ventilator door motor does not operate.

RJIA0290E

ATC-84
 TROUBLE DIAGNOSIS

1. CHECK FOR AUTO AMP. OUTPUT A

Set up code Nos.41 and 42 in self-diagnosis STEP 4.
Terminal No.s
B
Code No. (+)
Voltage
Terminal (-)
Connector
(Wirecolor) C
M93 1 (LG) Approx. 12V
41
M93 2 (W/B) Approx. 0V
Ground
M93 1 (LG) Approx. 0V D
42
RJIA0291E
M93 2 (W/B) Approx.12V
OK or NG E
OK >> Replace rear ventilator door motor.
NG >> GO TO 2

2. CHECK CIRCUIT CONTINUITY BETWEEN REAR VENTILATOR DOOR MOTOR AND AUTO AMP. F

G
Terminals
Terminal (Wire Terminal (Wire Continuity
Connector Connector
color) color)
H
M93 1 (LG) M119 6 (LG)
Yes
M93 2 (W/B) M119 16 (W/B)
OK or NG I
OK >> Replace auto amp.
NG >> Repair harness or connector. RJIA0292E

ATC

ATC-85
 TROUBLE DIAGNOSIS

Blower Motor Circuit EJS0016A

SYMPTOM:
● Blower motor operation is malfunctioning.
● Blower motor operation is malfunctioning under out of starting fan speed control.
INSPECTION FLOW

RJIA0264E

*1 Operational Check ATC-67 *2 Self-diagnosis ATC-60 , see No.1 *3 Self-diagnosis ATC-60 , see No.5
*4 Self-diagnosisATC-60 , see No.7 *5 Self-diagnosis ATC-60 , see No.14 *6 Blower motor circuit ATC-88
*7 Blower motor circuit ATC-88 *8 Ambient sensor circuit ATC-116 *9 In-vehicle sensor circuit ATC-118
*10 Sunload sensor circuit ATC-121 *11 Intake sensor circuit ATC-124 *12 Operational Check ATC-67
*13 Symptom tableATC-34

ATC-86
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Component Parts A
Fan speed control system components are:
● Auto amp.
B
● A/C LAN system (PBR built-in mode door motor and air mix door motor)
● In-vehicle sensor
● Ambient sensor C
● Sunload sensor
● Intake sensor
System Operation D

RJIA0265E ATC
Automatic Mode
In the automatic mode, the blower motor speed is calculated by the automatic amplifier based on input from
the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. K
When the air flow is increased, the duty ratio of the blower fan motor's drive signal is changed at 8%/sec. to
prevent a sudden increase in air flow.
In addition to manual air flow control and the normal automatic air flow control, starting air flow control, low L
water temperature starting control and high passenger compartment temperature starting control are avail-
able.
When the audio-recognition signal is input to the auto amplifier, the maximum fan speed is limited to the 3rd
step. (Except DEF). M

Starting Fan Speed Control

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

Start Up From Normal or HOT SOAK Condition (Automatic mode)

The blower will begin operation momentarily after the A/C button is pushed. The blower speed will gradually
rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective
blower speed).

ATC-87
 TROUBLE DIAGNOSIS

Blower Speed Compensation

Sunload
When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low
speed. The low speed will vary depending on the sunload. During conditions of low or no sunload, the blower
low speed is normal low speed (duty ratio 25%). During high sunload conditions, the auto amp causes the
blower fan speed to increase.(duty ratio 49%).
Fan Speed Control Specification

RJIA0266E

COMPONENT DESCRIPTION
Brush-less Motor
The blower motor utilizes a brush-less motor with a rotating magnet.
Quietness is improved over previous motors where the brush was
the point of contact and the coil rotated.

ZHA152H

DIAGNOSTIC PROCEDURE
SYMPTOM: Blower motor operation is malfunctioning under Starting
Fan Speed Control.

RJIA0267E

ATC-88
 TROUBLE DIAGNOSIS

1. CHECK POWER SUPPLY FOR BLOWER MOTOR A

Disconnect blower motor harness connector.
Terminal No.
B
(+)
Voltage
Terminal (Wire (-)
Connector
color) C
M112 4 (BR/W) Ground Approx. 12V
OK or NG
OK >> GO TO 2. D
NG >> Check power supply circuit and 15A fuses (Nos. 31 and RJIA0268E

33, located in the fuse block). Refer to PG-4, "BATTERY

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
Terminal No.
(+)
Continuity
Terminal (Wire (-) H
Connector
color)
M112 1 (B) Ground Yes
I
OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector. RJIA0269E
ATC
3. CHECK CIRCUIT CONTINUITY BLOWER MOTOR AND AUTO AMP.
Disconnect auto amp. connector. K
Terminal No.s
(+) (-)
Continuity L
Terminal Terminal
Connector Connector
(Wire color) (Wire color)
M112 3 (L/OR) M120 35 (L/OR) Yes
M
OK or NG
OK >> GO TO 4.
NG >> Repair harness or connector. RJIA0270E

ATC-89
 TROUBLE DIAGNOSIS

4. CHECK FOR AUTO AMP. OUTPUT

1. Reconnect blower motor connector and auto amp. connector, turn the key switch ON.
2. Vary the fan speed between Lo and Hi and confirm the blower motor connector's terminal No.3 duty ratios
using an oscilloscope. Normal No.3 terminal drive signal duty ratios are shown in the table below.

RJIA0338E

OK or NG
OK >> GO TO 5.
NG >> Replace auto amp.

5. CHECK BLOWER MOTOR DRIVE SIGNAL

If the fan air flow does not change, normal No.3 terminal drive signal duty ratios are shown in the table above.
OK or NG
OK >> Replace blower motor.
NG >> INSPECTION END
COMPONENT INSPECTION
Blower Motor
Confirm smooth rotation of the blower motor.
● Ensure that there are no foreign particles inside the intake unit.

RJIA0271E

ATC-90
 TROUBLE DIAGNOSIS

Magnet Clutch Circuit EJS0016B

A
SYMPTOM: Magnet clutch does not engage.
INSPECTION FLOW
B

ATC

RJIA0293E

*1 Self-diagnosis ATC-60 , see No.1. *2 Ambient sensor circuit ATC-116 *3 In-vehicle sensor circuit ATC-118
*4 Sunload sensor circuit ATC-121 *5 Air mix door motor circuit ATC-79 *6 Self-diagnosis ATC-60 , see No. 14.
*7 Magnet clutch circuit ATC-92ATC-91 *8 Trouble diagnoses for abnormal *9 Operational check ATC-67
pressure ATC-101
*10 Self-diagnosis ATC-60 , see No.7. *11 Operational check ATC-67 *12 Symptom table ATC-34
*13 Intake sensor circuit ATC-132

ATC-91
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Auto amplifier controls compressor operation by ambient temperature and signal from ECM.
Low Temperature Protection Control
Auto amplifier will turn the compressor ON or OFF as determined by
a signal detected by ambient sensor.
When ambient temperatures are greater than -2°C (28°F), the com-
pressor turns ON. The compressor turns OFF when ambient temper-
atures are less than -5°C (23°F).

RHA094GB

DIAGNOSTIC PROCEDURE
SYMPTOM: Magnet clutch does not engage when A/C switch is ON.

RJIA0294E

1. CHECK POWER SUPPLY FOR COMPRESSOR

Disconnect compressor harness connector.
Terminals
(+)
Voltage
Terminal (Wire (-)
Connector
color)
F2 1 (Y/R) Ground Battery voltage
OK or NG
OK >> Check magnet clutch coil.
1. If NG, replace magnet clutch. Refer to ATC-91 . RJIA0295E

2. Go to self-diagnosis step-by-step procedure ATC-60 and perform self-diagnosis STEP-4.Con-

firm that magnet clutch operation is normal.
NG >> Disconnect A/C relay. And GO TO 2.

ATC-92
 TROUBLE DIAGNOSIS

2. CHECK CIRCUIT CONTINUITY BETWEEN A/C RELAY AND COMPRESSOR A

Terminal No.s
B
Compressor connector A/C relay connector
Continuity
Terminal (Wire Terminal (Wire
Connector Connector
color) color) C
F2 1 (Y/R) E3-2 3 (Y/R) Yes

OK or NG
OK >> Check harness for short. And GO TO 3. D
NG >> Repair harness or connector. RJIA0296E

3. CHECK POWER SUPPLY FOR A/C RELAY E

Disconnect A/C relay.

Terminal No.s F
(+)
(-) Voltage
Terminal (Wire
Connector G
color)
E3-2 2
Ground Battery voltage
E3-2 5
H
OK or NG
OK >> GO TO 4. RJIA0297E

NG >> Check power supply circuit and 10A (No.51) fuse at fuse I
block. Refer to PG-4, "BATTERY 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. ATC
4. CHECK A/C RELAY AFTER DISCONNECTING IT
Refer to ATC-96, "A/C Relay" . K
OK or NG
OK >> Reconnect A/C relay. And GO TO 5.
NG >> 1. replace A/C relay. L
2. Go to self-diagnosis step-by-step procedure ATC-60 and perform self-diagnosis STEP-4.Con-
firm that magnet clutch operation is normal.
M
5. CHECK COIL SIDE CIRCUIT OF A/C RELAY

Terminal No.
(+)
Voltage
Terminal (Wire- (-)
Connector
color)
F101, F102 24 (G/W) Ground Battery voltage
OK or NG
OK >> GO TO 7.
NG >> 1. Disconnect A/C relay. RJIA0298E

2. Disconnect ECM harness connector.

3. GO TO 6.

ATC-93
 TROUBLE DIAGNOSIS

6. CHECK CIRCUIT CONTINUITY BETWEEN ECM AND A/C RELAY

Terminal No.s
A/C rely connector ECM connector
Continuity
Terminal
Connector Connector Wire color
(Wire color)
E3-2 1 F101,F102 24 (G/W) Yes

OK or NG
OK >> Replace A/C relay.
NG >> Repair harness or connector. RJIA0299E

7. CHECK VOLTAGE FOR COMBINATION METER (FAN ON SIGNAL)

Terminal No.
(+)
Condition Voltage
Terminal (wire (-)
Connector
color)
Blower fan: ON Approx. 0V
M120 29 (SB) Ground Blower fan:
Approx. 4.8V
OFF

OK or NG RJIA0300E

OK >> GO TO 8.
NG >> GO TO 11.

8. CHECK VOLTAGE FOR COMBINATION METER (COMPRESSOR ON SIGNAL)

Terminal No.
(+)
Condition Voltage
Terminal (Wire (-)
Connector
color)
A/C SW: ON Approx. 0V
M120 22 Ground
A/C SW: OFF Approx. 4.8V

OK or NG
OK >> GO TO 9. RJIA0301E

NG >> GO TO 12.

ATC-94
 TROUBLE DIAGNOSIS

9. CHECK VOLTAGE FOR COMBINATION METER (COMPRESSOR FEED BACK SIGNAL) A

Terminal No.
B
(+)
Condition Voltage
Terminal No. (-)
Connector
(Wire color) C
A/C SW: ON Approx. 0V
A/C SW: ON
M119 18 (OR) Ground (Disconnect refrig- D
Approx. 4.8V
erant pressure
RJIA0302E
sensor connector)
OK or NG E
OK >> GO TO 10.
NG >> GO TO 13.

10. CHECK REFIREGERANT PRESSURE SENSOR CIRCUIT F

Refer to ATC-96, "Refrigerant Pressure Sensor" .

OK or NG G
OK >> INSPECTION END
NG >> Repair or replace the malfunctioning part(s).
H
11. CHECK CIRCUIT CONTINUITY BETWEEN COMBINATION METER AND AUTO AMP.
Disconnect combination meter and auto amp. connector.
I
Terminal No.s
Combination meter Auto amp.
Continuity
Terminal (Wire Terminal (Wire
ATC
Connector Connector
color) color)
M42 35 (SB) M120 29 (SB) Yes
K
OK or NG
OK >> Replace auto amp.
NG >> Repair harness or connector. RJIA0303E
L
12. CHECK CIRCUIT CONTINUITY BETWEEN COMBINATION METER AND AUTO AMP.
Disconnect combination meter and auto amp. connector. M
Terminal No.s
Combination meter Auto amp.
Continuity
terminal (Wire Terminal (Wire
Connector Connector
color) color)
M42 34 (Y) M120 22 (Y) Yes

OK or NG
OK >> Replace auto amp.
NG >> Repair harness or connector. RJIA0304E

ATC-95
 TROUBLE DIAGNOSIS

13. CHECK CIRCUIT CONTINUITY BETWEEN COMBINATION METER AND AUTO AMP.
Disconnect combination meter and auto amp. connector.
Terminal No.s
Combination meter Auto amp.
Continuity
Terminal (Wire Terminal (Wire
Connector Connector
color) color)
M42 24 (OR) M119 18 (OR) Yes
OK or NG
OK >> Check combination meter.
NG >> Repair harness or connector. RJIA0305E

COMPONENT INSPECTION
A/C Relay
Check continuity between terminal Nos. 3 and 5.
Conditions Continuity
12V direct current supply between terminal Nos. 1
Yes
and 2
No current supply No

If NG, replace relay.

SEF090M

Refrigerant Pressure Sensor

The refrigerant pressure sensor is attached to the liquid tank (con-
denser).
.

RJIA0306E

ATC-96
 TROUBLE DIAGNOSIS

Insufficient Cooling EJS0016C

A
SYMPTOM: Insufficient cooling
INSPECTION FLOW
B

ATC

RJIA0632E

*1 Self-diagnosis ATC-60 , see No.1. *2 Air mix door motor circuit ATC-79 *3 Test reading ATC-98
*4 Self-diagnosis ATC-66, "AUXILIARY *5 Self-diagnosis ATC-60 , see No. 14. *6 LAN system circuit ATC-72
MECHANISM: TEMPERATURE
SETTING TRIMMER" STEP6.
*7 Blower motor circuit ATC-86 *8 Magnet clutch circuit ATC-91 *9 ATC-98, "PERFORMANCE TEST
DIAGNOSES"
*10 Operational check ATC-67 *11 Self-diagnosis ATC-60 , see No.5 or *12 EM-13, "Checking Drive Belts"
7.
*13 Cooling fan motor operation CO-21, *14 ATC-104, "DIAGNOSTIC PROCE-
"COOLING FAN" ,EC-343, "Descrip- DURE FOR ECV CIRCUIT (RHD
tion" MODELS)"

ATC-97
 TROUBLE DIAGNOSIS

PERFORMANCE TEST DIAGNOSES

SHA344F

*1 Performance chart ATC-79 *2 Performance chart ATC-100 *3 Trouble diagnoses for abnormal
pressure ATC-101
*4 Air mix door motor circuit ATC-79

ATC-98
 TROUBLE DIAGNOSIS

ATC

SHA329F

*1 ATC-150, "Removal and Installation *2 Trouble diagnoses for blower motor *3 EM-13, "Checking Drive Belts"
for Compressor Clutch" ATC-86

ATC-99
 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 - LHD models

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 - 12.3 (50-54)
50 - 60 30 (86) 13.2 - 15.3 (56-60)
35 (95) 17.2 - 21.0 (63-70)
25 (77) 12.3 - 14.9 (54-59)
60 - 70 30 (86) 15.3 - 19.3 (60-67)
35 (95) 21.0 - 24.4 (70-76)

Ambient Air Temperature-to-operating Pressure Table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (kg/cm2, psi) kPa (kg/cm2, psi)
% °C (°F)
1,040 - 1,275 221- 275
25 (77)
(10.6 - 13.0, 151- 185) (2.25 - 2.80, 32.0 - 39.8)
1,220 - 1,500
30 (86) 240 - 295 (2.45 - 3.01, 34.8 - 42.8)
(12.44 - 15.30, 176.9 - 217.5)
50 - 70
1,360 - 1,690
35 (95) 275 - 335 (2.81- 3.62, 39.9 - 51.5)
(13.87 - 17.24, 197.2 - 245.1)
1,500 - 1,830
40 (104) 310 - 375 (3.16 - 3.83, 45.0 - 54.4)
(15.30 - 18.67, 217.58 - 265.4)

Test Reading - RHD models

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) 5.7 - 7.9 (42 - 46)
50 - 60 30 (86) 7.5 - 10.4 (46 - 51)
35 (95) 10.0 - 13.4 (50 - 56)
25 (77) 7.9 - 10.2 (46 - 50)
60 - 70 30 (86) 10.4 - 13.3 (51 - 56)
35 (95) 13.4 - 16.8 (56 - 62)

ATC-100
 TROUBLE DIAGNOSIS

Ambient Air Temperature-to-operating Pressure Table

Ambient air A
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (kg/cm2, psi) kPa (kg/cm2, psi)
% °C (°F)
B
1,138 - 1,373 221 - 255
25 (77)
(11.6 - 14.0, 165 - 199) (2.25 - 2.60, 32 - 37)
1,324 - 1,618 235 - 284
30(86) C
50 - 70 (13.5 - 16.5, 192 - 235) (2.4 - 2.9, 34 - 41)
1,550 - 1,903 269.7 - 328.5
35 (95)
(15.8 - 19.4, 225 - 276) (2.75 - 3.35, 39 - 48)
1,804 - 2,207 314 - 328 D
40 (104)
(18.4 - 22.5, 262 - 320) (3.2 - 3.9, 46 - 55)

TROBLE DIAGNOSES FOR ABNORMAL PRESSURE E

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

Both High and Low-pressure Sides are Too High.

Gauge indication Refrigerant cycle Probable cause Corrective action G
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. H
Insufficient condenser cooling
performance
↓ ● Clean condenser.
Air suction by cooling fan is
● Check and repair cooling fan I
insufficient. 1. Condenser fins are clogged.
as necessary.
2. Improper fan rotation of cool-
ing fan
ATC
● 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 K
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 L
thereafter.
Engine cooling systems mal- Check and repair each engine
Engine tends to overheat.
function. cooling system.
AC359A
M
● 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

ATC-101
 TROUBLE DIAGNOSIS

High-pressure Side is Too High and Low-pressure Side is Too Low.

Gauge indication Refrigerant cycle Probable cause Corrective action
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

High-pressure Side is Too Low and Low-pressure Side is Too High.

Gauge indication Refrigerant cycle Probable cause Corrective action
Compressor pressure opera-
High-pressure side is too low and
High and low-pressure sides tion is improper.
low-pressure side is too high.
become equal soon after com- ↓ Replace compressor.
pressor operation stops. Damaged inside compressor
packings
Compressor pressure opera-
No temperature difference tion is improper.
between high and low-pres- ↓ Replace compressor.
sure sides Damaged inside compressor
AC356A
backings.

ATC-102
 TROUBLE DIAGNOSIS

Both High- and Low-pressure Sides are Too Low.

Gauge indication Refrigerant cycle Probable cause Corrective action
A

● There is a big temperature

difference between receiver
● Replace desiccant assem- B
drier outlet and inlet. Outlet
Liquid tank inside is slightly bly.
temperature is extremely
clogged. ● Check lubricant for contami-
low.
nation.
● Liquid tank inlet and expan- C
sion valve are frosted.
● Temperature of expansion
valve inlet is extremely low D
as compared with areas
near liquid tank. ● Check and repair malfunc-
High-pressure pipe located tioning parts.
● Expansion valve inlet may between receiver drier and
be frosted. expansion valve is clogged. ● Check lubricant for contami- E
nation.
● Temperature difference
Both high- and low-pressure sides occurs somewhere in high-
are too low. pressure side F
Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
tank are warm or only cool ↓ Refer to Checking Refrigerant
when touched. Leaking fittings or components Leaks, ATC-159 . G
Expansion valve closes a little
compared with the specifica-
tion.
AC353A
↓
H
There is a big temperature dif- ● Remove foreign particles by
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. I
valve
3. Outlet and inlet may be
clogged. ATC
● 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- K
the evaporator outlet.
nation.
● Check thermo control amp.
Air flow volume is not enough operation.
Evaporator is frozen. L
or is too low.
● Replace compressor.

Low-pressure Side Sometimes Becomes Negative.

M
Gauge indication Refrigerant cycle Probable cause Corrective action
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 desiccant assem-
tions for a certain period of ↓ bly.
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A

ATC-103
 TROUBLE DIAGNOSIS

Low-pressure Side Becomes Negative.

Gauge indication Refrigerant cycle Probable cause Corrective action
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. ● If due to foreign particles,
expansion valve's pipe is ↓ remove expansion valve
frosted or dewed. Expansion valve or liquid tank and remove the particles
is frosted. with dry and compressed air
(not shop air).
AC362A
● If either of the above meth-
ods cannot correct the prob-
lem, replace expansion
valve.
● Replace desiccant assem-
bly.
● Check lubricant for contami-
nation.

DIAGNOSTIC PROCEDURE FOR ECV CIRCUIT (RHD MODELS)

SYMPTOM: Insufficient cooling

RJIA0633E

1. CHECK POWER SUPPLY FOR ECV

1. Disconnect the ECV connector.
Terminals
(+)
Voltage
Connector (Wire (-)
Terminal
color)
F57 2 (W/G) Ground Approx. 12V
OK or NG
OK >> GO TO 2.
NG >> Check power supply circuit and 10A (No.2) fuse at fuse RJIA0634E

block. Refer to PG-4, "BATTERY 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.

ATC-104
 TROUBLE DIAGNOSIS

2. CHECK ECV SIGNAL A

1. Reconnect the ECV connector.
Terminals
B
(+)
Condition Voltage
Terminal (Wire (-)
Connector
color C
Self-diagnosis
Approx. 12V
Auto amp. STEP-41
23 (L/W) Ground
M120 Self-diagnosis
Approx. 0V D
STEP-44
RJIA0635E
OK or NG
OK >> GO TO 3. E
NG >> Replace auto amp.

3. CHECK ECV SIGNAL USING AN OSCILLOSCOPE F

Terminals
Condition Output data
(+) (-) G

M120 - 23 (L/W) Ground Self-diagnosis STEP-42 I

ATC
RJIA0150E

OK or NG K
OK >> GO TO 4.
NG >> Replace the auto amp.

4. CHECK CIRCUIT CONTINUITY BETWEEN ECV AND AUTO AMP. L

1. Disconnect the ECV connector and auto amp. connector.

M
Terminals
ECV Auto amp.
Continuity
Terminal Terminal
connector connector
(Wire color) (Wire color)
F57 3 (L/R) M120 23 (L/W) Yes

OK or NG
OK >> Replace the ECV (compressor).
NG >> Repair harness or connector. RJIA0636E

ATC-105
 TROUBLE DIAGNOSIS

Insufficient Heating EJS001EJ

SYMPTOM: Insufficient heating

INSPECTION FLOW

RJIA0308E

*1 Operational check ATC-67 *2 Self-diagnosisATC-60 , see No.1. *3 Self-diagnosis ATC-60 , see No.5.
*4 Self-diagnosis ATC-60 , see No.7. *5 Air mix door motor circuit ATC-79 *6 Self-diagnosis ATC-60 , see No.14.
*7 LAN system circuit ATC-72 *8 Blower motor circuit ATC-86 *9 Air mix door motor circuitATC-79
*10 ThermostatCO-29 *11 CO-10, "Changing Engine Coolant" *12 CO-10, "Changing Engine Coolant"
*13 CO-15, "CHECKING RADIATOR
CAP (Reservoir Tank Cap for the
Middle East )"

ATC-106
 TROUBLE DIAGNOSIS

Noise EJS001EK

A
SYMPTOM: Noise
INSPECTION FLOW
B

ATC

SHA331F

*1 ATC-150, "Removal and Installation *2 ATC-149 *3 ATC-22, "Maintenance of Lubricant

for Compressor Clutch" Quantity in Compressor"
*4 Operational check ATC-67 *5 EM-13, "Checking Drive Belts"

ATC-107
 TROUBLE DIAGNOSIS

Self-diagnosis EJS001EL

SYMPTOM: Self-diagnosis cannot be performed.

INSPECTION FLOW

RJIA0309E

*1 Main power supply and ground cir- *2 Ambient sensor circuit ATC-116 *3 In-vehicle sensor circuit ATC-118
cuit ATC-71, "DIAGNOSTIC PRO-
CEDURE"
*4 Sunload sensor circuit ATC-121 *5 Intake sensor circuit ATC-124 *6 Air mix door motor circuit ATC-79
*7 Operational check ATC-67 *8 Symptom tableATC-34 *9 Operational check ATC-67

ATC-108
 TROUBLE DIAGNOSIS

Memory Function EJS001EM

A
SYMPTOM: Memory function does not operate.
INSPECTION FLOW
B

ATC

K
RJIA0310E

*1 Main power supply and ground cir- *2 Operational check ATC-67 *3 Self-diagnosis ATC-60
cuit ATC-70
L
*4 A/C system circuit ATC-70, "Power
Supply and Ground Circuit for Auto
Amp."
M

ATC-109
 TROUBLE DIAGNOSIS

ECON (ECONOMY) Mode EJS001EN

SYMPTOM: ECON mode does not operate.

INSPECTION FLOW

RJIA0311E

*1 Main power supply and ground cir- *2 Operational check ATC-67 *3 Self-diagnosis ATC-60
cuit ATC-70
*4 A/C system circuit PG-4, "BATTERY
POWER SUPPLY— IGNITION SW.
IN ANY POSITION"

ATC-110
 TROUBLE DIAGNOSIS

Air Purifier Circuit EJS001EO

DIAGNOSTIC PROCEDURE A
SYMPTOM: Air purifier does not operate.
1. CHECK POWER SUPPLY FOR AIR PURIFIER B
1. Disconnect the air purifier connector.
Terminals
C
(+)
Voltage
Terminal (wire (-)
Connector
color) D
B72 1 (OR/L) Ground Approx. 12V

OK or NG
OK >> GO TO 2. E
NG >> Check power supply circuit and 10A fuse (No.1) at fuse RJIA0637E

block. Refer to PG-4, "BATTERY POWER SUPPLY—

IGNITION SW. IN ANY POSITION" . F
● 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.
G
2. CHECK VOLTAGE FOR AUTO AMP.
1. Reconnect the air purifier connector.
H
2. Disconnect the auto amp. connector.
Terminals
(+) I
Condition Voltage
Terminal (-)
Connector
(Wire color)
ATC
Air purifier :
M120 24 (R/L) Ground Approx. 12V
Hi-speed

RJIA0638E
K
OK or NG
OK >> GO TO 3.
NG >> GO TO 6.
L
3. CHECK VOLTAGE FOR AUTO AMP.
M
Terminals
(+)
Condition Voltage
Terminal (-)
Connector
(Wire color)
Air purifier :
M120 32 (P/L) Ground Approx. 12V
Lo-speed

OK or NG
OK >> GO TO 4. RJIA0639E
NG >> GO TO 7.

ATC-111
 TROUBLE DIAGNOSIS

4. CHECK AIR PURIFIER ON SIGNAL

1. Reconnect the auto amp. connector.
Terminals
(+)
Condition Voltage
Terminal (-)
Connector
(wire color)
Air purifier :
M120 24 (R/L) Approx. 0V
Lo-speed
Ground
Air purifier :
M120 32 (P/L) Approx. 0V
Hi-speed
RJIA0640E
OK or NG
OK >> GO TO 5.
NG >> Replace the auto amp.

5. CHECK BODY GROUND CIRCUIT FOR AIR PURIFIER

1. Disconnect the air purifier connector.
Terminals
(+)
Continuity
Terminal (Wire (-)
Connector
color)
B72 4 (B) Ground Yes

OK or NG
OK >> Replace the air purifier assembly.
NG >> Repair harness or connector. RJIA0641E

6. CHECK CIRCUIT CONTINUITY BETWEEN AIR PURIFIER AND AUTO AMP.

1. Disconnect the air purifier connector and auto amp. connector.
Terminals
Air purifier Terminal (Wire Auto amp. Terminal (Wire Continuity
connector color) connector color)
B72 2 (R/B) M120 24 (R/L) Yes

OK or NG
OK >> Replace the air purifier.
NG >> Repair harness or connector.
RJIA0642E

7. CHECK CIRCUIT CONTINUITY BETWEEN AIR PURIFIER AND AUTO AMP.

1. Disconnect the air purifier connector and auto amp. connector.
Terminals
Air purifier Terminal Auto amp. Terminal (Wire Continuity
connector (Wire color) connector color)
B72 3 (P/L) M120 32 (P/L) Yes
OK or NG
OK >> Replace the air purifier.
NG >> Repair harness or connector.
RJIA0643E

ATC-112
 TROUBLE DIAGNOSIS

A/C display is malfunctioning. EJS0016I

DIAGNOSTIC PROCEDURE A
SYMPTOM: A/C display is not shown.
1. HARNESS CHECK B
1. Disconnect A/C AUTO AMP. connector and AV control unit connector.
2. Check continuity between AV control unit connector M77 and ground.
C
Terminals
AV control unit (+) Continuity
(-)
Connector Terminal (wire color) D
M77 44 (W), 45 (B) Ground No
3. Check continuity between A/C AUTO AMP. and AV control unit
connector M77. E

Terminals
AV control unit (+) A/C AUTO AMP. (-)
Continuity RJIA0460E F
Terminal Terminal
Connector Connector
(wire color) (wire color)
44 (W) M119 9 (W) Yes G
M77
45 (B) M119 20 (B) Yes

OK or NG
H
OK >> GO TO 2.
NG >> ● Check harness between A/C AUTO AMP. and AV control unit.
● Check connector housings for disconnected or loose terminals.
I
2. A/C–AV, AC–CLK COMMUNICATION SIGNAL CHECK
1. Connect A/C AUTO AMP. connector. ATC
2. Turn the ignition switch ON.
3. Check voltage between AV control unit connector M77 and ground.
Terminals K
(+) Voltage (V)
(-)
Connector Terminal (wire color) L
M77 44(W), 45 (B) Ground Approx. 3.5 or more

OK or NG
OK >> GO TO 3. M
NG >> Replace A/C AUTO AMP.

RJIA0461E

ATC-113
 TROUBLE DIAGNOSIS

3. A/C - AV, AC - CLK COMMUNICATION SIGNAL CHECK

1. Connect AV control unit connector.
2. Turn the ignition switch ON.
3. Check voltage between AV control unit connector M77 terminals 44, 45 and ground.
Terminals
(+)
Reference signal
Terminal (wire (-)
Connector
color)
DI-93, "Terminals and Reference
M77 44(W), 45 (B) Ground
Value for AV Control Unit"
OK or NG
OK >> Replace A/C auto amplifier.
NG >> Replace AV control unit. RJIA0462E

A/C operation is malfunctioning. EJS0016J

DIAGNOSTIC PROCEDURE
SYMPTOM: A/C operation is not possible.
1. HARNESS CHECK
1. Disconnect A/C AUTO AMP. connector and AV control unit connector.
2. Check continuity between AV control unit connector M77 and ground.
Terminals
AV control unit(+) Continuity
(-)
Connector Terminal (wire color)
M77 43 (R) , 45 (B) Ground NO
3. Check continuity between A/C AUTO AMP. and AV control unit
connector M77.
Terminals
AV control unit (+) A/C AUTO AMP. (-)
Continuity RJIA0463E
Terminal Terminal
Connector Connector
(wire color) (wire color)
43 (R) M119 10 (R) YES
M77
45 (B) M119 20 (B) YES
OK or NG
OK >> GO TO 2.
NG >> ● Check harness for open or short between A/C AUTO AMP. and AV control unit.
● Check connector housings for disconnected or loose terminals.

ATC-114
 TROUBLE DIAGNOSIS

2. AV - A/C, AC - CLK COMMUNICATION SIGNAL CHECK A

1. Connect A/C AUTO AMP. connector.
2. Turn the ignition switch ON.
3. Check voltage between AV control unit connector M77 terminal 43 and ground. B

Terminals
(+) Reference voltage (V) C
(-)
Connector Terminal (wire color)
M77 43 (R) Ground Approx. 3.5 or more
D
OK or NG
OK >> GO TO 3.
NG >> Replace A/C auto amplifier.
E
RJIA0464E

3. AV–A/C, AC–CLK COMMUNICATION SIGNAL CHECK F

1. Connect AV control unit connector.

2. Turn the ignition switch ON. G
3. Check voltage between AV control unit connector M77 terminals 43, 45 and ground.
Terminals
H
(+)
Reference signal
Terminal (wire (-)
Connector
color)
I
DI-93, "Terminals and Reference
M77 43 (R),45 (B) ground
Value for AV Control Unit"

OK or NG
ATC
OK >> Replace A/C auto amplifier.
NG >> Replace AV control unit.
RJIA0465E

ATC-115
 TROUBLE DIAGNOSIS

Ambient Sensor Circuit EJS0016K

COMPONENT DESCRIPTION
Ambient Sensor
The ambient sensor is attached on the hood lock stay. It detects
ambient temperature and converts it into a resistance value which is
then input into the auto amplifier.

RJIA0243E

AMBIENT TEMPERATURE INPUT PROCESS

The automatic amplifier includes a processing circuit for the ambient sensor input. However, when the temper-
ature detected by the ambient sensor increases quickly, the processing circuit retards the auto amp. function.
It only allows the auto amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds.
As an example, consider stopping for a cup of coffee after high speed driving. Although the actual ambient
temperature has not changed, the temperature detected by the ambient sensor will increase. This is because
the heat from the engine compartment can radiate to the front grille area, location of the ambient sensor.
DIAGNOSTIC PROCEDURE
SYMPTOM: Ambient sensor circuit is open or shorted. (21 or -21 is
indicated on auto amp. As a result of conducting Self-diagnosis
STEP 2.)

RHA051GA

1. CHECK VOLTAGE BETWEEN AMBIENT SENSOR HARNESS CONNECTOR AND GROUND

Disconnect ambient sensor harness connector.
Terminals
(+)
Voltage
Terminal (Wire (-)
Connector
color)
E58 1 (G/R) Ground Approx. 5V
Yes or No
Yes >> GO TO 2.
No >> GO TO 4. RJIA0244E

ATC-116
 TROUBLE DIAGNOSIS

2. CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU) A
Disconnect auto amp. (LCU) harness connector.
Terminals
B
Terminal Terminal Continuity
Connector Connector
(Wire color) (Wire color)
E58 2 (R/Y) M119 11 (R/Y) Yes C
OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector. D
RJIA0245E

3. CHECK AMBIENT SENSOR E

Refer to ATC-116, "Ambient Sensor Circuit"

OK or NG
F
OK >> 1. Replace auto amp. (LCU).
2. Go to self-diagnoses procedure ATC-59, "Self-diagnosis Function" and perform self-diagnosis
STEP-2.Confirm that code No. 20 is displayed. G
NG >> Replace ambient sensor.

4. CHECK AMBIENT SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU) H
Disconnect auto amp. (LCU) harness connector.
Terminals
I
Terminal Terminal Continuity
Connector Connector
(Wire color) (Wire color)
E58 1 (G/R) M119 2 (G/R) Yes ATC
OK or NG
OK >> 1. Replace auto amp. (LCU).
2. Go to self-diagnosis step-by-step procedureATC-59, K
"Self-diagnosis Function" and perform self-diagnosis RJIA0246E

STEP-2.Confirm that code No. 20 is displayed.

NG >> Repair harness or connector. L

ATC-117
 TROUBLE DIAGNOSIS

COMPONENT INSPECTION
Ambient Sensor
After disconnecting ambient sensor harness connector, measure
resistance between terminals 2 and 1 at sensor harness side, using
the table below.
Temperature °C (°F) Resistance kΩ
-15 (5) 12.73
-10 (14) 9.92
-5 (23) 7.80
0 (32) 6.19
5 (41) 4.95
10 (50) 3.99
15 (59) 3.24
20 (68) 2.65
25 (77) 2.19
30 (86) 1.81
35 (95) 1.51
40 (104) 1.27
45 (113) 1.07
RJIA0247E
If NG, replace ambient sensor.
In-vehicle Sensor Circuit EJS0016L

COMPONENT DESCRIPTION
In-vehicle sensor
The in-vehicle sensor is located on instrument lower panel. It con-
verts variations in temperature of compartment air drawn from the
aspirator into a resistance value. It is then input into the auto ampli-
fier.

RJIA0248E

Aspirator
The aspirator is located on driver's side of heater & cooling unit. It
produces vacuum pressure due to air discharged from the heater &
cooling unit, continuously taking compartment air in the aspirator.

RJIA0249E

ATC-118
 TROUBLE DIAGNOSIS

RHA482A

D
DIAGNOSTIC PROCEDURE
SYMPTOM: In-vehicle sensor circuit is open or shorted. (22 or -22 is
indicated on auto amp. as a result of conducting Self-diagnosis
STEP 2.) E

RHA056GB

1. CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND GROUND H

Disconnect in-vehicle sensor harness connector.
Terminals I
(+)
Voltage
Terminal (Wire- (-)
Connector ATC
color)
M68 2 (LG/B) Ground Approx. 5V

Yes or No
K
Yes >> GO TO 2.
No >> GO TO 4. RJIA0250E

2. CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. (LCU) L

Disconnect auto amp. (LCU) harness connector.

M
Terminals
Terminal Terminal Continuity
Connector Connector
(Wire color) (Wire color)
M68 1 (R/Y) M119 11 (R/Y) Yes

OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector.
RJIA0251E

ATC-119
 TROUBLE DIAGNOSIS

3. CHECK IN-VEHICLE SENSOR

Refer to ATC-118, "In-vehicle Sensor Circuit"
OK or NG
OK >> 1. Replace auto amp.
2. Go to self-diagnosis step-by-step procedure ATC-59 and perform self-diagnosis STEP-2. Con-
firm that code No. 20 is displayed.
NG >> 1. Replace in-vehicle sensor.
2. Go to self-diagnosis step-by-step procedure ATC-60 and perform self-diagnosis STEP-2. Con-
firm that code No. 20 is displayed.

4. CHECK IN-VEHICLE SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU)
Disconnect auto amp. (LCU) harness connector.
Terminals
Terminal (Wire Terminal (Wire Continuity
Connector Connector
color) color)
M68 2 (LG/B) M119 3 (LG/B) Yes

OK or NG
OK >> 1. Replace auto amp. (LCU).
2. Go to self-diagnosis step-by-step procedure ATC-60
and perform self-diagnosis STEP-2.Confirm that code RJIA0252E

No. 20 is displayed.
NG >> Repair harness or connector.
COMPONENT INSPECTION
In-vehicle Sensor
After disconnecting in-vehicle sensor harness connector, measure
resistance between terminals 1 and 2 at sensor harness side, using
the table below.
Temperature °C (°F) Resistance kΩ
-15 (5) 12.73
-10 (14) 9.92
-5 (23) 7.80
0 (32) 6.19
5 (41) 4.95
10 (50) 3.99
15 (59) 3.24
20 (68) 2.65
25 (77) 2.19
30 (86) 1.81
35 (95) 1.51
40 (104) 1.27
45 (113) 1.07
RJIA0253E
If NG, replace in-vehicle sensor.

ATC-120
 TROUBLE DIAGNOSIS

Sunload Sensor Circuit EJS0016M

COMPONENT DESCRIPTION A
The sunload sensor is located on the left defroster grille. It detects
sunload entering through windshield by means of a photo diode. The
sensor converts the sunload into a current value which is then input B
into the auto amplifier.

D
RJIA0109E

SUNLOAD INPUT PROCESS E

The auto amp. also includes a processing circuit which averages the variations in detected sunload over a
period of time. This prevents drastic swings in the ATC system operation due to small or quick variations in
detected sunload.
For example, consider driving along a road bordered by an occasional group of large trees. The sunload F
detected by the sun-load sensor will vary whenever the trees obstruct the sunlight. The processing circuit
averages the detected sun-load over a period of time, so that the (insignificant) effect of the trees momentarily
obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly G
after entering a long tunnel, the system will recognize the change in sun-load, and the system will react
accordingly.
DIAGNOSTIC PROCEDURE H
SYMPTOM: Sunload sensor circuit is open or shorted. (25 or -25) is
indicated on auto amp. as a result of conducting Self-diagnosis
STEP 2.) I

ATC

K
SHA301F

L
1. CHECK SUN-LOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND GROUND
Disconnect sunload sensor harness connector.
M
Terminals
(+)
Voltage
Terminal (Wire (-)
Connector
color)
M44 1 (SB) Ground Approx. 5V
OK or NG
OK >> GO TO 2.
NG >> GO TO 4. RJIA0254E

ATC-121
 TROUBLE DIAGNOSIS

2. CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. (LCU)
Disconnect auto amp. (LCU) harness connector.
Terminals
Terminal (Wire Terminal (Wire Continuity
Connector Connector
color) color)
M44 2 (R/Y) M119 11 (R/Y) Yes
OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector.
RJIA0255E

3. CHECK SUNLOAD SENSOR.

Refer to ATC-131, "SUNLOAD SENSOR" .
OK or NG
OK >> 1. Replace auto amp. (LCU).
2. Go to self-diagnosis step-by-step procedure ATC-60 and perform self-diagnosis STEP-2. Con-
firm that code No. 20 is displayed.
NG >> 1. Replace sunload sensor.
2. Go to self-diagnosis step-by-step procedure ATC-60 and perform self-diagnosis STEP-2. Con-
firm that code No. 20 is displayed.

4. CHECK SUNLOAD SENSOR CIRCUIT BETWEEN SUNLOAD SENSOR AND AUTO AMP. (LCU)
Disconnect auto amp. (LCU) harness connector.
Terminals
Terminal (Wire Terminal (Wire Continuity
Connector Connector
color) color)
M44 1 (SB) M119 12 (SB) Yes

OK or NG
OK >> 1. Replace auto amp.
2. Go to self-diagnosis step-by-step procedure ATC-60
and perform self-diagnosis STEP-2. Confirm that RJIA0256E
code No. 20 is displayed.
NG >> Repair harness or connector.

ATC-122
 TROUBLE DIAGNOSIS

COMPONENT INSPECTION
Sunload Sensor A
Measure voltage between auto amp. terminal 12 and body ground.
If NG, replace auto amp.
B

RJIA0257E H

● When checking sunload sensor, select a place where sun shines directly on it.
I

ATC

SHA930E

ATC-123
 TROUBLE DIAGNOSIS

Intake Sensor Circuit EJS0016N

COMPONENT DESCRIPTION
Intake Sensor
The intake sensor is located on the heater & cooling unit. It converts
temperature of air after it passes through the evaporator into a resis-
tance value which is then input to the auto amp.
After disconnecting intake sensor harness connector, measure resis-
tance between terminals 1 and 2 at sensor harness side, using the
table below.
Temperature °C (°F) Resistance kΩ
-15 (5) 12.34
-10 (14) 9.62
RJIA0110E
-5 (23) 7.56
0 (32) 6.00
5 (41) 4.80
10 (50) 3.87
15 (59) 3.15
20 (68) 2.57
25 (77) 2.12
30 (86) 1.76
35 (95) 1.47
40 (104) 1.23
45 (113) 1.04

If NG, replace intake sensor.

DIAGNOSTIC PROCEDURE
SYMPTOM: Intake sensor circuit is open or shorted. (24 or -24) is
indicated on auto amp. as a result of conducting Self-diagnosis
STEP 2.)

RHA056GA

1. CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND GROUND

Disconnect intake sensor harness connector.
Terminals
(+)
Voltage
Terminal (Wire (-)
Connector
color)
M90 32 (G/OR) Ground Approx. 5V

Yes or No
Yes >> GO TO 2.
No >> GO TO 4. RJIA0258E

ATC-124
 TROUBLE DIAGNOSIS

2. CHECK INTAKE SENSOR CIRCUIT BETWEEN INTAKE SENSOR AND AUTO AMP. (LCU) A
Disconnect auto amp. (LCU) harness connector.
Terminals
B
Terminal (Wire Terminal (Wire Continuity
Connector Connector
color) color)
M90 36 (R/Y) M119 11 (R/Y) Yes C
OK or NG
OK >> GO TO 3.
NG >> Repair harness or connector. D
RJIA0259E

3. CHECK INTAKE SENSOR E

Refer to ATC-124, "Intake Sensor Circuit"

OK or NG
F
OK >> 1. Replace auto amp.
2. Go to self-diagnosis step-by-step procedure ATC-60 and perform self-diagnosis STEP-2.Con-
firm that code No. 20 is displayed. G
NG >> 1. Replace intake sensor.
2. Go to self-diagnosis step-by-step procedureATC-60 and perform self-diagnosis STEP-2.Con-
firm that code No. 20 is displayed. H
4. CHECK INTAKE SENSOR CIRCUIT BETWEEN AMBIENT SENSOR AND AUTO AMP. (LCU)
Disconnect auto amp. (LCU) harness connector. I

Terminals
Terminal (Wire Terminal (Wire Continuity
Connector Connector ATC
color) color)
M90 32 (G/OR) M119 1 (G/OR) Yes

OK or NG K
OK >> 1. Replace auto amp.
2. Go to self-diagnosis step-by-step procedure ATC-60
and perform self-diagnosis STEP-2.Confirm that code RJIA0260E
L
No. 20 is displayed.
NG >> Repair harness or connector.
M
Multiplex Communication Circuit EJS0016O

DIAGNOSTIC PROCEDURE
SYMPTOM:
● A/C system does not come on.
● A/C system can not controlled.

RJIA0466E

ATC-125
 TROUBLE DIAGNOSIS

1. CHECK FOR AUTO AMP. OUTPUT

Confirm multiplex communication signal using an oscilloscope.
Terminals Voltage

M119-9

RJIA0212E

M119-20

HAK0363D

OK or NG
OK >> GO TO 2
NG >> Replace auto amp.

2. CHECK CIRCUIT CONTINUITY BETWEEN AV CONTROL UNIT AND AUTO AMP.

Disconnect AV control unit and auto amp. connector.

RJIA0467E

Terminals
AV control unit Auto amp. Continuity
Connector Terminal (Wire color) Connector Terminal (Wire color)
M77 44 (W) M119 9 (W)
Yes
M77 45 (B) M119 20 (B)
OK or NG
OK >> Reconnect AV control unit and auto amp. connector. And GO TO 3.
NG >> Repair harness or connector.

ATC-126
 TROUBLE DIAGNOSIS

3. CHECK FOR AUTO AMP. INPUT A

Confirm multiplex communication signal using an oscilloscope.
Terminal Voltage
B

C
M119-10

D
RJIA0213E

OK or NG
OK >> INSPECTION END E
NG >> GO TO 4.

4. CHECK CIRCUIT CONTINUITY BETWEEN AV CONTROL UNIT AND AUTO AMP. F

Disconnect AV control unit and auto amp. connector.
Terminals G
Continuity
AV control unit Auto amp.
M77 43 (R) M119 10 (R) Yes
H
OK or NG
OK >> Replace auto amp.
NG >> Repair harness or connector.
I
RJIA0468E

ATC

ATC-127
 CONTROL UNIT

CONTROL UNIT PFP:27500

Removal and Installation EJS0016P

Refer to DI-125, "Removal and Installation of AV Control Unit"

ATC-128
 AMBIENT SENSOR

AMBIENT SENSOR PFP:27722

A
Removal and Installation EJS0016Q

D
RJIA0243E

ATC

ATC-129
 IN-VEHICLE SENSOR

IN-VEHICLE SENSOR PFP:27720

Removal and Installation EJS0016R

1. Remove instrument lower driver panel.

2. Remove the in-vehicle sensor.

RJIA0312E

ATC-130
 SUNLOAD SENSOR

SUNLOAD SENSOR PFP:27721

A
Removal and Installation EJS0016S

1. Remove sunload sensor garnish.

2. Remove the sunload sensor. B

RJIA0109E

ATC

ATC-131
 INTAKE SENSOR CIRCUIT

INTAKE SENSOR CIRCUIT PFP:27723

Removal and Installation EJS0016T

1. Remove heater & cooling unit.

2. Remove the evaporator from heater & cooling unit.
3. Separate the heater & cooling unit case.
4. Remove the intake sensor.

RJIA0110E

ATC-132
 BLOWER UNIT

BLOWER UNIT PFP:27200

A
Removal and Installation EJS0016U

REMOVAL
1. Remove the glove box assembly.
B
2. Remove the glove box cover, the instrument lower assist panel
and instrument reinforcement.
3. Remove the ECM control unit and CD auto changer (If
C
equipped).
4. Disconnect the blower motor connector, intake door motor con-
nector and auto amp. connector.
D

RJIA0313E
E
5. Remove the screws from the blower unit, then remove it.
CAUTION:
Slide the blower unit toward the right, remove location pins (2 F
pieces), then move it downwards.

H
RJIA0314E

INSTALLATION I
CAUTION:
● Make sure the location pins (2 pieces) are securely installed.
NOTE: ATC
● When attaching the blower unit, the work will be easier if the blower motor is removed first.

ATC-133
 BLOWER UNIT

Disassembly and Assembly EJS0016V

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

RJIA0315E

1. Blower motor assembly 2. Screw 3. Lower case

4. Screw 5. Bell mouth 6. Screw
7. Clamp 8. Screw 9. Intake door lever No.1
10. Intake door motor 11. Screw 12. Auto amplifier
13. Screw 14. Intake door lever No.2 15. Intake door link
16. Screw 17. Filter cover 18. Ventilation air filter
19. Intake door No.2 20. Upper case 21. Intake door No.1

ATC-134
 BLOWER MOTOR

BLOWER MOTOR PFP:27226

A
Removal and Installation EJS0016W

1. Remove the glove box and instrument lower assist panel.

2. Remove the screws from blower motor, then remove it. B

RJIA0271E

ATC

ATC-135
 INTAKE DOOR MOTOR

INTAKE DOOR MOTOR PFP:27730

Removal and Installation EJS0016X

1. Remove the glove box, glove box cover, instrument lower assist
cover and instrument reinforcement.
2. Remove ECM control unit.
3. Remove the blower unit.
4. Remove the intake door motor from the blower unit.

RJIA0280E

ATC-136
 VENTILATION AIR FILTER

VENTILATION AIR FILTER PFP:27277

A
Removal and Installation EJS0016Y

FUNCTION
Air inside passenger compartment is kept clean at either recircula- B
tion or fresh mode by installing ventilation air filter into blower unit.

RJIA0316E
E
REPLACEMENT TIMING
Replace ventilation air filter.
Refer to MA-6, "CHASSIS AND BODY MAINTENANCE" and MA-7, F
"MAINTENANCE UNDER SEVERE DRIVING CONDITIONS" .

Caution label is fixed inside the glove box. G

SHA868E
I
REPLACEMENT PROCEDURES
1. Remove the glove box.
2. Remove the center cover of the glove box cover. ATC
3. Remove ventilation air filter cover.
4. Take out the ventilation air filter from blower unit.
5. Replace with new one and reinstall on cooling unit. K
6. Reinstall the glove box.

RJIA0317E

ATC-137
 HEATER & COOLING UNIT ASSEMBLY

HEATER & COOLING UNIT ASSEMBLY PFP:27110

Removal and Installation EJS00172

REMOVAL
1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover.
2. Remove the strut tower bar.
3. Discharge refrigerant from A/C system.
4. Drain coolant from cooling system. Refer to.
5. Disconnect two heater hoses from heater core pipe.
6. Remove the instrument panel.
7. Remove the blower unit.
8. Remove clips of vehicle harness from steering member.
RJIA0318E

9. Remove the instrument stays (driver side, passenger side).

10. Remove the defroster nozzle and ventilator ducts.

RJIA0115E

RJIA0319E

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.

ATC-138
 HEATER & COOLING UNIT ASSEMBLY

11. Remove the screws from heater & cooling unit.

12. Remove the heater & cooling unit. A

RJIA0117E

D
INSTALLATION
● Installation is basically the reverse order of removal.
E
NOTE:
When filling radiator with coolant, refer to CO-10, "Changing Engine Coolant" . Recharge the A/C system.

ATC

ATC-139
 HEATER & COOLING UNIT ASSEMBLY

Disassembly and Assembly EJS00173

RJIA0320E

ATC-140
 MODE DOOR MOTOR

MODE DOOR MOTOR PFP:27731

A
Removal and Installation EJS00174

DRIVER SIDE MODE DOOR MOTOR

1. Remove the instrument panel.
B
2. Disconnect the mode door motor connector.
3. Remove the mode door motor.
C

RJIA0284E
E
PASSENGER SIDE MODE DOOR MOTOR
1. Remove the blower unit.
2. Disconnect the mode door motor connector. F
3. Remove the mode door motor.

RJIA0283E

ATC

ATC-141
 AIR MIX DOOR MOTOR

AIR MIX DOOR MOTOR PFP:27732

Removal and Installation EJS00175

DRIVER SIDE AIR MIX DOOR MOTOR

1. Remove the instrument lower driver panel.
2. Remove the air mix door rod from rod holder.
3. Disconnect the air mix door motor connector.
4. Remove the air mix door motor.

RJIA0288E

PASSENGER SIDE AIR MIX DOOR MOTOR

1. Remove the blower unit.
2. Remove the air mix door rod from rod holder.
3. Disconnect the air mix door motor connector.
4. Remove the air mix door motor.

RJIA0287E

ATC-142
 DUCTS AND GRILLES

DUCTS AND GRILLES PFP:27860

A
Removal and Installation EJS00176

VENTILATOR DUCT, DEFROSTER NOZZLE AND DEFROSTER DUCTS

B

G
RJIA0321E

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite. H
CENTER VENTILATOR GRILLE
1. Remove cluster lid C.
I
2. Remove center ventilator grille.

ATC

RJIA0120E
L
SIDE VENTILATOR GRILLE
1. Remove instrument panel.
2. Remove side ventilator grille. M

RJIA0322E

ATC-143
 DUCTS AND GRILLES

REAR VENTILATOR GRILLE

1. Remove console box.
2. Remove rear ventilator grille.

RJIA0323E

REAR VENTILATOR GRILLE

RJIA0122E

REAR VENTILATOR DUCTS

1. Remove console box.
2. Remove rear ventilator duct No.2.
3. Remove instrument panel.

RJIA0337E

4. Disconnect rear ventilator door motor connector.

5. Remove rear ventilator duct No.1.

RJIA0125E

ATC-144
 DUCTS AND GRILLES

REAR VENTILATOR SIDE DUCTS

1. Remove front door finisher. A
2. Remove rear ventilator side duct No.1.

RJIA0126E
D

3. Remove center pillar upper garnish.

4. Remove rear ventilator side duct No.2. E

RJIA0127E

FOOT DUCT H
1. Remove heater & cooling unit.
2. Remove foot duct.
I

ATC

K
RJIA0324E

FLOOR DUCT L
1. Remove the front seats and console box.
2. Remove the front kicking plate, the footrest and the dash side
finisher. M
3. Peel back the floor trim to a point where the floor duct is visible.
4. Remove the floor duct No.2 (left and right).
5. Remove the mounting screw from the floor duct No.1.
6. Remove the floor duct No.1 (left and right).

RJIA0128E

ATC-145
 REFRIGERANT LINES

REFRIGERANT LINES PFP:92600

HFC-134a (R-134a) Service Procedure EJS0017G

SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant
WARNING:
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If
accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.

SHA539DE

Evacuating System and Charging Refrigerant

SHA540DC

ATC-146
 REFRIGERANT LINES

SHA383F ATC
*1 Lubricant ATC-22, "LUBRICANT *3 Refrigerant leaks ATC-161, *4 Performance test diagnoses ATC-
RETURN OPERATION" "CHECKING PROCEDURE" 100
*2 Checking for refrigerant leaksATC- K
159

ATC-147
 REFRIGERANT LINES

Components EJS0017H

Refer to ATC-6, "Precautions for Refrigerant Connection" .

RJIA0325E

ATC-148
 REFRIGERANT LINES

Removal and Installation for Compressor EJS0017I

REMOVAL A

RJIA0326E
G

1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover. H
2. Using recycling and recovery equipment (for HFC-134a), dis-
charge the refrigerant.
3. Remove the engine under cover. I
4. Remove the air cleaner assembly, air duct and air inlet pipe.
5. Remove the compressor-alternator belt.
Refer to EM-13, "Checking Drive Belts" . ATC

RJIA0327E

K
6. Remove the mounting nuts from the high-pressure flexible hose
and low-pressure flexible hose.
CAUTION: L
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
7. Disconnect the compressor connector. M
8. Remove the mounting bolt from radiator hose bracket.
9. Remove the mounting bolts from compressor.
10. Move the radiator hose to the right side of the vehicle.
11. Remove the compressor from the upper side of the vehicle RJIA0133E

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.
Bolts mounting the compressor
Tightening torque : 56.9 - 65.7 N-m (5.8 - 6.8 kg-m)
Nut mounting the high-pressure flexible hose
Tightening torque : 7.85 - 19.6 N-m (0.8 - 2.0 kg-m)

ATC-149
 REFRIGERANT LINES

Nut mounting the low-pressure flexible hose

Tightening torque : 7.85 - 19.6 N-m (0.8 - 2.0 kg-m)

Removal and Installation for Compressor Clutch EJS0017J

REMOVAL
Overhaul
1. When removing center bolt, hold clutch disc with wrench.

RHA136EB

RHA399FA

2. Remove the clutch disc using the clutch disc puller.

RHA124FA

3. Remove the snap ring using external snap ring pliers.

RHA138E

ATC-150
 REFRIGERANT LINES

4. Position the center pulley puller on the end of the drive shaft,
and remove the pulley assembly using any commercially avail- A
able pulley puller.
To prevent the pulley groove from being deformed, the puller
claws should be positioned into the edge of the pulley assembly.
B

RHA139E

D
5. Remove the field coil harness clip using a pair of pliers.

G
RHA125F

6. Remove the snap ring using external snap ring pliers. H

ATC

K
RHA145E

Inspection
Clutch disc L
If the contact surface shows signs of damage due to excessive heat,
replace clutch disc and pulley.

Pulley M
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.

RHA126F

Coil
Check coil for loose connection or cracked insulation.

ATC-151
 REFRIGERANT LINES

INSTALLATION
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.

RHA143E

4. Install the clutch disc on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.

RHA127F

5. Using the holder to prevent clutch disc rotation, tighten the bolt
to 14 N-m (1.4 kg-m, 10 ft-lb) torque.
After tightening the bolt, check that the pulley rotates smoothly.

RHA086E

ATC-152
 REFRIGERANT LINES

6. Check clearance around the entire periphery of clutch disc.

Disc to pulley clearance: 0.3 - 0.6 mm (0.012 - 0.024 in) A

If the specified clearance is not obtained, replace adjusting

spacer and readjust.
B

RHA087E

D
Break-in Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
E
Removal and Installation for Low-pressure Flexible Hose EJS0017K

REMOVAL
1. Remove the master cylinder cover, ABS unit cover and airflow F
meter cover.
2. Using the recycling and recovery machine (for HFC134a), drain
the refrigerant. G
3. Drain the coolant from cooling system, and disconnect two
heater hoses.
4. Remove the strut tower bar, air cleaner assembly, air duct and H
air inlet pipe.

RJIA0318E I

5. Remove the vehicle harness from the clip.

6. Remove the mounting bolts from the low-pressure flexible hose ATC
bracket.
7. Remove the clip from the low-pressure flexible hose.
8. Remove the mounting bolts from the low-pressure flexible hose. K
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as
vinyl tape to avoid the entry of air. L
9. Remove the low-pressure flexible hose.
RJIA0328E

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.
● When pouring refrigerant, check for leaks.
Low-pressure flexible hose and bolts mounting the high-pressure
pipe (evaporator side)
Tightening torque :2.9 - 5.9 N-m (0.29 - 0.6 kg-m)
Bolts mounting the low-pressure flexible hose (compressor side)
Tightening torque :7.8 - 19.6 N-m (0.8 - 2.0 kg-m)

ATC-153
 REFRIGERANT LINES

Removal and Installation for High-Pressure Flexible Hose EJS0017L

REMOVAL
1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover.
2. Using the recycling and recovery machine (for HFC134a), drain
the refrigerant.
3. Remove the air cleaner assembly, air duct and air inlet pipe.
4. 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
vinyl tape to avoid the entry of air. RJIA0138E

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.
● When pouring refrigerant, check for leaks.
Bolt and nut mounting the high-pressure flexible hose
Tightening torque :7.8 - 19.6 N-m (0.8 - 2.0 kg-m)

Removal and Installation for High-Pressure Pipe EJS0017M

REMOVAL
1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover.
2. Using the recycling and recovery machine (for HFC134a), drain
the refrigerant.
3. Drain the coolant from cooling system, disconnect two heater
hoses.
4. Remove the strut tower bar, air cleaner assembly, air duct and
air inlet pipe.

RJIA0318E

5. Remove the vehicle harness from the clip.

6. Remove the low-pressure flexible hose and high-pressure flexi-
ble hose.
7. Remove the front grille, battery, battery tray and radiator mount-
ing bracket.
8. Slide the radiator assembly to the right side of vehicle.

RJIA0328E

ATC-154
 REFRIGERANT LINES

9. Remove the mounting bolt from the high-pressure pipe.

10. Remove the clips from the high-pressure pipe, then remove the A
high-pressure pipe.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as B
vinyl tape to avoid the entry of air.

RJIA0329E

D
INSTALLATION
CAUTION:
● Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it. E
● When pouring refrigerant, check for leaks.
Bolts mounting the high-pressure pipe (condenser side, F
evaporator side)
Tightening torque :2.9 - 5.9 N-m (0.29 - 0.6 kg-m)
G
Removal and Installation for Refrigerant Pressure Sensor EJS0017N

1. Remove the condenser.

2. Remove the refrigerant pressure sensor from condenser. H
CAUTION:
● When working, be careful not to damage the compressor
fan. I
● Apply compressor oil to the O-ring of the refrigerant pres-
sure sensor when installing it.
Tightening torque :9.8 - 11.7 N-m (1.0 - 1.2kg-m) ATC

RJIA0330E

Removal and Installation for Refrigerant Pressure Sensor (To be applied after K
the middle of June 2001.) EJS001OF

1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant.

L
2. Remove front grille.
3. Disconnect connector and remove refrigerant pressure sensor.
CAUTION: M
● Secure refrigerant pressure sensor installation pipe with an
open-end wrench. Be careful not to deform pipe during the
operation.
● Be careful not to damage the core surface of the condenser
during the operation.
● Replace refrigerant pressure sensor O-ring with a new one.
Apply compressor oil prior to installation.
Refrigerant pressure SJIA0134E

sensor : 9.8 - 11.7 N-m (1.0 - 1.2 kg·m)

Tightening torque

ATC-155
 REFRIGERANT LINES

Removal and Installation for Condenser EJS0017O

REMOVAL
1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover.
2. Using the recycling and recovery machine (for HFC134a), drain
the refrigerant.
3. Remove the strut tower bar, air cleaner assembly, air duct and
air inlet pipe.
4. Disconnect the high-pressure flexible hose and the high-pres-
sure pipe from the condenser.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such RJIA0141E
as vinyl tape to avoid the entry of air.
5. Remove the oil cooler pipe clips from the left and right sides of the condenser.
6. Slide the condenser up, then remove the condenser from the radiator clip.
7. Remove the oil cooler from the condenser.

RJIA0142E

8. Remove the front grille, battery, battery tray and radiator mount-
ing bracket.
9. Remove power steering oil tank and canister.

RJIA0331E

10. Remove the mounting bolts from condenser.

11. Slide the condenser up, then remove the condenser from the
radiator clip.
12. 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.
RJIA0332E

ATC-156
 REFRIGERANT LINES

INSTALLATION
CAUTION: A
● Replace the O-rings of the high-pressure pipe and the high-
pressure flexible hose with new ones, then apply compres-
sor oil to them after installing them. B
● When pouring refrigerant, check for leaks.
High-pressure flexible hose mounting bolts
C
Tightening torque :7.8 - 19.6 N-m (0.8 - 2.0 kg-m)
High-pressure pipe mounting bolts
Tightening torque :2.9 - 5.9 N-m (0.29 - 0.6 kg-m) D
Condenser mounting bolts RJIA0333E

Tightening torque :3.82 - 4.51 N-m (0.39 - 0.46 kg-m)

E
Removing and Installation for Liquid Tank (To be applied after the middle of
June 2001.) EJS001OG

ATC

SJIA0132J

1. Liquid tank 2. Liquid tank securing bands 3. Screw L

4. Securing bracket piping 5. Screw 6. O-ring
7. Condenser 8. Refrigerant pressure sensor
M
REMOVAL
1. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
2. Remove front grille.
3. Unscrew, and remove the securing bracket piping.
4. Unscrew liquid tank securing bands.
5. Pull out the liquid tank and liquid tank securing bands through
the top.

SJIA0133E

ATC-157
 REFRIGERANT LINES

INSTALLATION
CAUTION:
Replace refrigerant pressure sensor O-ring with a new one. Apply compressor oil prior to installation.
Securing bracket piping mounting screws
: 4 - 5 (0.41 - 0.51)
Tightening torque [N-m (kg·m)]
Liquid tank securing band mounting screw
: 2.94 - 3.82 (0.3 - 0.38)
tightening torque [N-m (kg·m)]

Removal and Installation for Evaporator EJS0017P

REMOVAL
1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover.
2. Using the recycling and recovery machine (for HFC134a), dis-
charge the refrigerant.
3. Drain the coolant from cooling system, disconnect two heater
hoses.
4. 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 RJIA0318E
the high-pressure pipe with a suitable tool such as a vinyl
tape to avoid the entry of air.

5. Remove the heater & cooling unit.

6. Remove the cooler grommet, expansion valve cover, expansion
valve.
7. Remove the air mix door motor and mode door motor bracket.
8. Remove the evaporator cover.
9. Slide the evaporator, then remove it from the heater & cooling
unit.
10. Remove the intake sensor from the evaporator, then remove the
evaporator.
RJIA0110E

INSTALLATION
CAUTION:
● Replace the O-rings of the low-pressure flexible hose and the high-pressure pipe with new ones,
then apply compressor oil to them when installing them.
● Mark the mounting position of the intake sensor bracket.
Removal and Installation for Expansion Valve EJS0017Q

1. Remove the master cylinder cover, ABS unit cover and airflow
meter cover.
2. Using the recycling and recovery equipment (for HFC-134a),
discharge the refrigerant.
3. Drain the coolant from cooling system, disconnect two heater
hoses.
4. Disconnect the low-pressure flexible hose and high-pressure
pipe from the evaporator.

RJIA0318E

ATC-158
 REFRIGERANT LINES

5. Remove the expansion valve cover.

6. Remove the expansion valve. A

Expansion valve mounting bolts

Tightening torque :2.9 - 5.0 N-m (0.30 - 0.50 kg-m) B

RJIA0334E

D
Removal and Installation for Desiccant Assembly EJS0017R

REMOVAL
1. Remove the condenser.
E
2. Clean the area around the snap ring. Remove any dirt or rust.
CAUTION:
Be sure to clean carefully.
F
3. Remove the snap ring from the lower side of liquid tank.
4. Remove the cap, filter and desiccant assembly.
G

RJIA0335E
H
INSTALLATION
1. Install the new desiccant, filter, cap, O-ring, and snap ring.
2. The work must be performed with clean hands. (Gloves may I
not be worn.)
3. The desiccant, filter, cap, O-ring, and snap ring cannot be
reused. ATC
4. When inserting the desiccant, be sure to insert it all the way in,
taking care not to allow any dirt to contact the surrounding area.
5. Do not install the filter backwards. K
6. When inserting the cap, be certain to avoid having the O-ring
catch on something, fall out, or contact dirt RJIA0336E

7. Apply lubricating oil to the cap O-ring, then insert all the way to L
the end.
8. Check that there is no dust or dirt adhering to the snap ring installation groove.
9. The snap ring must be installed securely into the groove. M
Checking for Refrigerant Leaks EJS0017S

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.

ATC-159
 REFRIGERANT LINES

Checking System for Leaks Using the Fluorescent Leak Detector EJS0017T

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 TXV) 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. Confirm any suspected leaks with an approved electronic refrigerant leak detector.
4. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag-
nosis.
5. 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.
Dye Injection EJS0017U

(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).
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.
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).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.
Electronic Refrigerant Leak Detector EJS0017V

PRECAUTION FOR HANDLING LEAK DETECTOR

When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.

SHA705EB

ATC-160
 REFRIGERANT LINES

1. Position probe approximately 5 mm (3/16 in) away from point to

be checked. A

SHA707EA

D
2. When testing, circle each fitting completely with probe.

G
SHA706E

3. Move probe along component approximately 25 to 50 mm (1 to H

2 in)/sec.

ATC

K
SHA708EA

CHECKING PROCEDURE
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette L
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. M
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 e) to the low side
(evaporator drain hose f to shaft seal j). Refer to ATC-148 . Perform a leak check for the following areas
carefully. Clean the component to be checked and move the leak detected probe completely around the
connection/component.
Compressor
Check the fitting of high and low pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
ATC-161
 REFRIGERANT LINES

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
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.

Refrigerant leaks should be checked immediately after stopping the

engine. Begin with the leak detector at the compressor. The pres-
sure on the high pressure side will gradually drop after refrigerant
circulation stops and pressure on the low pressure side will gradually
rise, as shown in the graph. Some leaks are more easily detected
when pressure is high.

SHA839E

11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
pressure is displayed, recover refrigerant from equipment lines.
12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
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.

ATC-162
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

A
COMPRESSOR EJS0017W

Model CALSONIC KANSEI make V-6

B
Type V-6 variable displacement

Displacement Max. 184 (11.228)

cm3 (cu in)/rev Min. 14.5 (0.885) C
Cylinder bore × stroke
37 (1.46) × [2.3 - 28.6 (0.091 - 1.126)]
mm (in)
Direction of rotation Clockwise (viewed from drive end) D
Drive belt Poly V

LUBRICANT EJS001V8 E

Model CALSONIC KANSEI make V-6

Name Nissan A/C System Oil Type S F
Part number KLH00-PAGS0
Total in system 230 (8.1)
Capacity
Compressor (Service part) charg- G
ml (lmp fl oz) 230 (8.1)
ing amount

REFRIGERANT EJS001V9
H
Type HFC-134a (R-134a)

Capacity Middle East 0.65 (1.43)

I
kg (lb) Except for Middle East 0.55 (1.22)

ENGINE IDLING SPEED EJS001VA

ATC
Refer to EC-509, "Idle Speed and Ignition Timing" .
BELT TENSION EJS001VB

K
Refer to EM-13, "Checking Drive Belts" .

ATC-163
 AIR PURIFIER

AIR PURIFIER PFP:27445

Removal and Installation EJS001EP

1. Remove the grilles from the rear parcel shelf.

2. Remove the mounting bolts from the air purifier.
3. Remove the trunk room front finisher.
4. Disconnect the air purifier connector.
5. Remove the rear side clip of air purifier, then slide the air purifier
to rear side.
6. Remove the air purifier.

RJIA0148E

Disassembly and Assembly EJS001EQ

RJIA0149E

Replacement Procedure for Air filter EJS001ER

1. Remove the trunk room front finisher.

RJIA0644E

ATC-164