Professional Documents
Culture Documents
J AIR CONDITIONER
B
SECTION
MANUAL AIR CONDITIONER C
E
CONTENTS
PRECAUTIONS .......................................................... 4 LUBRICANT .............................................................. 19 F
Precautions for Supplemental Restraint System Maintenance of Lubricant Quantity in Compressor... 19
(SRS) AIR BAG and SEAT BELT PRE-TEN- LUBRICANT ........................................................ 19
SIONER .................................................................. 4 LUBRICANT RETURN OPERATION .................. 19 G
Precautions for Working with HFC-134a (R-134a)..... 4 LUBRICANT AJUSTING PROCEDURE FOR
General Refrigerant Precautions .............................. 4 COMPONENTS REPLACEMENT EXCEPT
Lubricant Precautions .............................................. 5 COMPRESSOR .................................................. 20
H
Precautions for Leak Detection Dye ......................... 5 LUBRICANT ADJUSTING PROCEDURE FOR
IDENTIFICATION .................................................. 5 COMPRESSOR REPLACEMENT ....................... 20
IDENTIFICATION LABEL FOR VEHICLE ............. 6 AIR CONDITIONER CONTROL ............................... 22
Precautions for Refrigerant Connection ................... 6 Control Operation ................................................... 22 I
FEATURES OF NEW TYPE REFRIGERANT FAN CONTROL KNOB ........................................ 22
CONNECTION ...................................................... 6 MODE CONTROL KNOB .................................... 22
O-RING AND REFRIGERANT CONNECTION..... 7 TEMPERATURE CONTROL KNOB .................... 22 MTC
Precautions for Servicing Compressor ................... 10 RECIRCULATION (REC) SWITCH ..................... 22
Precautions for Service Equipment ........................ 10 AIR CONDITIONER SWITCH ............................. 22
RECOVERY/RECYCLING EQUIPMENT ............ 10 REAR COOLER FAN CONTROL
K
ELECTRONIC LEAK DETECTOR ...................... 10 KNOB(FRONT) ................................................... 23
VACUUM PUMP ..................................................11 REAR COOLER FAN SWITCH ........................... 23
MANIFOLD GAUGE SET .....................................11 Discharge Air Flow ................................................. 24
SERVICE HOSES ................................................11 Component Layout ................................................. 25 L
SERVICE COUPLERS ........................................ 12 Component Location .............................................. 26
REFRIGERANT WEIGHT SCALE ...................... 12 System Description ................................................. 27
CALIBRATING ACR4 WEIGHT SCALE .............. 12 SWITCHES AND THEIR CONTROL FUNCTION... 27 M
CHARGING CYLINDER ...................................... 12 TROUBLE DIAGNOSIS ............................................ 28
Wiring Diagrams and Trouble Diagnosis ................ 12 How to Perform Trouble Diagnoses for Quick and
PREPARATION ......................................................... 14 Accurate Repair ...................................................... 28
Special Service Tools ............................................. 14 WORK FLOW ...................................................... 28
HFC-134a (R-134a) Service Tools and Equipment... 14 SYMPTOM TABLE .............................................. 28
Commercial Service Tool ....................................... 17 Component Parts and Harness Connector Location... 29
REFRIGERATION SYSTEM ..................................... 18 ............................................................................ 29
Refrigerant Cycle ................................................... 18 Wiring Diagram HEATER ................................ 30
REFRIGERANT FIOW ........................................ 18 Schematic A/C ................................................. 31
Refrigerant System Protection ............................... 18 Wiring Diagram A/C ......................................... 32
DUAL PRESSURE SWITCH ............................... 18 Wiring Diagram R/COOL ................................. 36
PRESSURE RELIEF VALVE ............................... 18 Operational Check .................................................. 38
CONDITIONS: ..................................................... 38
PROCEDURE: .................................................... 38
Blower Motor Circuit ............................................... 40
Rear Cooler Fan Motor Circuit ................................ 44
MTC-1
Magnet Clutch Circuit ............................................. 50 5 DOOR) ..............................................................85
Intake Door Circuit .................................................. 55 FOOR-TYPE REAR HEATER (MICROBUS) .......86
Insufficient Cooling ................................................. 55 Rear Blower Fan Motor ...........................................86
INSPECTION FLOW ........................................... 56 REMOVAL AND INSTALLATION .........................86
PERFORMANCE TEST DIAGNOSES ................ 57 Rear Blower Fan Resistor .......................................87
PERFORMANCE CHART ................................... 59 REMOVAL AND INSTALLATION .........................87
TROUBLE DIAGNOSES FOR ABNORMAL Rear Heater Duct (4 Door) ......................................87
PRESSURE ......................................................... 60 Rear Heater Control ................................................87
Insufficient Heating ................................................. 63 REMOVAL AND INSTALLATION .........................87
INSPECTION FLOW ........................................... 64 DISASSEMBLY AND ASSEMBLY .......................88
Noise ...................................................................... 65 Rear Heater Hose ...................................................88
INSPECTION FLOW ........................................... 65 REMOVAL AND INSTALLATION .........................88
CONTROLLER .......................................................... 66 MODE DOOR ............................................................90
Removal and Installation ........................................ 66 Adjustment of Cable ................................................90
Disassembly and Assembly .................................... 67 AIR MIX DOOR ..........................................................91
BLOWER AND COOLING UNIT ASSEMBLY .......... 68 Adjustment of Cable ................................................91
Removal and Installation ........................................ 68 DUCT AND GRILLE ..................................................92
REMOVAL ........................................................... 68 Removal and Installation .........................................92
INSTALLATION .................................................... 69 VENTILATOR DUCT, DEFROSTER NOZZLE,
Disassembly and Assembly .................................... 70 AND DUCT ..........................................................92
BLOWER FAN MOTOR ............................................ 71 CENTRAL VENTILATOR GRILLE .......................92
Removal and Installation ........................................ 71 SIDE VENTILATOR GRILLE ...............................93
BLOWER FAN RESISTOR ....................................... 72 FOOT DUCT ........................................................93
Removal and Installation ........................................ 72 REAR VENTILATOR GRILLE ..............................93
INTAKE DOOR ACTUATOR ..................................... 73 REAR INTAKE GRILLE .......................................93
Removal and Installation ........................................ 73 A/C CYCLE ................................................................94
HEATER UNIT ASSEMBLY ...................................... 74 Component Parts Drawing ......................................94
Removal and Installation ........................................ 74 WITHOUT REAR A/C ..........................................95
REMOVAL ........................................................... 74 WITH REAR A/C ..................................................96
INSTALLATION .................................................... 75 Compressor ............................................................97
Disassembly and Assembly .................................... 76 REMOVAL ............................................................97
HEATER CORE ......................................................... 77 INSTALLATION ....................................................98
Removal and Installation ........................................ 77 Overhaul .................................................................99
REAR A/C UNIT ASSEMBLY ................................... 78 Removal ..................................................................99
Removal and Installation ........................................ 78 Inspection .............................................................. 100
INSTALLATION .................................................... 78 CLUTCH DISC ................................................... 100
INSTALLATION .................................................... 78 PULLEY ............................................................. 100
Disassembly and Assembly .................................... 79 COIL ................................................................... 100
REAR BLOWER FAN MOTOR ................................. 80 Installation ............................................................. 100
Removal and Installation ........................................ 80 BREAK-IN OPERATION .................................... 101
REMOVAL ........................................................... 80 High-Pressure Flexible Hose 1 and Low-Pressure
INSTALLATION .................................................... 80 Flexible Hose 1 ..................................................... 102
REAR BLOWER FAN RESISTOR ............................ 81 REMOVAL .......................................................... 102
Removal and Installation ........................................ 81 INSTALLATION .................................................. 103
DRAIN HOSE ............................................................ 82 Low-Pressure Pipe 1 ............................................. 103
Removal and Installation ........................................ 82 REMOVAL .......................................................... 103
DRAIN HOSE (RH) .............................................. 82 INSTALLATION .................................................. 104
DRAIN HOSE (LH) .............................................. 82 Low-Pressure Pipe 2 ............................................. 104
REAR A/C CONTROLLER ....................................... 83 REMOVAL .......................................................... 104
Removal and Installation ........................................ 83 INSTALLATION .................................................. 104
Disassembly and Assembly .................................... 83 High-Pressure Pipe 1 ............................................ 105
REAR HEATER UNIT ASSEMBLY ........................... 84 REMOVAL .......................................................... 105
Removal and Installation ........................................ 84 INSTALLATION .................................................. 105
BUILT-IN TYPE REAR HEATER (4 DOOR AND High-Pressure Pipe 2 ............................................ 106
5 DOOR) .............................................................. 84 REMOVAL .......................................................... 106
FOOR-TYPE REAR HEATER (MICROBUS) ....... 84 INSTALLATION .................................................. 106
Disassembly and Assembly .................................... 85 High-Pressure Pipe 3 ............................................ 107
BUILT-IN TYPE REAR HEATER (4 DOOR AND REMOVAL .......................................................... 107
MTC-2
INSTALLATION ................................................. 107 REMOVAL AND INSTALLATION ...................... 109
High-Pressure Flexible Hose 2 and Low-Pressure DISASSEMBLY AND ASSEMBLY ......................111 A
Flexible Hose 2 (Rear A/C Side) .......................... 107 Rear Evaporator ....................................................111
REMOVAL ......................................................... 107 REMOVAL AND INSTALLATION .......................111
INSTALLATION ................................................. 108 Front Expansion Valve .......................................... 112 B
High-Pressure Pipe 4 ........................................... 108 REMOVAL AND INSTALLATION ...................... 112
REMOVAL ......................................................... 108 Rear Expansion Valve .......................................... 112
INSTALLATION ................................................. 109 REMOVAL AND INSTALLATION ...................... 112
Pressure Switch ................................................... 109 Liquid Tank ........................................................... 113 C
REMOVAL AND INSTALLATION ...................... 109 REMOVAL AND INSTALLATION ...................... 113
Condenser Assembly ........................................... 109
D
MTC
MTC-3
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Supplemental Restraint System (SRS) AIR BAG and SEAT
BELT PRE-TENSIONER EJS0011K
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 harness connectors.
Precautions for Working with HFC-134a (R-134a) EJS0011L
WARNING:
CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
are mixed and compressor failure is likely to occur, refer to CONTAMINATED REFRIGERANT
below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refriger-
ant Recovery/Recycling Recharging equipment (ACR4) (J-39500-INF) and Refrigerant Identifier.
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. Remove R-134a from the A/C system, using certified service equipment meeting require-
ments of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If acci-
dental 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 may result.
General Refrigerant Precautions EJS0011M
WARNING:
Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or
air conditioning system.
Do not store or heat refrigerant containers above 52C (125F).
Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
Do not intentionally drop, puncture, or incinerate refrigerant containers.
Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
MTC-4
PRECAUTIONS
Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation. A
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 B
property damage. Additional health and safety information may be obtained from refrigerant man-
ufacturers.
Lubricant Precautions EJS0011N C
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 D
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. E
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. F
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. G
Remove R-134a from the A/C system, using certified service equipment meeting requirements of SAE
J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system dis-
charge occurs, ventilate work area before resuming service. Additional health and safety information may
H
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.
I
Precautions for Leak Detection Dye EJS001FO
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. MTC
Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of
the fluorescent dye.
The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo- K
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to (J-
41995) pin-point refrigerant leaks.
For your safety and your Customer's satisfaction, read and follow all manufacture's operating instructions L
and precautions prior to performing the work.
A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal
should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995). M
Always remove any remaining 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
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.
Leak detection dyes for R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye
in R-12 A/C system or R-12 leak detector dye in R-134a A/C systems or A/C system damage may result.
The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure
occurs.
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label.
MTC-5
PRECAUTIONS
SHA436FA
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
Expansion valve to cooling unit
Dual pressure switch 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
MTC-6
PRECAUTIONS
MTC
SJIA0001E
MTC-7
PRECAUTIONS
SJIA0002E
MTC-8
PRECAUTIONS
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O- A
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 B
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) C
8
Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
D
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) E
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 F
Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
New 24 92195 AH300 21.8 (0.858) 2.4 (0.094)
WARNING: G
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: H
When replacing or cleaning refrigerant cycle components, observe the following.
When the compressor is removed, store it in the same position as it is when mounted on the car.
Failure to do so will cause lubricant to enter the low pressure chamber. I
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- MTC
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 K
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. L
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 M
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.
MTC-9
PRECAUTIONS
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
Plug all openings to prevent moisture and foreign matter from entering.
When the compressor is removed, store it in the same position as it is when mounted on the car.
When replacing or repairing compressor, follow Maintenance of Lubricant Quantity in Compres-
sor exactly. Refer to MTC-19, "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.
Precautions for Service Equipment EJS0011Q
RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
MTC-10
PRECAUTIONS
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible A
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump B
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows. C
Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump. D
For pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump. E
If the hose has an automatic shut off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
open and lubricating oil may migrate. F
Some one-way valves open when vacuum is applied and close
under a no vacuum condition. Such valves may restrict the pump's
ability to pull a deep vacuum and are not recommended.
G
RHA270DA
MTC
K
SHA533D
SERVICE HOSES L
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
M
opposite the manifold gauge.
RHA272D
MTC-11
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
RHA274D
MTC-12
PRECAUTIONS
MTC
MTC-13
PREPARATION
PREPARATION PFP:00002
Tool number
Description
Tool name
NT204
RJIA0194E
NT206
NT207
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.
MTC-14
PREPARATION
Tool number
(Kent-Moore No.) Description
A
Tool name
B
Container color:Light blue
Container marking:HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size:Thread size C
large container 1/22 -16 ACME
S-NT196
D
Type:Poly alkylene glycol oil (PAG),
type S
KLH00-PAGS0 Application:HFC-134a (R-134a)
(-) Swash plate compressors (Nissan E
Nissan A/C System Oil Type S only)
Lubricity:40 ml [Litre] (1.4 US fl oz,
S-NT197
1.4 Imp fl oz)
F
(J-39500-INF)
Function:Refrigerant Recovery and
Recovery/Recycling
Recycling and Recharging H
Recharging equipment (ACR4)
I
RJIA0195E
MTC
Power supply: K
(J-41995)
Electrical leak detector DC 12V (Cigarette lighter)
AHA281A
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
MTC-15
PREPARATION
Tool number
(Kent-Moore No.) Description
Tool name
(J-41459)
HFC-134a (R-134a) Dye injector For injecting 1/4 ounce of fluorescent
Use with J-41447, 1/4 ounce leak detection dye into A/C system.
bottle
SHA440F
(J-43872)
For cleaning dye spills.
Dye cleaner
SHA441F
Identification:
(J-39183)
Manifold gauge set (with hoses The gauge face indicates R-134a.
and couplers) Fitting size:Thread size
1/22 -16 ACME
RJIA0196E
MTC-16
PREPARATION
Tool number
(Kent-Moore No.) Description A
Tool name
Service couplers B
High side coupler Hose fitting to service hose:
(J-39500-20) M14 x 1.5 fitting is optional or
Low side coupler permanently attached. C
(J-39500-24)
S-NT202
S-NT200
F
Capacity:
Air displacement:4 CFM
(J-39649)
Micron rating:20 microns G
Vacuum pump
(Including the isolator valve) Oil capacity:482 g (17 oz)
Fitting size:Thread size
S-NT203 1/22 -16 ACME H
MTC
RJIA0197E
MTC-17
REFRIGERATION SYSTEM
REFRIGERANT FIOW
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.
Refrigerant System Protection EJS0011Y
SJIA0003E
MTC-18
LUBRICANT
LUBRICANT PFP:KLG00
A
Maintenance of Lubricant Quantity in Compressor EJS0011Z
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large gas leakage occurred. It is important to maintain the speci- B
fied amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
Lack of lubricant: May lead to a seized compressor C
Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
D
Name :Nissan A/C System Oil Type S
Part number :KLH00-PAGS0
LUBRICANT RETURN OPERATION E
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION F
Can lubricant return operation be performed?
A/C system works properly.
G
There is no evidence of a large amount of lubricant leakage.
Yes or No
Yes >> GO TO 2. H
No >> GO TO 3.
3. CHECK COMPRESSOR
Should the compressor be replaced?
Yes or No
Yes >> Go to MTC-20, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
No >> GO TO 4.
MTC-19
LUBRICANT
MTC-20
LUBRICANT
RHA065DD MTC
MTC-21
AIR CONDITIONER CONTROL
SJIA0004E
MTC-22
AIR CONDITIONER CONTROL
MTC
MTC-23
AIR CONDITIONER CONTROL
SJIA0005E
MTC-24
AIR CONDITIONER CONTROL
MTC
SJIA0006E
MTC-25
AIR CONDITIONER CONTROL
ZJIA0003E
MTC-26
AIR CONDITIONER CONTROL
I
SJIA0103E
MTC
SJIA0104E
MTC-27
TROUBLE DIAGNOSIS
How to Perform Trouble Diagnoses for Quick and Accurate Repair EJS001FP
WORK FLOW
*1:Operational Check MTC-38
SHA900E
SYMPTOM TABLE
Symptom Reference Page
Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor. MTC-40
Rear cooler fan motor operation is malfunc-
Go to Trouble Diagnosis Procedure for Rear cooler fan Motor. MTC-44
tioning.
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. MTC-50
Insufficient cooling. Go to Trouble Diagnosis Procedure for Insufficient Cooling. MTC-55
Intake door does not change.
Go to Trouble Diagnosis Procedure for Intake Door Motor. MTC-55
Intake door motor does not operate normally.
Insufficient heating. Go to Trouble Diagnosis Procedure for Insufficient Heating. MTC-63
Noise. Go to Trouble Diagnosis Procedure for Noise. MTC-65
MTC-28
TROUBLE DIAGNOSIS
MTC
ZJIA0003E
MTC-29
TROUBLE DIAGNOSIS
TJWH0001E
MTC-30
TROUBLE DIAGNOSIS
MTC
TJWH0002E
MTC-31
TROUBLE DIAGNOSIS
TJWH0003E
MTC-32
TROUBLE DIAGNOSIS
MTC
TJWH0004E
MTC-33
TROUBLE DIAGNOSIS
TJWH0005E
MTC-34
TROUBLE DIAGNOSIS
MTC
TJWH0006E
MTC-35
TROUBLE DIAGNOSIS
TJWH0007E
MTC-36
TROUBLE DIAGNOSIS
MTC
TJWH0008E
MTC-37
TROUBLE DIAGNOSIS
The purpose of the operational check is to confirm that the system operates as it should. The systems which
are checked are the blower, mode (discharge air), intake air (recirculation), temperature decrease, tempera-
ture increase, and A/C compressor.
CONDITIONS:
Engine running at normal operating temperature.
PROCEDURE:
1. Check Blower Motor
1. Turn fan control knob to 1-speed.
Blower should operate on 1-speed.
2. Then turn fan control knob to 2-speed, and continue checking
blower speed until all four speeds are checked.
3. Leave blower on 4-speed.
If NG, go to MTC-40, "Blower Motor Circuit"
If OK, continue with the check.
SJIA0043E
SJIA0045E
MTC-38
TROUBLE DIAGNOSIS
2. Confirm that discharge air comes out according to the air distri-
bution table at left. A
Refer to MTC-24, "Discharge Air Flow" .
If NG, go toMTC-90, "Adjustment of Cable" .
If OK, continue with next check. B
G
SJIA0046E
4. Check Recirculation
1. Press recirculation switch. H
Recirculation indicator should light.
2. Listen for intake door position to change (you should hear
blower sound change slightly). I
If NG, go to MTC-55, "Intake Door Circuit" .
If OK, continue with next check.
MTC
SJIA0047E K
5. Check Temperature Decrease
1. Turn temperature control knob to full cold.
L
2. Check for cold air at discharge air outlets.
If NG, go toMTC-55, "Insufficient Cooling" .
If OK, continue with next check.
M
SJIA0048E
MTC-39
TROUBLE DIAGNOSIS
SJIA0049E
SYMPTOM:
Blower motor does not rotate.
1. DIAGNOSTIC PROCEDURE
Check if blower motor rotates properly at each fan speed.
OK or NG
OK >> GO TO 3
NG >> GO TO 13
SJIA0051E
MTC-40
TROUBLE DIAGNOSIS
I
SJIA0053E
MTC-41
TROUBLE DIAGNOSIS
Harness for open or short between blower motor and fan switch, resistor.
Terminals
Continuity
Resistor
M222-1
M222-3
M222-2 Yes
M222-4
M222-6
Yes or No
Yes >> GO TO 9
No >> Replace resistor.
MTC-42
TROUBLE DIAGNOSIS
OK or NG E
OK >> GO TO 12
NG >> GO TO 11
F
11. CHECK CIRCUIT CONTINUITY
G
Terminals
Continuity
Blower motor Resistor
Connectors Wire color Connectors Wire color H
M13-2 L/B M222-3 L/B
M13-3 L/W M222-6 L/W Yes
I
M13-4 L/Y M222-4 L/Y
M13-5 L/G M222-1 L/G
SJIA0059E
MTC
Continuity should exist.
Yes or No
Yes >> Check the following. K
If NG, repair harness or connectors.
Harness for open or short between blower motor and fan switch, fan resistor
MTC-43
TROUBLE DIAGNOSIS
Terminals
Continuity
Blower motor relay
M39 (J/B) -1 M39 (J/B) -2 Yes
Harness for open or short between blower motor relay and fuse block (J/B)
SYMPTOM:
Rear cooler fan motor does not rotate.
1. DIAGNOSTIC PROCEDURE
1. Engine running and A/C ON.
2. Turn fan control knob (front) to the desired (1 to 4 speed) position.
3. Check if rear cooler fan motor rotate properly at each fan speed.
OK or NG
OK >> GO TO 3
NG >> GO TO 13
SJIA0062E
MTC-44
TROUBLE DIAGNOSIS
Yes >> GO TO 4
No >> GO TO 5 E
I
SJIA0064E
MTC-45
TROUBLE DIAGNOSIS
Harness for open or short between rear cooler fan motor and fan switch, fan resistor.
Terminals
Continuity
Fan switch
Connectors Wire color
Ground
R102-1 B Yes
R102-6 B
Yes or No
Yes >> GO TO 8
No >> Repair harness or connector.
Yes >> GO TO 9
No >> Replace resistor.
MTC-46
TROUBLE DIAGNOSIS
Check continuity between rear cooler fan switch and rear cooler
resister.
I
Terminals
Continuity
Fan switch Resistor
Connectors Wire color Connectors Wire color MTC
R102-2 L/B R104-1 L/B
Yes
R102-3 L/W R104-4 L/W
K
R102-4 L/Y R104-6 L/Y
SJIA0070E
Continuity should exist.
L
Yes or No
Yes >> Check the following.
If NG, repair harness or connectors. M
Harness connectors R102, R104 and R107
Harness for open or short between blower motor and fan switch, fan resistor
MTC-47
TROUBLE DIAGNOSIS
Terminals
Continuity
Rear cooler relay
R106-3 R106-5 Yes
Harness for open or short between blower relay and fuse block (J/B).
If OK, GO TO 14
MTC-48
TROUBLE DIAGNOSIS
OK or NG
OK >> GO TO 17 MTC
NG >> Repair harness or connector.
MTC-49
TROUBLE DIAGNOSIS
Terminals
Continuity
Switch position Fan switch
ON-1 M16-3
M16-2 Yes
ON-2 M16-1
Harness for open or short between blower relay and fuse block (J/B).
SYMPTOM:
Magnet clutch does not engage when A/C switch and fan switch are ON.
MTC-50
TROUBLE DIAGNOSIS
terminals
Continuity
Compressor connectors A/C relay connector C
F9-1 (Gasoline engine) R/W M128-5 R/W
Yes
A10-1 (Diesel engine) R/Y M128-5 R/Y
D
Continuity should exist.
SJIA0079E
Yes or No
E
Yes >> GO TO 3
No >> Repair harness or connector.
Terminals G
Voltage
(+) (-)
Connector Wire color H
Ground Approx. 12 V
M128 -1, 3 and 6 L
OK or NG
OK >> GO TO 4. I
NG >> Check power supply circuit and 10A(No.13), 15A(No.15,
16) fuse at fuse block. Refer to PG-78, "FUSE BLOCK- SJIA0080E
JUNCTION BOX(J/B)" . MTC
MTC-51
TROUBLE DIAGNOSIS
Yes >> GO TO 6
No >> Repair harness or connector.
MTC-52
TROUBLE DIAGNOSIS
OK or NG
D
OK >> GO TO 12
>> When compressor ON, do not approx. 0V. GO TO 9
SJIA0085E
When compressor OFF, do not approx. 12 V. Refer to
E
KA Engine (Gasoline) EC-61, "ECM INSPECTION TABLE" , ZD Engine (Diesel) EC-222, "ECM
INSPECTION TABLE" .
OK or NG
OK >> GO TO 10 I
NG >> Repair harness or connector.
SJIA0086E
MTC
10. CHECK CIRCUIT CONTINUITY FOR THERMO CONTROL AMP.
Disconnect thermo control amp. connector and A/C switch connec-
tor. K
Terminals
Continuity
Thermo control amp. A/C switch L
Connector Wire color Connector Wire color
Yes
M6-2 R M10-1 R
M
Continuity should exist.
Yes or No SJIA0087E
Yes >> GO TO 11
No >> Repair harness or connector.
MTC-53
TROUBLE DIAGNOSIS
OK or NG
OK >> GO TO 12
NG >> Replacer thermo control amp.
SJIA0088E
Terminals
Continuity
Fan switch
Connector Wire color Ground
Yes
M13-6 B
MTC-54
TROUBLE DIAGNOSIS
SYMPTOM:
Intake door does not operate. F
OK or NG K
OK >> GO TO 3
NG >> Check power supply circuit and 10A(No.13), 15A(No.15, 16) fuse at fuse block. Refer to PG-78,
"FUSE BLOCK-JUNCTION BOX(J/B)" . L
If OK, replace intake door motor.
MTC-55
TROUBLE DIAGNOSIS
INSPECTION FLOW
WHA292
MTC-56
TROUBLE DIAGNOSIS
MTC
MHA649A
MTC-57
TROUBLE DIAGNOSIS
LHA260
MTC-58
TROUBLE DIAGNOSIS
PERFORMANCE CHART
Test Condition A
Testing must be performed as follows:
Vehicle location Indoors or in the shade (in a well-ventilated place)
B
Doors Closed
Door windows Open
Hood Open C
TEMP. Max. COLD
Mode door (Ventilation) set
D
Intake door (Recirculation) set
MTC-59
TROUBLE DIAGNOSIS
Rear
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature C (F)
% C (F)
25 (77) 10.5 - 13.0 (51 - 55)
MTC-60
TROUBLE DIAGNOSIS
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. M
however, liquid tank is not so and condenser are clogged or Check lubricant for contami-
hot. crushed. nation.
AC360A
MTC-61
TROUBLE DIAGNOSIS
MTC-62
TROUBLE DIAGNOSIS
MTC-63
TROUBLE DIAGNOSIS
INSPECTION FLOW
LHA261
MTC-64
TROUBLE DIAGNOSIS
Noise EJS0012B
A
SYMPTOM: Noise
INSPECTION FLOW
B
MTC
SHA336FA
MTC-65
CONTROLLER
CONTROLLER PFP:27500
ZJIA0008E
ZJIA0007E
ZJIA0009E
MTC-66
CONTROLLER
ZJIA0010J
MTC
MTC-67
BLOWER AND COOLING UNIT ASSEMBLY
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove instrument lower assistance panel.
4. Remove headlight (LH).
ZJIA0012E
ZJIA0013E
ZJIA0015E
ZJIA0008E
MTC-68
BLOWER AND COOLING UNIT ASSEMBLY
11. Remove door lock relay, SRS air bag connector, air bag harness
clip, and keyless entry control connector. A
12. Remove instrument panel stay (LH).
13. Displace cover, and remove blower and cooling unit.
B
ZJIA0014E
D
INSTALLATION
1. Install blower and cooling unit.
Blower & cooling unit assembly mounting bolts and nuts E
Tightening torque : 4.31 - 5.78 Nm (0.44 - 0.59 kgm, 39 - 51 in-lb)
MTC-69
BLOWER AND COOLING UNIT ASSEMBLY
ZJIA0016J
MTC-70
BLOWER FAN MOTOR
ZJIA0015E
E
4. Disconnect coolant hose, and remove blower fan motor.
H
ZJIA0017E
MTC
MTC-71
BLOWER FAN RESISTOR
ZJIA0018E
MTC-72
INTAKE DOOR ACTUATOR
ZJIA0019E
MTC
MTC-73
HEATER UNIT ASSEMBLY
REMOVAL
1. Drain engine coolant.
2. Loosen clamps as shown in the figure, and disconnect heater
hoses from heater & cooling unit assembly. Close coolant inlet/
outlet on heater core (2 locations) with shop cloths.
ZJIA0023E
ZJIA0020E
ZJIA0021E
ZJIA0022E
MTC-74
HEATER UNIT ASSEMBLY
SJIA0099E
D
INSTALLATION
1. Install heater unit assembly.
Heater unit assembly mounting nuts E
Tightening torque : 4.31 - 5.78 Nm (0.44 - 0.59 kgm, 39 - 51 in-lb)
2. Perform removal steps of 2 to 6 in reverse order.
F
Instrument panel stay mounting nuts
Tightening torque : 11 - 13 Nm (1.1 - 1.4 kgm, 6 - 10 in-lb)
G
3. Fill engine coolant.
MTC
MTC-75
HEATER UNIT ASSEMBLY
ZJIA0024E
MTC-76
HEATER CORE
ZJIA0026E
MTC
MTC-77
REAR A/C UNIT ASSEMBLY
INSTALLATION
1. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
2. Remove roof headlining.
3. Disconnect drain hose (RH), and connector.
ZJIA0028E
ZJIA0029E
ZJIA0030E
INSTALLATION
1. Install rear A/C unit assembly.
Rear A/C unit assembly mounting bolts
Tightening : 4.31 - 5.78 Nm (0.44 - 0.59 kgm,
torque 39 - 51 in-lb)
2. Perform removal steps from 2 to 5 in reverse order.
CAUTION:
Replace O-rings on high-pressure and low-pressure flexible
hoses with new ones. Install new O-rings with compressor
oil applied.
ZJIA0031E
After filling refrigerant, check system for refrigerant leak.
Replace insulator on connections of rear A/C unit assembly and low-pressure flexible hose 2 with
new ones.
High-pressure flexible hose 2 union nut
Tightening : 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 -
torque 173 in-lb)
MTC-78
REAR A/C UNIT ASSEMBLY
MTC
ZJIA0032J
K
1 Cover 2 Bolt 3 Screw
4 Rear blower fan motor 5 Rear A/C harness 6 Lower case
7 Seal 8 Bracket 1 9 Evaporator L
10 Bracket 2 11 Screw 12 Rear blower fan resistor
13 Relay 14 Upper case 15 Air duct (LH)
16 Air duct (RH) 17 Bracket 3 18 Bolt M
MTC-79
REAR BLOWER FAN MOTOR
REMOVAL
1. Remove roof headlining.
2. Disconnect coolant hose and connectors.
3. Remove bracket 1.
4. Remove screws, and remove cover.
ZJIA0030E
5. Remove rear blower fan motor from rear A/C unit assembly.
ZJIA0033E
INSTALLATION
CAUTION:
Make sure that locating pins (2 locations) of rear A/C unit assembly (upper) and cover (lower) are
inserted into holes of motor side.
MTC-80
REAR BLOWER FAN RESISTOR
ZJIA0078E
E
3. Remove connector and screws, and remove resistor.
H
ZJIA0034E
MTC
MTC-81
DRAIN HOSE
ZJIA0028E
ZJIA0035E
ZJIA0076E
ZJIA0077E
MTC-82
REAR A/C CONTROLLER
1. Push clip side of rear A/C controller, and pull it out in the direc-
tion shown by arrow. B
ZJIA0037E
E
Disassembly and Assembly EJS0018D
MTC
ZJIA0038J
MTC-83
REAR HEATER UNIT ASSEMBLY
RJIA0359E
RJIA0360E
RJIA0361E
MTC-84
REAR HEATER UNIT ASSEMBLY
I
RJIA0362J
MTC-85
REAR HEATER UNIT ASSEMBLY
RJIA0363J
RJIA0364E
MTC-86
REAR HEATER UNIT ASSEMBLY
RJIA0365E
G
Floor-type rear heater (microbus)
1. Drain engine coolant.
2. Remove rear heater unit, and disconnect connectors of rear blower fan resistor. H
3. Remove mounting screws of rear blower fan resistor, and remove rear blower fan resistor. Refer to MTC-
85, "Disassembly and Assembly" in Rear Heater Unit.
I
Rear Heater Duct (4 Door) EJS0018I
M
RJIA0366E
RJIA0367E
MTC-87
REAR HEATER UNIT ASSEMBLY
5 door
1. Remove rear side finisher.
2. Remove rear heater control mounting screws, and remove rear
heater control.
RJIA0368E
RJIA0369J
RJIA0370E
MTC-88
REAR HEATER UNIT ASSEMBLY
RJIA0371E
D
7. Remove heater hose assembly A.
G
RJIA0372E
MTC
RJIA0373E
K
RJIA0374E
MTC-89
MODE DOOR
MTC-90
AIR MIX DOOR
MTC
MTC-91
DUCT AND GRILLE
ZJIA0040J
1 Cluster lid C 2 Central ventilator grille (LH) 3 Central ventilator grille (RH)
4 Instrument panel assembly 5 Side ventilator duct (LH) 6 Side ventilator grille (LH)
7 Central ventilator duct (LH) 8 Central ventilator duct (RH) 9 Side ventilator grille (RH)
10 Side ventilator duct (RH) 11 Central ventilator adapter 12 Side defroster duct
13 Central defroster nozzle
ZJIA0041E
MTC-92
DUCT AND GRILLE
ZJIA0042E D
FOOT DUCT
1. Remove foot duct.
E
ZJIA0043E
H
REAR VENTILATOR GRILLE
1. Remove rear ventilator grille.
I
MTC
ZJIA0044E
L
REAR INTAKE GRILLE
1. Remove rear intake grille from clip.
ZJIA0045E
MTC-93
A/C CYCLE
MTC-94
A/C CYCLE
MTC
SJIA0097E
MTC-95
A/C CYCLE
SJIA0098E
MTC-96
A/C CYCLE
Compressor EJS0018Q
REMOVAL A
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant. B
3. Remove cover.
4. Remove engine undercover.
5. Remove auxiliary drive belt. KA20 and KA24 engines: EM-14, C
"DRIVE BELTS" ZD engine:EM-107, "DRIVE BELTS"
D
ZJIA0048E
MTC
ZJIA0051E
L
ZJIA0050E
MTC-97
A/C CYCLE
ZJIA0052E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and low-
pressure flexible hose 1 with new ones. Install new O-rings
with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
ZJIA0053E
torque in-lb)
MTC-98
A/C CYCLE
Overhaul EJS001FK
SHA493F
G
Removal EJS001FL
When removing center bolt, hold clutch disc with clutch disc
wrench. H
MTC
SHA792E
K
Remove the drive plate using the clutch disc puller.
Insert holder's three pins into the drive plate. Rotate the holder
clockwise to hook it onto the plate. Tighten the center bolt to L
remove the drive plate.
After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
M
SHA098EA
SHA794E
MTC-99
A/C CYCLE
Pulley removal:
Use a commercially available pulley puller. Position the center of
the puller on the end of the drive shaft. Remove the pulley
assembly with the puller.
For pressed pulleys:
To prevent deformation of the pulley groove, the puller
claws should be hooked under (not into) the pulley groove.
For machine latched pulleys:
Align the pulley puller groove with the pulley groove, and
then remove the pulley assembly.
SHA050F
SHA494F
Inspection EJS001FM
CLUTCH DISC
If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.
PULLEY
Check the appearance of the pulley assembly. If contact surface of pulley shows 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.
COIL
Check coil for loose connection or cracked insulation.
RHA075C
Installation EJS001FN
SHA494F
MTC-100
A/C CYCLE
Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers. A
SHA797EA
D
Install the drive plate on the drive shaft, together with the original
shim(s). Press the drive plate down by hand.
E
G
SHA798E
Using the holder to prevent drive plate rotation, tighten the bolt H
to 12 to 14 N-m (1.2 to 1.4 kg-m, 9 to 10 ft-lb) torque.
MTC
SHA799E
K
After tightening the bolt, check that the pulley rotates smoothly.
L
Check clearance all the way around the clutch disc.
Disc-to-pulley clearance :
0.24 - 0.42 mm (0.0094 - 0.0165 in) M
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
SHA052FA
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct 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.
MTC-101
A/C CYCLE
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove condenser.MTC-109, "Condenser Assembly"
4. Remove cover.
ZJIA0048E
ZJIA0056E
ZJIA0055E
ZJIA0049E
MTC-102
A/C CYCLE
ZJIA0051E
D
8. Remove band clip and clip. Disconnect high-pressure flexible
hose 1 and low-pressure flexible hose 1 from bracket, respec-
tively. E
G
ZJIA0075E
INSTALLATION H
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new ones.
Install new O-rings with compressor oil applied.
I
Replace band clips on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new
ones.
When charging refrigerant, check for refrigerant leaks.
MTC
High-pressure flexible hose 1 mounting bolt
Tightening torque : 8 - 10 Nm (0.8 - 1.1 kgm, 70 - 95 in-lb)
K
Low-pressure flexible hose 1 mounting bolt
Tightening torque : 8 - 10 Nm (0.8 - 1.1 kgm, 70 - 95 in-lb)
L
High-pressure flexible hose 1 union nut
Tightening torque : 14.7 - 24.5 Nm (1.5 - 2.5 kgm, 11 - 18 ft-lb)
M
Low-pressure flexible hose 1 union nut
Tightening torque : 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove condenser.
4. Remove mounting bolts of low-pressure pipe 1, and disconnect
it from blower and cooling unit.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere. ZJIA0013E
MTC-103
A/C CYCLE
ZJIA0056E
INSTALLATION
CAUTION:
O-rings on low-pressure pipe 1 and low-pressure flexible hose 1 must be replaced with new ones.
Install new O-rings with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
Low-pressure pipe 1 union nut
Tightening torque : 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove front LH wheel.
4. Remove condenser.
5. Remove splash board (LH).
6. Disconnect low-pressure pipe 2 from low-pressure pipe 1.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo- ZJIA0056E
sphere.
7. Remove clip fixing bolts, and disconnect low-pressure pipe 2
from low-pressure flexible hose 2.
8. Disconnect high-pressure pipe 4 from clip of low-pressure pipe
2.
9. Remove clip fixing bolts and clips, and remove low-pressure
pipe 2 from wheel housing.
ZJIA0057E
INSTALLATION
CAUTION:
Replace O-rings on low-pressure pipe 1 and low-pressure flexible hose 2 with new ones. Install
new O-rings with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
MTC-104
A/C CYCLE
REMOVAL C
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant. D
3. Remove undercover.
4. Disconnect high-pressure pipe 1 from liquid tank.
CAUTION: E
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere. F
ZJIA0059E
ZJIA0061E MTC
ZJIA0060E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipe 1 with new ones. Install new O-rings with compressor oil
applied.
When charging refrigerant, check for refrigerant leaks.
High-pressure pipe 1 mounting bolt
Tightening torque : 2.9 - 3.9 Nm (0.29 - 0.4 kgm, 26 - 34 in-lb)
MTC-105
A/C CYCLE
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove undercover.
4. Disconnect high-pressure pipe 2 from liquid tank.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere.
ZJIA0059E
ZJIA0013E
ZJIA0060E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipes with new ones. Install new O-rings with compressor oil
applied.
When charging refrigerant, check for refrigerant leaks.
High-pressure pipe 2 mounting bolts
Tightening torque : 2.9 - 3.9 Nm (0.3 - 0.4 kgm, 26 - 34 in-lb)
MTC-106
A/C CYCLE
REMOVAL A
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant. B
3. Remove undercover.
4. Disconnect high-pressure pipe 2 from high-pressure pipe 3. (For
models with rear A/C only) C
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo- D
sphere. ZJIA0060E
5. Disconnect high-pressure pipe 3 from high-pressure pipe 4.
6. Remove clip fixing bolts, and remove high-pressure pipe 3. E
ZJIA0061E H
INSTALLATION
CAUTION:
I
Replace O-rings on high-pressure pipes 3 and 4 with new ones. Install new O-rings with compres-
sor oil applied.
When charging refrigerant, check for refrigerant leaks.
MTC
High-pressure pipe 3 unit nut
Tightening torque : 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
K
High-Pressure Flexible Hose 2 and Low-Pressure Flexible Hose 2 (Rear A/C
Side) EJS0018Y
REMOVAL L
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
M
3. Remove splash board (LH).
4. Remove roof headlining.
5. Remove insulator, and disconnect high-pressure flexible hose 2
and low-pressure flexible hose 2 from rear A/C unit assembly.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo- ZJIA0029E
sphere.
6. Disconnect drain hose (LH).
CAUTION:
When disconnecting drain hoses, be careful to avoid spilling water.
MTC-107
A/C CYCLE
ZJIA0057E
ZJIA0036E
INSTALLATION
CAUTION:
O-rings on high-pressure flexible hose 2 and low-pressure flexible hose 2 must be replaced with
new ones. Install new O-rings with compressor oil applied.
Replace insulator on connections of rear A/C unit assembly and low-pressure flexible hose 2 with
new ones.
When charging refrigerant, check for refrigerant leaks.
High-pressure flexible hose 2 union nut
Tightening torque : 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
REMOVAL
1. Remove front grille.
2. Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
3. Remove front LH wheel.
4. Remove splash board (LH).
5. Disconnect high-pressure pipe 4 from high-pressure pipe 3.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmo-
sphere. ZJIA0061E
MTC-108
A/C CYCLE
ZJIA0057E
D
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipe 4 and high-pressure flexible hose 2 with new ones. Install
new O-rings with compressor oil applied. E
When charging refrigerant, check for refrigerant leaks.
High-pressure pipe 4 union nut F
Tightening torque : 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
ZJIA0062E
MTC-109
A/C CYCLE
ZJIA0063E
ZJIA0061E
ZJIA0060E
ZJIA0064E
8. Remove condenser assembly mounting bolts and clips. Remove condenser assembly from lower front of
vehicle.
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and high-pressure pipe 1 with new ones. Install
new O-rings with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
High-pressure flexible hose 1 union nut
Tightening torque : 14.7 - 24.5 Nm (1.5 - 2.5 kgm, 16 - 18 ft-lb)
MTC-110
A/C CYCLE
ZJIA0065J MTC
MTC-111
A/C CYCLE
CAUTION:
O-rings on high-pressure flexible hose 2 and low-pressure flexible hose 2 must be replaced with
new ones. Install new O-rings with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
High-pressure flexible hose 2 union nut
Tightening torque : 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
ZJIA0070E
ZJIA0071E
MTC-112
A/C CYCLE
MTC
MTC-113
A/C CYCLE
MTC-114