MTC PDF

MANUAL AIR CONDITIONER
J AIR CONDITIONER
A
SECTION
MANUAL AIR CONDITIONER
CONTENTS
PRECAUTIONS .......................................................... 4
Precautions for Supplemental Restraint System
(SRS) AIR BAG and SEAT BELT PRE-TENSIONER .................................................................. 4
Precautions for Working with HFC-134a (R-134a)..... 4
General Refrigerant Precautions .............................. 4
Lubricant Precautions .............................................. 5
Precautions for Leak Detection Dye ......................... 5
IDENTIFICATION .................................................. 5
IDENTIFICATION LABEL FOR VEHICLE ............. 6
Precautions for Refrigerant Connection ................... 6
FEATURES OF NEW TYPE REFRIGERANT
CONNECTION ...................................................... 6
O-RING AND REFRIGERANT CONNECTION..... 7
Precautions for Servicing Compressor ................... 10
Precautions for Service Equipment ........................ 10
RECOVERY/RECYCLING EQUIPMENT ............ 10
ELECTRONIC LEAK DETECTOR ...................... 10
VACUUM PUMP ..................................................11
MANIFOLD GAUGE SET .....................................11
SERVICE HOSES ................................................11
SERVICE COUPLERS ........................................ 12
REFRIGERANT WEIGHT SCALE ...................... 12
CALIBRATING ACR4 WEIGHT SCALE .............. 12
CHARGING CYLINDER ...................................... 12
Wiring Diagrams and Trouble Diagnosis ................ 12
PREPARATION ......................................................... 14
Special Service Tools ............................................. 14
HFC-134a (R-134a) Service Tools and Equipment... 14
Commercial Service Tool ....................................... 17
REFRIGERATION SYSTEM ..................................... 18
Refrigerant Cycle ................................................... 18
REFRIGERANT FIOW ........................................ 18
Refrigerant System Protection ............................... 18
DUAL PRESSURE SWITCH ............................... 18
PRESSURE RELIEF VALVE ............................... 18
LUBRICANT .............................................................. 19
Maintenance of Lubricant Quantity in Compressor... 19
LUBRICANT ........................................................ 19
LUBRICANT RETURN OPERATION .................. 19
LUBRICANT AJUSTING PROCEDURE FOR
COMPONENTS REPLACEMENT EXCEPT
COMPRESSOR .................................................. 20
LUBRICANT ADJUSTING PROCEDURE FOR
COMPRESSOR REPLACEMENT ....................... 20
AIR CONDITIONER CONTROL ............................... 22
Control Operation ................................................... 22
FAN CONTROL KNOB ........................................ 22
MODE CONTROL KNOB .................................... 22
TEMPERATURE CONTROL KNOB .................... 22
RECIRCULATION (REC) SWITCH ..................... 22
AIR CONDITIONER SWITCH ............................. 22
REAR COOLER FAN CONTROL
KNOB(FRONT) ................................................... 23
REAR COOLER FAN SWITCH ........................... 23
Discharge Air Flow ................................................. 24
Component Layout ................................................. 25
Component Location .............................................. 26
System Description ................................................. 27
SWITCHES AND THEIR CONTROL FUNCTION... 27
TROUBLE DIAGNOSIS ............................................ 28
How to Perform Trouble Diagnoses for Quick and
Accurate Repair ...................................................... 28
WORK FLOW ...................................................... 28
SYMPTOM TABLE .............................................. 28
Component Parts and Harness Connector Location... 29
............................................................................ 29
Wiring Diagram HEATER ................................ 30
Schematic A/C ................................................. 31
Wiring Diagram A/C ......................................... 32
Wiring Diagram R/COOL ................................. 36
Operational Check .................................................. 38
CONDITIONS: ..................................................... 38
PROCEDURE: .................................................... 38
Blower Motor Circuit ............................................... 40
Rear Cooler Fan Motor Circuit ................................ 44
MTC-1
MTC
Magnet Clutch Circuit ............................................. 50

Intake Door Circuit .................................................. 55
Insufficient Cooling ................................................. 55
INSPECTION FLOW ........................................... 56
PERFORMANCE TEST DIAGNOSES ................ 57
PERFORMANCE CHART ................................... 59
TROUBLE DIAGNOSES FOR ABNORMAL
PRESSURE ......................................................... 60
Insufficient Heating ................................................. 63
INSPECTION FLOW ........................................... 64
Noise ...................................................................... 65
INSPECTION FLOW ........................................... 65
CONTROLLER .......................................................... 66
Removal and Installation ........................................ 66
Disassembly and Assembly .................................... 67
BLOWER AND COOLING UNIT ASSEMBLY .......... 68
REMOVAL ........................................................... 68
INSTALLATION .................................................... 69
BLOWER FAN MOTOR ............................................ 71
BLOWER FAN RESISTOR ....................................... 72
INTAKE DOOR ACTUATOR ..................................... 73
HEATER UNIT ASSEMBLY ...................................... 74
REMOVAL ........................................................... 74
INSTALLATION .................................................... 75
HEATER CORE ......................................................... 77
REAR A/C UNIT ASSEMBLY ................................... 78
INSTALLATION .................................................... 78
INSTALLATION .................................................... 78
REAR BLOWER FAN MOTOR ................................. 80
REMOVAL ........................................................... 80
INSTALLATION .................................................... 80
REAR BLOWER FAN RESISTOR ............................ 81
DRAIN HOSE ............................................................ 82
DRAIN HOSE (RH) .............................................. 82
DRAIN HOSE (LH) .............................................. 82
REAR A/C CONTROLLER ....................................... 83
REAR HEATER UNIT ASSEMBLY ........................... 84
BUILT-IN TYPE REAR HEATER (4 DOOR AND
5 DOOR) .............................................................. 84
FOOR-TYPE REAR HEATER (MICROBUS) ....... 84
BUILT-IN TYPE REAR HEATER (4 DOOR AND
5 DOOR) ..............................................................85
FOOR-TYPE REAR HEATER (MICROBUS) .......86
Rear Blower Fan Motor ...........................................86
REMOVAL AND INSTALLATION .........................86
Rear Blower Fan Resistor .......................................87
Rear Heater Duct (4 Door) ......................................87
Rear Heater Control ................................................87
DISASSEMBLY AND ASSEMBLY .......................88
Rear Heater Hose ...................................................88
MODE DOOR ............................................................90
Adjustment of Cable ................................................90
AIR MIX DOOR ..........................................................91
Adjustment of Cable ................................................91
DUCT AND GRILLE ..................................................92
Removal and Installation .........................................92
VENTILATOR DUCT, DEFROSTER NOZZLE,
AND DUCT ..........................................................92
CENTRAL VENTILATOR GRILLE .......................92
SIDE VENTILATOR GRILLE ...............................93
FOOT DUCT ........................................................93
REAR VENTILATOR GRILLE ..............................93
REAR INTAKE GRILLE .......................................93
A/C CYCLE ................................................................94
Component Parts Drawing ......................................94
WITHOUT REAR A/C ..........................................95
WITH REAR A/C ..................................................96
Compressor ............................................................97
REMOVAL ............................................................97
INSTALLATION ....................................................98
Overhaul .................................................................99
Removal ..................................................................99
Inspection .............................................................. 100
CLUTCH DISC ................................................... 100
PULLEY ............................................................. 100
COIL ................................................................... 100
Installation ............................................................. 100
BREAK-IN OPERATION .................................... 101
High-Pressure Flexible Hose 1 and Low-Pressure
Flexible Hose 1 ..................................................... 102
REMOVAL .......................................................... 102
INSTALLATION .................................................. 103
Low-Pressure Pipe 1 ............................................. 103
REMOVAL .......................................................... 103
INSTALLATION .................................................. 104
Low-Pressure Pipe 2 ............................................. 104
REMOVAL .......................................................... 104
INSTALLATION .................................................. 104
High-Pressure Pipe 1 ............................................ 105
REMOVAL .......................................................... 105
INSTALLATION .................................................. 105
REMOVAL .......................................................... 106
INSTALLATION .................................................. 106
REMOVAL .......................................................... 107
MTC-2
INSTALLATION ................................................. 107

High-Pressure Flexible Hose 2 and Low-Pressure
Flexible Hose 2 (Rear A/C Side) .......................... 107
REMOVAL ......................................................... 107
INSTALLATION ................................................. 108
High-Pressure Pipe 4 ........................................... 108
REMOVAL ......................................................... 108
INSTALLATION ................................................. 109
Pressure Switch ................................................... 109
REMOVAL AND INSTALLATION ...................... 109
Condenser Assembly ........................................... 109

DISASSEMBLY AND ASSEMBLY ......................111
Rear Evaporator ....................................................111
REMOVAL AND INSTALLATION .......................111
Front Expansion Valve .......................................... 112
Rear Expansion Valve .......................................... 112
Liquid Tank ........................................................... 113
MTC
MTC-3
PRECAUTIONS
PFP:00001
PRECAUTIONS
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 performed by an authorized NISSAN/INFINITI dealer.
Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal 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 Refrigerant 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) 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 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 possible to minimize the entry of moisture into system.
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. 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 requirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
Do not allow lubricant (Nissan A/C System Oil Type S) 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.
Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning 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 manufacturers.
Lubricant Precautions
EJS0011N
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
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 possible to minimize the
entry of moisture into system.
Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. 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 requirements of SAE
J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may
be obtained from refrigerant and lubricant manufacturers.
Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage
may result.
Precautions for Leak Detection Dye
EJS001FO
The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
MTC
(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.
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 (J41995) 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
IDENTIFICATION LABEL FOR VEHICLE
Vehicles with factory installed fluorescent dye have this identification
label on the front side of hood.
SHA436FA
Precautions for Refrigerant Connection
EJS0011O
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 eliminates 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 facilitating piping connections.
SHA815E
MTC-6
PRECAUTIONS
O-RING AND REFRIGERANT CONNECTION
A
MTC
SJIA0001E
MTC-7
PRECAUTIONS
SJIA0002E
MTC-8
PRECAUTIONS
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings 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
Connection type
New
Former
Former
New
O-ring
size
8
10
12
Former
New
16
Former
New
SHA814E
19
Former
New
24
Part number
mm (in)
mm (in)
92471 N8210
6.8 (0.268)
1.85 (0.0728)
92470 N8200
6.07 (0.2390)
1.78 (0.0701)
J2476 89956
9.25 (0.3642)
1.78 (0.0701)
92472 N8210
10.9 (0.429)
2.43 (0.0957)
92475 71L00
11.0 (0.433)
2.4 (0.094)
92473 N8210
13.6 (0.535)
2.43 (0.0957)
92475 72L00
14.3 (0.563)
2.3 (0.091)
92474 N8210
16.5 (0.650)
2.43 (0.0957)
92477 N8200
17.12 (0.6740)
1.78 (0.0701)
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 connections of seal seat to the specified torque.
RHA861F
Precautions for Servicing Compressor
EJS0011P
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 Compressor 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 lubricant, 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
A
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 pressure. 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 hoseto-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
pump.
For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump.
If the hose has an automatic shut off valve, disconnect the hose
from the pump. As long as the hose is connected, the valve is
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
ability to pull a deep vacuum and are not recommended.
G
RHA270DA
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
hoses. Confirm the set has been used only with refrigerant HFC134a (R-134a) and specified lubricants.
MTC
K
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
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
REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC-134a (R-134a) and specified 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 (J-39500-INF):
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.
Wiring Diagrams and Trouble Diagnosis

When you read wiring diagrams, refer to the followings:
GI-13, "How to Read Wiring Diagrams" in GI section.
PG-3, "Wiring Diagram POWER "in PG section.

When you perform trouble diagnosis, refer to the followings:
GI-9, "How to Follow Trouble Diagnoses" in GI section.
MTC-12
EJS0011T
PRECAUTIONS
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

A
MTC
MTC-13
PREPARATION
PREPARATION
Special Service Tools
Tool number
Tool name
PFP:00002
EJS0011U
Description
KV99231260
Clutch disc wrench
Removing shaft nut and clutch disc
NT204
RJIA0194E
KV992T0001
Clutch disc puller
Removing clutch disc
NT206
KV992T0002
Pulley installer
Installing pulley
NT207
HFC-134a (R-134a) Service Tools and Equipment
EJS0011V
Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant.
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.)
Tool name
Description
Container color:Light blue

Container marking:HFC-134a (R134a)
Fitting size:Thread size
HFC-134a (R-134a) refrigerant
large container 1/22 -16 ACME
S-NT196
KLH00-PAGS0
(-)
Nissan A/C System Oil Type S
S-NT197
Type:Poly alkylene glycol oil (PAG),

type S
Application:HFC-134a (R-134a)
Swash plate compressors (Nissan
only)
Lubricity:40 ml [Litre] (1.4 US fl oz,
1.4 Imp fl oz)
G
(J-39500-INF)
Recovery/Recycling
Recharging equipment (ACR4)
Function:Refrigerant Recovery and

Recycling and Recharging
I
RJIA0195E
MTC
Power supply:
(J-41995)
Electrical leak detector
DC 12V (Cigarette lighter)
L
AHA281A
M
(J-43926)
Refrigerant dye leak detection kit
Kit includes:
(J-42220) UV lamp and UV safety
glasses
(J-41459) Refrigerant dye injector
(J-41447) qty. 24
HFC-134a (R-134a) refrigerant
dye
(J-43872) Refrigerant dye cleaner
Power supply:
DC 12V (Battery terminal)
SHA437F
MTC-15
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
(J-42220)
Fluorescent dye leak detector
SHA438F
Power supply: DC 12V (Battery

terminal)
For checking refrigerant leak when
fluorescent dye is installed in A/C
system.
Includes: UV lamp and UV safety
glasses
Application: For HFC-134a (R-134a)
PAG oil
Container: 1/4 ounce (7.4cc) bottle
(Includes self-adhesive dye
identification labels for affixing to
vehicle after charging system with
dye.)
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
SHA439F
(J-41459)
HFC-134a (R-134a) Dye injector
Use with J-41447, 1/4 ounce
bottle
For injecting 1/4 ounce of fluorescent

leak detection dye into A/C system.
SHA440F
(J-43872)
Dye cleaner
For cleaning dye spills.
SHA441F
Identification:
(J-39183)
Manifold gauge set (with hoses
and couplers)
The gauge face indicates R-134a.

1/22 -16 ACME
RJIA0196E
Hose color:
Service hoses
High side hose
(J-39501-72)
Low hose:Blue with black stripe
High hose:Red with black stripe
Low side hose

(J-39502-72)
Utility hose
(J-39476-72)
Utility hose:Yellow with black stripe

or green with black stripe
Hose fitting to gauge:
S-NT201
MTC-16
1/22 -16 ACME
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
Description
Service couplers
High side coupler

(J-39500-20)
Low side coupler

(J-39500-24)
Hose fitting to service hose:
M14 x 1.5 fitting is optional or

permanently attached.
S-NT202
D
For measuring of refrigerant
(J-39650)
Refrigerant weight scale
1/22 -16 ACME
S-NT200
Capacity:
(J-39649)
Vacuum pump
(Including the isolator valve)
S-NT203
Commercial Service Tool

Tool name
Air displacement:4 CFM
Micron rating:20 microns
Oil capacity:482 g (17 oz)

1/22 -16 ACME
H
EJS0011W
Description
MTC
For checks refrigerant purity and for

system contamination
Refrigerant identifier equipment
L
RJIA0197E
MTC-17
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM
Refrigerant Cycle
PFP:KA990
EJS0011X
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
DUAL PRESSURE SWITCH

The refrigerant system is protected against excessively high or low pressures by the dual-pressure switch,
located on the liquid tank. If the system pressure rises above or falls below the specifications, the dual-pressure switch, located on the liquid tank.If the system pressure rises above or falls below the specifications,the
dual-pressure switch opens to interrupt the compressor operation.
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.
SJIA0003E
MTC-18
LUBRICANT
LUBRICANT
Maintenance of Lubricant Quantity in Compressor
PFP:KLG00
A
EJS0011Z
The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas leakage occurred. It is important to maintain the specified 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:

Start engine, and set the following conditions:
Test condition
Engine speed: Idling to 1,200 rpm
A/C switch:ON
Blower speed:Max. position
Temp. control: Optional [Set so that intake air temperature is 25 to 30C (77 to 86F).]
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.
1.
MTC
>> GO TO 3.
3. CHECK COMPRESSOR
Should the compressor be replaced?
Yes or No
Yes
>> Go to MTC-20, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" .
No
>> GO TO 4.
MTC-19
LUBRICANT
4. CHECK ANY PART

Is there any part to be replaced? (Evaporator, condenser,liquid tank or in case there is evidence of a large
amount of lubricant leakage.)
Yes or No
Yes
>> Go to MTC-20, "LUBRICANT AJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT
EXCEPT COMPRESSOR" .
No
>> Carry out the A/C performance test.
LUBRICANT AJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR

After replacing any of the following major components, add the correct amount of lubricant to the system.
Amount of lubricant to be added
Lubricant to be added to system
Part replaced
Evaporator
Amount of lubricant
ml [Litre] (US fl oz, Imp fl oz)
Remarks
75 (2.5, 2.6)
Rear evaporator
20 (0.6, 0.7)
Condenser
35 (1.2, 1.2)
Liquid tank
10 (0.3, 0.4)
30 (1.0, 1.1)
Large leak
Small leak *1
In case of refrigerant leak
*1:If refrigerant leak is small, no addition of lubricant is needed.
LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

1.
2.
3.
4.
5.
6.
7.
Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If
NG, recover refrigerant from equipment lines.
Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
Drain the lubricant from the new compressor into a separate, clean container.
Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this
lubricant to new compressor through the suction port opening.
Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant
to new compressor through the suction port opening.
If the liquid tank also needs to be replaced, add an additional 5 ml [Litre] (0.2 US fl oz, 0.2 Imp fl oz) of
lubricant at this time.
Do not add this 5 ml(0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor.
MTC-20
LUBRICANT
A
RHA065DD
MTC
MTC-21
AIR CONDITIONER CONTROL

Control Operation
PFP:27500
EJS001ED
SJIA0004E
FAN CONTROL KNOB

This knob turns the fan ON and OFF, and controls fan speed.
MODE CONTROL KNOB

This knob controls the direction of air flow through the front discharge outlets.
TEMPERATURE CONTROL KNOB

This knob allows adjustment of the outlet air temperature.
RECIRCULATION (REC) SWITCH

OFF position: Outside air is drawn into the passenger compartment.
ON position: Interior air is recirculated inside the vehicle. The indicator lamp will also light.
AIR CONDITIONER SWITCH

The air conditioner switch controls the A/C system. When the switch is depressed with the fan ON, the compressor will turn ON. The indicator lamp will also light.
The air conditioner cooling function operates only when the engine is running.
MTC-22

REAR COOLER FAN CONTROL KNOB(FRONT)
The control of the rear blower speed can be obtained by rotating the rear cooler fan control knob.
REAR COOLER FAN SWITCH

The rear cooler fan switch controls the rear blower speed regardless of the rear cooler fan control knob(front)
position. In any other position(1-4), it allows the rear cooler fan switch to control the rear blower speed,
MTC
MTC-23

Discharge Air Flow
EJS001EE
SJIA0005E
MTC-24

Component Layout
EJS001EF
MTC
SJIA0006E
MTC-25

Component Location
EJS001ES
ZJIA0003E
MTC-26

System Description
EJS001ET
SWITCHES AND THEIR CONTROL FUNCTION
I
SJIA0103E
MTC
SJIA0104E
MTC-27
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
How to Perform Trouble Diagnoses for Quick and Accurate Repair
PFP:00004
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 malfunctioning.
Go to Trouble Diagnosis Procedure for Rear cooler fan Motor.
MTC-44
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
Go to Trouble Diagnosis Procedure for Intake Door Motor.
MTC-55
Insufficient heating.
Go to Trouble Diagnosis Procedure for Insufficient Heating.
MTC-63
Noise.
Go to Trouble Diagnosis Procedure for Noise.
MTC-65
Intake door does not change.

Intake door motor does not operate normally.
MTC-28
TROUBLE DIAGNOSIS
Component Parts and Harness Connector Location
EJS00121
MTC
ZJIA0003E
MTC-29
TROUBLE DIAGNOSIS
Wiring Diagram HEATER
EJS00122
TJWH0001E
MTC-30
TROUBLE DIAGNOSIS
Schematic A/C
EJS001GQ
MTC
TJWH0002E
MTC-31
TROUBLE DIAGNOSIS
Wiring Diagram A/C
EJS001GR
TJWH0003E
MTC-32
TROUBLE DIAGNOSIS
A
MTC
TJWH0004E
MTC-33
TROUBLE DIAGNOSIS
TJWH0005E
MTC-34
TROUBLE DIAGNOSIS
A
MTC
TJWH0006E
MTC-35
TROUBLE DIAGNOSIS
Wiring Diagram R/COOL
EJS00123
TJWH0007E
MTC-36
TROUBLE DIAGNOSIS
A
MTC
TJWH0008E
MTC-37
TROUBLE DIAGNOSIS
Operational Check
EJS00124
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, temperature 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
2. Check A/C Switch

1.
2.
Turn fan control knob to the desired (1 to 4 speed) position.

Push the A/C switch to turn ON the air conditioner.
The indicator lamp should come on when air conditioner is ON.
3. Confirm that the compressor clutch engages (audio or visual
inspection).
4. Check for cold air at the appropriate discharge air outlets.
If NG, go to MTC-50, "Magnet Clutch Circuit" .
If OK, continue with next check.
If all operational checks are OK (symptom cannot be duplicated), go
to Incident Simulation Tests in MTC-28, "How to Perform Trouble
SJIA0044E
Diagnoses for Quick and Accurate Repair" , and perform tests as
outlined to simulate driving conditions environment. If symptom appears, refer to MTC-28, "SYMPTOM
TABLE" and perform applicable trouble diagnoses procedures.
3. Check Discharge Air

1.
Turn mode control knob to each mode position.
SJIA0045E
MTC-38
TROUBLE DIAGNOSIS
2.
Confirm that discharge air comes out according to the air distribution table at left.
Refer to MTC-24, "Discharge Air Flow" .
If NG, go toMTC-90, "Adjustment of Cable" .
SJIA0046E
4. Check Recirculation
1.
Press recirculation switch.

Recirculation indicator should light.
2. Listen for intake door position to change (you should hear
blower sound change slightly).
If NG, go to MTC-55, "Intake Door Circuit" .
MTC
SJIA0047E
5. Check Temperature Decrease

1. Turn temperature control knob to full cold.
2. Check for cold air at discharge air outlets.
If NG, go toMTC-55, "Insufficient Cooling" .
SJIA0048E
MTC-39
TROUBLE DIAGNOSIS
6. Check Temperature Increase
1. Turn temperature control knob to full hot.
2. Check for hot air at discharge air outlets.
If NG, go to MTC-63, "Insufficient Heating" .
SJIA0049E
7. Check rear cooler

1.
Turn fan control knob (front) to the desired (1 to 4 speed) position.

2. Push A/C switch to turn ON the air conditioner is ON.
3. Push rear cooler switch.
Blower should operate on 1-speed.
4. Then turn fan control knob to 2-speed, and continue checking
blower speed until all four speeds are checked.
5. Leave blower on 3-speed.
If NG, go to MTC-44, "Rear Cooler Fan Motor Circuit" .
If OK, continue with the check.
Blower Motor Circuit
SJIA0050E
EJS00125
SYMPTOM:
Blower motor does not rotate.
1. DIAGNOSTIC PROCEDURE
Check if blower motor rotates properly at each fan speed.
Does not rotate at any speed>>GO TO 2
Does not rotate at 1-4 speed>>GO TO 8
2. CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT

Disconnect blower motor harness connector.
Terminals
(+)
Connector
Wire color
M223-1
L/R
(-)
Ground
Voltage
Approx. 12V
OK or NG
OK
>> GO TO 3
NG
>> GO TO 13
SJIA0051E
MTC-40
TROUBLE DIAGNOSIS
3. CHECK BLOWER MOTOR GROUND CIRCUIT

1.
2.
Disconnect blower motor connector.

Turn fan control knob to 4-speed.
B
Terminals
Continuity
Blower motor
Connector
Wire color
M223-2
L/B
Ground
Yes
Continuity should exist.

SJIA0052E
Yes or No
Yes
>> GO TO 4
No
>> GO TO 5
4. CHECK BLOWER MOTOR

F
Apply 12 volt to blower motor terminal 1 and ground to blower motor

terminal 2.
Dose blower motor rotate?
Yes
>> INSPECTION END
No
>> Replace blower motor.
I
SJIA0053E
5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT

1.
2.
MTC
Connect blower motor connector.

Disconnect resistor connector.
K
Terminals
(+)
(-)
Connector
Wire color
M222 -2
L/B
Voltage
L
Ground
Approx. 12 V
OK or NG
OK
>> GO TO 7
NG
>> GO TO 6
M
SJIA0054E
MTC-41
TROUBLE DIAGNOSIS
6. CHECK CIRCUIT CONTINUITY

Disconnect blower motor connector.
Terminals
Blower motor
Continuity
Resistor
Connector
Wire color
Connector
Wire color
M223-2
L/B
M222-2
Yes

Yes or No
Yes
>> Check the following.
If NG, repair harness or connectors.
Harness connectors M13, M222 and M223.
Harness for open or short between blower motor and fan switch, resistor.
No
>> Repair harness or connector.
SJIA0055E
7. CHECK FAN SWITCH GROUND

Disconnect fan switch harness connector.
Terminals
Continuity
Fan switch
Connector
Wire color
M13-6
Ground
Yes

Yes or No
Yes
>> GO TO 8
No
SJIA0056E
8. CHECK FAN RESISTOR CONTINUITY

Terminals
Continuity
Resistor
M222-1
M222-3
M222-2
M222-4
Yes
M222-6
SJIA0057E
Yes or No
Yes
>> GO TO 9
No
>> Replace resistor.
9. CHECK FAN RESISTOR

1.
2.
Reconnect fan resistor and resistor.

Check if blower motor rotates properly at each fan speed.

MTC-42
TROUBLE DIAGNOSIS
10. FAN SWITCH POWER SUPPLY CIRCUIT
Turn fan control knob to off position.

Terminals
(+)
(-)
Voltage
Fan switch
Connectors
Wire color
M13-2
L/B
M13-3
L/W
M13-4
L/Y
M13-5
L/G
C
Ground
Approx. 12 V
D
SJIA0058E
OK or NG
OK
>> GO TO 12
NG
>> GO TO 11
G
Terminals
Blower motor
Continuity
Resistor
Connectors
Wire color
Connectors
Wire color
M13-2
L/B
M222-3
L/B
M13-3
L/W
M222-6
L/W
M13-4
L/Y
M222-4
L/Y
M13-5
L/G
M222-1
L/G
Yes
I
SJIA0059E

Yes or No
Yes
Harness for open or short between blower motor and fan switch, fan resistor
No
MTC
12. CHECK FAN SWITCH

M
Disconnect fan switch harness connector M13 and check continuity

between terminals at each fan switch position.
Terminals
Fan switch position
Continuity
Fan switch
1
2
3
M13-2
M13-6
M13-4
M13-3
Yes
M13-2
SJIA0060E

Yes or No
Yes
>> INSPECTION END
No
>> Replace fan switch
MTC-43
TROUBLE DIAGNOSIS
13. CHECK BLOWER MOTOR RELAY

1.
2.
Disconnect blower motor relay.

Apply 12 volt to blower motor relay terminal 3 and ground to
blower relay terminal 5.
Terminals
Continuity
Blower motor relay

M39 (J/B) -1
M39 (J/B) -2
Yes

Yes or No
Yes
Harness for open or short between blower motor relay and fuse block (J/B)
No
>> Replace blower motor relay.
Rear Cooler Fan Motor Circuit
SJIA0061E
EJS00126
SYMPTOM:
Rear cooler fan motor does not rotate.
1. DIAGNOSTIC PROCEDURE
1.
2.
3.
Engine running and A/C ON.

Check if rear cooler fan motor rotate properly at each fan speed.

Magnet clutch does not engage>> MTC-50, "Magnet Clutch Circuit" .
2. CHECK REAR COOLER FAN MOTOR POWER SUPPLY CIRCUIT

Disconnect rear cooler fan motor connector.
Terminals
(+)
Connector
Wire color
R107-1
L/R
(-)
Ground
Voltage
Approx. 12V
OK or NG
OK
>> GO TO 3
NG
>> GO TO 13
SJIA0062E
MTC-44
TROUBLE DIAGNOSIS
3. CHECK REAR COOLER FAN MOTOR GROUND CIRCUIT
Push rear cooler fan switch.

Terminals
(+)
(-)
Continuity
Blower motor
Connector
Wire color
R107-2
L/B
Ground
Yes
Yes or No
Yes
>> GO TO 4
No
>> GO TO 5
SJIA0063E
4. CHECK REAR COOLER FAN MOTOR

F
Apply 12 volts to rear cooler fan motor terminal 1 and ground to rear
cooler fan motor terminal 2.
Does rear cooler fan motor rotate?
Yes
>> INSPECTION END
No
>> Replace rear blower fan motor.
I
SJIA0064E
5. CHECK FAN RESISTOR POWER SUPPLY CIRCUIT

1.
2.
MTC
Connect rear cooler fan motor connector.

Disconnect resistor.
K
Terminals
(+)
(-)
Connector
Wire color
R104-1
L/R
Ground
Voltage
L
Approx. 12V
OK or NG
OK
>> GO TO 7
NG
>> GO TO 6
M
SJIA0065E
MTC-45
TROUBLE DIAGNOSIS

Disconnect rear cooler fan motor connector.
Terminals
Continuity
Blower motor
Resistor
Connector
Wire color
Connector
Wire color
R107-2
L/B
R104-2
Yes

OK or NG
OK
Harness connectors R102,R104 and R107.
Harness for open or short between rear cooler fan motor and fan switch, fan resistor.
NG
SJIA0066E
7. CHECK REAR COOLER FAN SWITCH GROUND

1.
2.
Disconnect rear cooler fan switch connector.

Check continuity between rear cooler fan switch connector terminal 6 and ground.
Terminals
Continuity
Fan switch
Connectors
Wire color
R102-1
R102-6
Ground
Yes
SJIA0067E
Yes or No
Yes
>> GO TO 8
No
8. CHECK FAN RESISTOR CONTINUITY

1.
2.
Disconnect fan resistor connector.

Check continuity between fan resistor terminals.
Terminals
Continuity
Resistor
R104-1
R104-2
R104-4
Yes
R104-6

Yes or No
Yes
>> GO TO 9
No
>> Replace resistor.
SJIA0068E
MTC-46
TROUBLE DIAGNOSIS
9. CHECK FAN RESISTOR

1.
2.
Reconnect rear cooler fan resistor.

Check if rear cooler fan motor rotates properly at each fan speed.
B

C
10. REAR COOLER FAN SWITCH POWER SUPPLY CIRCUIT

Push rear cooler switch to off.
Terminals
Voltage
Fan switch
Connectors
Wire color
R102-2
L/B
R102-3
L/W
R102-4
L/Y
E
Ground
Approx. 12 V
OK or NG
OK
>> GO TO 12
NG
>> GO TO 11
SJIA0069E
Check continuity between rear cooler fan switch and rear cooler
resister.
Terminals
Fan switch
Continuity
Resistor
Connectors
Wire color
Connectors
Wire color
R102-2
L/B
R104-1
L/B
R102-3
L/W
R104-4
L/W
R102-4
L/Y
R104-6
L/Y
MTC
Yes
K
SJIA0070E
Yes or No
Yes
Harness connectors R102, R104 and R107
Harness for open or short between blower motor and fan switch, fan resistor
No
MTC-47
TROUBLE DIAGNOSIS
12. CHECK REAR COOLER FAN SWITCH

Disconnect rear cooler fan switch connector and check continuity
between terminals at each fan switch position.
Terminals
Continuity
Fan switch position
Fan switch
R102-2
R102-1
R102-3
Yes
R102-4
SJIA0071E
Yes or No
Yes
>> INSPECTION END
No
>> Replace rear cooler fan switch
13. CHECK REAR COOLER

1.
2.
RELAY
Disconnect rear cooler relay.

Apply 12 volt to rear cooler relay terminal 1 and ground to rear
cooler relay terminal 2.
Terminals
Continuity
Rear cooler relay

R106-3
R106-5
Yes

Yes or No
Yes
Harness for open or short between blower relay and fuse block (J/B).
If OK, GO TO 14
No
>> Replace rear cooler relay.
SJIA0095E
14. CHECK REAR COOLER SWITCH (REAR)

Disconnect rear cooler switch (rear) connector.
Terminals
Switch position
ON-1
ON-2
Continuity
Fan switch
R103-2
R103-5
R103-4
Yes

Yes or No
Yes
>> GO TO 15
No
>> Replace rear cooler fan switch (rear)
SJIA0072E
MTC-48
TROUBLE DIAGNOSIS
Disconnect rear cooler relay.

Terminals
Connector
Continuity
Rear cooler switch
Rear cooler relay
Wire color
Connector
R103-3
Wire color
Yes
R106-2

D
Yes or No
Yes
>> GO TO 16
No
SJIA0073E
16. CHECK REAR COOLER SWITCH (FRONT)

1.
2.
3.
Connect rear cooler relay and rear cooler switch.

Terminals
Wire color
M16-2
Voltage
Rear cooler switch

Connector
Ground
Approx. 12 V
SJIA0074E
OK or NG
OK
>> GO TO 17
NG
MTC
Disconnect rear cooler switch and thermo control amp.

Terminals
Rear cooler switch
Continuity
Thermo control amp.
Connector
Wire color
Connector
Wire color
M16-2
M6-2
Yes

Yes or No
Yes
>> GO TO 18
No
SJIA0075E
MTC-49
TROUBLE DIAGNOSIS
18. CHECK REAR COOLER SWITCH (FRONT) CONTINUITY

Terminals
Continuity
Switch position
Fan switch
ON-1
M16-3
M16-2
ON-2
Yes
M16-1

Yes or No
Yes
>> GO TO 19
No
>> Replace rear cooler fan switch (front)
SJIA0076E

Description
Terminals
Rear cooler switch (front)
Rear cooler switch (rear)
Connectors
Wire color
Connectors
Wire color
M16-1
L/B
R103-4
L/B
M16-3
L/W
R103-5
L/W
Continuity
Yes

Yes or No
Yes
Harness for open or short between blower relay and fuse block (J/B).
No
Magnet Clutch Circuit
SJIA0077E
EJS00127
SYMPTOM:
Magnet clutch does not engage when A/C switch and fan switch are ON.
1. CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT

1.
2.
Disconnect A/C compressor harness connector.

Press the A/C switch ON.
Terminals
(+)
Connectors
Wire color
F9-1 (Gasoline
engine)
R/W
A10-1 (Diesel engine)
R/Y
(-)
Ground
Voltage
Approx. 12V
OK or NG
OK
>> 1. If NG, replace magnet clutch.
2. Check magnet clutch operation.
NG
>> GO TO 2
SJIA0078E
MTC-50
TROUBLE DIAGNOSIS

1.
2.
Disconnect A/C relay.

Check circuit continuity between A/C relay connector and A/C
compressor connector.
3.
terminals
Compressor connectors
Continuity
A/C relay connector
F9-1 (Gasoline engine)
R/W
M128-5
R/W
A10-1 (Diesel engine)
R/Y
M128-5
R/Y
Yes

SJIA0079E
Yes or No
Yes
>> GO TO 3
No
3. CHECK A/C RELAY POWER SUPPLY
Terminals
(+)
Voltage
(-)
Connector
Wire color
M128 -1, 3 and 6
Ground
Approx. 12 V
OK or NG
OK
>> GO TO 4.
NG
>> Check power supply circuit and 10A(No.13), 15A(No.15,
16) fuse at fuse block. Refer to PG-78, "FUSE BLOCKJUNCTION BOX(J/B)" .
I
SJIA0080E
MTC
4. CHECK CIRCUIT CONTINUITY BETWEEN TERMINAL ON A/C RELAY

1.
2.
Disconnect A/C relay.

When apply 12 volts between connector No.1 and 2, Check circuit continuity.
L
Terminals
Connectors
M128-3
M128-6
Wire color
Connectors
Wire colors
M128-5
(Gasoline engine)
R/W
M128-5
(Diesel engine)
R/Y
M128-7
R/W
Continuity
M
Yes

Yes or No
Yes
>> GO TO 5
No
>> Replace A/C relay.
MTC-51
SJIA0081E
TROUBLE DIAGNOSIS

1.
2.
Reconnect A/C relay.

Terminals
A/C relay
ECM
Connector
Wire color
M128-2
B/W
Connectors
F106-23 (Gasoline)
Continuity
Wire color
B/W
Yes
F111-15 (Diesel)

Yes or No
Yes
>> GO TO 6
No
SJIA0082E
6. CHECK A/C ON SIGNAL IN ECM

Terminals
(+)
(-)
Connectors
Condition
Voltage
Wire color
M106-23(Gasoline)
B/W
Ground
M111-15(Diesel)
COMP:ON
Approx. 0V
COMP:OFF
Approx. 12V
OK or NG
OK
>> INSPECTION END. Refer to MTC-28, "How to Perform
Trouble Diagnoses for Quick and Accurate Repair" .
SJIA0083E
>> When compressor ON, do not approx. 0 V. GO TO 7
When compressor OFF, do not approx. 12 V. Refer to KA Engine (Gasoline) EC-61, "ECM
INSPECTION TABLE" ,ZD Engine (Diesel)EC-222, "ECM INSPECTION TABLE" .
7. CHECK DUAL PRESSURE SWITCH

Disconnect dual pressure switch connector.
Terminals
Continuity
Dual pressure switch

Connector
Wire color
Connector
Wire color
H15-2
B/R
H15-1
BR/Y
Yes

Yes or No
Yes
>> GO TO 8
No
>> Replace dual pressure switch.
SJIA0084E
MTC-52
TROUBLE DIAGNOSIS
8. CHECK COMPRESSOR ON SIGNAL IN ECM

Terminals
(+)
Connectors
BR/Y
F111-21(Diesel)
Voltage
COMP:ON
Approx. 0V
COMP:OFF
Approx. 12V
(-)
Wire color
F106-46(Gassoline)
Condition
Ground
OK or NG
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
KA Engine (Gasoline) EC-61, "ECM INSPECTION TABLE" , ZD Engine (Diesel) EC-222, "ECM
INSPECTION TABLE" .
9. CHECK POWER SUPPLY FOR THERMO CONTROL AMP.
Disconnect thermo control amp.

G
Terminals
(+)
Voltage
(-)
Connector
Wire color
M6- 1 and (3)
L and (B/R)
Ground
Approx. 12V
OK or NG
OK
>> GO TO 10
NG
I
SJIA0086E
MTC
10. CHECK CIRCUIT CONTINUITY FOR THERMO CONTROL AMP.

Disconnect thermo control amp. connector and A/C switch connector.
Terminals
Continuity
Thermo control amp.
A/C switch
Connector
Wire color
Connector
Wire color
M6-2
M10-1
Yes

Yes or No
Yes
>> GO TO 11
No
SJIA0087E
MTC-53
TROUBLE DIAGNOSIS
11. CHECK THERMO CONTROL AMP.

1.
2.
Connect thermo control amp. and A/C switch connector.

Terminals
(+)
Voltage
(-)
Connector
Wire color
M6- 2
Ground
Approx. 12V
OK or NG
OK
>> GO TO 12
NG
>> Replacer thermo control amp.
SJIA0088E
12. CHECK POWER SUPPLY FOR A/C SWITCH

Disconnect A/C switch connector.
Terminals
Voltage
(+)
(-)
Connector
Wire color
M10- 1
Ground
Approx. 12V
OK or NG
OK
>> GO TO 13
NG
SJIA0089E

Disconnect fan switch.
Terminals
A/C switch
Continuity
Fan switch
Connector
Wire color
Connector
Wire color
M10-2
G/Y
M13-1
G/Y
Yes

Yes or No
Yes
>> GO TO 14
No
SJIA0090E
14. CHECK FAN SWITCH GROUND

Terminals
Continuity
Fan switch
Connector
Wire color
M13-6
Ground
Yes

Yes or No
Yes
>> GO TO 15
No
SJIA0091E
MTC-54
TROUBLE DIAGNOSIS
15. CHECK FAN SWITCH
Turn fan control knob to ON (any speed position except OFF).

Terminals
Continuity
Fan switch
Connector
Wire color
Connector
Wire color
M13-1
G/Y
M13-6
Yes

D
Yes or No
Yes
>> Replace A/C switch.
No
>> Replace fan switch.
SJIA0092E
Intake Door Circuit
EJS00128
SYMPTOM:
Intake door does not operate.
1. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR
Observe intake door operation when the REC switch is pushed ON

and OFF.
H
Terminals
REC switch
condition
ON
OFF
ON
OFF
(+)
Connectors
Wire color
M5-2
BR
Voltage
(-)
I
Approx. 12V
Approx. 0V
Ground
M5-4
MTC
Approx. 0V
L/W
Approx. 12V
SJIA0093E
OK or NG
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)" .
If OK, replace intake door motor.
Disconnect intake door connector and REC switch.

Terminals
Continuity
Fan switch
Connector
Wire color
Connector
Wire color
M13-1
G/Y
M13-6
Yes

Yes or No
Yes
>> Replace REC switch.
No
SJIA0094E
Insufficient Cooling
EJS00129
SYMPTOM: Insufficient cooling
MTC-55
TROUBLE DIAGNOSIS
INSPECTION FLOW
WHA292
*1
MTC-90
*2
MTC-60
*3
MTC-57
*4
MTC-38
*5
MTC-28
*6
MTC-97
*7
KA24DE;EM-14 ,ZD30DD;EM-107
*8
KA24DE;CO-20 ,ZD30DD;CO-42
MTC-56
TROUBLE DIAGNOSIS
PERFORMANCE TEST DIAGNOSES
A
MTC
MHA649A
*1
MTC-59
*2
MTC-59
*3
MTC-57
MTC-60
TROUBLE DIAGNOSIS
LHA260
*1
MTC-50
*2
MTC-58
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 door
(Ventilation) set
Intake door
(Recirculation) set
Max. speed set
(blower) speed
Engine speed
Idle speed
Operate the air conditioning system for 10 minutes before taking measurements.
Rear cooler
ON (For rear cooler equipped model only)
Test Reading (Single A/C equipped model)

Recirculating-to-discharge Air Temperature Table
G
Inside air (Recirculating air) at blower assembly inlet

Relative humidity
%
Discharge air temperature at center ventilator

C (F)
Air temperature
C (F)
25 (77)
6.5 - 9.0 (44 - 48)
30 (86)
11.3 - 14.0 (52 - 57)
35 (95)
16.4 - 20.0 (62 - 68)
40 (104)
21.7 - 26.0 (71 - 79)
25 (77)
9.0 - 11.5 (48 - 53)
30 (86)
14.0 - 17.3 (57 - 63)
35 (95)
20.0 - 23.4 (68 - 74)
40 (104)
26.0 - 29.7 (79 - 85)
50 - 60
60 - 70
Ambient Air Temperature-to-operating Pressure Table

Ambient air
Relative humidity
%
Air temperature
C (F)
High-pressure (Discharge side)

kPa (bar,kg/cm2, psi)
MTC
L
Low-pressure (Suction side)
25 (77)
950 - 1160
(9.5 - 11.6, 9.69 - 11.83, 137.8 168.2)
30 (86)
1300 - 1390
(13.0 - 13.9, 13.26 - 14.18, 188.5 201.6)
170 - 210
(1.7 - 2.1, 1.73 - 2.14, 24.7 - 30.5)
35 (95)
1320 - 1620
(13.2 - 16.2, 13.46 - 16.52, 191.4 234.9)
210 - 260
(2.1 - 2.6, 2.14 - 2.65, 30.5 - 37.7)
40 (104)
1510- 1850
(15.1 - 18.5, 15.40 - 18.87, 219.0 268.3)
50 - 70
MTC-59
130 - 160
(1.3 - 1.6, 1.33 - 1.63, 18.9 - 23.2)
250 - 300
(2.5 - 3.0, 2.55 - 3.06, 36.3 - 43.5)
TROUBLE DIAGNOSIS
Test Reading (Dual A/C equipped model)
Recirculating-to-discharge Air Temperature Table
Front
Relative humidity
%

C (F)
Air temperature
C (F)
50 - 60
60 - 70
25 (77)
12.4 - 14.9 (54- 59)
30 (86)
16.7 - 19.7 (62 - 67)
35 (95)
21.0 - 24.5 (70 - 76)
40 (104)
25.57 - 29.5 (78 - 85)
25 (77)
14.9 - 17.5 (59 - 64)
30 (86)
19.7 - 22.5 (67 - 73)
35 (95)
24.5 - 27.5 (76 - 82)
40 (104)
29.5 - 34.0 (85 - 93)
Rear
Relative humidity
%

C (F)
Air temperature
C (F)
50 - 60
60 - 70
25 (77)
10.5 - 13.0 (51 - 55)
30 (86)
15.5 - 18.5 (60 - 65)
35 (95)
20.5 - 24.0 (69 - 75)
40 (104)
25.5 - 29.5 (78 - 85)
25 (77)
13.0 - 15.5 (55 - 60)
30 (86)
18.5 - 21.5 (65 - 71)
35 (95)
24.0 - 27.4 (75 - 81)
40 (104)
29.5 - 34.0 (85 - 93)
Ambient Air Temperature-to-operating Pressure Table

Ambient air
Relative humidity
%
High-pressure (Discharge side)

Low-pressure (Suction side)

25 (77)
910 - 1010
(9.1 - 10.1, 9.28 - 10.30, 132.0 146.5)
240 - 270
(2.40 - 2.75, 2.45 - 2.75, 34.8 - 39.2)
30 (86)
1050 - 1170
(10.5 - 11.7, 10.71 - 11.93, 152.3 169.7)
.270 - 310
(2.7 - 3.1, 2.75 - 3.16, 39.2 - 45.0)
35 (95)
1240 - 1380
(12.4 - 13.8, 12.65 - 14.08,179.8 200.1)
330 - 360
(3.3 - 3.6, 3.37 - 3.67, 47.9 - 52.2)
40 (104)
1430- 1590
(14.3 - 15.9, 14.59 - 16.22, 207.4 230.6)
Air temperature
C (F)
50 - 70
360 - 400
(3.6 - 4.0, 3.67 - 4.08, 52.2 - 58.0)
TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE

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 standard (normal) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperatureto-operating pressure table).
MTC-60
TROUBLE DIAGNOSIS
Both High and Low-pressure Sides are Too High.
Gauge indication
Refrigerant cycle
Probable cause
Pressure is reduced soon after

water is splashed on condenser.
Excessive refrigerant charge in

refrigeration cycle
Air suction by cooling fan is

insufficient.
Insufficient condenser cooling

performance
1. Condenser fins are clogged.
Corrective action
Reduce refrigerant until specified pressure is obtained.
Clean condenser.
Check and repair cooling fan

as necessary.
2. Improper fan rotation of cooling fan
Both high and low-pressure

sides are too high.
Low-pressure pipe is not

cold.
When compressor is stopped
high-pressure value quickly
drops by approximately 196
kPa (2 kg/cm2, 28 psi). It
then decreases gradually
thereafter.
Engine tends to overheat.

AC359A
An area of the low-pressure

pipe is colder than areas
near the evaporator outlet.
Plates are sometimes covered with frost.
Evacuate repeatedly and

recharge system.
Engine cooling systems malfunction.
Check and repair each engine

cooling system.
Excessive liquid refrigerant

on low-pressure side
Excessive refrigerant discharge flow
Expansion valve is open a little compared with the specification.
Poor heat exchange in condenser

(After compressor operation
stops, high pressure decreases
too slowly.)
Air in refrigeration cycle
Replace expansion valve.
1. Improper thermal valve

installation
MTC
2. Improper expansion valve

adjustment
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 side are hot,
however, liquid tank is not so
hot.
High-pressure tube or parts

located between compressor
and condenser are clogged or
crushed.
AC360A
MTC-61
Check and repair or replace

malfunctioning parts.
Check lubricant for contamination.
TROUBLE DIAGNOSIS
High-pressure Side is Too Low and Low-pressure Side is Too High.
Gauge indication
High-pressure side is too low and
low-pressure side is too high.
AC356A
Refrigerant cycle
Probable cause
Corrective action
High and low-pressure sides

become equal soon after compressor operation stops.
Compressor pressure operation is improper.
Damaged inside compressor

packings
Replace compressor.
No temperature difference
between high and low-pressure sides
Compressor pressure operation is improper.
Damaged inside compressor

packings.
Replace compressor.
Both High- and Low-pressure Sides are Too Low.

Gauge indication
Refrigerant cycle
Liquid tank inlet and expansion valve are frosted.
Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank.
Both high- and low-pressure sides

are too low.
There is a big temperature

difference between receiver
drier outlet and inlet. Outlet
temperature is extremely
low.
Expansion valve inlet may

be frosted.
Probable cause
Liquid tank inside is slightly

clogged.
High-pressure pipe located

between receiver drier and
expansion valve is clogged.
Corrective action
Replace desiccant assy.
Check and repair malfunctioning parts.
Temperature difference
occurs somewhere in highpressure side
Expansion valve and liquid

tank are warm or only cool
when touched.
AC353A
There is a big temperature difference between expansion

valve inlet and outlet while the
valve itself is frosted.
Low refrigerant charge
Leaking fittings or components
Check refrigerant for leaks.
Expansion valve closes a little

compared with the specification.
1. Improper expansion valve

adjustment
Remove foreign particles by

using compressed air.
Check and repair malfunctioning parts.
Check thermo control amp.

operation.
Replace compressor.
2. Malfunctioning thermal
valve
3. Outlet and inlet may be
clogged.
An area of the low-pressure

pipe is colder than areas near
the evaporator outlet.
Low-pressure pipe is clogged

or crushed.
Air flow volume is not enough

or is too low.
Evaporator is frozen.
MTC-62
TROUBLE DIAGNOSIS
Low-pressure Side Sometimes Becomes Negative.
Gauge indication
Low-pressure side sometimes
becomes negative.
Refrigerant cycle
AC354A
Air conditioning system

does not function and does
not cyclically cool the compartment air.
The system constantly functions for a certain period of
time after compressor is
stopped and restarted.
Probable cause
Refrigerant does not discharge cyclically.
Moisture is frozen at expansion valve outlet and inlet.
Water is mixed with refrigerant.
Corrective action
Drain water from refrigerant

or replace refrigerant.
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.
Low-pressure side becomes negative.

Liquid tank or front/rear side of
expansion valve's pipe is
frosted or dewed.
High-pressure side is closed

and refrigerant does not flow.
Expansion valve or liquid tank

is frosted.
AC362A
Insufficient Heating
If water is the cause, initially

cooling is okay. Then the
water freezes causing a
blockage. Drain water from
refrigerant or replace refrigerant.
If due to foreign particles,
remove expansion valve
and remove the particles
with dry and compressed air
(not shop air).
If either of the above methods cannot correct the problem, replace expansion
valve.

EJS0012A
MTC
SYMPTOM: Insufficient heating

M
MTC-63
TROUBLE DIAGNOSIS
INSPECTION FLOW
LHA261
*1
MTC-91
*2
MTC-38
*4
KA24DE:CO-22, "WATER INLET

AND THERMOSTAT ASSY" ,
ZD30DD:CO-45, "THERMOSTAT
AND WATER PIPING"
*5
KA24DE:CO-9, "Changing Engine

*6
Coolant" , ZD30DD: CO-32, "Changing Engine Coolant"
*3
*7
KA24DE:CO-14, "CHECKING RADIATOR CAP" ,ZD30DD:CO-37,

"CHECKING RADIATOR CAP"
MTC-64
MTC-28
MTC-77, "HEATER CORE"
TROUBLE DIAGNOSIS
Noise
EJS0012B
SYMPTOM: Noise
INSPECTION FLOW
B
MTC
SHA336FA
*1
MTC-100
*4
*2
MTC-100
*3
MTC-65
MTC-19
CONTROLLER
CONTROLLER
Removal and Installation
1.
2.
3.
PFP:27500
EJS0017X
Remove cluster lid finisher C.

Remove air mix door, and mode door cable.
Remove air mix door, and mode door cable fixing clips.
ZJIA0008E
ZJIA0007E
4.
5.
Remove screws (4), and pull out controller.

Disconnect the connector, and remove controller.
ZJIA0009E
MTC-66
CONTROLLER
Disassembly and Assembly
EJS0017Y
F
ZJIA0010J
Finisher
Mode control dial
Temperature control dial
Fan control dial
E-ring
A/C panel
Mode door cable
Air mix door cable
Clips
10 REC switch knob
11 REC switch
12 Valve
13 A/C switch knob
14 A/C switch
15 Controller
16 Fan switch
17 Valve
18 Harness
MTC
MTC-67
BLOWER AND COOLING UNIT ASSEMBLY

PFP:27210
EJS0017Z
REMOVAL
1.
2.
3.
4.
Remove front grille.

Use refrigerant collecting equipment (for HFC134a) to discharge
refrigerant.
Remove instrument lower assistance panel.
Remove headlight (LH).
ZJIA0012E
5.
6.
Disconnect high-pressure pipe 2 and low-pressure pipe 1 from

evaporator.
CAUTION:
Seal the connecting points of the pipes with caps and vinyl
tape, etc. to prevent them from being exposed to the atmosphere.
Remove fixing nuts of blower and cooling unit.
ZJIA0013E
7.
8.
9.
Remove connectors and clips.

Separate instrument panel at points shown in the figure at left.
Remove bolts and screws, and displace cover and lower duct.
ZJIA0015E
10. Remove air mix door cable fixing clip.
ZJIA0008E
MTC-68

11. Remove door lock relay, SRS air bag connector, air bag harness
clip, and keyless entry control connector.
12. Remove instrument panel stay (LH).
13. Displace cover, and remove blower and cooling unit.
C
ZJIA0014E
INSTALLATION
1.
Install blower and cooling unit.

Blower & cooling unit assembly mounting bolts and nuts
Tightening torque
: 4.31 - 5.78 Nm (0.44 - 0.59 kgm, 39 - 51 in-lb)
Blower & cooling unit assembly mounting screws

Tightening torque
: 0.59 - 1.18 Nm (0.06 - 0.12 kgm, 6 - 10 in-lb)
2. Perform removal steps of 3 - 12 in reverse order.
CAUTION:
Replace O-rings on high-pressure and low-pressure pipes with new ones. Install new O-rings with
compressor oil applied.
After filling refrigerant, check system for refrigerant leak.

Instrument panel stay mounting nuts
Tightening torque
: 11 - 13 Nm (1.1 - 1.4 kgm, 98 - 115 in-lb)
High-pressure pipe 2 mounting bolts

Tightening torque
: 2.9 - 3.9 Nm (0.29 - 0.4 kgm, 26 - 34 in-lb)
MTC
Low-pressure pipe 1 mounting bolts

Tightening torque
3.
: 8 - 10 Nm (0.8 - 1.1 kgm, 70 - 95 in-lb)
Charge refrigerant using refrigerant recovery unit (for HFC134a).

L
MTC-69

EJS00180
ZJIA0016J
Support bracket (RH)
Evaporator lower case
Blower case 1
Support bracket (LH)
Screw
Intake case
Intake door
Blower case 2
Intake door lever
10 Intake door rod
11 Screw
12 Intake door actuator
13 Sub-harness
14 Seal
15 Bolt
16 Insulator
17 Piping block
18 Expansion valve
19 Evaporator
20 Thermal amplifier
21 Blower fan motor
22 Blower fan resistor
23 Screw
24 Blower fan harness
25 Coolant hose
26 Evaporator upper case
27 Drain hose
28 Clips
MTC-70
BLOWER FAN MOTOR

BLOWER FAN MOTOR
1.
2.
3.
PFP:27226
A
EJS00181

Remove connectors and clips.
Separate instrument panel at points shown in the figure at left.
D
ZJIA0015E
4.
Disconnect coolant hose, and remove blower fan motor.

F
H
ZJIA0017E
MTC
MTC-71
BLOWER FAN RESISTOR

BLOWER FAN RESISTOR
1.
2.
PFP:27150
EJS00182

Remove blower fan resistor.
CAUTION:
When thermal fuse of blower fan resistor is blown, inspect
blower fan motor and harness, and then replace blower fan
resistor with new one. Never repair thermal fuse.
ZJIA0018E
MTC-72
INTAKE DOOR ACTUATOR

INTAKE DOOR ACTUATOR
1.
2.
PFP:27730
A
EJS00183

Remove intake door actuator.
D
ZJIA0019E
MTC
MTC-73
HEATER UNIT ASSEMBLY

PFP:27100
EJS00184
REMOVAL
1.
2.
Drain engine coolant.

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
3.
4.
Remove instrument panel assembly.

Remove instrument panel stay (LH).
ZJIA0020E
5.
Remove instrument panel stay (RH).
ZJIA0021E
6.
Dislocate lower duct, and displace cover.
ZJIA0022E
MTC-74

7.
8.
Remove heater unit assembly mounting nuts.

Remove heater unit assembly.
C
SJIA0099E
INSTALLATION
1.
Install heater unit assembly.

Heater unit assembly mounting nuts
Tightening torque
2.
: 4.31 - 5.78 Nm (0.44 - 0.59 kgm, 39 - 51 in-lb)
Perform removal steps of 2 to 6 in reverse order.
Instrument panel stay mounting nuts

Tightening torque
3.
: 11 - 13 Nm (1.1 - 1.4 kgm, 6 - 10 in-lb)

G
Fill engine coolant.
MTC
MTC-75

EJS00185
ZJIA0024E
MTC-76
HEATER CORE
HEATER CORE
1.
2.
3.
PFP:27140
A
EJS00186
Remove heater unit assembly.

Remove heater core support.
Pull out heater core from heater case.
D
ZJIA0026E
MTC
MTC-77
REAR A/C UNIT ASSEMBLY

PFP:27400
EJS00187
INSTALLATION
1.
2.
3.

refrigerant.
Remove roof headlining.
Disconnect drain hose (RH), and connector.
ZJIA0028E
4.
Remove insulator, and disconnect high-pressure flexible hose 2

and low-pressure flexible hose 2 from rear A/C unit assembly.
CAUTION:
Seal connecting points of pipes with caps or vinyl tape, etc. to
prevent them from being exposed to atmosphere.
5. Disconnect drain hose (LH)
ZJIA0029E
6.
Remove mounting bolts, and remove rear A/C unit assembly.
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
torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 173 in-lb)
MTC-78

Low-pressure flexible hose 2 union nut
Tightening
torque
3.
: 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 21 ft-lb)
Charge refrigerant using refrigerant recovery unit (for HFC134a).
EJS00188
MTC
ZJIA0032J
Cover
Bolt
Screw
Rear blower fan motor
Rear A/C harness
Lower case
Seal
Bracket 1
Evaporator
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
MTC-79
REAR BLOWER FAN MOTOR

REAR BLOWER FAN MOTOR
PFP:27220
EJS00189
REMOVAL
1.
2.
3.
4.

Disconnect coolant hose and connectors.
Remove bracket 1.
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

REAR BLOWER FAN RESISTOR
1.
2.
PFP:27761
A
EJS0018A
Remove rear intake grille (RH).

Disconnect rear A/C relay.
D
ZJIA0078E
3.
Remove connector and screws, and remove resistor.

F
H
ZJIA0034E
MTC
MTC-81
DRAIN HOSE
DRAIN HOSE
PFP:92591
EJS0018B
DRAIN HOSE (RH)

1. Remove roof headlining.
2. Disconnect drain hoses from rear A/C unit assembly.
CAUTION:
When disconnecting drain hoses, be careful to avoid spilling
water.
ZJIA0028E
3.
4.
Remove grommet, and pull out drain hoses upward.

Disconnect drain hose from clip.
ZJIA0035E
DRAIN HOSE (LH)

1.
2.
Disconnect drain hose (LH), high-pressure flexible hose 2, and

low-pressure flexible hose 2.
Remove band clip, and pull out drain hose.
ZJIA0076E
ZJIA0077E
MTC-82
REAR A/C CONTROLLER

REAR A/C CONTROLLER
1.
PFP:27571
A
EJS0018C
Push clip side of rear A/C controller, and pull it out in the direction shown by arrow.
D
ZJIA0037E
EJS0018D
MTC
M
ZJIA0038J
Finisher
Clips
Clips
Fan switch dial
Control assembly
Screw
Fan switch
Valve
MTC-83
REAR HEATER UNIT ASSEMBLY

PFP:27300
EJS0018E
BUILT-IN TYPE REAR HEATER (4 DOOR AND 5 DOOR)

1. Drain engine coolant.
CAUTION:
Be sure to drain rear heater coolant from rear heater pipe under vehicle.
2. Remove rear side finisher.
3. Disconnect connectors of blower fan and fan resistor.
RJIA0359E
4. Disconnect rear heater core hose.

CAUTION:
Some coolant may spill when the heater hoses are disconnected.
Close coolant inlet/outlet on heater core (2 locations), and air bleeding hose with shop cloths.
5. Remove rear heater mounting bolts and nuts, and remove rear heater unit.
FOOR-TYPE REAR HEATER (MICROBUS)

1.
2.
3.

Remove third seat.
Disconnect rear heater unit hose.
RJIA0360E
4.
Remove rear heater mounting bolts and rear heater connectors,

and remove rear heater unit.
RJIA0361E
MTC-84

EJS0018F
BUILT-IN TYPE REAR HEATER (4 DOOR AND 5 DOOR)
I
RJIA0362J
Blower fan motor
Washer
Blower fan
Nut
Screw
Blower fan resistor
Rear heater case 1
Screw
Rear heater core (4 door)
10 Rear heater case 2
11 Rear heater cover
12 Adapter case
13 Heater core support
14 Screw
15 Screw (5 door)
16 Rear heater duct (5 door)
17 Screw (5 door)
18 Tube bracket (5 door)
19 Tube clip (5 door)
20 Rear heater hose (5 door)
21 Screw (5 door)
22 Rear heater core (5 door)
MTC
MTC-85

FOOR-TYPE REAR HEATER (MICROBUS)
RJIA0363J
Sub-harness
Nut
Blower fan
Washer
Blower fan motor
Screw
Screw
Bracket A
Screw
10 Blower fan resistor
Heater pipe assembly (with water

11
cock)
12 Bracket B
13 Screw
14 Screw
15 Heater case (upper)
16 Rear heater core
17 Bracket C
18 Heater case (lower)
19 Screw
20 Screw
21 Rear heater duct
22 Screw
Rear Blower Fan Motor
EJS001EA
REMOVAL AND INSTALLATION

Built-in type rear heater (4 door and 5 door)
1.
2.
3.
Remove rear side finisher.

Remove connectors and mounting screws (3) of rear blower fan motor.
Remove rear blower fan motor.
RJIA0364E
MTC-86

Floor-type rear heater (microbus)
1.
2.
3.

Remove rear heater unit.
Disassemble rear heater unit, and remove rear blower fan motor. Refer to MTC-85, "Disassembly and
Assembly" in Rear Heater Unit.
Rear Blower Fan Resistor
EJS001EB

Built-in type rear heater (4 door and 5 door)
1.
2.

Remove connectors and mounting screws of rear blower fan
resistor, and remove rear blower fan resistor.
RJIA0365E
Floor-type rear heater (microbus)

1.
2.
3.

Remove rear heater unit, and disconnect connectors of rear blower fan resistor.
Remove mounting screws of rear blower fan resistor, and remove rear blower fan resistor. Refer to MTC85, "Disassembly and Assembly" in Rear Heater Unit.
Rear Heater Duct (4 Door)

1.
2.
3.
EJS0018I

Remove rear heater unit. Refer to MTC-84, "Removal and Installation" in Rear Heater Unit.
Remove clips, and remove rear heater duct.
MTC
M
RJIA0366E
Rear Heater Control
EJS0018J

4 door, microbus
1.
2.
Pull left side of rear heater control, and remove clips (2).
Slide rear heater control to side (vehicle front), and remove rear
heater control.
RJIA0367E
MTC-87

5 door
1.
2.

Remove rear heater control mounting screws, and remove rear
heater control.
RJIA0368E
DISASSEMBLY AND ASSEMBLY
RJIA0369J
Finisher (4 door)
Fan switch knob
Clip (4 door)
Screw
Control assembly
Clip (4 door)
Screw
Fan switch
Valve
Rear Heater Hose
EJS0018K

1.
2.
3.

Remove engine undercover.
Remove clamp and screws (2), and disconnect heater tube. (ZD
engine)
RJIA0370E
MTC-88

4. Remove bolts (4), and bracket.
5. Remove clamp and bolts (3).
6. Release parking brake.
CAUTION:
When releasing parking brake, be sure to prevent vehicle from
moving by setting wheel blocks.
C
RJIA0371E
7.
Remove heater hose assembly A.

E
G
RJIA0372E
8.
Remove clamp and nut (1). (4 door)
MTC
RJIA0373E
9. Disconnect heater hose from rear heater unit. (4 door)

10. Remove bolt (1), and remove heater hose assembly B. (4
door)
RJIA0374E
MTC-89
MODE DOOR
MODE DOOR
Adjustment of Cable
1.
2.
3.
4.
PFP:27731
EJS0018M
Remove outer cable from the clamp.

Set mode adjustment dial to DEF.
Push side link in the direction shown by arrow. Slightly pull outer
cable to controller side, and install it to clamp.
CAUTION:
When clamping the outer cable, do not move the inner
cable.
Operate mode adjustment dial, and check that inner cable
moves smoothly.
SJIA0100E
MTC-90
AIR MIX DOOR

AIR MIX DOOR
Adjustment of Cable
1.
2.
3.
4.
PFP:27732
A
EJS0018N
Remove outer cable from the clamp.

Set temperature adjustment dial to FULL COLD.
Push air mix door lever in the direction shown by arrow. Slightly
pull outer cable toward controller side, and install clamp.
CAUTION:
When clamping the outer cable, do not move the inner
cable.
Operate the temperature adjustment dial to insure that the inner
cable moves smoothly.
D
ZJIA0039E
MTC
MTC-91
DUCT AND GRILLE

DUCT AND GRILLE
PFP:27860
EJS0018O
VENTILATOR DUCT, DEFROSTER NOZZLE, AND DUCT
ZJIA0040J
Cluster lid C
Central ventilator grille (LH)
Central ventilator grille (RH)
Instrument panel assembly
Side ventilator duct (LH)
Side ventilator grille (LH)
Central ventilator duct (LH)
Central ventilator duct (RH)
Side ventilator grille (RH)
10 Side ventilator duct (RH)
11 Central ventilator adapter
12 Side defroster duct
13 Central defroster nozzle
1.
Remove instrument panel.

Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY" in IP Instrument Panel.
CENTRAL VENTILATOR GRILLE

1.
2.
Remove cluster lid C.

Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY"
Instrument Panel.
Remove central ventilator grille.
in IP
ZJIA0041E
MTC-92
DUCT AND GRILLE

SIDE VENTILATOR GRILLE
1.
2.
Remove instrument panel.

Refer to IP-3, "INSTRUMENT PANEL ASSEMBLY"
Instrument Panel.
Remove side ventilator grille.
in IP
B
ZJIA0042E
FOOT DUCT
1.
Remove foot duct.
ZJIA0043E
REAR VENTILATOR GRILLE

1.
Remove rear ventilator grille.

I
MTC
K
ZJIA0044E
REAR INTAKE GRILLE

1.
Remove rear intake grille from clip.

M
ZJIA0045E
MTC-93
A/C CYCLE
A/C CYCLE
Component Parts Drawing
PFP:92600
EJS0018P
MTC-94
A/C CYCLE
WITHOUT REAR A/C
A
MTC
SJIA0097E
MTC-95
A/C CYCLE
WITH REAR A/C
SJIA0098E
MTC-96
A/C CYCLE
Compressor
EJS0018Q
REMOVAL
1.
2.
3.
4.
5.

refrigerant.
Remove cover.
Remove engine undercover.
Remove auxiliary drive belt. KA20 and KA24 engines: EM-14,
"DRIVE BELTS" ZD engine:EM-107, "DRIVE BELTS"
D
ZJIA0048E
6.
7.
8.
Disconnect high-pressure flexible hose 1 and low-pressure flexible hose 1 from compressor.
CAUTION:
Disconnect the connector of the compressor.
Remove harness bracket fixing bolts, and clip, and remove vehicle harness aside (ZD engine only).
ZJIA0049E
MTC
K
ZJIA0051E
9.
Remove compressor mounting bolts.

M
ZJIA0050E
MTC-97
A/C CYCLE
10. Remove compressor from underbody of vehicle, in case of KA
engine, and from vehicle, in case of ZD engine.
ZJIA0052E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure flexible hose 1 and lowpressure flexible hose 1 with new ones. Install new O-rings
with compressor oil applied.
When charging refrigerant, check for refrigerant leaks.
ZJIA0053E
Compressor mounting bolt (KA engine)

Tightening
: 57 - 66 Nm (5.8 - 6.7 kgm, 42 - 48
torque
ft-lb)
Compressor mounting bolt (ZD engine)
Tightening
: 59 - 69 Nm (6.0 - 7.0 kgm, 44 - 50
torque
ft-lb)
High-pressure flexible hose 1 mounting bolt
Tightening
torque
: 8 - 10 Nm (0.8 - 1.0 kgm, 70 - 95

in-lb)
Low-pressure flexible hose 1 mounting bolt

Tightening
torque
: 8 - 10 Nm (0.8 - 1.0 kgm, 70 - 95

in-lb)
MTC-98
ZJIA0054E
A/C CYCLE
Overhaul
EJS001FK
F
SHA493F
Removal
EJS001FL
When removing center bolt, hold clutch disc with clutch disc
wrench.
MTC
SHA792E
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
remove the drive plate.
After removing the drive plate, remove the shims from either the
drive shaft or the drive plate.
SHA098EA
Remove the snap ring using external snap ring pliers.
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
Remove the snap ring using external snap ring pliers.

Remove the field coil harness clip using a screwdriver. The three
field coil fixing screws and remove the field coil.
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
Install the field coil.

Be sure to align the coil pin with the hole in the compressor
front head.
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.
C
SHA797EA
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
to 12 to 14 N-m (1.2 to 1.4 kg-m, 9 to 10 ft-lb) torque.
MTC
SHA799E
After tightening the bolt, check that the pulley rotates smoothly.
Check clearance all the way around the clutch disc.
Disc-to-pulley clearance
0.24 - 0.42 mm (0.0094 - 0.0165 in)
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 engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
MTC-101
A/C CYCLE
High-Pressure Flexible Hose 1 and Low-Pressure Flexible Hose 1
EJS0018R
REMOVAL
1.
2.
3.
4.

refrigerant.
Remove condenser.MTC-109, "Condenser Assembly"
Remove cover.
ZJIA0048E
5.
Disconnect low-pressure flexible hose 1 from low-pressure pipe

2.
CAUTION:
ZJIA0056E
6.
Remove fixing nuts of high-pressure flexible hose 1 and lowpressure flexible hose 1.
ZJIA0055E
7.
Remove mounting bolts of high-pressure flexible hose 1 and

low-pressure flexible hose 1, and remove hoses from vehicle.
ZJIA0049E
MTC-102
A/C CYCLE
A
C
ZJIA0051E
8.
Remove band clip and clip. Disconnect high-pressure flexible

hose 1 and low-pressure flexible hose 1 from bracket, respectively.
G
ZJIA0075E
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.
Replace band clips on high-pressure flexible hose 1 and low-pressure flexible hose 1 with new
ones.
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

Tightening torque
: 14.7 - 24.5 Nm (1.5 - 2.5 kgm, 11 - 18 ft-lb)

M

Tightening torque
: 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)
Low-Pressure Pipe 1
EJS0018S
REMOVAL
1.
2.
3.
4.

refrigerant.
Remove condenser.
Remove mounting bolts of low-pressure pipe 1, and disconnect
it from blower and cooling unit.
CAUTION:
MTC-103
ZJIA0013E
A/C CYCLE
5.
6.
7.
Disconnect low-pressure pipe 1 from low-pressure flexible hose

1.
Disconnect low-pressure pipe 1 from low-pressure pipe 2. (For
models with rear A/C only)
Remove clip fixing bolts, and remove low-pressure pipe 1.
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.

Low-pressure pipe 1 union nut
Tightening torque
: 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)
Low-pressure pipe 1 mounting bolts
Tightening torque
: 8 - 10 Nm (0.8 - 1.1 kgm, 70 - 95 in-lb)
Tightening torque
: 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)
Low-Pressure Pipe 2
EJS0018T
REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
9.

refrigerant.
Remove front LH wheel.
Remove condenser.
Remove splash board (LH).
Disconnect low-pressure pipe 2 from low-pressure pipe 1.
CAUTION:
Remove clip fixing bolts, and disconnect low-pressure pipe 2
from low-pressure flexible hose 2.
Disconnect high-pressure pipe 4 from clip of low-pressure pipe
2.
Remove clip fixing bolts and clips, and remove low-pressure
pipe 2 from wheel housing.
ZJIA0056E
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.
MTC-104
A/C CYCLE
Low-pressure pipe 1 union nut
Tightening torque
: 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)

Tightening torque
: 19.6 - 29.4 Nm (2.0 - 3.0 kgm, 15 - 21 ft-lb)
High-Pressure Pipe 1
EJS0018U
REMOVAL
1.
2.
3.
4.

refrigerant.
Remove undercover.
Disconnect high-pressure pipe 1 from liquid tank.
CAUTION:
F
ZJIA0059E
5.
Disconnect high-pressure pipe 1 from the condenser.
ZJIA0061E
6.
Remove connector and clip fixing bolts, and remove high-pressure pipe 1.
MTC
M
ZJIA0060E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipe 1 with new ones. Install new O-rings with compressor oil
applied.

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
EJS0018V
REMOVAL
1.
2.
3.
4.

refrigerant.
Remove undercover.
Disconnect high-pressure pipe 2 from liquid tank.
CAUTION:
ZJIA0059E
5.
Disconnect high-pressure pipe 2 from blower and cooling unit.
ZJIA0013E
6.
Remove clip fixing bolts, and disconnect high-pressure pipe 2

from high-pressure pipe 3. (For models with rear A/C only)
ZJIA0060E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipes with new ones. Install new O-rings with compressor oil
applied.

High-pressure pipe 2 mounting bolts
Tightening torque
: 2.9 - 3.9 Nm (0.3 - 0.4 kgm, 26 - 34 in-lb)
High-pressure pipe union nut

Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
MTC-106
A/C CYCLE
EJS0018W
REMOVAL
1.
2.
3.
4.
5.
6.

refrigerant.
Remove undercover.
Disconnect high-pressure pipe 2 from high-pressure pipe 3. (For
models with rear A/C only)
CAUTION:
Disconnect high-pressure pipe 3 from high-pressure pipe 4.
Remove clip fixing bolts, and remove high-pressure pipe 3.
D
ZJIA0060E
ZJIA0061E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipes 3 and 4 with new ones. Install new O-rings with compressor oil applied.
MTC
High-pressure pipe 3 unit nut

Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
High-Pressure Flexible Hose 2 and Low-Pressure Flexible Hose 2 (Rear A/C

Side)
K
EJS0018Y
REMOVAL
1.
2.
3.
4.
5.
6.

refrigerant.
Remove insulator, and disconnect high-pressure flexible hose 2
and low-pressure flexible hose 2 from rear A/C unit assembly.
CAUTION:
Disconnect drain hose (LH).
CAUTION:
When disconnecting drain hoses, be careful to avoid spilling water.
MTC-107
ZJIA0029E
A/C CYCLE
7.
8.
Disconnect high-pressure flexible hose 2 from high-pressure

pipe 4.
Disconnect low-pressure flexible hose 2 from low-pressure pipe
2.
ZJIA0057E
9.
Remove clips and grommets. Pull out high-pressure flexible

hose 2, low-pressure flexible hose 2, and drain hose (LH) all
together in upward direction.
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.

Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)

Tightening torque
: 24.5 - 34.3 Nm (2.5 - 3.5 kgm, 18 - 25 ft-lb)
EJS0018X
REMOVAL
1.
2.
3.
4.
5.

refrigerant.
Remove front LH wheel.
Disconnect high-pressure pipe 4 from high-pressure pipe 3.
CAUTION:
MTC-108
ZJIA0061E
A/C CYCLE
6.
7.
Disconnect high-pressure pipe 4 from high-pressure flexible

hose 2, and remove clips.
Remove clip fixing bolts and clips, and remove high-pressure
pipe 4 from wheel housing.
C
ZJIA0057E
INSTALLATION
CAUTION:
Replace O-rings on high-pressure pipe 4 and high-pressure flexible hose 2 with new ones. Install

High-pressure pipe 4 union nut
Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)

Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
Pressure Switch
EJS0018Z

1.
2.
3.

refrigerant.
Remove liquid tank.
Using a vise, secure liquid tank, and remove pressure switch.
CAUTION:
Wrap shop cloths around liquid tank to avoid any damage
to it.
When installing, apply compressor oil to O-rings on pressure switch.
Tightening torque
MTC
: 9.8 - 11.7 Nm (1.0 - 1.2 kgm, 87 - 104 in-lb)
Condenser Assembly
L
EJS00190
3.
4.
SJIA0101E
Pressure switch
1.
2.

refrigerant.
Remove undercover.
Remove lower cover.
ZJIA0062E
MTC-109
A/C CYCLE
5.
Disconnect high-pressure flexible hose 1 from condenser

assembly.
CAUTION:
ZJIA0063E
6.
Disconnect high-pressure pipe 1 from condenser assembly.
ZJIA0061E
7.
Disconnect condenser fan connector.
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

Tightening torque
: 14.7 - 24.5 Nm (1.5 - 2.5 kgm, 16 - 18 ft-lb)
MTC-110
A/C CYCLE
High-pressure pipe 1 mounting bolt
Tightening torque
: 2.9 - 3.9 Nm (0.3 - 0.4 kgm, 26 - 34 in-lb)
DISASSEMBLY AND ASSEMBLY

B
ZJIA0065J
Bracket (RH)
Lower cover
Bolt
Bracket (LH)
Condenser
Bolt
Air guide
Bolt
Condenser fan motor
10 Bolt
11 Bolt
13 Nut
14 Fan shroud
12 Condenser fan
Rear Evaporator
EJS00191

1.
2.
3.
4.
5.
6.
MTC

refrigerant.
Disconnect high-pressure flexible hose 2 and low-pressure flexible hose 2 from rear A/C assembly.
CAUTION:
Remove lower case of rear A/C assembly.
Remove screws, and remove rear evaporator.
MTC-111
ZJIA0069E
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.

Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
Tightening torque
: 24.5 - 34.3 Nm (2.5 - 3.5 kgm, 18 - 25 ft-lb)
Front Expansion Valve
EJS00192

1. Remove blower and cooling unit.
2. Remove insulator.
3. Remove piping block and expansion valve.
CAUTION:
Replace O-rings on piping block and evaporator with new

ones. Install new O-rings with compressor oil applied.
ZJIA0070E
Mounting bolts of piping block (expansion valve)

Tightening torque
: 3.0 - 4.4 Nm (0.30 - 0.45 kgm, 27 - 39 in-lb)
Rear Expansion Valve
EJS00193

1.
2.
Remove rear evaporator.

Remove insulator, and then rear expansion valve.
CAUTION:
Replace O-rings on rear expansion valve inlet tube and
rear evaporator with new ones. Install new O-rings with
compressor oil applied.
Replace the insulator with new one.
ZJIA0071E
Rear evaporator inlet tube union nut

Tightening torque
: 9.8 - 19.6 Nm (1.0 - 2.0 kgm, 87 - 173 in-lb)
Rear evaporator union nut
Tightening torque
: 14.7 - 24.5 Nm (1.5 - 2.5 kgm, 11 - 18 ft-lb)
MTC-112
A/C CYCLE
Liquid Tank
EJS00194

1.
2.

Using a refrigerant recovery unit (for HFC134a), remove refrigerant.
3. Disconnect connector, and disconnect high-pressure pipes 1
and 2 from liquid tank.
CAUTION:
4. Remove bracket fixing bolts, and pull out liquid tank from lower
ZJIA0059E
side.
CAUTION:
Replace O-ring on high-pressure pipe with new one. Install new O-ring with compressor oil
applied.
Mounting bolts of high-pressure pipes 1 and 2

Tightening torque
: 2.9 - 3.9 Nm (0.29 - 0.4 kgm, 26 - 34 in-lb)
G
MTC
MTC-113
A/C CYCLE
MTC-114

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MANUAL AIR CONDITIONER

MANUAL AIR CONDITIONER

Magnet Clutch Circuit ............................................. 50

INSTALLATION ................................................. 107

REMOVAL AND INSTALLATION ...................... 109

Precautions for Working with HFC-134a (R-134a)

General Refrigerant Precautions

Do not store or heat refrigerant containers above 52C (125F).

Do not intentionally drop, puncture, or incinerate refrigerant containers.

Precautions for Leak Detection Dye

Precautions for Refrigerant Connection

Expansion valve to cooling unit

Dual pressure switch to liquid tank

FEATURES OF NEW TYPE REFRIGERANT CONNECTION

O-Ring Part Numbers and Specifications

Always replace used O-rings.

O-ring must be closely attached to dented portion of tube.

Precautions for Servicing Compressor

Precautions for Service Equipment

ELECTRONIC LEAK DETECTOR

The lubricant contained inside the vacuum pump is not compatible

Usually vacuum pumps have a manual isolator valve as part of

MANIFOLD GAUGE SET

Be certain that the service hoses display the markings described

A/C service valve

REFRIGERANT WEIGHT SCALE

CALIBRATING ACR4 WEIGHT SCALE

Wiring Diagrams and Trouble Diagnosis

GI-13, "How to Read Wiring Diagrams" in GI section.

PG-3, "Wiring Diagram POWER "in PG section.

GI-9, "How to Follow Trouble Diagnoses" in GI section.

GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

Removing shaft nut and clutch disc

Removing clutch disc

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

Container color:Light blue

HFC-134a (R-134a) refrigerant

large container 1/22 -16 ACME

Type:Poly alkylene glycol oil (PAG),

Function:Refrigerant Recovery and

DC 12V (Cigarette lighter)

Power supply: DC 12V (Battery

For injecting 1/4 ounce of fluorescent

For cleaning dye spills.

The gauge face indicates R-134a.

Low hose:Blue with black stripe

High hose:Red with black stripe

Low side hose

Utility hose:Yellow with black stripe

1/22 -16 ACME

High side coupler

Low side coupler

Hose fitting to service hose:

M14 x 1.5 fitting is optional or

1/22 -16 ACME

Commercial Service Tool

Air displacement:4 CFM

Micron rating:20 microns

Oil capacity:482 g (17 oz)

1/22 -16 ACME

For checks refrigerant purity and for

Refrigerant identifier equipment

Refrigerant System Protection