Manual Air Conditioner: Section

AIR CONDITIONER
MTC
A
B
SECTION
MANUAL AIR CONDITIONER C
E
CONTENTS
SERVICE INFORMATION ............................ 2 Component Part Location ........................................23 F
Wiring Diagram - Heater - ........................................27
PRECAUTIONS ................................................... 2 Wiring Diagram - A/C - ............................................28
Precaution for Supplemental Restraint System Operational Check ...................................................32 G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Mode Door ...............................................................33
SIONER" ................................................................... 2 Air Mix Door .............................................................34
Precaution for Working with HFC-134a (R-134a)...... 2 Intake Door ..............................................................35
H
Contaminated Refrigerant ......................................... 2 Blower Motor ...........................................................36
General Refrigerant Precaution ................................ 3 Magnet Clutch (KA24DE Models) ............................39
Precaution for Leak Detection Dye ........................... 3 Magnet Clutch (YD25DDTi Models) ........................44
A/C Identification Label ............................................. 3 Insufficient Cooling ..................................................50 I
Precaution for Refrigerant Connection ...................... 3 Cooling Fan .............................................................57
Precaution for Service of Compressor ...................... 8 Insufficient Heating ..................................................60
Precaution for Service Equipment ............................. 8 Noise .......................................................................61 MTC
PREPARATION ..................................................11 HEATER CORE ................................................. 63
Special Service Tool ............................................... 11 Removal and Installation .........................................63
HFC-134a (R-134a) Service Tool and Equipment.... 11 K
Commercial Service Tool ........................................ 13 REFRIGERANT LINES ..................................... 64
HFC-134a (R-134a) Service Procedure ..................64
REFRIGERATION SYSTEM ..............................15 Component ..............................................................66 L
Refrigeration Cycle .................................................. 15 Removal and Installation for Compressor ...............68
Component Part Location ....................................... 16 Removal and Installation for Compressor Clutch ....69
Removal and Installation for Evaporator .................71
OIL ......................................................................19 M
Checking for Refrigerant Leaks ...............................71
Maintenance of Oil Quantity in Compressor ........... 19 Checking System for Leaks Using the Fluorescent
AIR CONDITIONER CONTROL .........................21 Dye Leak Detector ...................................................72
Dye Injection ............................................................72 N
Control Operation .................................................... 21
Electronic Refrigerant Leak Detector .......................72
Discharge Air Flow .................................................. 21
TROUBLE DIAGNOSIS .....................................23 SERVICE DATA AND SPECIFICATIONS

O
How to Perform Trouble Diagnosis for Quick and (SDS) ................................................................. 76
Accurate Repair ...................................................... 23 General Specification ..............................................76
Revision: March 2008 MTC-1 2009 D22 LCV

PRECAUTIONS
< SERVICE INFORMATION >
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000003937183
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 and/or orange harnesses or har-
ness connectors.
Precaution for Working with HFC-134a (R-134a) INFOID:0000000003937479
WARNING:
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants
are mixed compressor failure is likely to occur. Refer to MTC-2, "Contaminated Refrigerant". To
determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recov-
ery/Recycling Recharging equipment and Refrigerant Identifier.
• Use only specified oil for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If
oil other than that specified is used, compressor failure is likely to occur.
• The specified HFC-134a (R-134a) oil 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 oil from a sealed container. Immediately reseal containers of oil. Without
proper sealing, oil will become moisture saturated and should not be used.
- Avoid breathing A/C refrigerant and oil vapor or mist. Exposure may irritate eyes, nose and throat.
Remove HFC-134a (R-134a) from the A/C system using certified service equipment meeting require-
ments of SAE J2210 [HFC-134a (R-134a) recycling equipment], or SAE J2209 [HFC-134a (R-134a)
recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming
service. Additional health and safety information may be obtained from refrigerant and oil manufac-
turers.
- Do not allow oil, Genuine NISSAN A/C System Oil Type S to come in contact with styrofoam parts.
Damage may result.
Contaminated Refrigerant INFOID:0000000003937480
If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are:
• Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into
the atmosphere.
• Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant
supply.
• Suggest the customer return the vehicle to the location of previous service where the contamination may
have occurred.
• If you choose to perform the repair, recover the refrigerant using only dedicated equipment and contain-
ers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does
not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available ser-

PRECAUTIONS
vice. This refrigerant must be disposed of in accordance with all regulations. In addition, replacement of all
refrigerant system components on the vehicle is recommended. A
• If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NISSAN Cus-
tomer Affairs for further assistance.
General Refrigerant Precaution INFOID:0000000003937481 B
WARNING:
• Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the C
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.
D
• Do not store or heat refrigerant containers above 52°C (125°F).
• Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
• Do not intentionally drop, puncture, or incinerate refrigerant containers. E
• Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
• Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suf-
focation.
F
• Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condition-
ing systems with compressed air during repair. Some mixtures of air and HFC-134a (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 manu- G
facturers.
Precaution for Leak Detection Dye INFOID:0000000003937482
H
• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet
(UV) lamp is required to illuminate the dye when inspecting for leaks.
• Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of I
the fluorescent dye.
• The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluo-
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector.
• For your safety and the customer's satisfaction, read and follow all manufacturer's operating instructions and MTC
precautions prior to performing 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. K
• Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis dur-
ing a future service.
• Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, L
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. M
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-
134a (R-134a) leak detection dye in CFC-12 (R-12) A/C systems or CFC-12 (R-12) leak detection dye in
HFC-134a (R-134a) A/C systems or A/C system damage may result. N
• The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure occurs.
A/C Identification Label INFOID:0000000003937483
O
Vehicles with factory installed fluorescent dye have an identification label on the underside of hood.
Precaution for Refrigerant Connection INFOID:0000000003937484
P
A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.
• Expansion valve to cooling unit
• Evaporator pipes to evaporator (inside cooling unit)
• Refrigerant pressure sensor
FEATURES OF NEW TYPE REFRIGERANT CONNECTION
• The O-ring has been relocated. It has also been provided with a groove for proper installation. This reduces
the possibility of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-
PRECAUTIONS
ring is now set vertically in relation to the contacting surface of the mating part to improve sealing character-
istics.
• The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facili-
tating piping connections.
SHA815E
O-RING AND REFRIGERANT CONNECTION

PRECAUTIONS
KA24DE A/C System
A
MTC
ALJIA0295GB
P
1. High-pressure A/C pipe 2. High-pressure A/C connector pipe 3. Refrigerant pressure sensor
4. Liquid tank 5. Liquid tank bracket 6. Condenser
7. Compressor shaft seal 8. Compressor 9. High-pressure service valve
10. High-pressure flexible A/C hose 11. Low-pressure flexible A/C hose 12. Low-pressure service valve
13. Low-pressure A/C pipe 14. A/C drain hose A. 25 N·m (2.6 kg-m, 18 ft-lb)
B. 14.7 N·m (1.5 kg-m, 11 ft-lb) C. 13.7 N·m (1.4 kg-m, 10 ft-lb) D. 4.16 N·m (0.42 kg-m, 37 in-lb)

PRECAUTIONS
E. Refrigerant leak checking order (a - m) F. Tightening torque (A - D) G. Wrench size
H. O-ring size J. Purse lock clip
YD25DDTi A/C System
ALJIA0296GB

PRECAUTIONS
B. 14.7 N·m (1.5 kg-m, 11 ft-lb) C. 13.7 N·m (1.4 kg-m, 10 ft-lb) D. 4.16 N·m (0.42 kg-m, 37 in-lb) A
H. O-ring size
B
CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at or
around the connection. C
O-Ring Part Numbers and Specifications

D
Connec- O-ring
Part number* D mm (in) W mm (in)
tion type size
New 8 92471 N8210 6.8 (0.268) 1.85 (0.0728)
E
Former 10 J2476 89956 9.25 (0.3642) 1.78 (0.0701)
New 92472 N8210 10.9 (0.429) 2.43 (0.0957)
12
Former 92475 71L00 11.0 (0.433) 2.4 (0.094) F
New 92473 N8210 13.6 (0.535) 2.43 (0.0957)
16
Former 92475 72L00 14.3 (0.563) 2.3 (0.091)
G
New 92474 N8210 16.5 (0.650) 2.43 (0.0957)
19
SHA814E Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)
New 24 92195 AH300 21.8 (0.858) 2.4 (0.094) H
*: Always check with the Parts Department for the latest parts information.
WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is I
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following. MTC
• 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 oil to enter the low pressure chamber.
• When connecting tubes, always use a torque wrench and a back-up wrench.
• After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. K
• When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for con-
nection. L
• Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
• Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
• Always replace used O-rings. M
• When connecting tube, apply oil to circle of the O-rings shown in illustration. Be careful not to apply
oil to threaded portion.
Oil name: Genuine NISSAN A/C System Oil Type S or equivalent. N
• 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. O

PRECAUTIONS
• After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then tighten
connections of seal seat to the specified torque.
RHA861F
Precaution for Service of Compressor INFOID:0000000003937485
• 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 vehicle.
• When replacing or reinstalling the old compressor, follow “Maintenance of Oil Quantity in Compres-
sor” exactly. Refer to MTC-19, "Maintenance of Oil Quantity in Compressor".
• After compressor service operation, turn the compressor shaft by hand more than five turns in both
directions. This will equally distribute oil inside the compressor. After the compressor is installed,
let the engine idle and operate the compressor for 1 hour.
• After replacing the compressor magnet clutch, apply voltage to the new one and check for normal
operation. Refer to MTC-69, "Removal and Installation for Compressor Clutch".
Precaution for Service Equipment INFOID:0000000003937486
RECOVERY/RECYCLING EQUIPMENT
Follow the manufacturer's instructions for machine operation and machine maintenance. Never introduce any
refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
Follow the manufacturer's instructions for tester operation and tester maintenance.
VACUUM PUMP

PRECAUTIONS
The oil contained inside the vacuum pump is not compatible with the
specified oil for HFC-134a (R-134a) A/C systems. The vent side of A
the vacuum pump is exposed to atmospheric pressure so the vac-
uum pump oil may migrate out of the pump into the service hose.
This is possible when the pump is switched off after evacuation (vac-
B
uuming) and hose is connected to it.
To prevent this migration, use a manual valve situated near the
hose-to-pump connection, as follows.
• Usually vacuum pumps have a manual isolator valve as part of the C
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 D
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. E
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. F
G
RHA270D
MANIFOLD GAUGE SET

Be certain that the gauge face indicates HFC-134a (R-134a). Make H
sure the gauge set has 1/2″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) along with specified oil.
I
MTC
SHA533D K
SERVICE HOSES
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must include positive shut- L
off devices (either manual or automatic) near the end of the hoses
opposite the manifold gauge.
M
RHA272D
O
SERVICE COUPLERS

PRECAUTIONS
Never attempt to connect HFC-134a (R-134a) service couplers to a
CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will
not properly connect to the CFC-12 (R-12) system. 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 HFC134a (R-134a) and specified
oils have been used with the scale. If the scale controls refrigerant
flow electronically, the hose fitting must be 1/2”-16 ACME.
RHA274D
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.

PREPARATION
PREPARATION
A
Special Service Tool INFOID:0000000003492236
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B
Tool number
(Kent-Moore No.) Description
Tool name
C
KV99231260 Removing shaft nut and clutch disc
(J-38874)
Clutch disc wrench
D
E
NT204
HFC-134a (R-134a) Service Tool and Equipment INFOID:0000000003939703
F
Never mix HFC-134a (R-134a) refrigerant and/or the specified oil with CFC-12 (R-12) refrigerant and/or the
oil.
Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/oil.
Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles G
refrigerant and/or oil) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed
use of the refrigerants/oil.
Adapters that convert one size fitting to another must never be used refrigerant/oil contamination will occur H
and compressor malfunction will result.
Tool number Description

(Kent-Moore No.)
I
Tool name
HFC-134a (R-134a) Container color: Light blue
( — ) Container marking: HFC-134a (R- MTC
Refrigerant 134a)
Fitting size: Thread size
• large container 1/2”-16 ACME
K
S-NT196
L
— Type: Poly alkylene glycol oil (PAG),
( — ) type S
NISSAN A/C System Oil Application: HFC-134a (R-134a)
Type S swash plate compressors (NISSAN M
only)
Lubricity: 40 m (1.4 US fl oz, 1.4 Imp
fl oz)
N
S-NT197
KV991J0130 Refrigerant Recovery and Recycling

(ACR2005-NI) and Recharging
ACR5 A/C Service Center O
WJIA0293E

PREPARATION
(Kent-Moore No.)
Tool name
— Power supply:
(J-41995) • DC 12V (battery terminal)
Electronic refrigerant leak detector
AHA281A
— Power supply:
Refrigerant dye leak detection kit
Kit includes:
(J-42220)
UV lamp and UV safety goggles
(J-41459)
Refrigerant dye injector
(J-41447)
HFC-134a (R-134a) Fluorescent
leak detection dye (box of 24, 1/4
ounce bottles)
(J-43872) ZHA200H
Refrigerant dye cleaner
— Power supply:
Fluorescent dye leak detector For checking refrigerant leak when flu-
orescent dye is installed in A/C system.
Includes: UV lamp and UV safety gog-
gles
SHA438F
— Application: For HFC-134a (R-134a)

(J-41447) PAG oil
HFC-134a (R-134a) Fluorescent Container: 1/4 ounce (7.4cc) bottle
leak detection dye (Includes self-adhesive dye identifica-
(box of 24, 1/4 ounce bottles) tion labels for affixing to vehicle after
charging system with dye.)
SHA439F
— For injecting 1/4 ounce of fluorescent

(J-41459) leak detection dye into A/C system.
HFC-134a (R-134a) Refrigerant
dye injector
Use with J-41447, 1/4 ounce bottle
SHA440F
— For cleaning dye spills.

(J-43872)
Refrigerant dye cleaner
SHA441F

PREPARATION
(Kent-Moore No.) A
Tool name
— Identification:
(J-39183-C) • The gauge face indicates R-134a. B
Manifold gauge set (with hoses Fitting size-Thread size
and couplers) • 1/2”-16 ACME
RJIA0196E
E
Service hoses: Hose color:
• High side hose • Low side hose: Blue with black stripe
(J-39500-72B) • High side hose: Red with black stripe
• Low side hose • Utility hose: Yellow with black stripe F
(J-39500-72R) or green with black stripe
• Utility hose Hose fitting to gauge:
(J-39500-72Y) • 1/2”-16 ACME
S-NT201
G
Service couplers Hose fitting to service hose:

• High side coupler • M14 x 1.5 fitting is optional or perma-
(J-39500-20A) nently attached. H
• Low side coupler
(J-39500-24A)
S-NT202
— For measuring of refrigerant MTC

(J-39699) Fitting size-Thread size
Refrigerant weight scale • 1/2”-16 ACME
S-NT200
L
— Capacity:
(J-39649) • Air displacement: 4 CFM
Vacuum pump • Micron rating: 20 microns
(Including the isolator valve) • Oil capacity: 482 g (17 oz) M
Fitting size-Thread size
• 1/2”-16 ACME
N
S-NT203
Commercial Service Tool INFOID:0000000003939704

O

PREPARATION
Tool name Description
(J-41810-NI) For checking refrigerant purity and
Refrigerant identifier equipment (R- system contamination
134a)
RJIA0197E
Power tool Loosening bolts and nuts
PBIC0190E

REFRIGERATION SYSTEM
A
Refrigeration Cycle INFOID:0000000003492239
I
AWIIA0054ZZ
1. Electric compressor 2. Pressure relief valve 3. Liquid tank MTC

4. Triple pressure switch 5. Condenser 6. Expansion valve
7. Evaporator 8. Blower motor A. High-pressure gas
B. High-pressure liquid C. Low-pressure liquid D. Low-pressure gas K
E. Suction port F. Discharge port G Outside air
REFRIGERANT FLOW
L
The refrigerant flows in the standard pattern. Refrigerant flows through the compressor, condenser, liquid tank,
expansion valve, 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.
M
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When the
evaporator coil temperature falls below a specified point, the thermo control amp interrupts the compressor
operation. When the evaporator coil temperature rises above the specification, the thermo control amp allows N
compressor operation.
REFRIGERANT SYSTEM PROTECTION
O
Triple Pressure Switch
The refrigerant system is protected against excessively high or low pressure. The protection is effected by a
triple pressure switch that is located on the liquid tank. If the pressure falls out of specification, the switch P
opens to interrupt compressor operation.
Pressure Relief Valve
The refrigerant system is also protected by a pressure relief valve located in the compressor. When the refrig-
erant pressure in the system increases to an abnormal level, the release port on the pressure relief valve auto-
matically opens and releases refrigerant into the atmosphere.

Component Part Location INFOID:0000000003492240
KA24DE A/C System
ALJIA0295GB

E. Refrigerant leak checking order (a - m) F. Tightening torque (A - D) G. Wrench size A
YD25DDTi A/C System B
MTC
ALJIA0296GB

H. O-ring size

OIL
OIL
A
Maintenance of Oil Quantity in Compressor INFOID:0000000003940320
The oil in the compressor circulates through the system with the refrigerant. Add oil to compressor when B
replacing any component or after a large refrigerant leakage has occurred. It is important to maintain the spec-
ified amount.
If oil quantity is not maintained properly, the following malfunctions may result:
• Lack of oil: May lead to a seized compressor C
• Excessive oil: Inadequate cooling (thermal exchange interference)
OIL
D
Name: NISSAN A/C System Oil Type S or equivalent
CHECKING AND ADJUSTING
CAUTION: E
If excessive oil leakage is noted, do not perform the oil return operation.
Start the engine and set the following conditions:
Test Condition F
• Engine speed: Idling to 1,200 rpm
• A/C switch: On
• Blower fan speed: Maximum position
• Temp. control: Optional [Set so that intake air temperature is 25° to 30° C (77° to 86°F)] G
• Intake position: Recirculation ( )
• Perform oil return operation for about ten minutes
Adjust the oil quantity according to the following table. H
Oil Adjusting Procedure for Components Replacement Except Compressor
After replacing any of the following major components, add the correct amount of oil to the system.
I
Amount of Oil to be Added
Oil to be added to system

Part replaced Amount of oil Remarks MTC
m (US fl oz, Imp fl oz)
Evaporator 75 (2.5, 2.6) —
Condenser 75 (2.5, 2.6) — K
Liquid tank 5 (0.2, 0.2) Add if compressor is not replaced.
30 (1.0, 1.1) Large leak
In case of refrigerant leak L
— Small leak *1
*1: If refrigerant leak is small, no addition of oil is needed.
Oil Adjustment Procedure for Compressor Replacement M

OIL
WJIA1716E
1. New compressor 2. Old compressor 3. Recovery/recycling equipment

4. Measuring cup X 5. Measuring cup Y 6. New oil
A. Drain oil from the new compressor B. Record amount of oil recovered C. Add an additional 5 m (0.2 US fl oz,
into a clean container 0.2 Imp fl oz) of new oil when replacing
the liquid tank
D. Install new oil equal to recorded
amounts in measuring cups X plus Y
1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.

No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines.
2. Connect recovery/recycling equipment to vehicle. Confirm refrigerant purity in supply tank using recovery/
recycling equipment and refrigerant identifier. If NG, refer to MTC-2, "Contaminated Refrigerant".
3. Confirm refrigerant purity in vehicle A/C system using recovery/recycling equipment and refrigerant identi-
fier. If NG, refer to MTC-2, "Contaminated Refrigerant".
4. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure oil discharged into the
recovery/recycling equipment.
5. Drain the oil from the “old” (removed) compressor into a graduated container and recover the amount of
oil drained.
6. Drain the oil from the “new” compressor into a separate, clean container.
7. Measure an amount of new oil installed equal to the amount drained from “old” compressor. Add this oil to
the ““new” compressor through the suction port opening.
8. Measure an amount of new oil equal to the amount recovered during discharging. Add this oil to the “new”
compressor through the suction port opening.
9. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz, 0.2 Imp fl oz) of oil at this
time.
Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of oil if only replacing the compressor.

AIR CONDITIONER CONTROL
A
Control Operation INFOID:0000000003492242
ALIIA0282ZZ
1. Rear window defogger switch (if 2. Intake door control lever 3. Air conditioner switch G
equipped)
4. Fan control lever 5. Temperature control lever 6. Mode door control lever
H
FAN CONTROL LEVER
This lever controls the fan ON and OFF, and controls fan speed.
MODE DOOR CONTROL LEVER I
This lever controls the direction of air flow through the front discharge outlets. The air conditioner compressor
turns on when the lever is slid to the defrost or foot/defrost position. It will remain on until the key is
turned off or the fan switch is turned off (it will remain off only while the fan is off). MTC
TEMPERATURE CONTROL LEVER
This lever allows adjustment of the outlet air temperature.
K
INTAKE DOOR ( ) LEVER
FRESH ( ) position: Outside air is drawn into the passenger compartment.
REC ( ) position: Interior air is recirculated inside the vehicle.
L
AIR CONDITIONER SWITCH
The air conditioner switch controls the A/C system. When the switch is depressed with the blower ON, the A/C
relay is activated by the ECM allowing compressor operation. The indicator lamp will also light. M
The air conditioner cooling function operates only when the engine is running and ambient air temper-
ature is above 2°C (35°F).
REAR WINDOW DEFOGGER SWITCH (IF EQUIPPED) N
When switch is ON, rear window is defogged.
Discharge Air Flow INFOID:0000000003492243 O

AWIIA0992ZZ
Mode door position Air outlet/distribution

Vent Foot Defroster
100% — —
60% 40% —
— 80% 20%
— 60% 40%
— — 100%

TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS
A
How to Perform Trouble Diagnosis for Quick and Accurate Repair INFOID:0000000003492244
WORK FLOW B
E
AWIIA1045GB
*1: MTC-32
F
Symptom Table
Symptom Reference page G

• Blower motor does not rotate. • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR
MTC-36
BLOWER MOTOR”.
• Mode door does not change positions. • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR H
MTC-33
MODE DOOR”.
• Air mix door does not change positions. • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR AIR
MTC-34
MIX DOOR”. I
• Intake door position does not change. • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR IN-
MTC-35
TAKE DOOR”.
• Magnet clutch does not engage when A/C switch and fan • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR MTC-39 MTC
switch are ON. MAGNET CLUTCH ”. (KA24DE) or
MTC-44
(YD25DDTi)
K
• Insufficient cooling • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR IN-
MTC-50
SUFFICIENT COOLING”.
• Cooling fan does not operate. • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR
MTC-57 L
COOLING FAN”.
• Insufficient heating • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR IN-
MTC-60
SUFFICIENT HEATING”.
M
• Noise • Go to “TROUBLE DIAGNOSIS PROCEDURE FOR
MTC-61
NOISE”.
Component Part Location INFOID:0000000003492245 N
ENGINE COMPARTMENT
KA24DE Models O

TROUBLE DIAGNOSIS
ALIIA0283ZZ
1. Cooling fan fuse 2. Air conditioner relay 3. Cooling fan relay

4. Triple pressure switch (if equipped) 5. Cooling fan (if equipped) 6. Compressor (if equipped)
YD25DDTi Models

TROUBLE DIAGNOSIS
MTC
N
ALIIA0284ZZ
1. Cooling fan fuse 2. Air conditioner relay 3. Cooling fan relay O

4. Triple pressure switch (if equipped) 5. Cooling fan (if equipped) 6. Compressor (if equipped)
PASSENGER COMPARTMENT P

TROUBLE DIAGNOSIS
ALIIA0285ZZ
1. Thermo control amp. 2. Blower motor fuses 3. Blower motor

4. Fan resistor

TROUBLE DIAGNOSIS
Wiring Diagram - Heater - INFOID:0000000003492246
MTC
AAIWA0006GB
P

TROUBLE DIAGNOSIS
Wiring Diagram - A/C - INFOID:0000000003492247
AAIWA0002GB

TROUBLE DIAGNOSIS
MTC
AAIWA0003GB

TROUBLE DIAGNOSIS
AAIWA0004GB

TROUBLE DIAGNOSIS
MTC
AAIWA0005GB

TROUBLE DIAGNOSIS
AAIWA0007GB
Operational Check INFOID:0000000003492248
The purpose of the operational check is to confirm that the system operates as it should. The systems which
are checked are the blower, mode (discharge air), intake air (recirculation), temperature decrease, tempera-
ture increase, and A/C compressor.
CONDITIONS:
Engine running at normal operating temperature.

TROUBLE DIAGNOSIS
PROCEDURE:
A
CHECKING BLOWER MOTOR
1. Move fan control lever to 1-speed.
Fan should operate on 1-speed.
2. Then move fan control lever to 2-speed, and continue checking fan speed until all four speeds are B
checked.
3. Leave fan on 4-speed.
If NG, go to MTC-36, "Blower Motor". C
If OK, continue with the check.
CHECKING DISCHARGE AIR
1. Move mode control lever to each mode position. D
2. Confirm that discharge air comes out according to the air distribution table. Refer to MTC-21, "Discharge
Air Flow". E
NOTE:
Confirm that the compressor clutch is engaged (sound or visual inspection) and intake door position is at
fresh position when the DEF is selected.
If NG, go to MTC-33, "Mode Door". F
If OK, continue with next check.
CHECK RECIRCULATION
G
1. Move intake door lever to REC position.
2. Listen for intake door position to change (you should hear fan sound change slightly).
If NG, go to MTC-35, "Intake Door".
If OK, continue with next check. H
CHECKING TEMPERATURE DECREASE
1. Move temperature control lever to full cold.
2. Check for cold air at discharge air outlets. I
If NG, go to MTC-50, "Insufficient Cooling".
CHECK TEMPERATURE INCREASE MTC
1. Move temperature control lever to full hot.
2. Check for hot air at discharge air outlets.
If NG, go to MTC-60, "Insufficient Heating". K
CHECKING A/C SWITCH (IF EQUIPPED)
1. Move fan control lever to the desired (1 to 4 speed) position. L
2. 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). M
4. Check for cold air at the appropriate discharge air outlets.
If NG, go to MTC-39, "Magnet Clutch (KA24DE Models)" or MTC-44, "Magnet Clutch (YD25DDTi Models)".
If all operational checks are OK (symptom cannot be duplicated), go to GI-25, "How to Perform Efficient Diag- N
nosis for an Electrical Incident", and perform tests as outlined to simulate driving conditions environment. If
symptom appears, refer to MTC-23, "How to Perform Trouble Diagnosis for Quick and Accurate Repair" and
perform applicable trouble diagnoses procedures. O
Mode Door INFOID:0000000003492249
Trouble Diagnosis Procedure For Mode Door P
Symptom:
• Air outlet does not change.
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - DISCHARGE AIR
1. Move the mode door control lever to each position.

TROUBLE DIAGNOSIS
2. Confirm that discharge air comes out according to the air distribution table. Refer to MTC-21, "Discharge
Air Flow".
NOTE:
Confirm that the compressor clutch (with A/C) is engaged (visual inspection) when DEF ( ) or D/F ( )
is selected.
Can a symptom be duplicated?
YES >> GO TO 3.
NO >> GO TO 2.
2.PERFORM COMPLETE OPERATIONAL CHECK
Perform a complete operational check and check for any symptoms. Refer to MTC-32, "Operational Check".
YES >> Refer to MTC-23, "How to Perform Trouble Diagnosis for Quick and Accurate Repair".
NO >> System OK.
3.CHECK FOR SERVICE BULLETINS
Check for any service bulletins.
>> GO TO 4.
4.CHECK MODE DOOR CONTROL CABLE
Check and verify mode door mechanism for smooth operation in each mode.
Is the inspection result normal?
YES >> If the symptom still exists, perform a complete operational check and check for other symptoms.
Refer to MTC-32, "Operational Check". If other symptoms exist, refer to MTC-23, "How to Perform
Trouble Diagnosis for Quick and Accurate Repair".
NO >> Repair or adjust mode door control cable.
MODE DOOR CONTROL LINKAGE ADJUSTMENT
Mode door control linkage
• Move the mode door control lever to mode.
• Set mode door in DEF position.
• Push mode door cable end on mode door lever.
• Pull on outer cable in direction of arrow and then attach to the clip.
• ⇐ : Front.
• After positioning mode door control cable, check that it oper-
ates properly.
ALIIA0305GB
Air Mix Door INFOID:0000000003980628
Trouble Diagnosis Procedure For Air Mix Door

Symptom:
• Air mix door does not change.
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - TEMPERATURE INCREASE
1. Move the temperature control lever to the right to maximum heat.
2. Check for hot air at discharge air outlets.
>> GO TO 2.
2.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - TEMPERATURE DECREASE
TROUBLE DIAGNOSIS
Move the temperature control lever to the left to maximum cold.
Can a symptom be duplicated? A
YES >> GO TO 4.
NO >> GO TO 3.
3.PERFORM COMPLETE OPERATIONAL CHECK B
Can a symptom be duplicated? C
NO >> System OK.
4.CHECK FOR SERVICE BULLETINS D
E
>> GO TO 5.
5.CHECK AIR MIX DOOR CONTROL CABLE
Check and verify air mix door mechanism for smooth operation in each mode. F
YES >> If the symptom still exists, perform a complete operational check and check for other symptoms.
Refer to MTC-32, "Operational Check". If other symptoms exist, refer to MTC-23, "How to Perform G
Trouble Diagnosis for Quick and Accurate Repair".
NO >> Repair or adjust air mix door control cable.
AIR MIX DOOR CONTROL LINKAGE ADJUSTMENT H
Air mix door control linkage

• Move the air mix door control lever to maximum cold. I
• Set air mix door in maximum cold position.
• Push air mix door cable end on air mix door lever.
• ⇐ : Front. MTC
• After positioning air mix door control cable, check that it oper-
ates properly.
K
ALIIA0306GB L
Intake Door INFOID:0000000003492250
Trouble Diagnosis Procedure for Intake Door M
Symptom:
• Intake door position does not change. N
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - REC ( )
O
1. Move the intake door lever to the REC ( ) position.
2. Move the blower motor to maximum speed.
3. Move the intake door lever to the FRE position.
P
4. Listen for intake door position change (you should hear blower sound change slightly).
YES >> GO TO 3.
NO >> GO TO 2.

TROUBLE DIAGNOSIS
NO >> System OK.
>> GO TO 4.
4.CHECK INTAKE DOOR CONTROL LINKAGE
Check intake door control linkage mechanism for smooth operation.
YES >> If the symptom still exists, perform a complete operational check. Refer to MTC-32, "Operational
Check". If other symptoms exist, refer to MTC-23, "How to Perform Trouble Diagnosis for Quick
and Accurate Repair".
NO >> Repair or adjust control linkage.
INTAKE DOOR CONTROL LINKAGE ADJUSTMENT

Intake door control linkage
• Move the intake door control lever to REC ( ) mode.
• Set intake door in REC position.
• Push intake door cable end on intake door lever.
• ⇐ : Front.
• After positioning intake door control cable, check that it oper-
ates properly.
ALIIA0309GB
Blower Motor INFOID:0000000003492251
Trouble Diagnosis Procedure for Blower Motor

Symptom:
• Blower motor does not rotate.
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - BLOWER MOTOR
1. Move fan control lever to "1" position. Blower should operate on low speed.
2. Move the fan control lever to "2" position, and continue checking blower speed until all speeds are
checked.
Can the symptom be duplicated?
YES >> GO TO 3.
NO >> GO TO 2.
NO >> System OK.

TROUBLE DIAGNOSIS
>> GO TO 4.
4.CHECK BLOWER MOTOR CIRCUIT A
Check blower motor circuit. Refer to "DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR CIRCUIT".
Is the inspection result normal? B
C
NO >> Repair as necessary.
BLOWER MOTOR CIRCUIT
D
SYMPTOM:
• Blower motor does not rotate.
E
1.DIAGNOSTIC PROCEDURE
Check if blower motor rotates properly at each blower speed.
F
Does not rotate at any speed>>GO TO 2.
Does not rotate at 1-3 speed>>GO TO 6.
Does not rotate at 4 speed>>GO TO 7. G
2.CHECK FUSES
Check 15A fuse (No. 15 and 16 located in the fuse block). For fuse layout, refer to PG-3. H
Are fuses OK?
YES >> GO TO 3.
NO >> GO TO 9. I
3.CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT
1. Disconnect blower motor harness connector.
2. Turn ignition switch ON. MTC
3. Check voltage between blower motor harness connector M51
terminal 1 and ground.
K
1 - Ground : Battery Voltage
YES >> GO TO 4. L
NO >> Check the following.
• If NG, repair harness or connector.
- Harness for open between blower motor and fuse M
block.
AWIIA0993ZZ
4.CHECK BLOWER MOTOR GROUND CIRCUIT N

1. Turn ignition switch OFF.
2. Turn fan control lever to 4-speed.
3. Check continuity between blower motor harness connector M51
O
Continuity should exist.

P
YES >> GO TO 5.
NO >> Check the following. If NG, repair harness or connec-
tor.
• Harness for open between blower motor and ground.
AWIIA0994ZZ

TROUBLE DIAGNOSIS
5.CHECK BLOWER MOTOR
Apply 12 volts to blower motor terminal 1 and ground to blower
motor terminal 2.
Does blower motor rotate?
YES >> Reconnect blower motor connector and GO TO 6.
NO >> Replace blower motor.
AWIIA0995ZZ
6.CHECK FAN RESISTOR

1. Disconnect fan resistor harness connector M12.
2. Check resistance between fan resistor terminals.
Terminal No. Resistance

Ω
(+) (–) (Approx.)
2 0.2 - 0.3
1 3 0.8 - 1.0
4 2.0 - 2.4
YES >> GO TO 7.
NO >> Replace fan resistor. AWIIA0996ZZ
7.CHECK FAN SWITCH

Disconnect fan switch harness connector M55 and check continuity
between terminals at each fan switch position.
YES >> GO TO 8.
NO >> Replace fan switch.
AWIIA0998ZZ
8.CHECK FAN SWITCH GROUND

Check continuity between fan switch harness connector M55 termi-
nal 26 and ground.

YES >> Check the following.
• If NG, repair harness or connectors.
- Harness for open or short between blower motor and
fan switch, blower motor resistor.
NO >> Repair harness or connector.
AWIIA1002ZZ
9.REPLACE FUSE
1. Replace fuse(s).
2. Activate the blower motor system.
Do the fuses blow when the blower motor is activated?
TROUBLE DIAGNOSIS
YES >> GO TO 10.
NO >> Inspection End. A
10.CHECK BLOWER MOTOR POWER SUPPLY CIRCUIT FOR A SHORT
1. Disconnect battery cable and blower motor harness connector.
B
2. Check continuity between blower motor harness connector M51
Continuity should not exist. C

Does continuity exist?
YES >> Check the following. If NG, repair harness or connec-
D
tor.
• Harness for short between blower motor and fuse
block.
NO >> Check blower motor. Refer to MTC-36, "Blower Motor". E
AWIIA1043ZZ
If necessary, clear intake unit. If OK, replace blower
motor.
Magnet Clutch (KA24DE Models) INFOID:0000000003492252 F
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH

G
Symptom:
• Magnet clutch does not engage when A/C switch and fan switch are ON.
INSPECTION FLOW H
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - MAGNET CLUTCH
1. Start the engine. I
2. Move the fan control lever to the desired (1 to 4 speed) position.
3. Press the A/C switch ON (indicator light ON).
4. Confirm that the magnet clutch engages (sound or visual inspection).
MTC
YES >> GO TO 3.
NO >> GO TO 2.
K
2.CHECK FOR ANY SYMPTOMS
Perform a complete operational check for any symptoms. Refer to MTC-32, "Operational Check".
Does another symptom exist? L
NO >> System OK.
3.CHECK FOR SERVICE BULLETINS M

N
>> GO TO 4.
4.CHECK COMPRESSOR BELT TENSION
Check compressor belt tension. Refer to EM-15, "Checking Drive Belts". O
YES >> GO TO 5.
P
NO >> Adjust or replace compressor belt. Refer to EM-15, "Checking Drive Belts".
5.CHECK REFRIGERANT PRESSURE
Check refrigerant pressure using the "Ambient Air Temperature-to-Operating Pressure Table" with manifold
gauge connected. Refer to MTC-50, "Insufficient Cooling".
YES >> GO TO 6.

TROUBLE DIAGNOSIS
NO >> Perform "Trouble Diagnosis For Abnormal Pressure". Refer to MTC-50, "Insufficient Cooling".
6.CHECK MAGNET CLUTCH CIRCUIT
Perform diagnostic procedure for "Magnet Clutch Circuit".
MAGNET CLUTCH CIRCUIT
SYMPTOM:
1.CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT

1. Disconnect compressor connector.
2. Start the engine.
5. Check voltage between compressor connector M113 terminal 1
and ground.
1 - Ground :Battery voltage

YES >> Replace magnet clutch. Refer to MTC-69, "Removal and
Installation for Compressor Clutch".
AWIIA1044ZZ
NO >> GO TO 2.
2.CHECK FUSE
Check 10A fuse (No. 13, located in the fuse block). For fuse layout, refer to PG-3.
Is the fuse OK?
YES >> GO TO 3
NO >> GO TO 17.
3.CHECK A/C RELAY POWER SUPPLY CIRCUIT
1. Disconnect air conditioner relay.
2. Turn ignition switch ON.
3. Check voltage between air conditioner relay connector E30 ter-
minals 2, 3 and ground?
2, 3 - Ground :Battery voltage

YES >> GO TO 4.
AWIIA1005ZZ
4.CHECK AIR CONDITIONER RELAY

TROUBLE DIAGNOSIS
Check continuity between terminals 3 and 5.
A
Conditions Continuity
12V direct current supply between terminals 1 and 2 Yes
B
No current supply No
YES >> GO TO 5. C
NO >> Replace air conditioner relay.
AWIIA1006ZZ
5.CHECK CONTINUITY BETWEEN COMPRESSOR AND AIR CONDITIONER RELAY D

2. Check continuity between air conditioner relay connector E30
E
(B) terminal 5 and compressor connector M113 (A) terminal 1.

F
YES >> GO TO 6.
G
AWIIA1007ZZ
6.CHECK CONTINUITY BETWEEN AIR CONDITIONER RELAY AND ECM H

1. Disconnect ECM harness connector.
2. Check continuity between air conditioner relay harness connec-
tor E30 (B) terminal 1 and ECM connector M11 (A) terminal 16. I

Is the inspection result normal? MTC
YES >> GO TO 7.
K
AWIIA1008ZZ
L
7.CHECK TRIPLE PRESSURE SWITCH OUTPUT VOLTAGE
2. Press the A/C switch ON (indicator light ON). M
4. Check voltage between ECM harness connector M11 terminal
85 and ground.
N
Is inspection result normal?
O
YES >> Replace ECM.
NO >> GO TO 8.
AWIIA1009ZZ P
8.CHECK TRIPLE PRESSURE SWITCH POWER SUPPLY

TROUBLE DIAGNOSIS
2. Disconnect triple pressure switch connector.
4. Check voltage between triple pressure switch harness connec-
tor E23 terminal 1 and ground.

YES >> GO TO 9.
NO >> GO TO10.
AWIIA1010ZZ
9.CHECK CONTINUITY BETWEEN TRIPLE PRESSURE SWITCH AND ECM

2. Check continuity between triple pressure switch harness con-
nector E23 (A) terminal 4 and ECM harness connector M14 (B)
terminal 85.

YES >> Replace triple pressure switch.
AWIIA1011ZZ
10.CHECK THERMO CONTROL AMP. OUTPUT VOLTAGE

Check voltage between thermo control amp. harness connector M16

YES >> Repair harness or connector.
NO >> GO TO 11.
AWIIA1012ZZ
11.CHECK THERMO CONTROL AMP. POWER SUPPLY

2. Disconnect thermo control amp. connector.
4. Check voltage between thermo control amp. harness connector
M16 terminal 1 and ground?

YES >> GO TO 12.
AWIIA1013ZZ
12.CHECK A/C SWITCH POWER SUPPLY

TROUBLE DIAGNOSIS
2. Disconnect A/C switch connector. A
4. Check voltage between A/C switch harness connector M56 ter-
minal 14 and ground?
B
Is the inspection result normal? C
YES >> GO TO 13.
AWIIA1014ZZ
13.CHECK THERMO CONTROL AMP. GROUND CIRCUIT D
Check for continuity between A/C switch connector M56 (B) terminal
13 and thermo control amp. harness connector M16 (A) terminal 2.
E
Is the inspection result normal? F
YES >> GO TO 14.
G
AWIIA1015ZZ
14.CHECK A/C SWITCH GROUND CIRCUIT H

2. Fan control lever must be in the desired (1 to 4 speed) position.
3. Check for continuity between A/C switch connector M56 termi- I
nal 12 to ground.
Continuity should exist. MTC

YES >> GO TO 16.
NO >> GO TO 15. K
AWIIA1016ZZ
15.CHECK FAN SWITCH L

1. Disconnect fan switch connector.
2. Check continuity between fan switch terminal 25 and terminal
26. M
Terminal Terminal Condition Continuity

25 26 Fan control lever in 1-4 speed position Yes N
25 26 Fan control lever OFF No
O
NO >> Replace fan switch. AWIIA1017ZZ
16.CHECK A/C SWITCH P

TROUBLE DIAGNOSIS
Check A/C switch.

12 13 A/C switch ON Yes
12 13 A/C switch OFF No
YES >> Replace thermo control amp.
NO >> Replace A/C switch.
AWIIA1018ZZ
17.REPLACE FUSE
1. Replace fuse.
3. Activate the compressor.
Does fuse blow when A/C is activated?
YES >> GO TO 18.
NO >> Inspection End.
18.CHECK AIR CONDITIONER RELAY SUPPLY CIRCUITS FOR SHORT
2. Fan switch in OFF position.
terminals 2, 3 and ground.
Continuity should not exist.

YES >> GO TO 19.
AWIIA1019ZZ
19.CHECK AIR CONDITIONER RELAY OUTPUT CIRCUIT FOR SHORT
1. Disconnect IACV-FICD solenoid valve connector and compres-
sor connector.

YES >> Inspection End.
AWIIA1020ZZ
Magnet Clutch (YD25DDTi Models) INFOID:0000000003950022
TROUBLE DIAGNOSIS PROCEDURE FOR MAGNET CLUTCH

Symptom:
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - MAGNET CLUTCH
4. Confirm that the magnet clutch engages (sound or visual inspection).
TROUBLE DIAGNOSIS
YES >> GO TO 3. A
NO >> GO TO 2.
B
Does another symptom exist?
YES >> Refer to MTC-23, "How to Perform Trouble Diagnosis for Quick and Accurate Repair". C
NO >> System OK.
Check for any service bulletins. D
>> GO TO 4.
E
4.CHECK COMPRESSOR BELT TENSION
Check compressor belt tension. Refer to EM-88, "Checking Drive Belts".
Is the inspection result normal? F
YES >> GO TO 5.
NO >> Adjust or replace compressor belt. Refer to EM-88, "Checking Drive Belts".
5.CHECK REFRIGERANT PRESSURE G
gauge connected. Refer to MTC-50, "Insufficient Cooling". H
YES >> GO TO 6.
NO >> Perform "Trouble Diagnosis For Abnormal Pressure". Refer to MTC-50, "Insufficient Cooling". I
6.CHECK MAGNET CLUTCH CIRCUIT
Perform diagnostic procedure for "Magnet Clutch Circuit".
Is the inspection result normal? MTC
and Accurate Repair". K
MAGNET CLUTCH CIRCUIT
L
SYMPTOM:
M
1.CHECK A/C COMPRESSOR POWER SUPPLY CIRCUIT
1. Disconnect compressor connector. N
5. Check voltage between compressor connector E241 terminal 1 O
and ground.
1 - Ground :Battery voltage P

YES >> Replace magnet clutch. Refer to MTC-69, "Removal and
Installation for Compressor Clutch".
AWIIA1044ZZ
NO >> GO TO 2.
2.CHECK FUSE
Check 10A fuse (No. 13, located in the fuse block). For fuse layout, refer to PG-3.
TROUBLE DIAGNOSIS
Is the fuse OK?
YES >> GO TO 3
NO >> GO TO 18.
3.CHECK A/C RELAY POWER SUPPLY CIRCUIT
4. Check voltage between air conditioner relay connector E30 ter-
minals 2, 3 and ground?

YES >> GO TO 4.
AWIIA1005ZZ
4.CHECK AIR CONDITIONER RELAY

Check continuity between terminals 3 and 5.
YES >> GO TO 5.
NO >> Replace air conditioner relay.
AWIIA1006ZZ
5.CHECK CONTINUITY BETWEEN COMPRESSOR AND AIR CONDITIONER RELAY

(B) terminal 5 and compressor harness connector E241 (A) ter-
minal 1.

YES >> GO TO 6.
AWIIA1007ZZ
6.CHECK TRIPLE PRESSURE SWITCH POWER SUPPLY

3. Check voltage between triple pressure switch harness connec-
tor E23 terminal 1 and ground.

YES >> GO TO 7.
NO >> GO TO 11.
AWIIA1010ZZ
7.CHECK TRIPLE PRESSURE SWITCH OUTPUT VOLTAGE

TROUBLE DIAGNOSIS
2. Reconnect the triple pressure switch connector. A
3. Disconnect the combination meter connector.
5. Check voltage between combination meter harness connector
B
M206 terminal 13 and ground.

C
Is inspection result normal?
YES >> GO TO 9
AWIIA1021ZZ
NO >> GO TO 8.
D
8.CHECK CONTINUITY BETWEEN TRIPLE PRESSURE SWITCH AND COMBINATION METER
2. Disconnect the triple pressure switch connector. E
3. Check continuity between triple pressure switch harness con-
nector E23 (B) terminal 4 and combination meter harness con-
nector M206 (A) terminal 13.
F

G
AWIIA1022ZZ
NO >> Repair harness or connector. H
9.CHECK FAN SWITCH GROUND CIRCUIT
2. Check continuity between combination meter harness connector I
Continuity should exist. MTC

YES >> GO TO 10.
NO >> Repair harness or connector. K
AWIIA1023ZZ
L
10.CHECK AIR CONDITIONER RELAY CONTROL CIRCUIT
Check continuity between combination meter harness connector
M207 (A) terminal 72 and air conditioner relay E30 (B) terminal 1. M

Is the inspection result normal? N
YES >> Replace combination meter.
O
AWIIA1024ZZ
11.CHECK A/C SWITCH GROUND CIRCUIT P

TROUBLE DIAGNOSIS
2. Disconnect fan switch connector.
4. Check voltage between fan switch connector M55 terminal 25
and ground.

YES >> GO TO 12.
NO >> GO TO 13.
AWIIA1025ZZ
12.CHECK FAN SWITCH GROUND CIRCUIT

2. Check continuity between fan switch harness connector M55

YES >> Replace fan switch.
AWIIA1026ZZ
13.CHECK THERMO CONTROL AMP. POWER SUPPLY

3. Check voltage between thermo control amp. harness connector

YES >> GO TO 14.
AWIIA1013ZZ
14.CHECK CONTINUITY BETWEEN THERMO CONTROL AMP. AND TRIPLE PRESSURE SWITCH
2. Check continuity between thermo control amp. harness connec-
tor M16 (A) terminal 3 and triple pressure switch E23 (B) termi-
nal 1.

YES >> GO TO 15.
AWIIA1027ZZ
15.CHECK CONTINUITY BETWEEN THERMO CONTROL AMP. AND A/C SWITCH

TROUBLE DIAGNOSIS
Check for continuity between A/C switch harness connector M56 (B)
terminal 13 and thermo control amp. harness connector M16 (A) ter- A
minal 2.
Continuity should exist. B

YES >> GO TO 16.
NO >> Repair harness or connector. C
AWIIA1015ZZ
16.CHECK A/C SWITCH GROUND CIRCUIT D

2. Fan control lever must be in the desired (1 to 4 speed) position.
E
3. Check for continuity between A/C switch connector M56 termi-
nal 12 and ground.
Continuity should exist. F

YES >> GO TO 17.
G
AWIIA1016ZZ
17.CHECK A/C SWITCH H

Check A/C switch.
I
12 13 A/C switch ON Yes
12 13 A/C switch OFF No MTC
YES >> Replace thermo control amp.
NO >> Replace A/C switch. K
AWIIA1018ZZ
18.REPLACE FUSE L
1. Replace fuse.
3. Activate the compressor. M
Does fuse blow when A/C is activated?
YES >> GO TO 19.
NO >> Inspection End. N
19.CHECK AIR CONDITIONER RELAY SUPPLY CIRCUITS FOR SHORT
2. Fan switch in OFF position. O
5. Check continuity between air conditioner relay connector E30 P
terminals 2, 3 and ground.

YES >> GO TO 20.
AWIIA1019ZZ

TROUBLE DIAGNOSIS
20.CHECK AIR CONDITIONER RELAY OUTPUT CIRCUIT FOR SHORT
Check continuity between air conditioner relay connector E30 termi-
nal 5 and ground.

YES >> Inspection End.
AWIIA1020ZZ
Insufficient Cooling INFOID:0000000003492253
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT COOLING

Symptom:
• Insufficient cooling
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - TEMPERATURE DECREASE
1. Start engine.
2. Slide temperature control lever to maximum cold position.
3. Check for cold air at discharge air outlets.
YES >> GO TO 3.
NO >> GO TO 2.
NO >> System OK.
>> GO TO 4.
4.CHECK COMPRESSOR DRIVE BELT TENSION
Check compressor belt tension. Refer to EM-15, "Checking Drive Belts" (KA24DE models) EM-88, "Checking
Drive Belts" (YD25DDTi models).
YES >> GO TO 5.
NO >> Adjust or replace compressor belt. Refer to EM-16, "Removal and Installation" (KA24DE models)
EM-89, "Removal and Installation" (YD25DDTi models).
5.CHECK AIR MIX DOOR CABLE
Check and verify air mix door cable operation. Refer to MTC-34, "Air Mix Door".
Does air mix door operate correctly?
YES >> GO TO 6.
NO >> Repair or replace as necessary.
6.CHECK COOLING FAN OPERATION
Check and verify cooling fan motor for smooth operation. Refer to MTC-57, "Cooling Fan".
Does cooling fan motor operate correctly?
TROUBLE DIAGNOSIS
YES >> GO TO 7.
NO >> Perform cooling fan diagnostics procedure. Refer to MTC-57, "Cooling Fan". A
7.CHECK FOR EVAPORATOR FREEZE UP
Start engine and run A/C. Check for evaporator freeze up.
B
Does evaporator freeze up?
YES >> Perform "PERFORMANCE TEST DIAGNOSIS" below.
NO >> GO TO 8.
C
8.CHECK REFRIGERANT PRESSURE
gauge connected. Refer to "Test Reading". D
YES >> GO TO 9.
NO >> Perform "Trouble Diagnosis For Abnormal Pressure". E
9.CHECK AIR DUCTS
Check ducts for air leaks. F
Check". If other symptoms exist, refer to MTC-23, "How to Perform Trouble Diagnosis for Quick G
NO >> Repair air leaks.
H
DIAGNOSTIC WORK FLOW
MTC

TROUBLE DIAGNOSIS
AWIIA0999GB
*1 MTC-72, "Checking System for *2 MTC-68, "Removal and Installation *3 MTC-50, "Insufficient Cooling"
Leaks Using the Fluorescent Dye for Compressor"
Leak Detector"
*4 MTC-60, "Insufficient Heating" *5 MTC-34, "Air Mix Door"

TROUBLE DIAGNOSIS
MTC
N
AWIIA1029GB
*1 MTC-36, "Blower Motor" *2 MTC-69, "Removal and Installation *3 EM-15, "Checking Drive Belts" O
for Compressor Clutch" (KA24DE models) or EM-88, "Check-
ing Drive Belts" (YD25DDTi models)
*4 MTC-68, "Removal and Installation
for Compressor" P
PERFROMANCE CHART
Test Condition
Testing must be performed as follows:

TROUBLE DIAGNOSIS
Vehicle location Indoors or in the shade (in a well-ventilated place)

Doors Closed
Door windows Open
Hood Open
TEMP. switch Max. COLD
Mode switch
(Ventilation) set
REC switch
(Recirculation) set
4-speed
(blower) speed
Engine speed 1,500 rpm
Operate the air conditioning system for 10 minutes before taking measurements.
Test Reading
Recirculating-to-Discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator °C (°F)
Relative humidity % Air temperature °C (°F)
20 (68) 6.6 - 8.3 (44 - 47)
25 (77) 10.4 - 12.4 (51 - 54)
50 - 60 30 (86) 14.2 - 16.7 (58 - 62)
35 (95) 18.2 - 21 (65 - 70)
40 (104) 22.0 - 25.2 (72 - 77)
20 (68) 8.3 - 9.8 (47 - 50)
25 (77) 12.4 - 14.4 (54 - 58)
60 - 70 30 (86) 16.7 - 18.9 (62 - 66)
35 (95) 21.0 - 23.6 (70 - 74)
40 (104) 25.2 - 28.1 (77 - 83)
Ambient Air Temperature-to-Operating Pressure Table
Ambient air
High-pressure (Discharge side) kPa (kg/ Low-pressure (Suction side) kPa (kg/cm2,
Relative humidity % Air temperature °C 2
cm , psi) psi)
(°F)
20 (68) 961 - 1,187 (9.8 - 12.1, 139 - 172) 108 - 157 (1.1 - 1.6, 16 - 23)
25 (77) 1,295 - 1,599 (13.2 - 16.3, 186 - 228) 161.8 - 215.8 (1.65 - 2.2, 23.5 - 31.3)
50 - 70 30 (86) 1,285 - 1,599 (13.1 - 16.0, 186 - 228) 167 - 216 (1.7 - 2.2, 24 - 31)
35 (95) 1,520 - 1,863 (15.5 - 19.0, 220 - 279) 235 - 284 (2.4 - 2.9, 34 - 41)
40 (104) 1,765 - 2,158 (18 - 22, 256 - 313) 289.3 - 353.1 (2.95 - 3.6, 41.9 - 51.2)
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 stan-
dard (normal) pressure, however, differs from vehicle to vehicle, refer to "AMBIENT AIR TEMPERATURE-TO-
OPERATING PRESSURE TABLE".
Both High- and Low-Pressure Sides Are Too High.

TROUBLE DIAGNOSIS
Gauge indication Refrigerant cycle Probable cause Corrective action A

Both high- and low-pressure sides • Pressure is reduced soon Excessive refrigerant charge Reduce refrigerant until speci-
are too high. after water is splashed on in refrigeration cycle fied pressure is obtained.
condenser.
B
Air suction by cooling fan is in- Insufficient condenser cooling • Clean condenser.
sufficient. performance • Check and repair cooling
↓ fan as necessary.
1. Condenser fins are C
clogged.
2. Improper fan rotation of
cooling fan
AC359A D
• Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and re-
cold. denser charge system.
• When compressor is (After compressor operation
stopped high-pressure val- stops, high pressure decreas- E
ue quickly drops by approxi- es too slowly.)
mately 196 kPa (2 kg/cm2, ↓
28 psi). It then decreases Air in refrigeration cycle
F
gradually thereafter.
Engine tends to overheat. Engine cooling systems mal- Check and repair each engine
function. cooling system.
G
• An area of the low-pressure • Excessive liquid refrigerant Replace expansion valve.
pipe is colder than areas on low-pressure side
near the evaporator outlet. • Excessive refrigerant dis-
• Plates are sometimes cov- charge flow H
ered with frost. • Expansion valve is open a
little compared with the
specification.
↓ I
1. Improper thermal valve
installation
2. Improper expansion
valve adjustment MTC
High-Pressure Side is Too High and Low-Pressure Side is Too Low.

K
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too high and Upper side of condenser and High-pressure tube or parts lo- • Check and repair or replace
low-pressure side is too low. high-pressure side are hot, cated between compressor malfunctioning parts.
however, liquid tank is not so and condenser are clogged or • Check oil for contamination.
L
hot. crushed.
N
AC360A
High-Pressure Side is Too Low and Low-Pressure Side is Too High.

O

TROUBLE DIAGNOSIS

High-pressure side is too low and High and low-pressure sides Compressor pressure opera- Replace compressor.
low-pressure side is too high. become equal soon after com- tion is improper.
pressor operation stops. ↓
Damaged inside compressor
packings
No temperature difference be- Compressor pressure opera- Replace compressor.
tween high and low-pressure tion is improper.
sides ↓
Damaged inside compressor
packings.
AC356A
Both High- and Low-Pressure Sides are Too Low.

Both high- and low-pressure sides • There is a big temperature Compressor discharge capac- • Replace liquid tank.
are too low. difference between receiver ity does not change. (Com- • Check oil for contamination.
drier outlet and inlet. Outlet pressor stroke is set at
temperature is extremely maximum.)
low.
• Liquid tank inlet and expan-
sion valve are frosted.
• Temperature of expansion High-pressure pipe located • Check and repair malfunc-
valve inlet is extremely low between receiver drier and ex- tioning parts.
as compared with areas pansion valve is clogged. • Check oil for contamination.
AC353A
near liquid tank.
• Expansion valve inlet may
be frosted.
• Temperature difference oc-
curs somewhere in high-
pressure side
• Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
tank are warm or only cool ↓ Refer to MTC-72, "Checking
when touched. Leaking fittings or components System for Leaks Using the
Fluorescent Dye Leak Detec-
tor".
There is a big temperature dif- Expansion valve closes a little • Remove foreign particles by
ference between expansion compared with the specifica- using compressed air.
valve inlet and outlet while the tion. • Check oil for contamination.
valve itself is frosted. ↓
1. Improper expansion
valve adjustment
2. Malfunctioning thermal
valve
3. Outlet and inlet may be
clogged.
An area of the low-pressure Low-pressure pipe is clogged • Check and repair malfunc-
pipe is colder than areas near or crushed. tioning parts.
the evaporator outlet. • Check oil for contamination.
Air flow volume is not enough Evaporator is frozen. • Check thermo control amp.
or is too low. ↓ operation. Refer to MTC-39,
Compressor discharge capac- "Magnet Clutch (KA24DE
ity does not change. (Com- Models)" or MTC-44, "Mag-
pressor stroke is set at net Clutch (YD25DDTi Mod-
maximum length.) els)".
• Replace compressor.
Low-Pressure Side Sometimes Becomes Negative.

TROUBLE DIAGNOSIS
Gauge indication Refrigerant cycle Probable cause Corrective action A

Low-pressure side sometimes be- • Air conditioning system Refrigerant does not dis- • Drain water from refrigerant
comes negative. does not function and does charge cyclically. or replace refrigerant.
not cyclically cool the com- ↓ • Replace liquid tank.
B
partment air. Moisture is frozen at expan-
• The system constantly func- sion valve outlet and inlet.
tions for a certain period of ↓
time after compressor is Water is mixed with refriger- C
stopped and restarted. ant.
AC354A D
Low-Pressure Side Becomes Negative.

E
Low-pressure side becomes nega- Liquid tank or front/rear side of High-pressure side is closed Leave the system at rest until
tive. expansion valve's pipe is frost- and refrigerant does not flow. no frost is present. Start it
ed or dewed. ↓ again to check whether or not F
Expansion valve or liquid tank the problem is caused by wa-
is frosted. ter or foreign particles.
• If water is the cause, initially
cooling is okay. Then the G
water freezes causing a
blockage. Drain water from
refrigerant or replace refrig-
H
AC362A erant.
• If due to foreign particles, re-
move expansion valve and
remove particles with dry I
and compressed air (not
shop air).
• If either of the above meth-
ods cannot correct the prob- MTC
lem, replace expansion
valve.
• Replace liquid tank.
• Check oil for contamination. K
Cooling Fan INFOID:0000000003980621
L
TROUBLE DIAGNOSIS PROCEDURE FOR COOLING FAN (KA24DE models only)
NOTE:
Trouble Diagnosis Procedure For Cooling Fan for Diesel engine (YD25DDTi models) Refer to EC-571, "Diag-
M
nosis Procedure" (type 1) or EC-831, "Diagnosis Procedure" (type 2).
SYMPTOM:
• Cooling fan does not operate. N
1.CHECK COOLING FAN RELAY CONTROL CIRCUIT O

3. Ground triple pressure switch harness connector E23 terminal 2.
P
Does the cooling fan motor operate?
YES >> GO TO 2.
NO >> GO TO 3.
AWIIA1031ZZ

TROUBLE DIAGNOSIS
2.CHECK TRIPLE PRESSURE SWITCH GROUND CIRCUIT
2. Check for continuity between triple pressure switch connector
E23 terminal 3 to ground.

AWIIA1032ZZ
3.CHECK COOLING FAN RELAY POWER SUPPLY CIRCUIT

2. Disconnect cooling fan relay.
4. Check voltage between cooling fan relay connector E66 termi-
nals 2, 5 and ground?

YES >> GO TO 5.
NO >> GO TO 4.
AWIIA1034ZZ
4.CHECK FUSE
• Check 10A fuse (13, located in the fuse block). For fuse layout, refer to PG-3.
• Check 30A fuse (D, located in the fusible link and fuse box). For fuse layout, refer to PG-50.
Are the fuses OK?
NO >> GO TO 9.
5.CHECK COOLING FAN RELAY
2. Check continuity between terminals 3 and 5.
YES >> GO TO 6.
NO >> Replace cooling fan relay.
AWIIA1006ZZ
6.CHECK CONTINUITY BETWEEN TRIPLE PRESSURE SWITCH AND COOLING FAN RELAY

TROUBLE DIAGNOSIS
1. Disconnect cooling fan motor connector.
2. Check continuity between cooling fan relay connector E66 (B) A
terminal 1 and triple pressure switch harness connector E23 (A)
terminal 2.
B
YES >> GO TO 7. C
AWIIA1038ZZ
7.CHECK CONTINUITY BETWEEN COOLING FAN MOTOR AND COOLING FAN RELAY D
1. Disconnect cooling fan motor connector.

2. Check continuity between cooling fan relay connector E66 (B)
E
terminal 3 and cooling fan motor harness connector E67 (A) ter-
minal 1.
Continuity should exist. F

YES >> GO TO 8.
G
AWIIA1035ZZ
8.CHECK COOLING FAN MOTOR H

Check cooling fan motor. Refer to "Component Inspection".
I
YES >> Repair cooling fan motor ground circuit.
NO >> Replace cooling fan motor.
9.REPLACE FUSE MTC
1. Replace fuse.
2. Reconnect cooling fan relay.
3. Turn ignition switch ON. K
4. Ground triple pressure switch harness connector E23 terminal 2.
Does fuse blow when terminal 2 is grounded?
YES >> GO TO 10. L
NO >> Inspection End.
M
AWIIA1031ZZ
10.CHECK COOLING FAN RELAY POWER SUPPLY FOR SHORT N

2. Disconnect cooling fan relay.
3. Check continuity between cooling fan relay connector E66 termi-
nals 5 and ground. O

P
nal 2 and ground.

AWIIA1046ZZ
YES >> GO TO 11.

TROUBLE DIAGNOSIS
11.CHECK COOLING FAN RELAY OUTPUT CIRCUIT FOR SHORT
1. Disconnect cooling fan motor.
nal 3 and ground.

YES >> Replace cooling fan motor.
AWIIA1036ZZ
COMPONENT INSPECTION
Cooling Fan Motor
1. Disconnect cooling fan motor harness connector.
2. Supply cooling fan motor terminals with battery voltage and
ground.
3. Cooling fan motor should operate.
If NG, replace cooling fan motor.
AWIIA1037ZZ
Insufficient Heating INFOID:0000000003492254
TROUBLE DIAGNOSIS PROCEDURE FOR INSUFFICIENT HEATING

Symptom:
• Insufficient heating
INSPECTION FLOW
1.CONFIRM SYMPTOM BY PERFORMING OPERATIONAL CHECK - TEMPERATURE INCREASE
1. Start and warm up engine.
2. Move temperature control lever to maximum heat position.
3. Move fan control lever to maximum speed and check for hot air at discharge air outlets.
YES >> GO TO 3.
NO >> GO TO 2.
NO >> System OK.
>> GO TO 4.
4.CHECK COOLANT SYSTEM
1. Check engine coolant level. Refer to CO-9, "System Inspection" (KA24DE models) or CO-32, "System
Inspection" (YD25DDTi models).

TROUBLE DIAGNOSIS
2. Check hoses for leaks or kinks.
3. Check radiator cap. Refer to CO-9, "System Inspection" (KA24DE models) or CO-32, "System Inspection" A
(YD25DDTi models).
YES >> GO TO 5. B
NO >> Repair/replace as necessary.
5.CHECK AIR MIX DOOR CABLE
C
Check air mix door cable operation. Refer to MTC-34, "Air Mix Door".
YES >> GO TO 6. D
NO >> Adjust or replace air mix door cable. Refer to MTC-34, "Air Mix Door".
6.CHECK AIR DUCTS
Check ducts for air leaks. E
YES >> GO TO 7.
NO >> Repair air leaks. F
7.CHECK HEATER HOSE TEMPERATURES
1. Start engine and warm it up to normal operating temperature. G
2. Touch both the inlet and outlet heater hoses.
Is the inlet hose hot and the outlet hose warm?
YES >> GO TO 8. H
NO >> Both hoses warm: GO TO 9.
8.CHECK ENGINE COOLANT TEMPERATURE SENSOR
Check engine coolant temperature sensor. Refer to EC-112, "Component Inspection" (KA24DE models) or I
EC-547, "Component Inspection"(YD25DDTi models).
YES >> System OK. MTC
NO >> Repair or replace as necessary. Retest.
9.CHECK HEATER HOSES K
Check heater hoses for proper installation.
YES >> GO TO 10. L
NO >> Repair /replace as necessary. Retest, GO TO 7.
10.BACK FLUSH HEATER CORE
M
1. Back flush heater core.
2. Drain the water from the system.
3. Refill system with new engine coolant. Refer to CO-10, "Changing Engine Coolant" (KA24DE models) or
CO-33, "Changing Engine Coolant" (YD25DDTi models). N
4. Start engine and warm it up to normal operating temperature.
5. Touch both the inlet and outlet heater hoses.
Is the inlet hose hot and the outlet hose warm? O
YES >> System OK.
NO >> Replace heater core and refill engine coolant. Refer to MTC-63, "Removal and Installation".
Noise INFOID:0000000003492255
P
TROUBLE DIAGNOSIS PROCEDURE FOR NOISE

Symptom:
• Noise

TROUBLE DIAGNOSIS
Inspection Flow
AWIIA1030GB
*1 MTC-32, "Operational Check" *2 EM-15, "Checking Drive Belts" *3 MTC-50, "Insufficient Cooling"
(KA24DE models) or EM-88, "Check-
ing Drive Belts" (YD25DDi models)
*4 MTC-71, "Removal and Installation *5 MTC-69, "Removal and Installation *6 MTC-69, "Removal and Installation
for Evaporator" for Compressor Clutch" for Compressor Clutch"
*7 MTC-68, "Removal and Installation *8 MTC-19, "Maintenance of Oil Quanti-
for Compressor" ty in Compressor"

HEATER CORE
HEATER CORE
A
Removal and Installation INFOID:0000000003492258
I
ALJIA0297ZZ
1. Heater unit 2. Heater core pipe bracket 3. Heater core MTC

4. Heater core bracket Front
REMOVAL K
1. Drain the cooling system. Refer to CO-10, "Changing Engine Coolant" (KA24DE) or CO-33, "Changing
Engine Coolant" (YD25DDTi).
2. Disconnect the two heater hoses from the engine compartment side. L
3. If equipped with A/C, remove the cooling unit. Refer to MTC-71, "Removal and Installation for Evapora-
tor".
4. If not equipped with A/C, remove the connector duct. M
5. Remove the heater unit.
6. Remove the heater core pipe bracket and the heater core bracket.
7. Remove the heater core from the heater unit. N
INSTALLATION
Installation is in the reverse order of removal.
• Inspect the engine cooling system for coolant leaks. Refer to CO-10, "Changing Engine Coolant" (KA24DE) O
or CO-33, "Changing Engine Coolant" (YD25DDTi).

REFRIGERANT LINES
REFRIGERANT LINES
HFC-134a (R-134a) Service Procedure INFOID:0000000003492259
SETTING OF SERVICE TOOLS AND EQUIPMENT

WARNING:
Avoid breathing A/C refrigerant and oil vapor or mist. Exposure may irritate eyes, nose and throat.
Remove HFC-134a (R-134a) refrigerant from the A/C system using certified service equipment meeting
requirements of SAE J2210 HFC-134a (R-134a) recycling equipment or SAE J2201 HFC-134a (R-134a)
recovery equipment. If an accidental system discharge occurs, ventilate the work area before resum-
ing service. Additional health and safety information may be obtained from the refrigerant and oil man-
ufacturers.
Discharging Refrigerant
WJIA0668E
1. Shut-off valve 2. A/C service valve 3. Recovery/Recycling equipment
Evacuating System and Charging Refrigerant
WJIA0669E
1. Shut-off valve 2. A/C service valve 3. Recovery/Recycling equipment

4. Refrigerant container (HFC-134a) 5. Weight scale 6. Manifold gauge set
7. Evacuating vacuum pump

REFRIGERANT LINES
MTC
N
WJIA1923E
*1 MTC-19, "Maintenance of Oil Quanti- *2 MTC-71, "Checking for Refrigerant *3 MTC-71, "Checking for Refrigerant O
ty in Compressor" Leaks" Leaks"
*4 MTC-50, "Insufficient Cooling" *5 MTC-2, "Contaminated Refrigerant"

REFRIGERANT LINES
Component INFOID:0000000003492260
KA24DE A/C System
ALJIA0295GB

REFRIGERANT LINES
E. Refrigerant leak checking order (a - m) F. Tightening torque (A - D) G. Wrench size A
YD25DDTi A/C System B
MTC
ALJIA0296GB

REFRIGERANT LINES
H. O-ring size
Removal and Installation for Compressor INFOID:0000000003492261
KA24DE
ALJIA0298GB
1. A/C compressor 2. A/C compressor and idler pulley bracket A. E-ring snap type
B. Adjusting bolt

REFRIGERANT LINES
YD25DDTi
A
MTC
ALJIA0299GB
K
1. A/C compressor and idler pulley bracket 2. A/C compressor A. Adjusting bolt
B. E-ring snap type L
Removal and Installation for Compressor Clutch INFOID:0000000003492262
M
NOTE:
The KA24DE A/C compressor is shown, the YD25DDTi A/C compressor similar.
REMOVAL N
1. Remove the compressor clutch assembly bolt, while holding the
compressor clutch assembly using Tool as shown.
O
Tool number : KV99231260 (J-38874)
AHA841

REFRIGERANT LINES
2. Remove the compressor clutch assembly using a suitable tool
(pulley puller).
• Position the center of the suitable tool (pulley puller) on the
end of the compressor shaft to remove the compressor clutch
assembly with the puller.
CAUTION:
To prevent the deformation of the compressor clutch pulley
groove, the puller claws should be hooked under (not into)
the compressor clutch pulley groove.
RHA139E
INSPECTION AFTER REMOVAL

If there are signs of damage due to excessive heat, replace the compressor clutch assembly.
Check the appearance of the compressor clutch pulley. If the contact surface of pulley shows signs of exces-
sive grooving, replace the compressor clutch assembly.
The contact surfaces of the compressor clutch pulley should be cleaned with a suitable solvent before installa-
tion.
INSTALLATION
1. Using Tool to prevent compressor clutch assembly rotation,
tighten the compressor clutch assembly bolt to specification.
Tool number : KV99231260 (J-38874)
Compressor clutch : 15 - 18 N·m (1.5 - 1.8 kg-m,

assembly bolt 11- 13 ft-lb)
AHA847
2. After tightening the compressor clutch assembly bolt, check that the compressor clutch pulley rotates
smoothly.
BREAK-IN OPERATION
When replacing the compressor clutch assembly, always conduct the break-in operation. This is done by
engaging and disengaging the clutch about 30 times. The break-in operation raises the level of transmitted
torque.

REFRIGERANT LINES
Removal and Installation for Evaporator INFOID:0000000003492264
ALJIA0300ZZ
I
1. Cooling unit case seal 2. Cooling unit case, upper 3. Evaporator
4. Cooling unit case, lower 5. Drain hose 6. Expansion valve
7. Thermo control amp A. Cooling unit case clip Front MTC
REMOVAL
1. Discharge the A/C system. Refer to MTC-64, "HFC-134a (R-134a) Service Procedure". K
2. Disconnect the two evaporator core refrigerant lines from the engine compartment side.
CAUTION:
Cap the refrigerant lines to prevent moisture from entering the system. L
3. Remove the instrument panel. Refer to IP-10, "Removal and Installation".
4. Remove the blower motor case.
5. Disconnect the thermo control amp connector. M
6. Remove the cooling unit.
7. Separate the upper and lower cooling unit cases, and remove the evaporator.
N
INSTALLATION
Installation is in the reverse order of removal.
• Recharge the A/C system. Refer to MTC-64, "HFC-134a (R-134a) Service Procedure".
O
• Inspect the A/C system for refrigerant leaks. Refer to MTC-71, "Checking for Refrigerant Leaks".
Checking for Refrigerant Leaks INFOID:0000000003940840
P
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C oil leak-
age, damage, and corrosion. Any A/C oil leakage may indicate an area of refrigerant leakage. Allow extra
inspection time in these areas when using either an electronic refrigerant leak detector (J-41995) or fluores-
cent dye leak detector (J-42220).
If any dye is observed using a fluorescent dye leak detector (J-42220), confirm the leak using a electronic
refrigerant leak detector (J-41995). It is possible that the dye is from a prior leak that was repaired and not
properly cleaned.

REFRIGERANT LINES
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic refrigerant leak detector (J-41995), move the probe
along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the
component.
CAUTION:
Moving the electronic refrigerant leak detector probe slower and closer to the suspected leak area will
improve the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Dye Leak Detector INFOID:0000000003940841
1. Check the A/C system for leaks using the fluorescent dye leak detector and safety goggles (J-42220) in a
low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye
will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evapo-
rator drain opening indicates an evaporator core assembly leak (tubes, core or expansion valve).
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, then inspect the shop rag or cloth with the fluorescent dye leak detector (J-42220) for dye residue.
3. After the leak is repaired, remove any residual dye using refrigerant dye cleaner (J-43872) to prevent
future misdiagnosis.
4. Perform a system performance check and then verify the leak repair using a electronic refrigerant leak
detector (J-41995).
NOTE:
• Other gases in the work area or substances on the A/C components, for example, anti-freeze, wind-
shield washer fluid, solvents and oils, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
• Clean with a dry cloth or blow off with shop air.
• Do not allow the sensor tip of the electronic refrigerant leak detector (J-41995) to contact with any sub-
stance. This can also cause false readings and may damage the detector.
Dye Injection INFOID:0000000003940842
NOTE:
This procedure is only necessary when recharging the system or when the compressor has seized and must
be replaced.
1. Check the A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm2, 50 psi).
2. Pour one bottle 7.4 cc (1/4 ounce) of the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) into
the HFC-134a (R-134a) refrigerant dye injector (J-41459).
CAUTION:
If repairing the A/C system or replacing a component, pour the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) directly into the open system connection and proceed with the service
procedures.
3. Connect the refrigerant dye injector (J-41459) to the low-pressure service valve.
4. Start the engine and switch the A/C system ON.
5. When the A/C system is operating (compressor running), inject one bottle 7.4 cc (1/4 ounce) of HFC-134a
(R-134a) fluorescent leak detection dye (J-41447) through the low-pressure service valve using HFC-
134a (R-134a) refrigerant dye injector (J-41459). Refer to the manufacturer's operating instructions.
6. With the engine still running, disconnect the HFC-134a (R-134a) refrigerant dye injector (J-41459) from
the low-pressure service valve.
7. Operate the A/C system for a minimum of 20 minutes to mix the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) with the A/C system oil. Depending on the leak size, operating conditions and
location of the leak, it may take from minutes to days for the HFC-134a (R-134a) fluorescent leak detec-
tion dye to penetrate an A/C system leak and become visible.
Electronic Refrigerant Leak Detector INFOID:0000000003940843
PRECAUTIONS FOR HANDLING LEAK DETECTOR

NOTE:

REFRIGERANT LINES
When performing a refrigerant leak check, use a electronic refrigerant leak detector (J-41995) or equivalent.
Ensure that the electronic refrigerant leak detector (J-41995) is calibrated and set properly according to the A
manufacturer's operating instructions.
The electronic refrigerant leak detector (J-41995) is a delicate
device. To use the electronic refrigerant leak detector (J-41995)
B
properly, read the manufacturer's operating instructions and perform
any specified maintenance.
AHA281A
E
1. Position the probe approximately 5 mm (3/16 in) away from the
point to be checked as shown.
F
H
SHA707EA
2. When checking for leaks, circle each fitting completely with the I
probe as shown.
MTC
SHA706E L
3. Move the probe along each component at a speed of approxi-

mately 25 - 50 mm (1 - 2 in)/second as shown. M
SHA708EA
P
CHECKING PROCEDURE
NOTE:
To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette
smoke in the vicinity of the vehicle. Perform the leak test in a calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn the engine OFF.

REFRIGERANT LINES
2. Connect the manifold gauge set (J-39183-C) to the A/C service ports. Refer to MTC-64, "HFC-134a (R-
134a) Service Procedure".
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm2, 50 psi) above a temperature of
16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified
amount of refrigerant. Refer to MTC-76, "General Specification".
NOTE:
At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa
(3.52 kg/cm2, 50 psi) pressure.
4. Perform the leak test from the high-pressure side (A/C compressor discharge “a” to evaporator inlet “f”) to
the low-pressure side (A/C evaporator drain hose “g” to shaft seal “k”). Refer to MTC-66, "Component".
Clean the component to be checked and carefully move the electronic refrigerant leak detector probe
completely around the following connections and components.
• Check the compressor shaft seal
• Check the high and low-pressure pipe and hose fittings, relief valve, and compressor shaft seal
• Check the liquid tank
• Check the refrigerant pressure sensor
• Check all around the service valves. Check that the service valve caps are screwed tightly on the ser-
vice valves (to prevent leaks).
NOTE:
After removing manifold gauge set (J-39183-C) from the service valves, wipe any residue from the ser-
vice valves to prevent any false readings by the electronic refrigerant leak detector (J-41995).
• Evaporator
With engine OFF, turn blower fan on HIGH for at least 15 seconds to dissipate any refrigerant trace in
the heater and cooling unit assembly. Wait a minimum of 10 minutes accumulation time (refer to the
manufacturer's recommended procedure for actual wait time) before inserting the electronic refrigerant
leak detector probe into the heater and cooling unit assembly drain hose.
NOTE:
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak is detected, verify at least once by blowing compressed air into the area of the suspected leak,
then repeat the leak check.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components and
connections.
7. If no leaks are found, perform steps 8 - 11.
9. Set the heater A/C controls as follows:
a. A/C switch to ON
b. Air flow to VENT mode
c. Intake position to RECIRCULATION mode
d. Temperature to MAX cold
e. Blower fan speed to HIGH
10. Run the engine at 1,500 rpm for at least 2 minutes.

11. Turn the engine OFF and perform the leak check again following
steps 4 through 6 above.
Refrigerant leaks should be checked immediately after turning
the engine OFF. Begin with the leak detector at the compressor.
The pressure on the high pressure side will gradually drop after
the refrigerant circulation stops and pressure on the low pres-
sure side will gradually rise, as shown in the graph. Some leaks
are more easily detected when the pressure is high.
SHA839E

REFRIGERANT LINES
12. Before connecting the recovery/recycling equipment to the vehicle, check the recovery/recycling equip-
ment gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover the refriger- A
ant from the equipment lines and then check the refrigerant purity.
13. Confirm refrigerant purity in supply tank using recovery/recycling equipment and refrigerant identifier
equipment. B
14. Confirm the refrigerant purity in the vehicle's A/C system using recovery/recycling equipment and refriger-
ant identifier equipment.
15. Discharge the A/C system using recovery/recycling equipment. Repair the leaking fitting or component as C
necessary.
16. Evacuate and recharge the A/C system and perform the leak test to confirm that there are no refrigerant
leaks. D
17. Conduct the Operational Check to ensure system works properly. Refer to MTC-32, "Operational Check".
MTC

SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000003492268
COMPRESSOR
Model DKS-17CH
Type Swash plate
Displacement
168 (10.25)
cm3 (in3) / revolution
Direction of rotation Clockwise (viewed from drive end)
Drive belt Type A
OIL
Name Genuine NISSAN A/C System Oil type S or equivalent

Capacity (total in system)
200 (6.8, 7.0)
m (US fl oz, Imp fl oz)
REFRIGERANT
Type HFC 134a (R-134a)

kg (lb) 0.65 (1.43)
Refrigerant capacity
g (oz) 650 (22.93)

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AIR CONDITIONER

TROUBLE DIAGNOSIS .....................................23 SERVICE DATA AND SPECIFICATIONS

Revision: March 2008 MTC-1 2009 D22 LCV

Revision: March 2008 MTC-2 2009 D22 LCV

O-RING AND REFRIGERANT CONNECTION

Revision: March 2008 MTC-4 2009 D22 LCV

Revision: March 2008 MTC-5 2009 D22 LCV

YD25DDTi A/C System

Revision: March 2008 MTC-6 2009 D22 LCV

O-Ring Part Numbers and Specifications

Revision: March 2008 MTC-7 2009 D22 LCV

Precaution for Service of Compressor INFOID:0000000003937485

Revision: March 2008 MTC-8 2009 D22 LCV

MANIFOLD GAUGE SET

Revision: March 2008 MTC-9 2009 D22 LCV

Shut-off valve rotation A/C service valve

REFRIGERANT WEIGHT SCALE

Revision: March 2008 MTC-10 2009 D22 LCV

HFC-134a (R-134a) Service Tool and Equipment INFOID:0000000003939703

Tool number Description

KV991J0130 Refrigerant Recovery and Recycling

Revision: March 2008 MTC-11 2009 D22 LCV

— Application: For HFC-134a (R-134a)

— For injecting 1/4 ounce of fluorescent

— For cleaning dye spills.

Revision: March 2008 MTC-12 2009 D22 LCV

Service couplers Hose fitting to service hose:

— For measuring of refrigerant MTC

Commercial Service Tool INFOID:0000000003939704

Revision: March 2008 MTC-13 2009 D22 LCV

Power tool Loosening bolts and nuts

Revision: March 2008 MTC-14 2009 D22 LCV

1. Electric compressor 2. Pressure relief valve 3. Liquid tank MTC

Revision: March 2008 MTC-15 2009 D22 LCV

KA24DE A/C System

Revision: March 2008 MTC-16 2009 D22 LCV

YD25DDTi A/C System B

Revision: March 2008 MTC-17 2009 D22 LCV

Revision: March 2008 MTC-18 2009 D22 LCV

Oil to be added to system

Oil Adjustment Procedure for Compressor Replacement M

Revision: March 2008 MTC-19 2009 D22 LCV

1. New compressor 2. Old compressor 3. Recovery/recycling equipment

1. Before connecting recovery/recycling equipment to vehicle, check recovery/recycling equipment gauges.

Revision: March 2008 MTC-20 2009 D22 LCV

Discharge Air Flow INFOID:0000000003492243 O

Revision: March 2008 MTC-21 2009 D22 LCV

Mode door position Air outlet/distribution

Revision: March 2008 MTC-22 2009 D22 LCV

Symptom Reference page G

Component Part Location INFOID:0000000003492245 N

Revision: March 2008 MTC-23 2009 D22 LCV

1. Cooling fan fuse 2. Air conditioner relay 3. Cooling fan relay

Revision: March 2008 MTC-24 2009 D22 LCV

1. Cooling fan fuse 2. Air conditioner relay 3. Cooling fan relay O

Revision: March 2008 MTC-25 2009 D22 LCV

1. Thermo control amp. 2. Blower motor fuses 3. Blower motor

Revision: March 2008 MTC-26 2009 D22 LCV

Revision: March 2008 MTC-27 2009 D22 LCV

Revision: March 2008 MTC-28 2009 D22 LCV

Revision: March 2008 MTC-29 2009 D22 LCV

Revision: March 2008 MTC-30 2009 D22 LCV

Revision: March 2008 MTC-31 2009 D22 LCV