AUTOMATIC AIR CONDITIONER

J AIR CONDITIONER

SECTION
AUTOMATIC AIR CONDITIONER
ATC B

E
CONTENTS
PRECAUTIONS .......................................................... 4 V-6 Variable Displacement Compressor ................. 20 F
Precautions for Supplemental Restraint System GENERAL INFORMATION ................................. 20
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN- DESCRIPTION .................................................... 21
SIONER” .................................................................. 4 Component Layout ................................................. 23 G
Precautions for Battery Service ................................ 4 LUBRICANT .............................................................. 24
Precautions for Working with HFC-134a (R-134a)..... 4 Maintenance of Lubricant Quantity in Compressor... 24
General Refrigerant Precautions .............................. 5 LUBRICANT ........................................................ 24
H
Lubricant Precautions .............................................. 5 LUBRICANT RETURN OPERATION .................. 24
Precautions for Refrigerant Connection ................... 5 LUBRICANT ADJUSTING PROCEDURE FOR
ABOUT ONE-TOUCH JOINT ................................ 6 COMPONENTS REPLACEMENT EXCEPT
FEATURES OF NEW TYPE REFRIGERANT COMPRESSOR .................................................. 25 I
CONNECTION ...................................................... 8 LUBRICANT ADJUSTING PROCEDURE FOR
O-RING AND REFRIGERANT CONNECTION..... 9 COMPRESSOR REPLACEMENT ....................... 25
Precautions for Servicing Compressor ................... 10 AIR CONDITIONER CONTROL ............................... 27 ATC
Precautions for Service Equipment .........................11 Description of Air Conditioner LAN Control System... 27
RECOVERY/RECYCLING EQUIPMENT .............11 System Construction .............................................. 27
ELECTRONIC LEAK DETECTOR .......................11 OPERATION ........................................................ 28
K
VACUUM PUMP ..................................................11 TRANSMISSION DATA AND TRANSMISSION
MANIFOLD GAUGE SET .....................................11 ORDER ............................................................... 28
SERVICE HOSES ............................................... 12 AIR MIX DOOR CONTROL (AUTOMATIC TEM-
SERVICE COUPLERS ........................................ 12 PERATURE CONTROL) ..................................... 29 L
REFRIGERANT WEIGHT SCALE ...................... 12 FAN SPEED CONTROL ...................................... 29
CALIBRATING ACR4 WEIGHT SCALE .............. 12 INTAKE DOOR CONTROL ................................. 29
CHARGING CYLINDER ...................................... 13 OUTLET DOOR CONTROL ................................ 29 M
Precautions for Leak Detection Dye ....................... 13 MAGNET CLUTCH CONTROL ........................... 30
IDENTIFICATION ................................................ 13 SELF-DIAGNOSTIC SYSTEM ............................ 30
IDENTIFICATION LABEL FOR VEHICLE ........... 13 Description of Control System ................................ 31
Wiring Diagrams and Trouble Diagnosis ................ 13 Control Operation ................................................... 32
PREPARATION ......................................................... 15 TEMPERATURE CONTROL DIAL (POTENTIO
Special Service Tools ............................................. 15 TEMPERATURE CONTROL) .............................. 32
HFC-134a (R-134a) Service Tools and Equipment... 16 INTAKE SWITCH ................................................. 32
REFRIGERATION SYSTEM ..................................... 19 REAR WINDOW DEFOGGER SWITCH ............. 32
Refrigerant Cycle ................................................... 19 A/C SWITCH ....................................................... 32
REFRIGERANT FLOW ....................................... 19 MODE CONTROL DIAL ...................................... 32
FREEZE PROTECTION ..................................... 19 FAN CONTROL DIAL .......................................... 32
Refrigerant System Protection ............................... 19 Discharge Air Flow ................................................. 33
REFRIGERANT PRESSURE SENSOR ............. 19 System Description ................................................. 34
PRESSURE RELIEF VALVE ............................... 19 SWITCHES AND THEIR CONTROL FUNCTION... 34

ATC-1
 CAN Communication System Description .............. 35 DOOR ..................................................................82
CAN Communication Unit ....................................... 35 Air Mix Door Motor PBR Circuit ..............................82
TYPE 1 ................................................................ 35 DIAGNOSTIC PROCEDURE FOR AIR MIX
TYPE 2 ................................................................ 37 DOOR PBR ..........................................................82
TYPE 3 ................................................................ 38 Intake Door Motor Circuit ........................................83
TYPE 4 ................................................................ 40 INSPECTION FLOW ............................................83
TROUBLE DIAGNOSIS ............................................ 42 SYSTEM DESCRIPTION .....................................84
CONSULT-II ............................................................ 42 COMPONENT DESCRIPTION ............................85
CONSULT-II INSPECTION PROCEDURE .......... 42 DIAGNOSTIC PROCEDURE FOR INTAKE
DATA MONITOR .................................................. 43 DOOR MOTOR ....................................................85
How to Perform Trouble Diagnoses for Quick and Blower Motor Circuit ................................................86
Accurate Repair ...................................................... 44 INSPECTION FLOW ............................................86
WORK FLOW ...................................................... 44 SYSTEM DESCRIPTION .....................................87
SYMPTOM TABLE .............................................. 44 COMPONENT DESCRIPTION ............................88
Component Parts and Harness Connector Location... 45 DIAGNOSTIC PROCEDURE FOR BLOWER
ENGINE COMPARTMENT .................................. 45 MOTOR ................................................................88
PASSENGER COMPARTMENT .......................... 46 COMPONENT INSPECTION ...............................90
Schematic ............................................................... 48 Magnet Clutch Circuit ..............................................91
Wiring Diagram –A/C–, LHD Models ...................... 49 INSPECTION FLOW ............................................91
Wiring Diagram–A/C–, RHD Models ....................... 54 SYSTEM DESCRIPTION .....................................92
Auto Amp. Terminals and Reference Value ............ 59 DIAGNOSTIC PROCEDURE FOR MAGNET
PIN CONNECTOR TERMINAL LAYOUT ............ 59 CLUTCH ..............................................................92
TERMINALS AND REFERENCE VALUE FOR COMPONENT INSPECTION ...............................96
UNIFIED METER AND A/C AMP. ........................ 59 Insufficient Cooling ..................................................98
Self-diagnosis Function .......................................... 61 INSPECTION FLOW ............................................98
DESCRIPTION .................................................... 61 PERFORMANCE TEST DIAGNOSES ................99
FUNCTION CONFIRMATION PROCEDURE ...... 63 PERFORMANCE CHART .................................. 101
AUXILIARY MECHANISM: TEMPERATURE TROUBLE DIAGNOSIS FOR UNUSUAL PRES-
SETTING TRIMMER ........................................... 67 SURE ................................................................. 103
AUXILIARY MECHANISM: FOOT POSITION Insufficient Heating ............................................... 106
SETTING TRIMMER ........................................... 68 INSPECTION FLOW .......................................... 106
AUXILIARY MECHANISM: INLET PORT MEM- Noise ..................................................................... 107
ORY FUNCTION ................................................. 68 INSPECTION FLOW .......................................... 107
Operational Check .................................................. 69 Self-diagnosis ....................................................... 108
CHECKING BLOWER ......................................... 69 INSPECTION FLOW .......................................... 108
CHECKING DISCHARGE AIR ............................ 69 Ambient Sensor Circuit ......................................... 109
CHECKING INTAKE DOOR ................................ 69 COMPONENT DESCRIPTION .......................... 109
CHECKING TEMPERATURE DECREASE ......... 70 AMBIENT TEMPERATURE INPUT PROCESS .109
CHECKING TEMPERATURE INCREASE .......... 70 DIAGNOSTIC PROCEDURE FOR AMBIENT
CHECKING A/C SWITCH ................................... 70 SENSOR ............................................................ 109
Power Supply and Ground Circuit for Auto Amp. ... 71 COMPONENT INSPECTION ............................. 111
INSPECTION FLOW ........................................... 71 In-vehicle Sensor Circuit ....................................... 111
COMPONENT DESCRIPTION ............................ 71 COMPONENT DESCRIPTION .......................... 111
DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 72 DIAGNOSTIC PROCEDURE FOR IN-VEHICLE
LAN System Circuit ................................................ 73 SENSOR ............................................................ 112
DIAGNOSTIC PROCEDURE FOR LAN CIR- COMPONENT INSPECTION ............................. 114
CUIT .................................................................... 73 Sunload Sensor Circuit ......................................... 114
Mode Door Motor Circuit ........................................ 77 COMPONENT DESCRIPTION .......................... 114
INSPECTION FLOW ........................................... 77 SUNLOAD INPUT PROCESS ........................... 114
SYSTEM DESCRIPTION .................................... 78 DIAGNOSTIC PROCEDURE FOR SUNLOAD
COMPONENT DESCRIPTION ............................ 79 SENSOR ............................................................ 115
DIAGNOSTIC PROCEDURE FOR MODE COMPONENT INSPECTION ............................. 116
DOOR MOTOR ................................................... 79 Intake Sensor Circuit ............................................. 117
Air Mix Door Motor Circuit ...................................... 80 COMPONENT DESCRIPTION .......................... 117
INSPECTION FLOW ........................................... 80 DIAGNOSTIC PROCEDURE FOR INTAKE SEN-
SYSTEM DESCRIPTION .................................... 81 SOR ................................................................... 117
COMPONENT DESCRIPTION ............................ 82 COMPONENT INSPECTION ............................. 119
DIAGNOSTIC PROCEDURE FOR AIR MIX

ATC-2
A/C CONTROLLER ................................................ 120 REFRIGERANT LINES ........................................... 142
Removal and Installation ...................................... 120 HFC-134a (R-134a) Service Procedure ............... 142 A
REMOVAL ......................................................... 120 SETTING OF SERVICE TOOLS AND EQUIP-
INSTALLATION ................................................. 120 MENT ................................................................ 142
AUTO AMP ............................................................. 121 Components ......................................................... 144 B
Removal and Installation of Unified Meter and A/C LHD MODELS ................................................... 144
Amp. ..................................................................... 121 RHD MODELS .................................................. 145
REMOVAL ......................................................... 121 Removal and Installation of Compressor .............. 145
INSTALLATION ................................................. 121 REMOVAL ......................................................... 145 C
AMBIENT SENSOR ................................................ 122 INSTALLATION ................................................. 146
Removal and Installation ...................................... 122 Removal and Installation of Compressor Clutch . 146
REMOVAL ......................................................... 122 REMOVAL ......................................................... 146 D
INSTALLATION ................................................. 122 INSTALLATION ................................................. 148
IN-VEHICLE SENSOR ............................................ 123 Removal and Installation of Low-pressure Flexible
Removal and Installation ...................................... 123 Hose ..................................................................... 150 E
REMOVAL ......................................................... 123 REMOVAL ......................................................... 150
INSTALLATION ................................................. 123 INSTALLATION ................................................. 151
SUNLOAD SENSOR .............................................. 124 Removal and Installation of High-pressure Flexible
Removal and Installation ...................................... 124 Hose ..................................................................... 151 F
REMOVAL ......................................................... 124 REMOVAL ......................................................... 151
INSTALLATION ................................................. 124 INSTALLATION ................................................. 152
INTAKE SENSOR ................................................... 125 Removal and Installation of High-pressure Pipe 1 G
Removal and Installation ...................................... 125 (Engine Compartment) ......................................... 152
REMOVAL ......................................................... 125 REMOVAL ......................................................... 152
INSTALLATION ................................................. 125 INSTALLATION ................................................. 153 H
BLOWER UNIT ....................................................... 126 Removal and Installation of Low-pressure Pipe and
Removal and Installation ...................................... 126 High-pressure Pipe 2 ............................................ 153
REMOVAL ......................................................... 126 REMOVAL ......................................................... 153
I
INSTALLATION ................................................. 126 INSTALLATION ................................................. 154
Disassembly and Assembly ................................. 127 Removal and Installation of Liquid Tank ............... 155
BLOWER MOTOR .................................................. 128 REMOVAL ......................................................... 155
Removal and Installation ...................................... 128 INSTALLATION ................................................. 155 ATC
REMOVAL ......................................................... 128 Removal and Installation of Condenser ................ 156
INSTALLATION ................................................. 128 REMOVAL ......................................................... 156
INTAKE DOOR MOTOR ......................................... 129 INSTALLATION ................................................. 157 K
Removal and Installation ...................................... 129 Removal and Installation of Refrigerant Pressure
REMOVAL ......................................................... 129 Sensor .................................................................. 157
INSTALLATION ................................................. 129 REMOVAL ......................................................... 157 L
HEATER & COOLING UNIT ASSEMBLY .............. 130 INSTALLATION ................................................. 157
Removal and Installation ...................................... 130 Removal and Installation of Evaporator ................ 158
REMOVAL ......................................................... 130 REMOVAL ......................................................... 158
INSTALLATION ................................................. 131 INSTALLATION ................................................. 158 M
Disassembly and Assembly ................................. 133 Removal and Installation of Expansion Valve ....... 159
MODE DOOR MOTOR ........................................... 135 REMOVAL ......................................................... 159
Removal and Installation ...................................... 135 INSTALLATION ................................................. 159
REMOVAL ......................................................... 135 Checking for Refrigerant Leaks ............................ 160
INSTALLATION ................................................. 135 Checking System for Leaks Using the Fluorescent
AIR MIX DOOR MOTOR ......................................... 136 Leak Detector ....................................................... 160
Removal and Installation ...................................... 136 Dye Injection ......................................................... 160
REMOVAL ......................................................... 136 Electronic Refrigerant Leak Detector .................... 161
INSTALLATION ................................................. 136 PRECAUTIONS FOR HANDLING LEAK
HEATER CORE ...................................................... 137 DETECTOR ....................................................... 161
Removal and Installation ...................................... 137 CHECKING PROCEDURE ............................... 162
REMOVAL ......................................................... 137 SERVICE DATA AND SPECIFICATIONS (SDS) .... 164
INSTALLATION ................................................. 137 Compressor .......................................................... 164
DUCTS AND GRILLES .......................................... 138 Lubricant ............................................................... 164
Removal and Installation ...................................... 138 Refrigerant ............................................................ 164
REMOVAL ......................................................... 138 Engine Idling Speed ............................................. 164
INSTALLATION ................................................. 141 Belt Tension .......................................................... 164

ATC-3
 PRECAUTIONS

PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” AJS001C1

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SRS and SB section of
this Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be per-
formed by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air
Bag Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or
harness connectors.
Precautions for Battery Service AJS001FE

Before disconnecting the battery, lower both the driver and passenger windows. This will prevent any interfer-
ence between the window edge and the vehicle when the door is opened/closed. During normal operation, the
window slightly raises and lowers automatically to prevent any window to vehicle interference. The automatic
window function will not work with the battery disconnected.
Precautions for Working with HFC-134a (R-134a) AJS00191

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

ATC-4
 PRECAUTIONS

General Refrigerant Precautions AJS00192

A
WARNING:
● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the
refrigerant every time an air conditioning system is discharged.
● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or B
air conditioning system.
● Do not store or heat refrigerant containers above 52°C.
C
● Do not heat a refrigerant container with an open flame; if container warming is required, place the
bottom of the container in a warm pail of water.
● Do not intentionally drop, puncture, or incinerate refrigerant containers.
D
● Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns.
● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent
suffocation.
E
● Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and 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 refriger- F
ant manufacturers.
Lubricant Precautions AJS00193
G
● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components.
If lubricant other than that specified is used, compressor malfunction is likely to occur.
● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following H
handling precautions must be observed:
– When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize
the entry of moisture from the atmosphere.
I
– When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before con-
necting the components. Connect all refrigerant loop components as quickly as possible to minimize the
entry of moisture into system.
ATC
– Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. With-
out proper sealing, lubricant will become moisture saturated and should not be used.
● Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If acciden- K
tal system discharge occurs, ventilate work area before resuming service. Additional health and safety
information may be obtained from refrigerant and lubricant manufacturers.
● Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage L
may result.
Precautions for Refrigerant Connection AJS00194
M
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
● Expansion valve to evaporator
● Refrigerant pressure sensor to liquid tank

ATC-5
 PRECAUTIONS

ABOUT ONE-TOUCH JOINT

Description
● One-touch joints are pipe joints which do not require tools during piping connection.
● Unlike conventional connection methods using union nuts and flanges, controlling tightening torque at
connection point is not necessary.
● When removing a pipe joint, use a disconnector.
COMPONENT PARTS

RJIA0970E

FUNCTIONS OF COMPONENT PARTS

● Retains O-rings.
Pipe (Male side)
● Retains garter spring in cage.
Garter spring Anchors female side piping.
When connection is made properly, this is ejected from male-side piping. (This part is no longer neces-
Indicator ring
sary after connection.)
O-ring Seals connection point. (Not reusable)
● Seals connection by compressing O-rings.
Pipe (Female side)
● Anchors piping connection using flare and garter spring.

NOTE:
● Garter spring cannot be removed from cage of male-side piping.
● Indicator ring remains near piping connection point, however, this is not a malfunction. (This is to check
piping connection during factory assembly.)

ATC-6
 PRECAUTIONS

REMOVAL
A

SJIA0106E

1. Clean piping connection point, and set a disconnector. G

2. Slide disconnector in axial direction of piping, and stretch garter spring with tapered point of disconnector.
3. Slide disconnector farther so that inside diameter of garter spring becomes larger than outside diameter of
female-side piping flare. Then male-side piping can be disconnected. H
INSTALLATION

ATC

SJIA0107E

1. Clean piping connection points, and insert male-side piping into female-side piping.
2. Push inserted male-side piping harder so that female-side piping flare stretches garter spring.
3. If inside diameter of garter spring becomes larger than outside diameter of female-side piping flare, garter
spring seats on flare. Then, it fits in between male-side piping cage and female-side piping flare to anchor
piping connection point.
NOTICE:
When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare,
it clicks.
CAUTION:
● Female-side piping connection point is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert it in axial direction.
● Insert piping securely until a click is heard.

ATC-7
 PRECAUTIONS

● After piping connection is completed, pull male-side piping by hand to make sure connection
does not come loose.
NOTE:
One-touch joint connection is used in points below.
● Low-pressure flexible hose to evaporator (O-ring size: 16)

● High-pressure flexible hose to condenser (O-ring size: 12)

● High-pressure pipe 1 to evaporator (O-ring size: 8)

● High-pressure pipe 1 to condenser (O-ring size: 8)

FEATURES OF NEW TYPE REFRIGERANT CONNECTION

● The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-
nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of
the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing
characteristics.
● The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil-
itating piping connections.

SHA815E

ATC-8
 PRECAUTIONS

O-RING AND REFRIGERANT CONNECTION

A

ATC
RJIA1345E

CAUTION:
The new and former refrigerant connections use different O-ring configurations. Do not confuse O-
K
rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or
around, the connection.
O-Ring Part Numbers and Specifications L
Connection type Piping connection point Part number QTY O-ring size
Low-pressure flexible hose to low-pressure pipe (One-touch
92473 N8221 2 16 M
joint)
High-pressure pipe 1 to high-pressure pipe 2 (One-touch
92471 N8221 2 8
joint)
Condenser to high-pressure flexible hose (One-touch joint) 92472 N8221 2 12
Condenser to high-pressure pipe 1 (One-touch joint) 92471 N8221 2 8
New Low-pressure pipe to expansion valve 92473 N8210 1 16
High-pressure pipe 2 to expansion valve 92471 N8210 1 8
Compressor to low-pressure flexible hose 92474 N8210 1 19
Compressor to high-pressure flexible hose 92472 N8210 1 12
Inlet 1
Liquid tank to condenser pipe 92471 N8210 8
Outlet 1
Refrigerant pressure sensor to liquid tank J2476 89956 1 10
Former Inlet 92475 71L00 1 12
Expansion valve to evaporator
Outlet 92475 72L00 1 16

ATC-9
 PRECAUTIONS

WARNING:
Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
When replacing or cleaning refrigerant cycle components, observe the following.
● When the compressor is removed, store it in the same position as it is when mounted on the car.
Malfunction to do so will cause lubricant to enter the low pressure chamber.
● When connecting tubes, always use a torque wrench and a back-up wrench.
● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture.
● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-
tion. Do not remove the seal caps of pipes and other components until just before required for
connection.
● Allow components stored in cool areas to warm to working area temperature before removing seal
caps. This prevents condensation from forming inside A/C components.
● Thoroughly remove moisture from the refrigeration system before charging the refrigerant.
● Always replace used O-rings.
● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not
to apply lubricant to threaded portion.
Lubricant name: Nissan A/C System Oil Type S
Part number: KLH00-PAGS0
● O-ring must be closely attached to dented portion of tube.
● When replacing the O-ring, be careful not to damage O-ring and tube.
● Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that
the O-ring is installed to tube correctly.
● After connecting line, perform leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten con-
nections of seal seat to the specified torque.

RHA861F

Precautions for Servicing Compressor AJS00195

● Plug all openings to prevent moisture and foreign matter from entering.
● When the compressor is removed, store it in the same position as it is when mounted on the car.
● When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-
sor” exactly. Refer to ATC-24, "Maintenance of Lubricant Quantity in Compressor" .
● Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubri-
cant, wipe it off by using a clean waste cloth moistened with thinner.

ATC-10
 PRECAUTIONS

● 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 A
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 usual
operation. B
Precautions for Service Equipment AJS00196

RECOVERY/RECYCLING EQUIPMENT
Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never C
introduce any refrigerant other than that specified into the machine.
ELECTRONIC LEAK DETECTOR
D
Be certain to follow the manufacturer's instructions for tester operation and tester maintenance.
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible E
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. So the vacuum pump lubricant may migrate out of the pump
F
into the service hose. This is possible when the pump is switched off
after evacuation (vacuuming) and hose is connected to it.
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as follows. G
● Usually vacuum pumps have a manual isolator valve as part of
the pump. Close this valve to isolate the service hose from the
pump. H
● For pumps without an isolator, use a hose equipped with a man-
ual shut-off valve near the pump end. Close the valve to isolate
the hose from the pump. I
● 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. ATC
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.
K

RHA270DA

MANIFOLD GAUGE SET L

Be certain that the gauge face indicates HFC-134a or R-134a. Be
sure the gauge set has 1/2″-16 ACME threaded connections for ser-
vice hoses. Confirm the set has been used only with refrigerant M
HFC-134a (R-134a) and specified lubricants.

SHA533D

ATC-11
 PRECAUTIONS

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

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

RHA273D

REFRIGERANT WEIGHT SCALE

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

RHA274D

CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale every three months.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset ” and “Enter” at the same time.
2. Press “8787” . “A1 ” will be displayed.
3. Remove all weight from the scale.
4. Press “0” , then press “Enter” . “0.00 ” will be displayed and change to “A2 ”.
5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb.) on the center
of the weight scale.
6. Enter the known weight using four digits. (Example 10 lb. = 10.00, 10.5 lb. = 10.50)
7. Press “Enter” — the display returns to the vacuum mode.
8. Press “Shift/Reset ” and “Enter” at the same time.
9. Press “6 ” — the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00 ” will be displayed.
11. Press “Shift/Reset ” to return the ACR4 to the program mode.

ATC-12
 PRECAUTIONS

CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder′s top valve A
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.
B
Precautions for Leak Detection Dye AJS00197

● 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.
C
● Always wear fluorescence enhancing UV safety goggles 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- D
rescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to pin-
point refrigerant leaks.
● For your safety and your customer′s satisfaction, read and follow all manufacture′s operating instructions
E
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.
● Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis F
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 G
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. H
● 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 system or CFC-12 (R-12) leak detector dye
in HFC-134a (R-134a) A/C systems or A/C system damage may result. I
● The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction
occurs.
ATC
IDENTIFICATION
NOTE:
Vehicles with factory installed fluorescent dye have a green label.
Vehicles without factory installed fluorescent dye have a blue label. K

IDENTIFICATION LABEL FOR VEHICLE

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

RJIA2721E

Wiring Diagrams and Trouble Diagnosis AJS00198

When you read wiring diagrams, refer to the following:

● GI-15, "How to Read Wiring Diagrams" in GI section.
● PG-5, "Wiring Diagram - POWER -/For Middle East, Brazil and Argentina", PG-15, "Wiring Diagram -
POWER -/For South Africa" , PG-26, "Wiring Diagram - POWER -/LHD Models Except for Middle East,
Brazil, Argentina and South Africa" or PG-36, "Wiring Diagram - POWER -/RHD Models Except for Mid-
dle East, Brazil, Argentina and South Africa" in PG section.
When you perform trouble diagnosis, refer to the following:
● GI-11, "How to Follow Trouble Diagnoses" in GI section.
ATC-13
 PRECAUTIONS

● GI-24, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section.

ATC-14
 PREPARATION

PREPARATION PFP:00002
A
Special Service Tools AJS00199

Tool number
Description
Tool name B

D
KV99106100 S-NT232
Removing shaft nut and clutch disc
Clutch disc wrench
E

RJIA0194E

KV99232340
or H
Removing clutch disc
KV992T0001
Clutch disc puller

S-NT376
I

KV99106200
ATC
Installing pulley
Pulley installer

K
S-NT235

92530 89908 (for high-pressure

pipe 1)
(-) L
92530 89912 (for high-pressure
flexible hose)
Disconnect one-touch joint connection
(-)
M
92530 89916 (for low-pressure
pipe 1 and low-pressure flexible
hose) RJIA0391J

(-)

ATC-15
 PREPARATION

HFC-134a (R-134a) Service Tools and Equipment AJS0019A

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

Container color: Light blue

Container marking: HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size: Thread size
● Large container 1/2″-16 ACME
S-NT196

Type: Poly alkylene glycol oil (PAG),

type S (DH-PS)
KLH00-PAGS0
Application: HFC-134a (R-134a)
Nissan A/C System Oil Type S
wobble (swash) plate compressors
(DH-PS)
(Nissan only)
Lubricity: 40 m (1.4 Imp fl oz.)
S-NT197

Recovery/Recycling/ Function: Refrigerant Recovery and

Recharging equipment Recycling and Recharging

RJIA0195E

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

SHA705EB

ATC-16
 PREPARATION

Tool number
Description A
Tool name

(J-43926)
Refrigerant dye leak detection kit
Kit includes: B
(J-42220)
UV lamp and UV safety goggles
(J-41459)
HFC-134a (R-134a) dye injector C
Power supply:
Use with J-41447, 1/4 ounce
DC 12V (Battery terminal)
bottle
(J-41447)
D
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
(J-43872) ZHA200H
E
Refrigerant dye cleaner

Power supply: DC 12V (Battery

terminal) F
For checking refrigerant leak when
(J-42220)
fluorescent dye is installed in A/C
UV lamp and UV safety goggles
system.
Includes: UV lamp and UV safety G
goggles
SHA438F

Application: For HFC-134a (R-134a) H

PAG oil
(J-41447)
Container: 1/4 ounce (7.4 cc) bottle
HFC-134a (R-134a) fluorescent
(Includes self-adhesive dye
leak detection dye I
identification labels for affixing to
(Box of 24, 1/4 ounce bottles)
vehicle after charging system with
dye.)
SHA439F
ATC

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

SHA440F L

M
(J-43872)
For cleaning dye spills.
Refrigerant dye cleaner

SHA441F

Identification:
● The gauge face indicates HFC-134a
Manifold gauge set (with hoses
(R-134a).
and couplers)
Fitting size: Thread size
● 1/2″-16 ACME

RJIA0196E

ATC-17
 PREPARATION

Tool number
Description
Tool name

Hose color:
● Low hose: Blue with black stripe
Service hoses
● High-pressure side hose ● High hose: Red with black stripe

● Low -pressure side hose ● Utility hose: Yellow with black stripe
or green with black stripe
● Utility hose Hose fitting to gauge:
S-NT201 ● 1/2″-16 ACME

Service couplers Hose fitting to service hose:

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

S-NT202

For measuring of refrigerant

Refrigerant weight scale Fitting size: Thread size
● 1/2″-16 ACME

S-NT200

Capacity:
● Air displacement: 4 CFM
Vacuum pump ● Micron rating: 20 microns
(Including the isolator valve) ● Oil capacity: 482 g (17 oz.)
Fitting size: Thread size

S-NT203
● 1/2″-16 ACME

ATC-18
 REFRIGERATION SYSTEM

REFRIGERATION SYSTEM PFP:KA990

A
Refrigerant Cycle AJS0019C

REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, B
through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is
controlled by an externally equalized expansion valve, located inside the evaporator case.
FREEZE PROTECTION C
Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the
evaporator pressure, and therefore, temperature is controlled by the V-6 variable displacement compressor to
prevent freeze up.
D
Refrigerant System Protection AJS0019D

REFRIGERANT PRESSURE SENSOR

The refrigerant system is protected against excessively high- or low-pressure by the refrigerant pressure sen- E
sor, located on the liquid tank. If the system pressure rises above, or falls below the specifications, the refriger-
ant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM.
ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side F
detected by refrigerant pressure sensor is over about 2,746 kPa (27.46 bar, 28 kg/cm2 , 398 psi), or below
about 134 kPa (1.34 bar, 1.4 kg/cm2 , 20 psi).
PRESSURE RELIEF VALVE G
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 unusual level [more than 3,727 kPa (37.27 bar,
38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refriger- H
ant into the atmosphere.

ATC

RJIA1552E

ATC-19
 REFRIGERATION SYSTEM

V-6 Variable Displacement Compressor AJS0019E

GENERAL INFORMATION
1. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable com-
pressor do not drop too far below 5°C when:
Evaporator intake air temperature is less than 20°C.
Engine is running at speeds less than 1,500 rpm.
This is because the V-6 compressor provides a means of “capacity” control.
2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it
may not produce high refrigerant pressure discharge (compared to previous units) when used with air
conditioning systems.
3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt
angle of the wobble (swash) plate has changed and is not a malfunction.
4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system
main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or
when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.
5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It
normally ranges from 147 to 177 kPa (1.47 to 1.77 bar, 1.5 to 1.8 kg/cm2 , 21 to 26 psi) under varying con-
ditions. In previous compressors, however, suction pressure was reduced with increases in engine speed.

ATC-20
 REFRIGERATION SYSTEM

DESCRIPTION
General A
The variable compressor is basically a swash plate type that changes piston stroke in response to the required
cooling capacity.
The tilt of the wobble (swash) plate allows the piston′s stroke to change so that refrigerant discharge can be B
continuously changed from 14.5 to 146 cm3 (0.885 to 8.91 cu. in).

ATC

RJIA1346E

Operation
1. Operation Control Valve
Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response
to changes in refrigerant suction pressure.
Operation of the valve controls the internal pressure of the crankcase.
The angle of the wobble (swash) plate is controlled between the crankcase′s internal pressure and the
piston cylinder pressure.
2. Maximum Cooling
ATC-21
 REFRIGERATION SYSTEM

Refrigerant pressure on the low-pressure side increases with an increases in heat loads.
When this occurs, the control valve′s bellows compress to open the low-pressure side valve and close the
high-pressure side valve.
This cases the following pressure changes:
The crankcase′s internal pressure to equal the pressure on the low-pressure side.
The cylinder′s internal pressure to be greater than the crankcase′s internal pressure.
Under this condition, the wobble (swash) plate is set to the maximum stroke position.

RHA473C

3. Capacity Control
– Refrigerant pressure on suction side is low during high speed driving or when ambient or interior tempera-
ture is low.
– The bellows expands when refrigerant pressure on the suction pressure side drops below approximately
177 kPa (1.77 bar, 1.8 kg/cm2 , 26 psi).
– The force acts around the journal pin are located where the piston generates the highest pressure. Piston
pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If
crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the wobble
(swash) plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure
increase triggers pressure difference between the piston and the crankcase. The pressure difference
changes the angle of the wobble (swash) plate.

RHA474C

ATC-22
 REFRIGERATION SYSTEM

Component Layout AJS0019F

RJIA1347E I
NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite.
ATC

ATC-23
 LUBRICANT

LUBRICANT PFP:KLG00

Maintenance of Lubricant Quantity in Compressor AJS0019G

The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compres-
sor when replacing any component or after a large gas leakage occurred. It is important to maintain the speci-
fied amount.
If lubricant quantity is not maintained properly, the following malfunctions may result:
● Lack of lubricant: May lead to a seized compressor
● Excessive lubricant: Inadequate cooling (thermal exchange interference)
LUBRICANT
Name : Nissan A/C System Oil Type S
Part number : KLH00-PAGS0
LUBRICANT RETURN OPERATION
Adjust the lubricant quantity according to the test group shown below.
1. CHECK LUBRICANT RETURN OPERATION
Can lubricant return operation be performed?
● A/C system works properly.
● There is no evidence of a large amount of lubricant leakage.
CAUTION:
If excessive lubricant leakage is noted, do not perform the lubricant return operation.
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.

2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS:

1. Start engine, and set the following conditions:
– Test condition
Engine speed: Idling to 1,200 rpm
A/C switch: ON
Blower speed: Max. position
Temp. control: Optional (Set so that intake air temperature is 25 to 30°C)
Intake position: Recirculation (REC)
2. Perform lubricant return operation for about 10 minutes.
3. Stop engine.

>> GO TO 3.

3. CHECK REPLACEMENT PART

Should the compressor be replaced?

YES >> GO TO ATC-25, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACE-
MENT" .
NO >> GO TO ATC-25, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACE-
MENT EXCEPT COMPRESSOR" .

ATC-24
 LUBRICANT

LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COM-

PRESSOR A
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 B
Part replaced Amount of lubricant Remarks
m (Imp fl oz.)
C
Evaporator 75 (2.6) -
Condenser 35 (1.2) -
Liquid tank 10 (0.4) - D
30 (1.1) Large leak
In case of refrigerant leak
- Small leak *1
*1: If refrigerant leak is small, no addition of lubricant is needed.
E

LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT

1. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If F
NG, recover refrigerant from equipment lines.
2. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into
the recovery/recycling equipment.
G
3. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount
of lubricant drained.
4. Drain the lubricant from the new compressor into a separate, clean container. H
5. 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.
6. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant I
to new compressor through the suction port opening.
7. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 Imp fl oz.) of lubricant at this time.
Do not add this 5 m (0.2 Imp fl oz.) of lubricant if only replacing the compressor. ATC

ATC-25
LUBRICANT

RHA065DI

ATC-26
 AIR CONDITIONER CONTROL

AIR CONDITIONER CONTROL PFP:27500

A
Description of Air Conditioner LAN Control System AJS0019H

The LAN (Local Area Network) system consists of unified meter and A/C amp., mode door motor, air mix door
motor and intake door motor. B
A configuration of these components is shown in the diagram below.

SJIA0262E

System Construction AJS0019I F

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

SJIA0263E

ATC-27
 AIR CONDITIONER CONTROL

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

SJIA0264E

TRANSMISSION DATA AND TRANSMISSION ORDER

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

ATC-28
 AIR CONDITIONER CONTROL

At the end of each transmission, a stop operation, in-operation, or internal error message is delivered to the
unified meter and A/C amp. This completes one data transmission and control cycle. A

RJIA2100E
G
AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL)
The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined
value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload. H
FAN SPEED CONTROL
Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle tem-
perature, intake temperature, amount of sunload and air mix door position. I
With FAN control dial set to AUTO, the blower motor starts to gradually increase air flow volume.
When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flow-
ing. ATC
INTAKE DOOR CONTROL
The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle
temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor. K
OUTLET DOOR CONTROL
The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle tem-
L
perature, intake temperature and amount of sunload.

ATC-29
 AIR CONDITIONER CONTROL

MAGNET CLUTCH CONTROL

RJIA1348E

When A/C switch is pressed, turn fan control dial to ON or set mode control dial to DEF (D/F and D/F2: LHD
models only) position, unified meter and A/C amp. inputs compressor ON signal to BCM.
BCM sends compressor ON signal to ECM, via CAN communication line.
ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant-pressure sen-
sor signal, throttle angle, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to
IPDM E/R, via CAN communication line.
Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate com-
pressor.
When sending compressor ON signal to IPDM E/R via CAN communication line, ECM simultaneously sends
compressor feedback signal to unified meter and A/C amp. via CAN communication line.
Unified meter and A/C amp., then, uses input compressor feedback signal to control air inlet.
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system is built into the unified meter and A/C amp. to quickly locate the cause of symp-
toms.

ATC-30
 AIR CONDITIONER CONTROL

Description of Control System AJS0019J

A
The control system consists of input sensors, switches, unified meter and A/C amp. (microcomputer) and out-
puts.
The relationship of these components is shown in the diagram below:
B

ATC

K
RJIA2101E

ATC-31
 AIR CONDITIONER CONTROL

Control Operation AJS0019K

RJIA2102E

TEMPERATURE CONTROL DIAL (POTENTIO TEMPERATURE CONTROL)

Increases or decreases the set temperature.
INTAKE SWITCH
● When intake switch is ON, REC indicator turns ON, and air inlet is fixed to REC.
● Press intake switch again, FRE indicator turns ON, and air inlet is fixed to FRE.
● When intake switch is pressed for approximately 1.5 seconds or longer, REC and FRE indicators blink
twice. Then, automatic control mode is entered. Inlet status is displayed even during automatic control.
● When DEF switch or FRE indicator is turned ON, or when compressor is turned from ON to OFF, REC
indicator is automatically turned OFF (fixed to FRE mode).
REC mode can be re-entered by pressing intake switch again. [Except DEF (D/F or D/F2: LHD models
only) position]
REAR WINDOW DEFOGGER SWITCH
When illumination is ON, rear window is defogged.
A/C SWITCH
The compressor is ON or OFF.
(Pressing the A/C switch when the fan control dial is ON will turn off the A/C switch and compressor.)
MODE CONTROL DIAL
Controls the air discharge outlets.
Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.
When shifting mode control dial to DEF (D/F or D/F2: LHD models only) under the following conditions, com-
pressor is turned ON. (A/C LED ON)
● FAN: ON
● A/C: OFF
FAN CONTROL DIAL
Automatically or manually control the blower speed. Twenty five speeds are available for manual control.
Shifting fan control dial to AUTO, compressor is turned ON automatically.

ATC-32
 AIR CONDITIONER CONTROL

Discharge Air Flow AJS0019L

ATC

RJIA2150E

ATC-33
 AIR CONDITIONER CONTROL

System Description AJS0019M

SWITCHES AND THEIR CONTROL FUNCTION

RJIA2103E

SJIA0381E

ATC-34
 AIR CONDITIONER CONTROL

CAN Communication System Description AJS0019N

A
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2 B
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only..
CAN Communication Unit AJS001FG
C

Body type Roadster Coupe

Axle 2WD D
Engine VQ35DE
Transmission A/T M/T A/T M/T
E
Brake control TCS TCS VDC VDC
CAN communication unit
ECM × × × × F
TCM × ×
Data link connector × × × ×
Unified meter and A/C amp. × × × × G
BCM × × × ×
Steering angle sensor × ×
H
ABS actuator and electric unit (control unit) × ×
VDC/TCS/ABS control unit × ×
IPDM E/R × × × × I
CAN communication type ATC-35, "TYPE 1" ATC-37, "TYPE 2" ATC-38, "TYPE 3" ATC-40, "TYPE 4"
×: Applicable
ATC
TYPE 1
System diagram
K

PKIA2002E

Input/output signal chart

T: Transmit R: Receive
ABS actuator
Unified meter and electric
Signals ECM TCM BCM IPDM E/R
and A/C amp. unit (control
unit)
Engine speed signal T R R R
Engine coolant temperature signal T R R
Accelerator pedal position signal T R R
Closed throttle position signal T R
Wide open throttle position signal T R

ATC-35
 AIR CONDITIONER CONTROL

ABS actuator
Unified meter and electric
Signals ECM TCM BCM IPDM E/R
and A/C amp. unit (control
unit)
Battery voltage signal T R
Stop lamp switch signal R T
Fuel consumption monitor signal T R
A/T self-diagnosis signal R T
A/T CHECK indicator lamp signal T R
A/T position indicator signal T R R
Manual mode gear position signal T R
ABS operation signal R T
A/T shift schedule change demand
R T
signal
A/C switch signal R T
A/C compressor request signal T R
A/C compressor feedback signal T R
Blower fan motor switch signal R T
Cooling fan speed request signal T R
Position lights request signal R T R
Low beam request signal T R
Low beam status signal R T
High beam request signal R T R
High beam status signal R T
R T
Vehicle speed signal
R R T R
Sleep request 1 signal R T
Sleep request 2 signal T R
Wake up request 1 signal R T
Door switch signal R T R
Turn indicator signal R T
Seat belt buckle switch signal T R
Buzzer output signal R T
Malfunction indicator lamp signal T R
ASCD SET lamp signal T R
ASCD operation signal T R
ASCD CRUISE lamp signal T R
ASCD OD cancel request signal T R
Output shaft revolution signal R T
Turbine revolution signal R T
Front wiper request signal T R
Front wiper stop position signal R T
Rear window defogger switch signal T R
Rear window defogger control signal R T
Manual mode signal R T
Not manual mode signal R T
Manual mode shift up signal R T

ATC-36
 AIR CONDITIONER CONTROL

ABS actuator
Unified meter and electric A
Signals ECM TCM BCM IPDM E/R
and A/C amp. unit (control
unit)
Manual mode shift down signal R T B
Manual mode indicator signal T R
Hood switch signal R T
Theft warning horn request signal T R C
Horn chirp signal T R
Ignition switch signal T R
D
ABS warning lamp signal R T
TCS OFF indicator lamp signal R T
SLIP indicator lamp signal R T E
Brake warning lamp signal R T

TYPE 2 F
System diagram

PKIA2003E

Input/output signal chart ATC

T: Transmit R: Receive
ABS actuator
Unified meter
Signals ECM
and A/C amp.
BCM and electric unit IPDM E/R K
(control unit)
Engine speed signal T R R
Engine coolant temperature signal T R L
Accelerator pedal position signal T R
Fuel consumption monitor signal T R
M
A/C switch signal R T
A/C compressor request signal T R
A/C compressor feedback signal T R
Blower fan motor switch signal R T
Cooling fan speed request signal T R
Position lights request signal R T R
Low beam request signal T R
Low beam status signal R T
High beam request signal R T R
High beam status signal R T
R T
Vehicle speed signal
R T R
Sleep request 1 signal R T

ATC-37
 AIR CONDITIONER CONTROL

ABS actuator
Unified meter
Signals ECM BCM and electric unit IPDM E/R
and A/C amp.
(control unit)
Sleep request 2 signal T R
Wake up request 1 signal R T
Door switch signal R T R
Turn indicator signal R T
Seat belt buckle switch signal T R
Buzzer output signal R T
Malfunction indicator lamp signal T R
ASCD SET lamp signal T R
ASCD CRUISE lamp signal T R
Front wiper request signal T R
Front wiper stop position signal R T
Rear window defogger switch signal T R
Rear window defogger control signal R T
Hood switch signal R T
Theft warning horn request signal T R
Horn chirp signal T R
Ignition switch signal T R
ABS warning lamp signal R T
TCS OFF indicator lamp signal R T
SLIP indicator lamp signal R T
Brake warning lamp signal R T

TYPE 3
System diagram

SKIA8595E

Input/output signal chart

T: Transmit R: Receive
Unified Steering VDC/TCS/
Signals ECM TCM meter and BCM angle sen- ABS con- IPDM E/R
A/C amp. sor trol unit
Engine speed signal T R R R
Engine coolant temperature signal T R R
Accelerator pedal position signal T R R
Closed throttle position signal T R
Wide open throttle position signal T R
Battery voltage signal T R
Stop lamp switch signal R T

ATC-38
 AIR CONDITIONER CONTROL

Unified Steering VDC/TCS/

Signals ECM TCM meter and BCM angle sen- ABS con- IPDM E/R A
A/C amp. sor trol unit
Fuel consumption monitor signal T R
A/T self-diagnosis signal R T B
A/T CHECK indicator lamp signal T R
A/T position indicator signal T R R
C
Manual mode gear position signal T R
ABS operation signal R T
A/T shift schedule change demand D
R T
signal
A/C switch signal R T
A/C compressor request signal T R E
A/C compressor feedback signal T R
Blower fan motor switch signal R T
F
Cooling fan speed request signal T R
Position lights request signal R T R
Low beam request signal T R G
Low beam status signal R T
High beam request signal R T R
H
High beam status signal R T
R T
Vehicle speed signal
R R T R I
Sleep request 1 signal R T
Sleep request 2 signal T R
ATC
Wake up request 1 signal R T
Door switch signal R T R
Turn indicator signal R T K
Seat belt buckle switch signal T R
Buzzer output signal R T
Malfunction indicator lamp signal T R L
ASCD SET lamp signal T R
ASCD operation signal T R
M
ASCD CRUISE lamp signal T R
ASCD OD cancel request signal T R
Output shaft revolution signal R T
Turbine revolution signal R T
Front wiper request signal T R
Front wiper stop position signal R T
Rear window defogger switch signal T R
Rear window defogger control signal R T
Manual mode signal R T
Not manual mode signal R T
Manual mode shift up signal R T
Manual mode shift down signal R T
Manual mode indicator signal T R

ATC-39
 AIR CONDITIONER CONTROL

Unified Steering VDC/TCS/

Signals ECM TCM meter and BCM angle sen- ABS con- IPDM E/R
A/C amp. sor trol unit
Hood switch signal R T
Theft warning horn request signal T R
Horn chirp signal T R
Ignition switch signal T R
ABS warning lamp signal R T
VDC OFF indicator lamp signal R T
SLIP indicator lamp signal R T
Brake warning lamp signal R T
Steering angle sensor signal T R

TYPE 4
System diagram

PKIA2005E

Input/output signal chart

T: Transmit R: Receive
VDC/TCS/
Unified meter Steering
Signals ECM BCM ABS control IPDM E/R
and A/C amp. angle sensor
unit
Engine speed signal T R R
Engine coolant temperature signal T R
Accelerator pedal position signal T R
Fuel consumption monitor signal T R
A/C switch signal R T
A/C compressor request signal T R
A/C compressor feedback signal T R
Blower fan motor switch signal R T
Cooling fan speed request signal T R
Position lights request signal R T R
Low beam request signal T R
Low beam status signal R T
High beam request signal R T R
High beam status signal R T
R T
Vehicle speed signal
R T R
Sleep request 1 signal R T
Sleep request 2 signal T R
Wake up request 1 signal R T

ATC-40
 AIR CONDITIONER CONTROL

VDC/TCS/
Unified meter Steering
Signals ECM BCM ABS control IPDM E/R A
and A/C amp. angle sensor
unit
Door switch signal R T R
Turn indicator signal R T B
Seat belt buckle switch signal T R
Buzzer output signal R T
C
Malfunction indicator signal T R
ASCD SET lamp signal T R
ASCD CRUISE lamp signal T R D
Front wiper request signal T R
Front wiper stop position signal R T
E
Rear window defogger switch signal T R
Rear window defogger control signal R T
Hood switch signal R T F
Theft warning horn request signal T R
Horn chirp signal T R
Ignition switch signal T R
G

Steering angle sensor signal T R

ABS warning lamp signal R T H
VDC OFF indicator lamp signal R T
SLIP indicator lamp signal R T
Brake warning lamp signal R T I

ATC

ATC-41
 TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS PFP:00004

CONSULT-II AJS0019P

CONSULT-II performs the following functions communicating with BCM.

System part Check item, diagnosis mode Description
BCM Data monitor Displays BCM input data in real time.

CONSULT-II INSPECTION PROCEDURE

CAUTION:
If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be
detected in self-diagnosis depending on control unit which carry out CAN communication.
1. With the ignition switch OFF, connect CONSULT-II and CON-
SULT-II CONVERTER to the data link connector, then turn the
ignition switch ON.

PBIB1069E

2. Touch “START (NISSAN BASED VHCL)”.

SKIA3098E

3. Touch “BCM” on “SELECT SYSTEM” screen. If “BCM” is not

indicated, go to GI-36, "CONSULT-II Data Link Connector (DLC)
Circuit" .

PKIA2102E

ATC-42
 TROUBLE DIAGNOSIS

DATA MONITOR
Operation Procedure A
1. Touch “SIGNAL BUFFER” on “SELECT TEST ITEM” screen.

D
SJIA0268E

2. Touch “DATA MONITOR” on “SELECT DIAG MODE” screen. E

SJIA0269E H

3. Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on

“DATA MONITOR” screen.
I
All signals Monitors all the items.
Selection from menu Selects and monitors the individual item selected.
ATC
4. Touch “START”.
5. When “SELECTION FROM MENU” is selected, touch items to
be monitored. When “ALL SIGNALS” is selected, all the items K
will be monitored.
6. Touch “RECORD” while monitoring, then the status of the moni- SJIA0270E
tored item can be recorded. To stop recording, touch “STOP”.
L
Display Item List
Monitor item name “operation or
Contents
unit” M
IGN ON SW “ON/OFF” Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal.
COMP ON SIG “ON/OFF” Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal.
FAN ON SIG “ON/OFF” Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal.

ATC-43
 TROUBLE DIAGNOSIS

How to Perform Trouble Diagnoses for Quick and Accurate Repair AJS0019Q

WORK FLOW

SHA900E

*1 ATC-69, "Operational Check"

SYMPTOM TABLE
Symptom Reference Page
ATC-71, "Power
Supply and
A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System.
Ground Circuit for
Auto Amp."
Air outlet does not change. ATC-77, "Mode
Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN) Door Motor Cir-
Mode door motor does not operate normally. cuit"
Discharge air temperature does not change. ATC-80, "Air Mix
Air mix door motor does not operate nor- Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN) Door Motor Cir-
mally. cuit"

Intake door does not change. ATC-83, "Intake

Go to Trouble Diagnosis Procedure for Intake Door Motor. (LAN) Door Motor Cir-
Intake door motor does not operate normally. cuit"
Blower motor operation is malfunctioning.
ATC-86, "Blower
Blower motor operation is malfunctioning Go to Trouble Diagnosis Procedure for Blower Motor.
Motor Circuit"
under out of starting fan speed control.
ATC-91, "Magnet
Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch.
Clutch Circuit"
ATC-98, "Insuffi-
Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling.
cient Cooling"
ATC-106, "Insuffi-
Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating.
cient Heating"
Noise Go to Trouble Diagnosis Procedure for Noise. ATC-107, "Noise"
ATC-108, "Self-
Self-diagnosis cannot be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis.
diagnosis"

ATC-44
 TROUBLE DIAGNOSIS

Component Parts and Harness Connector Location AJS0019R

ENGINE COMPARTMENT A

ATC

RJIA1354E

ATC-45
 TROUBLE DIAGNOSIS

PASSENGER COMPARTMENT
LHD Models

RJIA1355E

ATC-46
 TROUBLE DIAGNOSIS

RHD Models
A

ATC

RJIA2105E

ATC-47
 TROUBLE DIAGNOSIS

Schematic AJS0019S

TJWT0080E

ATC-48
 TROUBLE DIAGNOSIS

Wiring Diagram –A/C–, LHD Models AJS0019T

ATC

TJWT0048E

ATC-49
TROUBLE DIAGNOSIS

TJWT0032E

ATC-50
TROUBLE DIAGNOSIS

ATC

TJWT0033E

ATC-51
TROUBLE DIAGNOSIS

TJWT0099E

ATC-52
TROUBLE DIAGNOSIS

ATC

TJWT0081E

ATC-53
 TROUBLE DIAGNOSIS

Wiring Diagram–A/C–, RHD Models AJS001BO

TJWT0051E

ATC-54
TROUBLE DIAGNOSIS

ATC

TJWT0052E

ATC-55
TROUBLE DIAGNOSIS

TJWT0053E

ATC-56
TROUBLE DIAGNOSIS

ATC

TJWT0097E

ATC-57
TROUBLE DIAGNOSIS

TJWT0082E

ATC-58
 TROUBLE DIAGNOSIS

Auto Amp. Terminals and Reference Value AJS0019U

A
Measure voltage between each terminal and ground by following ter-
minals and reference value for unified meter and A/C Amp.

D
RJIA1356E

PIN CONNECTOR TERMINAL LAYOUT

E

RJIA1357E H
TERMINALS AND REFERENCE VALUE FOR UNIFIED METER AND A/C AMP.
Terminal Wire Ignition Voltage
Item Condition I
No. color switch (V)
1 L CAN-H - - -
Multiplex communication signal
9 L/OR
(Tx)
- - - ATC

11 P CAN-L - - -
Multiplex communication signal
19 R/G - - - K
(Rx)
21 R/W Power supply for BAT OFF - Battery voltage
22 Y/G Power supply for IGN ON - Battery voltage L
29 B Ground (Power) ON - Approx. 0
30 B Ground ON - Approx. 0
Rear window defogger
M
Approx. 0
Rear window defogger ON sig- switch: Press ON
38 L/R ON
nal Rear window defogger
Approx. 12
switch: Press OFF
39 Y Ambient sensor - - -
40 BR In-vehicle sensor - - -
SB
(LHD
41 models) Intake sensor - - -
P (RHD
models)
Compressor: ON Approx. 0
42 G/Y Compressor ON signal ON
Compressor: OFF Approx. 5

ATC-59
 TROUBLE DIAGNOSIS

Terminal Wire Ignition Voltage

Item Condition
No. color switch (V)

43 G/B A/C LAN signal ON -

HAK0652D

ACC or
46 L/W Power supply for IGN2 - Battery voltage
ON
W/L
(LHD
models)
49 Sensor ground ON - Approx. 0
W/G
(RHD
models)
50 LG Sunload sensor - - -

53 G Blower motor control signal ON Blower speed: 1st step

SJIA0116J

Power supply for each door

54 Y/R ON - Battery voltage
motor
Rear window defogger
Approx. 12
Rear window defogger feedback switch: ON
56 B/W ON
signal Rear window defogger swi-
Approx. 0
itch: OFF
BR/W Fan control dial: ON (A/C
Approx. 0
(LHD systen operate)
models)
57 Blower motor ON signal ON
BR/Y
(RHD Fan control dial: OFF Approx. 5
models)

ATC-60
 TROUBLE DIAGNOSIS

Self-diagnosis Function AJS0019V

DESCRIPTION A
The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line.
Self-diagnosis is step-1 to 7. There are two ways of changing method during self-diagnosis.
● Switching to self-diagnosis step-1 to 4. B
Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing A/C switch for at least 5 seconds. The A/C switch must
be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be C
canceled by either pressing intake switch or turning the ignition switch OFF. Shifting from one step to
another is accomplished by means of turning fan control dial, as required.
● Switching to self diagnosis step-5 to 7 (Auxiliary mechanism).
D
Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning
the ignition switch from OFF to ON) and pressing intake switch for at least 5 seconds. The intake switch
must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system
will be canceled by either pressing A/C switch or turning the ignition switch OFF. Shifting from one step to E
another is accomplished by means of turning fan control dial, as required.

ATC

ATC-61
TROUBLE DIAGNOSIS

RJIA2106E

ATC-62
 TROUBLE DIAGNOSIS

FUNCTION CONFIRMATION PROCEDURE

A
1. SET IN SELF-DIAGNOSTIC MODE (STEP-1 TO 4)
1. Set the fan control dial to OFF position.
2. Turn ignition switch ON. B
3. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press A/C switch for at least 5 seconds.
CAUTION: C
If battery voltage drops below 12V during diagnosis step-3, actuator speed becomes slower and as a
result, the system may generate an error even when operation is usual. To avoid this, start engine
before performing this diagnosis. D

>> GO TO 2.
E
2. STEP-1: LEDS ARE CHECKED
Check intake and A/C switch LEDs illumination.
F
OK or NG
OK >> GO TO 3.
NG >> Refeer to ATC-108, "Self-diagnosis" .
G

RJIA2107E
I
3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP-2
1. Turn fan control dial to AUTO position. ATC
CAUTION:
When switched to STEP-2, LED of REC position blinks for
approximately 25 seconds. K
2. Advance to self-diagnosis STEP-2?
Check A/C LED illumination.
YES >> GO TO 4. L
NO >> 1. Malfunctioning fan control dial.
2. Replace A/C controller.
RJIA1480E M

4. CHECK TO RETURN SELF-DIAGNOSIS STEP-1

Turn fan control dial to OFF position.
Return to self-diagnosis STEP-1?
YES >> GO TO 5.
NO >> Replace A/C controller.

ATC-63
 TROUBLE DIAGNOSIS

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

1. Turn fan control dial to AUTO position.
2. Turn mode control dial to AUTO position.
CAUTION:
When switched to STEP-2, LED of REC position blinks for
approximately 25 seconds.
3. Check A/C switch LED is illuminate.
OK or NG
OK >> GO TO 6.
NG >> GO TO 9.
RJIA2108E

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

1. Turn fan control dial to 1st–12th speed.
2. Check A/C switch LED is illuminate.
OK or NG
OK >> GO TO 7.
NG >> GO TO 10.

RJIA2109E

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

1. Turn fan control dial to 13th–25th speed.
2. Change operation status of air conditioner by changing mode control dial position.

>> GO TO 8.

ATC-64
 TROUBLE DIAGNOSIS

8. CHECK ACTUATORS A
Refer to the following chart and confirm discharge air flow, air tem-
perature, blower motor voltage and compressor operation.
B

D
RJIA2110E

E
Mode control dial position
STEP No. *1 STEP-41 STEP-42 STEP-43 STEP-44 STEP-45 STEP-46
Mode control dial posi- FOOT or F
AUTO VENT B/L D/F or D/F2 DEF
tion FOOT2
Mode door position VENT VENT2 B/L FOOT *2 D/F DEF
Intake door position REC REC REC FRE FRE FRE
G
Air mix door position FULL COLD FULL COLD FULL COLD FULL HOT FULL HOT FULL HOT
Blower motor duty H
25% 25% 41% 57% 75% 91%
ratio
Compressor ON ON OFF OFF ON ON

Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for I
improper operation.
*1: Step No. 41 to 46 are for differentiation and will not be displayed.
*2: FOOT position during automatic control. Refer to ATC-68, "AUXILIARY MECHANISM: FOOT POSITION ATC
SETTING TRIMMER" .
OK or NG
OK >> 1. Turn ignition switch OFF or intake switch ON. K
2. INSPECTION END
NG >> ● Air outlet does not change.
Go to Mode Door Motor Circuit. Refer to ATC-77, "Mode Door Motor Circuit" . L
● Intake door does not change.
Go to Intake Door Motor Circuit. Refer to ATC-83, "Intake Door Motor Circuit" .
● Blower motor operation is malfunctioning. M
Go to Blower Motor Circuit. Refer to ATC-86, "Blower Motor Circuit" .
● Magnet clutch does not engage.
Go to Magnet Clutch Circuit. Refer to ATC-91, "Magnet Clutch Circuit" .
● Discharge air temperature does not change.
Go to Air Mix Door Motor Circuit. Refer to ATC-80, "Air Mix Door Motor Circuit" .

ATC-65
 TROUBLE DIAGNOSIS

9. CHECK MALFUNCTIONING SENSOR

Refer to the following chart.
*1: Perform self-diagnosis STEP-2 under sunshine.
When performing indoors, aim a light (more than 60W) at sunload
sensor, otherwise LED of A/C switch will not indicate despite that
sunload sensor is functioning properly.
CAUTION:
When switched to STEP-2, LED of REC position blinks for
approximately 25 seconds.

RJIA2111E

Mode control dial

Unusual Malfunctioning sensor (Including circuits) Reference page
position
VENT Ambient sensor *2
B/L In-vehicle sensor *3
FOOT or FOOT2 A/C LED: OFF Sunload sensor *1 *4
D/F or D/F2 Intake sensor *5
DEF Air mix door motor (LCU) PBR *6

*2: ATC-109, "DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR" .

*3: ATC-112, "DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR" .
*4: ATC-115, "DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR" .
*5: ATC-117, "DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR" .
*6: ATC-73, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .

>> INSPECTION END

10. CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH

Mode or (and) intake door motor PBR (s) is (are) malfunctioning.
CAUTION:
When switched to STEP-3, LED of REC position blinks for
approximately 25 seconds.
Unusual Mode or intake door position Reference page
REC LED: ON Mode door motor *1
FRE LED: ON Intake door motor *2

*1:ATC-79, "DIAGNOSTIC PROCEDURE FOR MODE DOOR

MOTOR" . RJIA2112E

*2:ATC-85, "DIAGNOSTIC PROCEDURE FOR INTAKE DOOR

MOTOR" .

>> INSPECTION END

ATC-66
 TROUBLE DIAGNOSIS

AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER

The trimmer compensates for differences in range of ±3°C between temperature setting (Temperature control A
dial position) and temperature felt by driver.
Operating procedures for this trimmer are as follows:
1. Set temperature at 25°C. B
2. Set fan control dial to OFF.
3. Turn ignition switch ON.
C
4. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
5. Turn temperature control dial as desired. temperature will change at a rate of 1°C each time a dial is
D
turned.

LED status of each switch

Setting temperature E
FRE REC A/C
−3°C ON ON ON
−2°C ON ON OFF
F
−1°C ON OFF ON
0°C (Initial setting) OFF OFF OFF
1°C OFF OFF ON G
2°C OFF ON OFF
3°C OFF ON ON
H
When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial
condition, i.e. 0°C.
I

ATC

ATC-67
 TROUBLE DIAGNOSIS

AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER

Wind distribution ratio in FOOT mode can be set.
Operating procedures for this trimmer are as follows:
1. Set temperature at 25°C.
2. Set fan control dial to AUTO.
3. Turn ignition switch ON.
4. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
5. Turn temperature control dial as desired.

RJIA1365E

LED status of each switch

Type
FRE REC A/C
Type-A (Initial setting) OFF OFF ON
Type-B OFF ON OFF
Type-C OFF ON ON
Type-D ON OFF OFF

AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION

When ignition key is turned from OFF to ON, inlet port can be set to AUTO or manual.
Operating procedures for this trimmer are as follows:
1. Set fan control dial to 1st-25th speed.
2. Turn ignition switch ON.
3. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned
ON.), press intake switch for at least 5 seconds.
4. Press the intake switch as desired.

LED status LED status Setting status

Setting changeover method
of FRE of REC FRE REC
OFF OFF AUTO control AUTO control
Manual REC status is memorized.
OFF ON AUTO control (Initial setting)
(Initial setting) Intake SW: ON
ON OFF Manual FRE status is memorized. AUTO control
ON ON Manual FRE status is memorized. Manual REC status is memorized.

ATC-68
 TROUBLE DIAGNOSIS

Operational Check AJS0019W

A
The purpose of the operational check is to confirm that the system operates properly.
Conditions : Engine running and at usual operating temperature
CHECKING BLOWER B
1. Turn fan control dial to 1st speed. Blower should operate on low
speed.
2. Turn fan control dial to 2nd speed, and continue checking C
blower speed until all speeds are checked.
3. Leave blower on MAX. speed.
If NG, go to trouble diagnosis procedure for ATC-86, "Blower Motor D
Circuit" .
If OK, continue with next check.
E
RJIA2113E

CHECKING DISCHARGE AIR F

1. Turn mode control dial to each position.

I
RJIA2114E

2. Confirm that discharge air comes out according to the air distri- ATC
bution table. Refer to ATC-33, "Discharge Air Flow" .
Mode door position is checked in the next step.
If NG, go to trouble diagnosis procedure for ATC-77, "Mode Door
Motor Circuit" . K
If OK, continue with next check.
NOTE:
Confirm that the compressor clutch is engaged (sound or visual L
inspection) and intake door position is at FRESH when the DEF (D/F
or D/F2: LHD models only) is selected.
RJIA2110E M
CHECKING INTAKE DOOR
1. Press intake switch. Recirculation indicator should illuminate.
2. Press intake switch again. Fresh indicator should illuminate.
3. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for ATC-83, "Intake Door
Motor Circuit" .
If OK, continue with next check.

RJIA2115E

ATC-69
 TROUBLE DIAGNOSIS

CHECKING TEMPERATURE DECREASE

1. Turn temperature control dial until 18°C.
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for ATC-98, "Insufficient
Cooling" .
If OK, continue with next check.

RJIA2116E

CHECKING TEMPERATURE INCREASE

1. Turn temperature control dial until 32°C.
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for ATC-106, "Insufficient
Heating" .
If OK, continue with next check.

RJIA2117E

CHECKING A/C SWITCH

1. Turn fan control dial to AUTO position. (Compressor is turned
ON automatically: LHD models only.)
2. Press A/C switch (RHD models only).
● Confirm that the compressor clutch engages (sound or visual
inspection). (Discharge air and blower speed will depend on
ambient, in-vehicle, and set temperatures.)
If NG, go to trouble diagnosis procedure for ATC-71, "Power Supply
and Ground Circuit for Auto Amp." , then if necessary, trouble diag-
nosis procedure for ATC-91, "Magnet Clutch Circuit" .
If all operational checks are OK (symptom cannot be duplicated), go
to Malfunction Simulation Tests in GI-24, "How to Perform Efficient RJIA2118E

Diagnosis for an Electrical Incident" and perform tests as outlined to

simulate driving conditions environment. If symptom appears, refer to ATC-44, "SYMPTOM TABLE" and per-
form applicable trouble diagnosis procedures.

ATC-70
 TROUBLE DIAGNOSIS

Power Supply and Ground Circuit for Auto Amp. AJS0019X

A
SYMPTOM: A/C system does not come on.
INSPECTION FLOW
B

RJIA2119E ATC
*1 ATC-69, "Operational Check". *2 ATC-72, "DIAGNOSTIC PROCE-
DURE FOR A/C SYSTEM".

COMPONENT DESCRIPTION K
Unified meter and A/C amp. (Automatic Amplifier)
The unified meter and A/C amp. has a built-in microcomputer which
L
processes information sent from various sensors needed for air con-
ditioner operation. The air mix door motor, mode door motor, intake
door motor, blower motor and compressor are then controlled.
The unified meter and A/C amp. is unitized with control mechanisms. M
When the various switches and temperature control dial are oper-
ated, data is input to the auto amp. from the A/C controller using mul-
tiplex communication.
Self-diagnostic functions are also built into unified meter and A/C
amp. to provide quick check of malfunctions in the auto air condi-
tioner system.
RJIA1356E

ATC-71
 TROUBLE DIAGNOSIS

Potentio Temperature Control (PTC)

The PTC is built into the A/C controller. It can be set at an interval of
1°C in the 18°C to 32°C temperature range by turning the tempera-
ture control dial.

RJIA2120E

DIAGNOSTIC PROCEDURE FOR A/C SYSTEM

SYMPTOM: A/C system does not come on.

RJIA1374E

1. CHECK POWER SUPPLY CIRCUIT FOR UNIFIED METER AND A/C AMP.
1. Disconnect unified meter and A/C amp. connector.
2. Turn ignition switch ON.
3. Check voltage between unified meter and A/C amp. harness
connector M49 terminal 21 (R/W) and 22 (Y/G), unified meter
and A/C amp. harness connector M50 terminal 46 (L/W) and
ground.

Terminals Ignition switch position

(+)
Unified RJIA2121E
meter and Terminal No. (-) OFF ACC ON
A/C amp. (wire color)
connector
Battery Battery Battery
M49 21 (R/W)
voltage voltage voltage
Battery
M49 22 (Y/G) Ground Approx. 0V Approx. 0V
voltage
Battery Battery
M50 46 (L/W) Approx. 0V
voltage voltage

OK or NG
OK >> GO TO 2.
NG >> Check 10A and 15A fuses [Nos. 10, 11, 12 and 19, located in the fuse block (J/B)]. Refer to PG-
164, "FUSE BLOCK - JUNCTION BOX (J/B)" .
● If fuses are OK, check harness for open circuit. Repair or replace as necessary.

● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace as neces-
sary.

ATC-72
 TROUBLE DIAGNOSIS

2. CHECK GROUND CIRCUIT FOR UNIFIED METER AND A/C AMP. A

1. Turn ignition switch OFF.
2. Check continuity between unified meter and A/C amp. harness
connector M49 terminal 29 (B), 30 (B) and ground. B

29, 30 – Ground : Continuity should exist.

OK or NG C
OK >> Replace unified meter and A/C amp.
NG >> Repair or replace harness.
D
RJIA1985E

LAN System Circuit AJS0019Y

E
SYMPTOM: Mode door motor, intake door motor and/or air mix door motor(s) does not operate normally.

ATC

K
RJIA2122E

DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT

1. CHECK POWER SUPPLY FOR UNIFIED METER AND A/C AMP. L

1. Turn ignition switch ON.

2. Check voltage between unified meter and A/C amp. harness M
connector M50 terminal 54 (Y/R) and ground.
54 – Ground : Battery voltage
OK or NG
OK >> GO TO 2.
NG >> Replace unified meter and A/C amp.

RJIA1986E

ATC-73
 TROUBLE DIAGNOSIS

2. CHECK SIGNAL FOR UNIFIED METER AND A/C AMP.

Confirm A/C LAN signal between unified meter and A/C amp. har-
ness connector M50 terminal 43 (G/B) and ground using an oscillo-
scope.
Terminals
(+)
Voltage
Unified meter (-)
Terminal No.
and A/C amp.
(wire color)
connector

RJIA1987E

M50 43 (G/B) Ground

HAK0652D

OK or NG
OK >> GO TO 3.
NG >> Replace unified meter and A/C amp.

3. CHECK POWER SUPPLY FOR MOTOR

Check voltage between mode door motor harness connector M252
terminal 1 (G), air mix door motor harness connector M253 (LHD
models) or M251 (RHD models) terminal 1 (G), intake door motor
connector M256 terminal 1 (G) and ground.
1 – Ground : Battery voltage
OK or NG
OK >> GO TO 4.
NG >> Replace harness or connector.

RJIA1988E

4. CHECK SIGNAL FOR MOTOR

Confirm A/C LAN signal between mode door motor harness connector M252 terminal 3 (L), air mix door motor
harness connector M253 (LHD models) or M251 (RHD models) terminal 3 (L), intake door motor harness con-
nector M256 terminal 3 (L) and ground using an oscilloscope.
Terminals
(+)
Door
Voltage
motor Terminal (-)
Connector No.
(wire color)
Mode M252 3 (L)
M253 (LHD
models)
Air mix 3 (L) Ground
M251 (RHD RJIA1989E
models)

Intake M256 3 (L) HAK0652D

OK or NG
OK >> GO TO 5.
NG >> Replace harness or connector.

ATC-74
 TROUBLE DIAGNOSIS

5. CHECK MOTOR GROUND CIRCUIT A

1. Turn ignition switch OFF.
2. Disconnect door motor connector.
3. Check continuity between mode door motor harness connector B
M252 terminal 2 (B), air mix door motor harness connector
M253 (LHD models) or M251 (RHD models) terminal 2 (B),
intake door motor harness connector M256 terminal 2 (B) and C
ground.
2 – Ground : Continuity should exist.
D
OK or NG
RJIA1990E
OK >> GO TO 6.
NG >> Replace harness or connector.
E
6. CHECK MOTOR OPERATION
1. Turn ignition switch OFF. F
2. Disconnect each door motor connector.
3. Reconnect each door motor connector.
4. Turn ignition switch ON. G
5. Confirm each door motor operation.
OK or NG
H
OK >> (Return to operate normally.)
● Poor contacting the motor connector

NG >> (Does not operate normally.) I

● GO TO 7.

7. CHECK AIR MIX AND INTAKE DOOR MOTORS OPERATION ATC

1. Turn ignition switch OFF.
2. Disconnect mode, air mix and intake door motor connectors.
3. Reconnect air mix and intake door motor connector. K
4. Turn ignition switch ON.
5. Confirm air mix and intake door motors operation.
L
OK or NG
OK >> (Air mix and intake door motors operate normally.)
● Replace mode door motor. M
NG >> (Air mix and intake door motors does not operate normally.)
● GO TO 8.

8. CHECK MODE AND INTAKE DOOR MOTORS OPERATION

1. Turn ignition switch OFF.
2. Disconnect air mix door motor connector.
3. Reconnect mode door motor connector.
4. Turn ignition switch ON.
5. Confirm mode and intake door motors operation.
OK or NG
OK >> (Mode and intake door motors operate normally.)
● Replace air mix door motor.

NG >> (Mode and intake door motor does not operate normally.)
● GO TO 9.

ATC-75
 TROUBLE DIAGNOSIS

9. CHECK MODE AND AIR MIX DOOR MOTORS OPERATION

1. Turn ignition switch OFF.
2. Disconnect intake door motor connector.
3. Reconnect air mix door motor connector.
4. Turn ignition switch ON.
5. Confirm mode and air mix door motors operation.
OK or NG
OK >> (Mode and air mix door motors operate normally.)
● Replace intake door motor.

NG >> (Mode and air mix door motors does not operate normally.)
● Replace unified meter and A/C amp.

ATC-76
 TROUBLE DIAGNOSIS

Mode Door Motor Circuit AJS0019Z

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

ATC

RJIA2123E

*1 ATC-33, "Discharge Air Flow". *2 ATC-69, "Operational Check". *3 ATC-63, "FUNCTION CONFIRMA-
TION PROCEDURE", see No. 1.
*4 ATC-63, "FUNCTION CONFIRMA- *5 ATC-109, "Ambient Sensor Cir- *6 ATC-111, "In-vehicle Sensor Circuit".
TION PROCEDURE", see No. 5 to 7. cuit".
*7 ATC-114, "Sunload Sensor Circuit". *8 ATC-117, "Intake Sensor Circuit". *9 ATC-80, "Air Mix Door Motor Cir-
cuit".

ATC-77
 TROUBLE DIAGNOSIS

*10 ATC-63, "FUNCTION CONFIRMA- *11 ATC-73, "DIAGNOSTIC PROCE- *12 ATC-129, "INTAKE DOOR
TION PROCEDURE", see No. 9. DURE FOR LAN CIRCUIT". MOTOR".
*13 ATC-44, "SYMPTOM TABLE".

SYSTEM DESCRIPTION
Component Parts
Mode door control system components are:
● Unified meter and A/C amp.
● Mode door motor (LCU)
● A/C LAN system (PBR built-in mode door motor, air mix door motor and intake door motor)
● In-vehicle sensor
● Ambient sensor
● Sunload sensor
● Intake sensor
System Operation
The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp. air
mix door, mode door and intake door opening angle data to the air mix door motor LCU, mode door motor LCU
and intake door motor LCU.
The air mix door motor, mode door motor and intake door motor read their respective signals according to the
address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of
the motor position sensors are compared by the LCUs in each motor with the existing decision and opening
angles. Subsequently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected.
The new selection data is returned to the unified meter and A/C amp.

RJIA1380E

Mode Door Control Specification

RJIA1778E

ATC-78
 TROUBLE DIAGNOSIS

COMPONENT DESCRIPTION
Mode Door Motor A
The mode door motor is attached to the heater & cooling unit. It rotates so that air is discharged from the outlet
set by the unified meter and A/C amp. Motor rotation is conveyed to a link which activates the mode door.
B
LHD Models

E
RJIA0890E

RHD Models F

I
RJIA2124E

DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR

SYMPTOM: Mode door motor does not operate normally. ATC
Perform diagnostic procedure for ATC-73, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .

ATC-79
 TROUBLE DIAGNOSIS

Air Mix Door Motor Circuit AJS001BP

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

RJIA2125E

*1 ATC-69, "Operational Check". *2 ATC-63, "FUNCTION CONFIRMA- *3 ATC-63, "FUNCTION CONFIRMA-

TION PROCEDURE", see No.1. TION PROCEDURE", see No. 5 to
7.
*4 ATC-109, "Ambient Sensor Circuit". *5 ATC-111, "In-vehicle Sensor Circuit". *6 ATC-114, "Sunload Sensor Circuit"
*7 ATC-117, "Intake Sensor Circuit". *8 ATC-80, "Air Mix Door Motor Cir- *9 ATC-44, "SYMPTOM TABLE".
cuit".
*10 ATC-63, "FUNCTION CONFIRMA- *11 ATC-73, "LAN System Circuit". *12 ATC-136, "AIR MIX DOOR
TION PROCEDURE", see No. 9. MOTOR".

ATC-80
 TROUBLE DIAGNOSIS

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

ATC

RJIA1382E

M
Air Mix Door Control Specification

RJIA1782E

ATC-81
 TROUBLE DIAGNOSIS

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

RJIA1383E

RHD Models

RJIA2126E

DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR

SYMPTOM: Discharge air temperature does not change.
Perform diagnostic procedure for ATC-73, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .
Air Mix Door Motor PBR Circuit AJS001A1

SYMPTOM:
● Discharge air temperature does not change.
● PBR circuit is open or shorted.
DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR PBR
Perform diagnostic procedure for ATC-73, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" .

ATC-82
 TROUBLE DIAGNOSIS

Intake Door Motor Circuit AJS001BQ

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

ATC

RJIA2127E

*1 ATC-69, "Operational Check". *2 ATC-63, "FUNCTION CONFIRMA- *3 ATC-63, "FUNCTION CONFIRMA-

TION PROCEDURE", see No.1. TION PROCEDURE", see No.5 to 7.
*4 ATC-109, "Ambient Sensor Circuit". *5 ATC-111, "In-vehicle Sensor Cir- *6 ATC-114, "Sunload Sensor Circuit".
cuit".
*7 ATC-117, "Intake Sensor Circuit". *8 ATC-80, "Air Mix Door Motor Cir- *9 ATC-44, "SYMPTOM TABLE".
cuit".
*10 ATC-63, "FUNCTION CONFIRMA- *11 ATC-73, "LAN System Circuit". *12 ATC-129, "INTAKE DOOR MOTOR".
TION PROCEDURE", see No. 9.

ATC-83
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Component Parts
Intake door control system components are:
● Unified meter and A/C amp.
● Intake door motor (LCU)
● A/C LAN system (PBR built-in mode door motor, air mix door motor and intaeke door motor)
● In-vehicle sensor
● Ambient sensor
● Sunload sensor
● Intake sensor
System Operation
The intake door control determines intake door position based on the ambient temperature, the intake air tem-
perature and the in-vehicle temperature. When set mode control dial to DEF (D/F or D/F2: LHD models only)
position, or OFF switch is pushed, the unified meter and A/C amp. sets the intake door at the FRESH position.

RJIA1385E

Intake Door Control Specification

RJIA1787E

ATC-84
 TROUBLE DIAGNOSIS

COMPONENT DESCRIPTION
Intake door motor A
The intake door motor is attached to the blower unit. It rotates so that air is drawn from inlets set by the unified
meter and A/C amp. Motor rotation is conveyed to a lever which activates the intake door.
LHD Models B

RJIA1386E
E

RHD Models
F

RJIA2128E
I
DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR
SYMPTOM: Intake door motor does not operate normally.
Perform diagnostic procedure for ATC-73, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . ATC

ATC-85
 TROUBLE DIAGNOSIS

Blower Motor Circuit AJS001A3

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

RJIA2129E

*1 ATC-69, "Operational Check". *2 ATC-63, "FUNCTION CONFIRMA- *3 ATC-63, "FUNCTION CONFIRMA-

TION PROCEDURE", see No.1. TION PROCEDURE", see No.5.
*4 ATC-63, "FUNCTION CONFIRMA- *5 ATC-109, "Ambient Sensor Circuit". *6 ATC-111, "In-vehicle Sensor Circuit".
TION PROCEDURE", see No.7.
*7 ATC-114, "Sunload Sensor Circuit". *8 ATC-117, "Intake Sensor Circuit". *9 ATC-44, "SYMPTOM TABLE".
*10 ATC-63, "FUNCTION CONFIRMA- *11 ATC-88, "DIAGNOSTIC PROCE- *12 TYPE 1*: EC-141, "DTC P0117,
TION PROCEDURE", see No.9. DURE FOR BLOWER MOTOR" P0118 ECT SENSOR" or TYPE 2*:
EC-591, "DTC P0117, P0118 ECT
SENSOR" .

ATC-86
 TROUBLE DIAGNOSIS

*:For further infomation refer to EC-10, "APPLICATION NOTICE" .

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

System Operation
E

ATC
RJIA1388E

Automatic Mode
K
In the automatic mode, the blower motor speed is calculated by the unified meter and A/C amp. based on
input from the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor.
When the air flow is increased, the duty ratio of the blower fan motor′s drive signal is changed at 8%/sec. to
prevent a sudden increase in air flow. L
In addition to manual air flow control and the usual automatic air flow control, starting air flow control, low
water temperature starting control and high passenger compartment temperature starting control are avail-
able. M
Starting Fan Speed Control
Start Up From COLD SOAK Condition (Automatic mode)
In a cold start up condition where the engine coolant temperature is below 56°C, the blower will not operate for
a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and
engine coolant temperature.
In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described
above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above
56°C, at which time the blower speed will increase to the objective speed.

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

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

ATC-87
 TROUBLE DIAGNOSIS

Blower Speed Compensation

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

RJIA1996E

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

ZHA152H

DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR

SYMPTOM: Blower motor operation is malfunctioning under starting
fan speed control.

SJIA0266E

ATC-88
 TROUBLE DIAGNOSIS

1. CHECK POWER SUPPLY FOR BLOWER MOTOR A

1. Disconnect blower motor connector.
2. Turn ignition switch ON.
3. Check voltage between blower motor harness connector M62 B
terminal 1 (L/W) and ground.
1 – Ground : Battery voltage
C
OK or NG
OK >> GO TO 2.
NG >> Check power supply circuit and 15A fuses [Nos. 10 and D
11, located in the fuse block (J/B)]. Refer to PG-164,
RJIA1997E
"FUSE BLOCK - JUNCTION BOX (J/B)" .
● If OK, check for open circuit in wiring harness. Repair or replace as necessary. E
● If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary.

2. CHECK BLOWER MOTOR GROUND CIRCUIT F

1. Turn ignition switch OFF.
2. Check continuity between blower motor harness connector M62
terminal 3 (B) and ground. G

3 – Ground : Continuity should exist.

OK or NG H
OK >> GO TO 3.
NG >> Repair harness or connector.
I
RJIA1998E

3. CHECK CIRCUIT CONTINUITY BLOWER MOTOR AND UNIFIED METER AND A/C AMP. ATC

1. Disconnect unified meter and A/C amp. connector.

2. Check continuity between blower motor harness connector M62 K
terminal 2 (G) and unified meter and A/C amp. harness connec-
tor M50 terminal 53 (G).
2 – 53 : Continuity should exist. L
OK or NG
OK >> GO TO 4.
NG >> Repair harness or connector. M

RJIA1999E

ATC-89
 TROUBLE DIAGNOSIS

4. CHECK FOR UNIFIED METER AND A/C AMP. OUTPUT SIGNAL

1. Reconnect blower motor connector and unified meter and A/C
amp. connector.
2. Turn ignition switch ON.
3. Vary the fan speed between Lo and Hi and confirm the blower
motor connector M62 terminal No. 2 (G) and ground duty ratios
using an oscilloscope. Usual No. 2 (G) terminal drive signal duty
ratios are shown in the table below.

RJIA2000E

RJIA1390E

OK or NG
OK >> GO TO 5.
NG >> Replace unified meter and A/C amp.

5. CHECK BLOWER MOTOR DRIVE SIGNAL

If the fan air flow does not change, usual No. 2 (G) terminal drive signal duty ratios are shown in the table
above.
OK or NG
OK >> Replace blower motor.
NG >> INSPECTION END
COMPONENT INSPECTION
Blower Motor
Confirm smooth rotation of the blower motor.
● Ensure that there are no foreign particles inside the blower unit.

RJIA0905E

ATC-90
 TROUBLE DIAGNOSIS

Magnet Clutch Circuit AJS001A4

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

ATC

RJIA2130E

*1 ATC-69, "Operational Check". *2 ATC-63, "FUNCTION CONFIRMA- *3 ATC-63, "FUNCTION CONFIRMA-

TION PROCEDURE", see No.1. TION PROCEDURE", see No.5 to 7.
*4 ATC-109, "Ambient Sensor Circuit". *5 ATC-117, "Intake Sensor Circuit". *6 ATC-44, "SYMPTOM TABLE".
*7 ATC-63, "FUNCTION CONFIRMA- *8 ATC-92, "DIAGNOSTIC PROCE- *9 ATC-103, "TROUBLE DIAGNOSIS
TION PROCEDURE", see No. 9. DURE FOR MAGNET CLUTCH". FOR UNUSUAL PRESSURE".

ATC-91
 TROUBLE DIAGNOSIS

SYSTEM DESCRIPTION
Unified meter and A/C amp. controls compressor operation by ambient temperature and signal from ECM.
Low Temperature Protection Control
Unified meter and A/C amp. Will Turn compressor ON or OFF as determined by a signal detected by ambient
sensor and intake sensor.
When ambient temperatures are greater than −2°C, the compressor
turns ON. The compressor turns OFF when ambient temperatures
are less than −5°C.

RHA094GB

When intake air temperatures are greater than 1°C, the compressor
turns ON. The compressor turns OFF when intake air temperatures
are less than −5°C.

SJIA0267E

DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH

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

SJIA0382E

ATC-92
 TROUBLE DIAGNOSIS

1. CHECK AMBIENT SENSOR CIRCUIT AND INTAKE SENSOR CIRCUIT A

Check ambient sensor and intake sensor. Refer to ATC-63, "FUNCTION CONFIRMATION PROCEDURE" ,
see No. 9.
OK or NG B
OK >> GO TO 2.
NG >> ● Malfunctioning ambient sensor: Refer to ATC-109, "Ambient Sensor Circuit" .
● Malfunctioning intake sensor: Refer to ATC-117, "Intake Sensor Circuit" . C

2. PERFORM AUTO ACTIVE TEST

D
Refer to PG-57, "Auto Active Test" .
Does the magnet clutch operate?
YES >> ● WITH CONSULT-II E
GO TO 5.
● WITHOUT CONSULT-II
GO TO 6.
F
NO >> Check 10A fuse (No. 79, located in IPDM E/R), and GO TO 3.

3. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR G

1. Turn ignition switch OFF.
2. Disconnect IPDM E/R connector and compressor (magnet
clutch) connector. H
3. Check continuity between IPDM E/R harness connector E8 ter-
minal 33 (L/Y) and compressor (magnet clutch) harness connec-
tor F24 terminal 1 (L/Y). I
33 – 1 : Continuity should exist.
OK or NG ATC
OK >> GO TO 4.
RJIA2004E
NG >> Repair harness or connector.

4. CHECK MAGNET CLUTCH CIRCUIT K

Check for operation sound when applying battery voltage direct cur-
rent to terminal. L
OK or NG
OK >> Replace IPDM E/R.
NG >> Replace magnet clutch. Refer to ATC-146, "Removal M
and Installation of Compressor Clutch" .

RJIA2005E

ATC-93
 TROUBLE DIAGNOSIS

5. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL

Check compressor ON/OFF signal. Refer to ATC-42, "CONSULT-II" .
A/C SW ON : COMP ON SIG ON
A/C SW OFF : COMP ON SIG OFF
OK or NG
OK >> GO TO 8.
NG >> GO TO 6.

SJIA0270E

6. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect BCM connector and unified meter and A/C amp.
connector.
3. Check continuity between BCM harness connector M3 terminal
58 (G/Y) and unified meter and A/C amp. harness connector
M50 terminal 42 (G/Y).
58 – 42 : Continuity should exist.
OK or NG
OK >> GO TO 7.
RJIA2134E
NG >> Repair harness or connector.

7. CHECK VOLTAGE FOR UNIFIED METER AND A/C AMP. (COMPRESSOR ON SIGNAL)
1. Reconnect BCM connector and unified meter and A/C amp.
connector.
2. Turn ignition switch ON.
3. Check voltage between unified meter and A/C amp. harness
connector M50 terminal 42 (G/Y) and ground.

Terminals
(+)
Condition Voltage
Unified meter (-)
Terminal No.
and A/C amp.
(wire color) RJIA2007E
connector
A/C switch: ON Approx. 0V
M50 42 (G/Y) Ground
A/C switch: OFF Approx. 5V

OK or NG
OK >> GO TO 8.
NG-1 >> If the voltage is approx. 5V when A/C switch is ON: Replace unified meter and A/C amp.
NG-2 >> If the voltage is approx. 0V when A/C switch is OFF: Replace BCM.

ATC-94
 TROUBLE DIAGNOSIS

8. CHECK REFRIGERANT PRESSURE SENSOR A

WITH CONSULT-II
1. Start the engine.
B
2. Check voltage of refrigerant pressure sensor. Refer to TYPE 1*: EC-93, "CONSULT-II Reference Value in
Data Monitor" or TYPE 2*: EC-552, "CONSULT-II Reference Value in Data Monitor" .
*:For further infomation refer to EC-10, "APPLICATION NOTICE" .
WITHOUT CONSULT-II C
1. Start the engine.
2. Check voltage between ECM harness connector F101 terminal
D
70 (G/R) and ground.
Terminals
(+) E
Condition Voltage
ECM con- Terminal No. (-)
nector (wire color)
F101 70 (G/R) Ground A/C switch: ON Approx. 1 - 4V F
OK or NG
OK >> ● WITH CONSULT-II PBIB1188E
G
GO TO 9.
● WITHOUT CONSULT-II
GO TO 10.
H
NG >> Refer to TYPE 1*: EC-431, "REFRIGERANT PRESSURE SENSOR" or TYPE 2*:EC-866,
"REFRIGERANT PRESSURE SENSOR" .

9. CHECK BCM INPUT (FAN ON) SIGNAL I

Check FAN ON/OFF signal. Refer to ATC-42, "CONSULT-II" .

FAN SW ON : FAN ON SIG ON ATC
FAN SW OFF : FAN ON SIG OFF
OK or NG
K
OK >> GO TO 12.
NG >> GO TO 10.
L

SJIA0270E

M
10. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect BCM connector and unified meter and A/C amp.
connector.
3. Check continuity between BCM harness connector M3 terminal
65 (BR/W: LHD models, BR/Y: RHD models) and unified meter
and A/C amp. harness connector M50 terminal 57 (BR/W: LHD
models, BR/Y: RHD models).
65 – 57 : Continuity should exist.
OK or NG
RJIA2135E
OK >> GO TO 11.
NG >> Repair harness or connector.

ATC-95
 TROUBLE DIAGNOSIS

11. CHECK VOLTAGE FOR UNIFIED METER AND A/C AMP. (FAN ON SIGNAL)
1. Reconnect BCM connector and unified meter and A/C amp.
connector.
2. Turn ignition switch ON.
3. Check voltage between unified meter and A/C amp. harness
connector M50 terminal 57 (BR/W: LHD models, BR/Y: RHD
models) and ground.

Terminals
(+)
Condition Voltage
Unified meter (-)
Terminal No. RJIA2010E
and A/C amp.
(wire color)
connector

57 Fan control dial: ON

(BR/W: LHD (Blower motor oper- Approx. 0V
M50 Ground ates)
models, BR/Y:
RHD models) Fan control dial: OFF Approx. 5V

OK or NG
OK >> GO TO 12.
NG-1 >> If the voltage is approx. 5V when blower motor is ON: Replace unified meter and A/C amp.
NG-2 >> If the voltage is approx. 0V when blower motor is OFF: Replace BCM. Refer to BCS-24, "Removal
and Installation of BCM" .

12. CHECK CAN COMMUNICATION

Check CAN communication. Refer to BCS-22, "CAN Communication Inspection Using CONSULT-II (Self-
Diagnosis)" .
● BCM – ECM
● ECM – IPDM E/R
● ECM – Unified meter and A/C amp.
OK or NG
OK >> INSPECTION END
NG >> Repair or replace malfunctioning part (s).
COMPONENT INSPECTION
Refrigerant Pressure Sensor
The refrigerant pressure sensor is attached to the liquid tank.
Make sure that the A/C refrigerant pressure and the sensor output
voltage are within the specified range as shown in the A/C operating
condition figure. Refer to TYPE 1*: EC-431, "REFRIGERANT PRES-
SURE SENSOR" or TYPE 2*:EC-866, "REFRIGERANT PRES-
SURE SENSOR" .
*:For further infomation refer to EC-10, "APPLICATION NOTICE" .

RJIA1393E

ATC-96
TROUBLE DIAGNOSIS

SHA315F

ATC

ATC-97
 TROUBLE DIAGNOSIS

Insufficient Cooling AJS001A5

SYMPTOM: Insufficient cooling.

INSPECTION FLOW

RJIA2136E

*1 ATC-69, "Operational Check". *2 ATC-63, "FUNCTION CONFIRMA- *3 ATC-63, "FUNCTION CONFIRMA-

TION PROCEDURE", see No.1. TION PROCEDURE", see No.5 to 7.
*4 EM-12, "Checking Drive Belts". *5 ATC-80, "Air Mix Door Motor Circuit". *6 ATC-101, "Test Reading (LHD mod-
els)" or ATC-102, "Test Reading
(RHD models)" .
*7 ATC-67, "AUXILIARY MECHA- *8 ATC-63, "FUNCTION CONFIRMA- *9 ATC-73, "LAN System Circuit".
NISM: TEMPERATURE SETTING TION PROCEDURE", see No. 9.
TRIMMER".

ATC-98
 TROUBLE DIAGNOSIS

*10 ATC-86, "Blower Motor Circuit". *11 ATC-91, "Magnet Clutch Circuit". *12 TYPE 1*: EC-247, "SYSTEM
DESCRIPTION" or TYPE 2*: EC- A
691, "SYSTEM DESCRIPTION" .
*13 ATC-99, "PERFORMANCE TEST
DIAGNOSES".
B
*:For further infomation refer to EC-10, "APPLICATION NOTICE" .
PERFORMANCE TEST DIAGNOSES
C

ATC

RJIA1601E

ATC-99
 TROUBLE DIAGNOSIS

*1 ATC-101, "PERFORMANCE *2 ATC-101, "PERFORMANCE *3 ATC-103, "TROUBLE DIAGNOSIS

CHART". CHART". FOR UNUSUAL PRESSURE".
*4 ATC-80, "Air Mix Door Motor Circuit".

RJIA1595E

*1 ATC-146, "Removal and Installation *2 ATC-86, "Blower Motor Circuit". *3 EM-12, "Checking Drive Belts".
of Compressor Clutch".

ATC-100
 TROUBLE DIAGNOSIS

PERFORMANCE CHART
Test Condition A
Testing must be performed as follows:
Vehicle location Indoors or in the shade (in a well-ventilated place)
B
Doors Closed
Door window Open
Hood Open C
TEMP. Max. COLD
Mode control dial (Ventilation) set
D
Intake switch (Recirculation) set

Fan (blower) speed Max. speed set

Engine speed Idle speed
E

Operate the air conditioning system for 10 minutes before taking measurements.

Test Reading (LHD models) F

Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator G
Relative humidity Air temperature °C
% °C
15 2.8 - 3.9
H
20 5.3 - 7.7
50 - 60 25 8.9 - 12.0
30 13.0 - 16.7 I
35 18.2 - 22.0
15 3.9 - 6.0
ATC
20 7.7 - 10.0
60 - 70 25 12.0 - 14.4
30 16.7 - 19.8 K
35 22.0 - 26.0

Ambient Air Temperature-to-operating Pressure Table

L
Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar, kg/cm2 , psi) kPa (bar, kg/cm2 , psi)
% °C
M
600 - 770 165 - 220
15
(6.00 - 7.70, 6.12 - 7.86, 87.0 - 111.7) (1.65 - 2.20, 1.68 - 2.24, 23.9 - 31.9)
640 - 840 170 - 235
20
(6.40 - 8.40, 6.53 - 8.57, 92.8 - 121.8) (1.70 - 2.35, 1.73 - 2.40, 24.7 - 34.1)
790 - 1,030 185 - 255
50 - 70 25
(7.90 - 10.30, 8.06 - 10.5, 114.6 - 149.4) (1.85 - 2.55, 1.89 - 2.60, 26.8 - 37.0)
1,050 - 1,340 205 - 290
30
(10.50 - 13.40, 10.7 - 13.7, 152.3 - 194.3) (2.05 - 2.90, 2.10 - 2.96, 29.7 - 42.1)
1,055 - 1,345 240 - 335
35
(10.55 - 13.45, 10.8 - 13.7, 153.0 - 195.0) (2.40 - 3.35, 2.45 - 3.42, 34.8 - 48.6)

ATC-101
 TROUBLE DIAGNOSIS

Test Reading (RHD models)

Recirculating-to-discharge Air Temperature Table
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature °C
% °C
20 5.8 - 8.0
25 9.9 - 13.0
50 - 60 30 14.5 - 18.0
35 18.6 - 22.1
40 22.3 - 25.8
20 8.0 - 10.4
25 13.0 - 16.1
60 - 70 30 18.0 - 21.6
35 22.1 - 25.6
40 25.8 - 29.3

Ambient Air Temperature-to-operating Pressure Table

Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar, kg/cm2 , psi) kPa (bar, kg/cm2 , psi)
% °C
640 - 855 168 - 236
20
(6.40 - 8.55, 6.53 - 8.72, 92.8 - 124.0) (1.68 - 2.36, 1.71 - 2.41, 24.4 - 34.2)
830 - 1,090 172 - 240
25
(8.30 - 10.90, 8.47 - 11.12, 120.4 - 158.1) (1.72 - 2.40, 1.75 - 2.45, 24.9 - 34.8)
1,085 - 1,400 190 - 275
50 - 70 30
(10.85 - 14.00, 11.07 - 14.28, 157.3 -203.0) (1.90 - 2.75, 1.94 - 2.81, 27.6 - 39.9)
1,330 - 1,690 230 - 325
35
(13.30 - 16.90, 13.57 - 17.24, 192.9 - 245.1) (2.30 - 3.25, 2.35 - 3.32, 33.4 - 47.1)
1,575 - 1,985 275 - 385
40
(15.75 - 19.85, 16.07 - 20.25, 228.4 - 287.8) (2.75 - 3.85, 2.81 - 3.93, 39.9 - 55.8)

ATC-102
 TROUBLE DIAGNOSIS

TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE

Whenever system′s high and/or low side pressure is unusual, diagnose using a manifold gauge. The marker A
above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the stan-
dard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-
to-operating pressure table). B
Both High- and Low-pressure Sides are Too High
Gauge indication Refrigerant cycle Probable cause Corrective action
C
Pressure is reduced soon after
Excessive refrigerant charge Reduce refrigerant until speci-
water is splashed on con-
in refrigeration cycle fied pressure is obtained.
denser.
Insufficient condenser cooling
D
performance
↓ ● Clean condenser.
Air suction by cooling fan is
insufficient. 1. Condenser fins are clogged. ● Check and repair cooling E
fan as necessary.
2. Improper fan rotation of
cooling fan
● Low-pressure pipe is not F
Both high- and low-pressure sides cold. Poor heat exchange in con-
are too high. ● When compressor is denser
stopped high-pressure value (After compressor operation
Evacuate repeatedly and G
quickly drops by approxi- stops, high pressure
recharge system.
mately 196 kPa (1.96 bar, 2 decreases too slowly.)
kg/cm2 , 28 psi). It then ↓
decreases gradually thereaf- Air in refrigeration cycle H
ter.
AC359A
Engine cooling systems mal- Check and repair each engine
Engine tends to overheat.
function. cooling system. I
● Excessive liquid refrigerant
on low-pressure side

● An area of the low-pressure

● Excessive refrigerant dis- ATC
charge flow
pipe is colder than areas
near the evaporator outlet. ● Expansion valve is open a Replace expansion valve.
little compared with the
● Plates are sometimes cov- K
specification.
ered with frost.
↓
Improper expansion valve
adjustment L

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

Gauge indication Refrigerant cycle Probable cause Corrective action M
High-pressure side is too high and
low-pressure side is too low.

Upper side of condenser and High-pressure tube or parts ● Check and repair or replace
high-pressure side are hot, located between compressor malfunctioning parts.
however, liquid tank is not so and condenser are clogged or ● Check lubricant for contami-
hot. crushed. nation.

AC360A

ATC-103
 TROUBLE DIAGNOSIS

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

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

Both High- and Low-pressure Sides are Too Low

Gauge indication Refrigerant cycle Probable cause Corrective action
● There is a big temperature
difference between receiver
drier outlet and inlet. Outlet ● Replace liquid tank.
temperature is extremely Liquid tank inside is slightly
clogged. ● Check lubricant for contami-
low. nation.
● Liquid tank inlet and expan-
sion valve are frosted.
● Temperature of expansion
valve inlet is extremely low
as compared with areas
near liquid tank. ● Check and repair malfunc-
High-pressure pipe located tioning parts.
● Expansion valve inlet may between receiver drier and
be frosted. expansion valve is clogged. ● Check lubricant for contami-
nation.
● Temperature difference
occurs somewhere in high-
Both high- and low-pressure sides pressure side
are too low.
Expansion valve and liquid Low refrigerant charge Check refrigerant for leaks.
tank are warm or only cool ↓ Refer to ATC-160, "Checking
when touched. Leaking fittings or components for Refrigerant Leaks" .
Expansion valve closes a little
compared with the specifica-
tion.
AC353A
↓ ● Remove foreign particles by
There is a big temperature dif-
ference between expansion 1. Improper expansion valve using compressed air.
valve inlet and outlet while the adjustment. ● Check lubricant for contami-
valve itself is frosted. 2. Malfunctioning expansion nation.
valve.
3. Outlet and inlet may be
clogged.
● Check and repair malfunc-
An area of the low-pressure tioning parts.
Low-pressure pipe is clogged
pipe is colder than areas near
or crushed. ● Check lubricant for contami-
the evaporator outlet.
nation.
● Check intake sensor circuit.
Air flow volume is not enough Refer to ATC-117, "Intake
Evaporator is frozen. Sensor Circuit" .
or is too low.
● Replace compressor.

ATC-104
 TROUBLE DIAGNOSIS

Low-pressure Side Sometimes Becomes Negative

Gauge indication Refrigerant cycle Probable cause Corrective action
A

Low-pressure side sometimes

● Air conditioning system Refrigerant does not dis-
becomes negative.
does not function and does charge cyclically. B
not cyclically cool the com- ↓ ● Drain water from refrigerant
partment air. Moisture is frozen at expan- or replace refrigerant.
● The system constantly func- sion valve outlet and inlet.
↓ ● Replace liquid tank. C
tions for a certain period of
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A
D
Low-pressure Side Becomes Negative
Gauge indication Refrigerant cycle Probable cause Corrective action
Leave the system at rest until E
no frost is present. Start it
again to check whether or not
the problem is caused by
water or foreign particles.
F
● If water is the cause, initially
cooling is okay. Then the
water freezes causing a G
Low-pressure side becomes nega-
blockage. Drain water from
tive.
refrigerant or replace refrig-
High-pressure side is closed
erant.
Liquid tank or front/rear side of and refrigerant does not flow. H
expansion valve′s pipe is ↓ ● If due to foreign particles,
frosted or dewed. Expansion valve or liquid tank remove expansion valve
is frosted. and remove the particles
with dry and compressed air I
AC362A
(not shop air).
● If either of the above meth-
ods cannot correct the prob- ATC
lem, replace expansion
valve.
● Replace liquid tank.
K
● Check lubricant for contami-
nation.

ATC-105
 TROUBLE DIAGNOSIS

Insufficient Heating AJS001BR

SYMPTOM: Insufficient heating

INSPECTION FLOW

RJIA2137E

*1 ATC-69, "Operational Check". *2 ATC-63, "FUNCTION CONFIRMA- *3 ATC-63, "FUNCTION CONFIRMA-

TION PROCEDURE", see No. 1. TION PROCEDURE", see No. 5 to 7.
*4 CO-10, "Changing Engine Coolant". *5 CO-15, "Checking Radiator Cap". *6 TYPE 1*: EC-141, "DTC P0117,
P0118 ECT SENSOR" or TYPE 2*:
EC-591, "DTC P0117, P0118 ECT
SENSOR" .
*7 ATC-63, "FUNCTION CONFIRMA- *8 ATC-73, "LAN System Circuit". *9 ATC-86, "Blower Motor Circuit".
TION PROCEDURE", see No. 9.
*10 ATC-80, "Air Mix Door Motor Cir-
cuit".

*:For further infomation refer to EC-10, "APPLICATION NOTICE" .

ATC-106
 TROUBLE DIAGNOSIS

Noise AJS001A7

A
SYMPTOM: Noise
INSPECTION FLOW
B

ATC

RJIA1596E

*1 Compressor Clutch, ATC-146, *2 Compressor Clutch, ATC-148, *3 ATC-24, "Maintenance of Lubricant

"REMOVAL" . "INSTALLATION" . Quantity in Compressor".
*4 ATC-69, "Operational Check". *5 EM-12, "Checking Drive Belts".

ATC-107
 TROUBLE DIAGNOSIS

Self-diagnosis AJS001BS

SYMPTOM: Self-diagnosis cannot be performed.

INSPECTION FLOW

RJIA2138E

*1 ATC-69, "Operational Check". *2 ATC-71, "Power Supply and Ground *3 ATC-44, "SYMPTOM TABLE".
Circuit for Auto Amp.".

ATC-108
 TROUBLE DIAGNOSIS

Ambient Sensor Circuit AJS001A9

COMPONENT DESCRIPTION A
Ambient Sensor
The ambient sensor is attached on the hood lock stay. It detects
ambient temperature and converts it into a resistance value which is B
then input into the unified meter and A/C amp.

RJIA1398E
E
AMBIENT TEMPERATURE INPUT PROCESS
The unified meter and A/C amp. includes a processing circuit for the ambient sensor input. However, when the
temperature detected by the ambient sensor increases quickly, the processing circuit retards the unified meter F
and A/C amp. function. It only allows the auto amp. to recognize an ambient temperature increase of 0.33°C
per 100 seconds.
As an example, consider stopping for a cup of coffee after high speed driving. Although the actual ambient
temperature has not changed, the temperature detected by the ambient sensor will increase. This is because G
the heat from the engine compartment can radiate to the front grille area, location of the ambient sensor.
DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR
H
SYMPTOM: Ambient sensor circuit is open or shorted.
LED of A/C switch does not illuminate as a result of performing self-
diagnosis STEP-2.
I

ATC

K
RJIA1461E

1. CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND L

1. Disconnect ambient sensor connector.

2. Turn ignition switch ON. M
3. Check voltage between ambient sensor harness connector E34
terminal 1 (Y/G) and ground.
1 – Ground : Approx. 5V
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
RJIA2017E

ATC-109
 TROUBLE DIAGNOSIS

2. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between ambient sensor harness connector
E34 terminal 2 (W/G) and unified meter and A/C amp. harness
connector M50 terminal 49 (W/L: LHD models, W/G: RHD mod-
els).
2 – 49 : Continuity should exist.
OK or NG
OK >> GO TO 3.
RJIA2018E
NG >> Repair harness or connector.

3. CHECK AMBIENT SENSOR

Refer to ATC-111, "Ambient Sensor" .
OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> 1. Replace ambient sensor.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.

4. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between ambient sensor harness connector
E34 terminal 1 (Y/G) and unified meter and A/C amp. harness
connector M50 terminal 39 (Y).
1 – 39 : Continuity should exist.
4. Check continuity between ambient sensor harness connector
E34 terminal 1 (Y/G) and ground.
1 – Ground : Continuity should not exist. RJIA2019E

OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> Repair harness or connector.

ATC-110
 TROUBLE DIAGNOSIS

COMPONENT INSPECTION
Ambient Sensor A
After disconnecting ambient sensor connector E34, measure resis-
tance between terminals 2 and 1 at sensor side, using the table
below. B

Temperature °C Resistance kΩ
−15 12.73 C
−10 9.92
−5 7.80
0 6.19 D
5 4.95
10 3.99
E
15 3.24
20 2.65
25 2.19 F
30 1.81
35 1.51
G
40 1.27
45 1.07

If NG, replace ambient sensor. RJIA2139E H

In-vehicle Sensor Circuit AJS001AA

COMPONENT DESCRIPTION I
In-vehicle sensor
The in-vehicle sensor is located on instrument lower panel. It con-
verts variations in temperature of compartment air drawn from the ATC
aspirator into a resistance value. It is then input into the unified meter
and A/C amp.
NOTE:
K
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.

RJIA1400E

Aspirator M
The aspirator is located on driver′s side of heater & cooling unit. It produces vacuum pressure due to air dis-
charged from the heater & cooling unit, continuously taking compartment air in the aspirator.
LHD Models

RJIA1401E

ATC-111
 TROUBLE DIAGNOSIS

RHD Models

RJIA2140E

RJIA1402E

DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR

SYMPTOM: In-vehicle sensor circuit is open or shorted.
LED of A/C switch does not illuminate as a result of performing self-
diagnosis STEP-2.

RJIA1452E

1. CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND

1. Disconnect in-vehicle sensor connector.
2. Turn ignition switch ON.
3. Check voltage between in-vehicle sensor harness connector
M42 terminal 1 (BR) and ground.
1 – Ground : Approx. 5V
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
RJIA2022E

ATC-112
 TROUBLE DIAGNOSIS

2. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C A
AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector. B
3. Check continuity between in-vehicle sensor harness connector
M42 terminal 2 (W/L: LHD models, W/G: RHD models) and uni-
fied meter and A/C amp. harness connector M50 terminal 49 C
(W/L: LHD models, W/G: RHD models).
2 – 49 : Continuity should exist.
D
OK or NG
OK >> GO TO 3.
RJIA2023E
NG >> Repair harness or connector.
E
3. CHECK IN-VEHICLE SENSOR
Refer to ATC-114, "In-vehicle Sensor" . F
OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self- G
diagnosis STEP-2.
NG >> 1. Replace in-vehicle sensor.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self- H
diagnosis STEP-2.

4. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C I
AMP.
1. Turn ignition switch OFF.
ATC
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between in-vehicle sensor harness connector
M42 terminal 1 (BR) and unified meter and A/C amp. harness
connector M50 terminal 40 (BR). K

1 – 40 : Continuity should exist.

4. Check continuity between in-vehicle sensor harness connector L
M42 terminal 1 (BR) and ground.
1 – Ground : Continuity should not exist. RJIA2024E
M
OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> Repair harness or connector.

ATC-113
 TROUBLE DIAGNOSIS

COMPONENT INSPECTION
In-vehicle Sensor
After disconnecting in-vehicle sensor connector M42, measure resis-
tance between terminals 1 and 2 at sensor side, using the table
below.
Temperature °C Resistance kΩ
−15 12.73
−10 9.92
−5 7.80
0 6.19
5 4.95
10 3.99
15 3.24
20 2.65
25 2.19
30 1.81
35 1.51
40 1.27
45 1.07
RJIA1403E
If NG, replace in-vehicle sensor.
Sunload Sensor Circuit AJS001AB

COMPONENT DESCRIPTION
The sunload sensor is located on the passenger′s side defroster
grille. It detects sunload entering through windshield by means of a
photo diode. The sensor converts the sunload into a current value
which is then input into the unified meter and A/C amp.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.

RJIA1404E

SUNLOAD INPUT PROCESS

The unified meter and A/C amp. also includes a processing circuit which averages the variations in detected
sunload over a period of time. This prevents drastic swings in the ATC system operation due to small or quick
variations in detected sunload.
For example, consider driving along a road bordered by an occasional group of large trees. The sunload
detected by the sunload sensor will vary whenever the trees obstruct the sunlight. The processing circuit aver-
ages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily
obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly
after entering a long tunnel, the system will recognize the change in sunload, and the system will react accord-
ingly.

ATC-114
 TROUBLE DIAGNOSIS

DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR

SYMPTOM: Sunload sensor circuit is open or shorted. A
LED of A/C switch does not illuminate as a result of performing self-
diagnosis STEP-2.
B

RJIA1455E
D

1. CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND E

1. Disconnect sunload sensor connector.
2. Turn ignition switch ON.
F
3. Check voltage between sunload sensor harness connector M18
terminal 1 (LG) and ground.
1 – Ground : Approx. 5V G
OK or NG
OK >> GO TO 2.
NG >> GO TO 4. H

RJIA2027E

2. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP. I

1. Turn ignition switch OFF.

2. Disconnect unified meter and A/C amp. connector. ATC
3. Check continuity between sunload sensor harness connector
M18 terminal 2 (W/L: LHD models, W/G: RHD models) and uni-
fied meter and A/C amp. harness connector M50 terminal 49 K
(W/L: LHD models, W/G: RHD models).
2 – 49 : Continuity should exist.
L
OK or NG
OK >> GO TO 3.
RJIA2028E
NG >> Repair harness or connector.
M
3. CHECK SUNLOAD SENSOR
1. Reconnect sunload sensor connector and unified meter and A/C amp. connector.
2. Refer to ATC-116, "Sunload Sensor" .
OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> 1. Replace sunload sensor.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.

ATC-115
 TROUBLE DIAGNOSIS

4. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between sunload sensor harness connector
M18 terminal 1 (LG) and unified meter and A/C amp. harness
connector M50 terminal 50 (LG).
1 – 50 : Continuity should exist.
4. Check continuity between sunload sensor harness connector
M18 terminal 1 (LG) and ground.
1 – Ground : Continuity should not exist. RJIA2029E

OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> Repair harness or connector.
COMPONENT INSPECTION
Sunload Sensor
Measure voltage between unified meter and A/C amp. harness con-
nector M50 terminal 50 (LG) and ground.
If NG, replace unified meter and A/C amp.

RJIA2141E

ATC-116
 TROUBLE DIAGNOSIS

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

SHA930E

Intake Sensor Circuit AJS001AC G

COMPONENT DESCRIPTION
Intake Sensor
The intake sensor is located on the heater & cooling unit. It converts H
temperature of air after it passes through the evaporator into a resis-
tance value which is then input to the unified meter and A/C amp.
NOTE: I
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.
ATC

RJIA1406E
K

DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR

SYMPTOM: Intake sensor circuit is open or shorted. L
LED of A/C switch does not illuminate as a result of performing self-
diagnosis STEP-2.
M

RJIA1458E

ATC-117
 TROUBLE DIAGNOSIS

1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND

1. Disconnect intake sensor connector.
2. Turn ignition switch ON.
3. Check voltage between intake sensor harness connector M255
terminal 2 (R) and ground.
2 – Ground : Approx. 5V
OK or NG
OK >> GO TO 2.
NG >> GO TO 4.
RJIA2031E

2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between intake sensor harness connector
M255 terminal 1 (W) and unified meter and A/C amp. harness
connector M50 terminal 49 (W/L: LHD models, W/G: RHD mod-
els).
1 – 49 : Continuity should exist.
OK or NG
OK >> GO TO 3.
RJIA2032E
NG >> Repair harness or connector.

3. CHECK INTAKE SENSOR

Refer to ATC-119, "Intake Sensor" .
OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> 1. Replace intake sensor.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.

4. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP.
1. Turn ignition switch OFF.
2. Disconnect unified meter and A/C amp. connector.
3. Check continuity between intake sensor harness connector
M255 terminal 2 (R) and unified meter and A/C amp. harness
connector M50 terminal 41 (SB: LHD models, P: RHD models).
2 – 41 : Continuity should exist.
4. Check continuity between intake sensor harness connector
M255 terminal 2 (R) and ground.
2 – Ground : Continuity should not exist. RJIA2033E

OK or NG
OK >> 1. Replace unified meter and A/C amp.
2. Go to self-diagnosis ATC-63, "FUNCTION CONFIRMATION PROCEDURE" and perform self-
diagnosis STEP-2.
NG >> Repair harness or connector.

ATC-118
 TROUBLE DIAGNOSIS

COMPONENT INSPECTION
Intake Sensor A
After disconnecting intake sensor connector M255, measure resis-
tance between terminals 1 and 2 at sensor side, using the table
below. B

Temperature °C Resistance kΩ
−15 12.34 C
−10 9.62
−5 7.56
0 6.00 D
5 4.80
10 3.87
E
15 3.15
20 2.57
25 2.12 F
30 1.76
35 1.47
G
40 1.23
45 1.04

If NG, replace intake sensor. RJIA1462E H

ATC

ATC-119
 A/C CONTROLLER

A/C CONTROLLER PFP:27500

Removal and Installation AJS001AD

REMOVAL
1. Remove console finisher (A/T) or console boot (M/T). Refer to IP-11, "Removal and Installation" .
2. Remove A/C controller from console finisher (A/T) or console
boot (M/T).

RJIA1407E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-120
 AUTO AMP

AUTO AMP PFP:27760

A
Removal and Installation of Unified Meter and A/C Amp. AJS001AE

REMOVAL
1. Remove the console finisher (A/T) or console boot (M/T). Refer to IP-11, "Removal and Installation" .
B
2. Remove the fixing screws, then remove the unified meter and A/
C amp.
C

E
RJIA1409E

INSTALLATION
Installation is basically the reverse order of removal. F

ATC

ATC-121
 AMBIENT SENSOR

AMBIENT SENSOR PFP:27722

Removal and Installation AJS001AF

REMOVAL
1. Remove the engine under cover.
2. Disconnect ambient sensor connector.
3. Remove ambient sensor.

RJIA1398E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-122
 IN-VEHICLE SENSOR

IN-VEHICLE SENSOR PFP:27720

A
Removal and Installation AJS001AG

REMOVAL
1. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
B
2. Remove in-vehicle sensor.
NOTE:
This illustration is for LHD models. The layout for RHD models is
C
symmetrically opposite.

E
RJIA1410E

INSTALLATION
Installation is basically the reverse order of removal. F

ATC

ATC-123
 SUNLOAD SENSOR

SUNLOAD SENSOR PFP:27721

Removal and Installation AJS001AH

REMOVAL
1. Pull out sunload sensor from instrument panel.
2. Disconnect sunload sensor connector, then remove sunload
sensor.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.

RJIA1404E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-124
 INTAKE SENSOR

INTAKE SENSOR PFP:27723

A
Removal and Installation AJS001AI

REMOVAL
1. Set the temperature control dial at 18°C.
B
2. Open the driver and front passenger window, and then disconnect the battery negative cable.
CAUTION:
After the battery cables are disconnected, do not open/close the driver and/or front passenger
C
door with the window in the full up position. The automatic window adjusting function will not
work and the side roof panel may be damaged.
3. Using a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
D
4. Remove low-pressure pipe and high-pressure pipe 2. Refer to ATC-153, "Removal and Installation of
Low-pressure Pipe and High-pressure Pipe 2" .
CAUTION:
E
Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere.
5. Slide the evaporator to passenger side, then remove the intake
sensor.
F
NOTE:
These illustrations are for LHD models. The layout for RHD
models is symmetrically opposite.
G

RJIA1406E

INSTALLATION I
Installation is basically the reverse order of removal.
CAUTION:
● Replace O-rings for A/C piping with new ones. Before installing, apply compressor oil to them. ATC
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
● Insert one-touch joint connection point securely until it clicks. K
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.
● When recharging refrigerant, check for leaks. L

ATC-125
 BLOWER UNIT

BLOWER UNIT PFP:27200

Removal and Installation AJS001AJ

REMOVAL
1. Remove instrument passenger panel lower. Refer to IP-11, "Removal and Installation" .
2. Remove ECM with bracket attached.
NOTE:
These illustrations are for LHD models. The layout for RHD
models is symmetrically opposite.
3. Disconnect intake door motor connector and blower fan motor
connector.
4. Remove mounting bolts and screws, then remove blower unit.
CAUTION:
Move blower unit rightward, and remove locating pin (1)
and joint. Then remove blower unit downward. RJIA1413E

5. Remove blower unit.

RJIA1414E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Make sure locating pin (1) and joint are securely inserted.

ATC-126
 BLOWER UNIT

Disassembly and Assembly AJS001AK

I
RJIA1415E

1. Intake upper case 2. Intake bell mouth 3. Intake lower case

4. Blower motor assembly 5. Intake door lever 2 6. Intake door motor
ATC
7. Intake door link 8. Intake door lever 3 9. Intake door 2
10. Intake door lever 1 11. Intake door 1

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

ATC-127
 BLOWER MOTOR

BLOWER MOTOR PFP:27226

Removal and Installation AJS001AL

REMOVAL
1. Disconnect blower motor connector.
2. Remove screws from blower motor, then remove it.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.

RJIA0946E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-128
 INTAKE DOOR MOTOR

INTAKE DOOR MOTOR PFP:27730

A
Removal and Installation AJS001AM

REMOVAL
1. Remove blower unit. Refer to ATC-126, "BLOWER UNIT" .
B
2. Remove intake door motor from the blower unit.
LHD Models
C

RJIA1416E

F
RHD Models

I
RJIA1529E

INSTALLATION
ATC
Installation is basically the reverse order of removal.

ATC-129
 HEATER & COOLING UNIT ASSEMBLY

HEATER & COOLING UNIT ASSEMBLY PFP:27110

Removal and Installation AJS001AN

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant.
2. Drain coolant from cooling system. Refer to CO-10, "Changing Engine Coolant" .
3. Remove cowl top cover. Refer to EI-20, "COWL TOP" .
4. Remove mounting bolt for low-pressure flexible hose bracket.
(RHD models)
5. Remove clip from high-pressure pipe 1. (RHD models)

RJIA1434E

6. Disconnect low-pressure flexible hose and high-pressure pipe 1

from evaporator.
a. Set a disconnector (low-pressure side: 92530-89916, high-pres-
sure side: 92530-89908) on A/C piping.
b. Slide a disconnector toward vehicle front until it clicks.
c. Slide A/C piping toward vehicle front and disconnect it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
7. Remove air hose and electronic control throttle assembly. Refer RJIA1417E
to EM-16, "INTAKE MANIFOLD COLLECTOR" .
8. Disconnect two heater hoses from heater core.

RJIA0423E

9. Remove instrument panel assembly. Refer to IP-11, "Removal and Installation" .

10. Remove blower unit. Refer to ATC-126, "BLOWER UNIT" .
11. Remove clips of vehicle harness from steering member.
12. Remove instrument stays (left and right).

ATC-130
 HEATER & COOLING UNIT ASSEMBLY

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

D
RJIA1418E

13. Remove defroster nozzle and ventilator ducts.

14. Remove mounting bolts from heater & cooling unit. E
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite. F

RJIA1420E H

15. Remove the steering member, and then remove heater & cooling unit.
I

ATC

RJIA1419E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
● Replace O-rings for A/C piping with new one, then apply compressor oil to it when installing it.
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
● Insert one-touch joint connection point securely until it clicks.
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.
● When recharging refrigerant, check for leaks.

ATC-131
 HEATER & COOLING UNIT ASSEMBLY

NOTE:
● When filling radiator with coolant, refer to CO-10, "Changing Engine Coolant" .
● Recharge the refrigerant.
Heater & cooling unit mounting bolt
Tightening torque : 6.9 N·m (0.7 kg·m, 61 in-lb.)
Steering member mounting nut and bolt
Tightening torque : 12 N·m (1.25 kg·m, 9 ft.-lb.)
Bolt mounting the low-pressure flexible hose bracket
Tightening torque : 4.2 N·m (0.43 kg·m, 37 in-lb.)

ATC-132
 HEATER & COOLING UNIT ASSEMBLY

Disassembly and Assembly AJS001AO

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

ATC

RJIA1421E

1. Heater pipe grommet 2. Heater core 3. Heater pipe cover

4. Aspirator 5. Aspirator duct 6. Rear foot cover
7. Max. cool door link 8. Max. cool door lever 9. Ventilator door lever
10. Ventilator door link 11. Air mix door motor 12. Intake sensor

ATC-133
 HEATER & COOLING UNIT ASSEMBLY

13. Foot duct (right) 14. Evaporator cover 15. Evaporator cover adapter
16. Heater pipe bracket 17. Insulator 18. Heater case (right)
19. Low-pressure pipe 20. High-pressure pipe 2 21. Expansion valve
22. Evaporator 23. Heater case (left) 24. Foot duct (left)
25. Air mix door (slide door) 26. Ventilator door 27. Side link
28. Mode door motor 29. Intake sensor bracket 30. Defroster door
31. Max. cool door 32. Defroster door lever 33. Defroster door link

ATC-134
 MODE DOOR MOTOR

MODE DOOR MOTOR PFP:27731

A
Removal and Installation AJS001BT

REMOVAL
LHD Models B
1. Remove blower unit. Refer to ATC-126, "BLOWER UNIT" .
2. Remove mounting screws from mode door motor.
3. Disconnect mode door motor connector. C
4. Remove mode door motor.

RJIA0954E

RHD Models F
1. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
2. Remove VDC/TCS/ABS C/U. Refer to BRC-134, "Removal and Installation" .
3. Disconnect mode door motor connector. G
4. Remove mode door motor.
H

ATC
RJIA1535E

INSTALLATION
Installation is basically the reverse order of removal. K

ATC-135
 AIR MIX DOOR MOTOR

AIR MIX DOOR MOTOR PFP:27732

Removal and Installation AJS001BU

REMOVAL
LHD Models
1. Set the temperature control dial at 18°C.
2. Open the driver and front passenger window, and then disconnect the battery negative cable.
CAUTION:
After the battery cables are disconnected, do not open/close the driver and/or front passenger
door with the window in the full up position. The automatic window adjusting function will not
work and the side roof panel may be damaged.
3. Remove blower unit. Refer to ATC-126, "BLOWER UNIT" .
4. Disconnect air mix door motor connector.
5. Remove air mix door motor.

RJIA1422E

RHD Models
1. Set the temperature control dial at 18°C.
2. Open the driver and front passenger window, and then disconnect the battery negative cable.
CAUTION:
After the battery cables are disconnected, do not open/close the driver and/or front passenger
door with the window in the full up position. The automatic window adjusting function will not
work and the side roof panel may be damaged.
3. Remove instrument driver panel lower. Refer to IP-11, "Removal and Installation" .
4. Remove VDC/TCS/ABS C/U. Refer to BRC-134, "Removal and Installation" .
5. Disconnect air mix door motor connector.
6. Remove air mix door motor.

RJIA1536E

INSTALLATION
Installation is basically the reverse order of removal.

ATC-136
 HEATER CORE

HEATER CORE PFP:27140

A
Removal and Installation AJS001C2

REMOVAL
1. Remove heater & cooling unit. Refer to ATC-130, "HEATER & COOLING UNIT ASSEMBLY" .
B
2. Remove foot duct (left). Refer to ATC-141, "Removal of Foot Ducts" .
3. Remove heater pipe cover.
4. Remove heater pipe support and heater pipe grommet. C
5. Slide heater core to driver side.

I
RJIA2142E

NOTE:
This illustration is for LHD models. The layout for RHD models is symmetrically opposite. ATC
INSTALLATION
Installation is basically the reverse order of removal.
K

ATC-137
 DUCTS AND GRILLES

DUCTS AND GRILLES PFP:27860

Removal and Installation AJS001AR

REMOVAL
NOTE:
These illustrations are for LHD models. The layout for RHD models is symmetrically opposite.

RJIA1423E

1. Defroster nozzle 2. Side defroster duct 1 (left) 3. Side ventilator duct 1 (left)
4. Side defroster duct 2 5. Instrument side finisher (left) 6. Side ventilator duct 2 (left)
7. Side ventilator grille (left) 8. Center ventilator grille (left) 9. Side ventilator grille (right)
10. Side ventilator grille (right) 11. Side ventilator duct 2 (right) 12. Instrument side finisher (right)
13. Instrument panel 14. Side defroster duct 2 (right) 15. Side ventilator duct 1 (right)
16. Side defroster duct 1 (right) 17. Center ventilator duct

Removal of Center Ventilator Grille

1. Remove instrument driver and passenger panel upper. Refer to IP-11, "Removal and Installation" .
2. Remove center ventilator grille.

RJIA1424E

ATC-138
 DUCTS AND GRILLES

Removal of Side Ventilator Duct 2 and Grille

1. Remove door finisher. Refer to EI-32, "DOOR FINISHER" . A
2. Remove side ventilator duct 2.

D
RJIA1425E

3. Remove side ventilator grille. E

H
RJIA1426E

Removal of Instrument Side Finisher

I
1. Remove instrument side finisher.

ATC

L
RJIA1463E

Removal of Defroster Nozzle, Ducts and Ventilator Ducts

1. Remove instrument panel. Refer to IP-11, "Removal and Installation" . M
2. Remove side defroster duct 1.

ATC-139
 DUCTS AND GRILLES

3. Remove steering member, and then remove defroster nozzle.

RJIA1427E

4. Remove side ventilator duct 1 and center ventilator duct from instrument panel.

RJIA1428E

5. Remove side defroster duct 2.

RJIA1444E

ATC-140
 DUCTS AND GRILLES

Removal of Foot Ducts

1. Remove heater & cooling unit. Refer to ATC-130, "HEATER & COOLING UNIT ASSEMBLY" . A
2. Remove evaporator cover, and then remove the foot duct (right).
3. Remove aspirator and heater pipe cover.
B
4. Remove foot duct (left).

D
RJIA1429E

INSTALLATION E
Installation is basically the reverse order of removal.

ATC

ATC-141
 REFRIGERANT LINES

REFRIGERANT LINES PFP:92600

HFC-134a (R-134a) Service Procedure AJS001AS

SETTING OF SERVICE TOOLS AND EQUIPMENT

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

SHA539DE

Evacuating System and Charging Refrigerant

SHA540DC

ATC-142
 REFRIGERANT LINES

ATC

RJIA2143E

*1 ATC-24, "LUBRICANT RETURN *2 ATC-160, "Checking for Refrigerant *3 ATC-162, "CHECKING PROCE-
OPERATION". Leaks". DURE".
*4 ATC-99, "PERFORMANCE TEST
DIAGNOSES".

ATC-143
 REFRIGERANT LINES

Components AJS001AT

Refer to ATC-5, "Precautions for Refrigerant Connection" .

LHD MODELS

RJIA2144E

ATC-144
 REFRIGERANT LINES

RHD MODELS
A

RJIA2145E I
Removal and Installation of Compressor AJS001AU

REMOVAL
ATC

RJIA1887E

ATC-145
 REFRIGERANT LINES

1. Use a refrigerant collecting equipment (for HFC-134a) to dis-

charge the refrigerant.
2. Remove air cleaner assembly and air duct. Refer to EM-14,
"AIR CLEANER AND AIR DUCT" .
3. Remove engine under cover.

RJIA1431E

4. Remove mounting nuts from low-pressure and high-pressure

flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
5. Disconnect compressor connector.
6. Remove the A/C compressor belt. Refer to EM-12, "DRIVE
BELTS" .

RJIA1432E

7. Remove mounting bolts from compressor.

8. Remove compressor from the lower side of the vehicle.

RJIA2146E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
● Replace the O-ring of the low-pressure flexible hose and high-pressure flexible hose with a new
one, then apply compressor oil to it when installing it.
● When recharging refrigerant, check for leaks.
Removal and Installation of Compressor Clutch AJS001AV

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

RHA136E

ATC-146
 REFRIGERANT LINES

RHA399FA

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

G
RHA124FA

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

H

ATC

RHA138E

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

RHA139E

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

RHA125F

ATC-147
 REFRIGERANT LINES

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

RHA145E

Inspection
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 the 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.

RHA126F

Coil
Check coil for loose connection or cracked insulation.
INSTALLATION
1. Install the field coil.
Be sure to align the coil′s pin with the hole in the compressor′s
front head.
2. Install the field coil harness clip using a screwdriver.

RHA142E

3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.

RHA143E

ATC-148
 REFRIGERANT LINES

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

RHA127F

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

G
RHA086E

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

Disc to pulley
: 0.25 - 0.60 mm (0.010 - 0.024 in)
clearance
I
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
ATC

K
RJIA0965E

Break-in Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag- L
ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.

ATC-149
 REFRIGERANT LINES

Removal and Installation of Low-pressure Flexible Hose AJS001AW

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove cowl top cover. Refer to EI-20, "COWL TOP" .
3. Remove air cleaner assembly and air duct. Refer to EM-14,
"AIR CLEANER AND AIR DUCT" .

RJIA1431E

4. Remove mounting bolt for low-pressure flexible hose bracket.

5. Remove clip from high-pressure pipe 1.

RJIA1434E

6. Remove battery negative cable and clip. (RHD models)

RJIA1545E

7. Disconnect one-touch joint between low-pressure flexible hose

and low-pressure pipe.
a. Set a disconnector (92530-89916) on A/C piping.
b. Slide a disconnector toward vehicle front until it clicks.
c. Slide A/C piping toward vehicle front and disconnect it.

RJIA1417E

ATC-150
 REFRIGERANT LINES

8. Remove mounting nut from low-pressure flexible hose. (com-

pressor side) A
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air. B
9. Remove low-pressure flexible hose.

RJIA1432E

D
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION: E
● Replace O-rings for A/C piping with new one, then apply compressor oil to it when installing it.
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
F
● Insert one-touch joint connection point securely until it clicks.
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.
G
● When recharging refrigerant, check for leaks.
Bolt mounting the low-pressure flexible hose bracket
Tightening torque : 4.2 N·m (0.43 kg-m, 37 in-lb) H

Removal and Installation of High-pressure Flexible Hose AJS001AX

REMOVAL I
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove air cleaner assembly and air duct. Refer to EM-14,
"AIR CLEANER AND AIR DUCT" . ATC

RJIA1431E

M
3. Remove mounting bolt for high-pressure flexible hose bracket.

RJIA1435E

ATC-151
 REFRIGERANT LINES

4. Disconnect one-touch joint between high-pressure flexible hose

and condenser.
a. Set a disconnector (92530-89912) on A/C piping.
b. Slide a disconnector backward until it clicks.
c. Slide A/C piping backward and disconnect it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.

RJIA1436E

5. Remove mounting nut for high-pressure flexible hose, and then

remove the high-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.

RJIA1432E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
● Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
● Insert one-touch joint connection point securely until it clicks.
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.
● When recharging refrigerant, check for leaks.
Bolt mounting high-pressure flexible hose bracket
Tightening torque : 4.2 N·m (0.43 kg-m, 37 in-lb)

Removal and Installation of High-pressure Pipe 1 (Engine Compartment) AJS001AY

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove cowl top cover. Refer to EI-20, "COWL TOP" .
3. Remove air cleaner assembly and air duct. Refer to EM-14,
"AIR CLEANER AND AIR DUCT" .
4. Remove tower bar. Refer to FSU-20, "TOWER BAR" .
5. Remove low-pressure flexible hose. Refer to ATC-150,
"Removal and Installation of Low-pressure Flexible Hose" .
6. Remove high-pressure flexible hose. Refer to ATC-151,
"Removal and Installation of High-pressure Flexible Hose" .

RJIA1431E

7. Remove high-pressure flexible hose from vehicle clips.

8. Disconnect one-touch joints of high-pressure pipe.

ATC-152
 REFRIGERANT LINES

a. Set a disconnector (92530-89908) on A/C piping.

b. Slide a disconnector toward vehicle front (or backward) until it clicks. A

RJIA1437E
G
c. Slide A/C piping toward vehicle front (or backward) and disconnect it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. H
9. Remove the high-pressure pipe 1.

INSTALLATION I
Installation is basically the reverse order of removal.
CAUTION:
● Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when ATC
installing it.
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction. K
● Insert one-touch joint connection point securely until it clicks.
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off. L
● When recharging refrigerant, check for leaks.
Removal and Installation of Low-pressure Pipe and High-pressure Pipe 2 AJS001BV
M
REMOVAL
1. Set the temperature control dial at 18°C.
2. Open the driver and front passenger window, and then disconnect the battery negative cable.
CAUTION:
After the battery cables are disconnected, do not open/close the driver and/or front passenger
door with the window in the full up position. The automatic window adjusting function will not
work and the side roof panel may be damaged.
3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
4. Remove cowl top cover. Refer to EI-20, "COWL TOP" .

ATC-153
 REFRIGERANT LINES

5. Remove mounting bolt for low-pressure flexible hose bracket.

6. Remove high-pressure pipe 1 from vehicle clips.

RJIA1434E

7. Disconnect one-touch joints.

a. Set a disconnector (High-pressure side: 92530-89908, Low-
pressure side: 92530-89916) on A/C piping.
b. Slide a disconnector toward vehicle front until it clicks.
c. Slide A/C piping toward vehicle front and disconnect it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
8. Remove instrument passenger panel lower. Refer to IP-11,
"Removal and Installation" . RJIA1417E

9. Remove blower unit. Refer to ATC-126, "BLOWER UNIT" .

10. Remove air mix door motor and mode door motor. (LHD models)
11. Remove evaporator cover.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.

RJIA1411E

12. Remove mounting bolt, then, remove low-pressure pipe and

high-pressure pipe 2.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.

RJIA1438E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it.
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
● Insert one-touch joint connection point securely until it clicks.

ATC-154
 REFRIGERANT LINES

● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off. A
● When recharging refrigerant, check for leaks.
Bolt mounting low-pressure flexible hose bracket
B
Tightening torque : 4.2 N·m (0.43 kg-m, 37 in-lb)

Removal and Installation of Liquid Tank AJS001B0

REMOVAL C
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove condenser. Refer to ATC-156, "Removal and Installation of Condenser" .
3. Clean liquid tank and its surrounding area, and remove dirt and rust from liquid tank. D
CAUTION:
Be sure to clean carefully.
E
4. Remove mounting bolt for liquid tank.

H
RJIA2147E

5. Lift liquid tank upwards. Remove bracket from protruding part of

I
condenser.
6. Slide liquid tank upward, then remove liquid tank.
ATC

RJIA1440E
L
INSTALLATION
Installation is basically the reverse order of removal.
CAUTION: M
● Make sure liquid tank bracket is securely installed at protru-
sion of condenser. (Make sure liquid tank bracket does not
move to a position below center of liquid tank.)
● Replace O-rings for A/C piping with new ones, then apply
compressor oil to it when installing it.
● When recharging refrigerant, check for leaks.

RJIA1441E

ATC-155
 REFRIGERANT LINES

Removal and Installation of Condenser AJS001B1

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
2. Remove engine undercover.
3. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant" .
4. Remove cover for condenser mounting bolt.

SJIA0249E

5. Remove engine cover, air cleaner assembly and air duct. Refer
to EM-16, "INTAKE MANIFOLD COLLECTOR" and EM-14,
"AIR CLEANER AND AIR DUCT" .
6. Remove radiator fan shroud after removing radiator upper hose.

RJIA1442E

7. Remove mounting bolt for high-pressure flexible hose bracket.

RJIA1435E

8. Disconnect high-pressure flexible hose and high-pressure pipe

1 from condenser.
a. Set a disconnector (condenser outlet: 92530-89908, condenser
inlet: 92530-89912) on A/C piping.
b. Slide a disconnector backward until it clicks.
c. Slide A/C piping backward and disconnect it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
9. Remove mounting bolt for condenser. RJIA1436E

10. Remove radiator upper mount, move radiator and condenser to

the engine side.
11. Disconnect refrigerant pressure sensor connector.

ATC-156
 REFRIGERANT LINES

12. Lift condenser up slightly and tilt it toward front of vehicle. (This
is because condenser lower bracket is on bottom of radiator A
tank.)

RJIA0669E

D
13. Pull condenser forward at an angle. Remove condenser from
radiator.
CAUTION: E
Be careful not to damage the core surface of the condenser
and the radiator.
F

G
RJIA1443E

INSTALLATION H
Installation is basically the reverse order of removal.
CAUTION:
● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it. I
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
● Insert one-touch joint connection point securely until it clicks. ATC
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.
● When recharging refrigerant, check for leaks. K
Bolt mounting the condenser
Tightening torque : 6.1 N·m (0.62 kg-m, 54 in-lb)
L
Removal and Installation of Refrigerant Pressure Sensor AJS001B2

REMOVAL
1. Remove liquid tank. Refer to ATC-155, "Removal and Installation of Liquid Tank" . M
2. Using a vise, secure liquid tank, and remove refrigerant pres-
sure sensor.
CAUTION:
When working, be careful not to damage the condenser
fins.

RJIA2148E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
Apply compressor oil to the O-ring of the refrigerant pressure sensor when installing it.

ATC-157
 REFRIGERANT LINES

Removal and Installation of Evaporator AJS001BW

REMOVAL
1. Set the temperature control dial at 18°C.
2. Open the driver and front passenger window, and then disconnect the battery negative cable.
CAUTION:
After the battery cables are disconnected, do not open/close the driver and/or front passenger
door with the window in the full up position. The automatic window adjusting function will not
work and the side roof panel may be damaged.
3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
4. Remove low-pressure pipe and high-pressure pipe 2. Refer to ATC-153, "Removal and Installation of
Low-pressure Pipe and High-pressure Pipe 2" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
5. Slide evaporator, then remove it from heater & cooling unit.
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite.
6. Remove intake sensor from evaporator, then remove evapora-
tor.

RJIA1406E

INSTALLATION
Installation is basically the reverse order of removal.
CAUTION:
● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it.
● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not
to deform female-side piping. Slowly insert in axial direction.
● Insert one-touch joint connection point securely until it clicks.
● After piping has been connected, pull male-side piping by hand to make sure piping does not
come off.
● The O-rings are different from low-pressure flexible hose (high-pressure pipe 1) and low-pressure
pipe (high-pressure pipe 2).
● Mark the mounting position of the intake sensor bracket.
● When recharging refrigerant, check for leaks.
Bolt mounting low-pressure flexible hose bracket
Tightening torque : 4.2 N·m (0.43 kg-m, 37 in-lb)

ATC-158
 REFRIGERANT LINES

Removal and Installation of Expansion Valve AJS001B4

REMOVAL A
1. Set the temperature control dial at 18°C.
2. Open the driver and front passenger window, and then disconnect the battery negative cable.
CAUTION: B
After the battery cables are disconnected, do not open/close the driver and/or front passenger
door with the window in the full up position. The automatic window adjusting function will not
work and the side roof panel may be damaged. C
3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant.
4. Remove low-pressure pipe and high-pressure pipe 2. Refer to ATC-153, "Removal and Installation of
Low-pressure Pipe and High-pressure Pipe 2" . D
CAUTION:
Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere.
5. Remove expansion valve. E
NOTE:
This illustration is for LHD models. The layout for RHD models is
symmetrically opposite. F

RJIA0969E H
INSTALLATION
Installation is basically the reverse order of removal.
I
CAUTION:
● Replace O-rings with new ones, then apply compressor oil to them when installing them.
● The O-rings are different from low-pressure flexible hose (high-pressure pipe 1) and low-pressure ATC
pipe (high-pressure pipe 2).
● When recharging refrigerant, check for leaks.
Bolts mounting expansion valve K
Tightening torque : 3.9N·m (0.40 kg-m, 35 in-lb)

ATC-159
 REFRIGERANT LINES

Checking for Refrigerant Leaks AJS001B5

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent
dye leak detector.
If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was
repaired and not properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected
leak area at 1 to 2 inches per second and no further than 1/4 inch from the component.
CAUTION:
Moving the electronic leak detector probe slower and closer to the suspected leak area will improve
the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Leak Detector AJS001B6

1. Check A/C system for leaks using the UV lamp 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 evaporator drain opening indi-
cates an evaporator core assembly (tubes, core or expansion valve) leak.
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, with the UV lamp for dye residue.
3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiag-
nosis.
4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant
leak detector.
NOTE:
Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield
washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be
checked are clean.
Clean with a dry cloth or blow off with shop air.
Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings
and may damage the detector.
Dye Injection AJS001B7

(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/m2 , 50
psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C Low-pressure side service fitting.
4. Start engine and switch A/C ON.
5. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye
through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture′s operat-
ing instructions).
6. With the engine still running, disconnect the injector tool from the service fitting.
CAUTION:
Be careful the A/C system or replacing a component, pour the dye directly into the open system con-
nection and proceed with the service procedures.
7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the
leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to
penetrate a leak and become visible.

ATC-160
 REFRIGERANT LINES

Electronic Refrigerant Leak Detector AJS001B8

PRECAUTIONS FOR HANDLING LEAK DETECTOR A

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

D
SHA705EB

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

be checked.

H
SHA707EA

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

I

ATC

SHA706E
L

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

2 in)/sec.
M

SHA708EA

ATC-161
 REFRIGERANT LINES

CHECKING PROCEDURE
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 calm area (low air/wind movement) so that the
leaking refrigerant is not dispersed.
1. Turn engine OFF.
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C. If
less than specification, recover/evacuate and recharge the system with the specified amount of refriger-
ant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45 bar,
3.52 kg/cm2 , 50 psi).
4. Perform the leak test from the high side (compressor discharge a to evaporator inlet g) to the low side
(evaporator drain hose h to shaft seal l). Refer to ATC-144, "Components" . Perform a leak check for the
following areas carefully. Clean the component to be checked and move the leak detected probe com-
pletely around the connection/component.
Compressor
Check the fitting of high- and low-pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant connection.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.

Cooling unit (Evaporator)

With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the
cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer′s recommended
procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7 - 10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Air outlet: Ventilation (VENT)
c. Intake position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4 through 6 above.

ATC-162
 REFRIGERANT LINES

Refrigerant leaks should be checked immediately after stopping the

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

SHA839E

D
11. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent as necessary.
12. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks. E
13. Perform A/C performance test to ensure system works properly.

ATC

ATC-163
 SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030

Compressor AJS001B9

Model Calsonic Kansei make V-6

Type V-6 variable displacement
Displacement Max. 146 (8.91)
cm3 (cu in)/rev Min. 14.5 (0.885)
Cylinder bore × stroke
35.2 (1.386) × [2.3 - 25 (0.091 - 0.98)]
mm (in)
Direction of rotation Clockwise (viewed from drive end)
Drive belt Poly V

Lubricant AJS001BA

Model Calsonic Kansei make V-6

Name Nissan A/C System Oil Type S (DH-PS)
Part number KLH00-PAGS0
Total in system 180 (6.3)
Capacity
m (lmp fl oz) Compressor (Service part) charg-
180 (6.3)
ing amount

Refrigerant AJS001BB

Type HFC-134a (R-134a)

Capacity
0.55 (1.21)
kg (lb.)

Engine Idling Speed AJS001BC

Refer to TYPE 1*: EC-37, "Idle Speed and Ignition Timing Check" or TYPE 2*:EC-498, "Idle Speed and Igni-
tion Timing Check" .
*:For further infomation refer to EC-10, "APPLICATION NOTICE" .
Belt Tension AJS001BD

Refer to EM-12, "DRIVE BELTS" .

ATC-164