Heater & Air Conditioning System: Section

VENTILATION, HEATER & AIR CONDITIONER
HEATER & AIR CONDITIONING SYSTEM

SECTION HA B
E
CONTENTS
YD25DDTi Description ...............................................................26 F
Inspection ................................................................26
PRECAUTION ............................................... 5 Perform Lubricant Return Operation .......................26
Lubricant Adjusting Procedure for Components G
PRECAUTIONS ................................................... 5 Replacement Except Compressor ...........................26
Precaution for Supplemental Restraint System Lubricant Adjusting Procedure for Compressor
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Replacement ...........................................................27
SIONER" ................................................................... 5 H
Precautions Necessary for Steering Wheel Rota- PERFORMANCE TEST .................................... 28
tion After Battery Disconnection ................................ 5 Inspection ................................................................28
Precautions for Removing Battery Terminal ............. 6 HA
Precaution for Procedure without Cowl Top Cover...... 6 SYMPTOM DIAGNOSIS .............................. 30
Precautions For Refrigerant System Service ............ 6
Service Equipment .................................................... 9
REFRIGERATION SYSTEM SYMPTOMS ........ 30
Trouble Diagnosis For Unusual Pressure ................30 J
PREPARATION ........................................... 11 Symptom Table .......................................................30
PREPARATION ..................................................11 NOISE ................................................................ 32 K

Special Service Tool ............................................... 11 Symptom Table .......................................................32
Commercial Service Tools ..................................... 12
Sealant or/and Lubricant ......................................... 13
REMOVAL AND INSTALLATION ............... 33
L
COMPRESSOR ................................................. 33
SYSTEM DESCRIPTION ............................. 15
Exploded View .........................................................33
COMPONENT PARTS .......................................15 COMPRESSOR ..........................................................34 M
Component Parts Location ...................................... 15 COMPRESSOR : Removal and Installation ............34
SYSTEM .............................................................18 MAGNET CLUTCH ....................................................35
System Diagram ...................................................... 18 N
MAGNET CLUTCH : Removal and Installation .......35
System Description ................................................. 18 Inspection ................................................................36
BASIC INSPECTION ................................... 20 COOLER PIPE AND HOSE .............................. 37 O
Exploded View .........................................................37
DIAGNOSIS AND REPAIR WORKFLOW .........20
Work Flow ............................................................... 20 HIGH-PRESSURE FLEXIBLE HOSE ........................38
HIGH-PRESSURE FLEXIBLE HOSE : Removal P
REFRIGERANT ..................................................22 and Installation ........................................................38
Description .............................................................. 22
Leak Test ................................................................ 22 LOW-PRESSURE FLEXIBLE HOSE .........................39
Recycle Refrigerant ................................................. 24 LOW-PRESSURE FLEXIBLE HOSE : Removal
Charge Refrigerant .................................................. 24 and Installation ........................................................39
LUBRICANT .......................................................26 HIGH-PRESSURE PIPE ............................................40
Revision: 2015 March HA-1 D23

HIGH-PRESSURE PIPE : Removal and Installa- Service Equipment .................................................. 68
tion .......................................................................... 40
PREPARATION .......................................... 70
LOW-PRESSURE PIPE ............................................ 41
LOW-PRESSURE PIPE : Removal and Installa- PREPARATION ................................................. 70
tion .......................................................................... 41 Special Service Tool ............................................... 70
Commercial Service Tools .................................... 71
CONDENSER .................................................... 43 Sealant or/and Lubricant ......................................... 72
Exploded View ........................................................ 43
SYSTEM DESCRIPTION ........................... 74
CONDENSER ............................................................ 43
CONDENSER : Removal and Installation .............. 43 COMPONENT PARTS ....................................... 74
Component Parts Location ..................................... 74
LIQUID TANK ............................................................ 45
LIQUID TANK : Removal and Installation ............... 45 SYSTEM ............................................................ 75
System Diagram ..................................................... 75
REFRIGERANT PRESSURE SENSOR .................... 45
System Description ................................................. 75
REFRIGERANT PRESSURE SENSOR : Remov-
al and Installation .................................................... 45 BASIC INSPECTION .................................. 77
CONDENSER PIPE ASSEMBLY .............................. 46 DIAGNOSIS AND REPAIR WORKFLOW ......... 77
CONDENSER PIPE ASSEMBLY : Removal and
Work Flow ............................................................... 77
Installation .............................................................. 46
REFRIGERANT ................................................. 79
HEATER & COOLING UNIT ASSEMBLY ......... 48 Description .............................................................. 79
Exploded View ........................................................ 48
Leak Test ................................................................ 79
HEATER & COOLING UNIT ASSEMBLY ................ 57 Recycle Refrigerant ................................................ 81
HEATER & COOLING UNIT ASSEMBLY : Re- Charge Refrigerant ................................................. 81
moval and Installation ............................................. 57
LUBRICANT ...................................................... 83
EXPANSION VALVE ................................................. 59 Description .............................................................. 83
EXPANSION VALVE : Removal and Installation ... 60 Inspection ................................................................ 83
Perform Lubricant Return Operation ....................... 83
EVAPORATOR ......................................................... 60 Lubricant Adjusting Procedure for Components
EVAPORATOR : Removal and Installation ............ 60 Replacement Except Compressor .......................... 83
Lubricant Adjusting Procedure for Compressor
HEATER CORE ......................................................... 61
Replacement ........................................................... 84
HEATER CORE : Removal and Installation ........... 61
PERFORMANCE TEST ..................................... 85
SERVICE DATA AND SPECIFICATIONS Inspection ................................................................ 85
(SDS) ........................................................... 63
SYMPTOM DIAGNOSIS ............................ 87
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................. 63 REFRIGERATION SYSTEM SYMPTOMS ........ 87
Compressor ............................................................ 63 Trouble Diagnosis For Unusual Pressure ............... 87
Lubricant ................................................................. 63 Symptom Table ....................................................... 87
Refrigerant .............................................................. 63
Engine Idling Speed ............................................... 63 NOISE ................................................................ 89
Belt Tension ............................................................ 63 Symptom Table ....................................................... 89
QR25DE REMOVAL AND INSTALLATION .............. 90
PRECAUTION ............................................. 64 COMPRESSOR ................................................. 90
PRECAUTIONS ................................................. 64 Exploded View ........................................................ 90
Precaution for Supplemental Restraint System COMPRESSOR ......................................................... 90
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- COMPRESSOR : Removal and Installation ............ 91
SIONER" ................................................................. 64
Precautions Necessary for Steering Wheel Rota- MAGNET CLUTCH .................................................... 92
tion After Battery Disconnection ............................. 64 MAGNET CLUTCH : Removal and Installation ....... 92
Precautions for Removing Battery Terminal ........... 65 Inspection ................................................................ 93
Precaution for Procedure without Cowl Top Cover... 65
Precautions For Refrigerant System Service .......... 65 COOLER PIPE AND HOSE ............................... 94

Exploded View ........................................................ 94 PRECAUTION ............................................ 115
A
HIGH-PRESSURE FLEXIBLE HOSE ........................ 94 PRECAUTIONS ............................................... 115
HIGH-PRESSURE FLEXIBLE HOSE : Removal Precaution for Supplemental Restraint System
and Installation ........................................................ 94 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
B
SIONER" ............................................................... 115
LOW-PRESSURE FLEXIBLE HOSE ........................ 95
LOW-PRESSURE FLEXIBLE HOSE : Removal Precautions Necessary for Steering Wheel Rota-
and Installation ........................................................ 95 tion After Battery Disconnection ............................ 115
Precautions for Removing Battery Terminal .......... 116 C
HIGH-PRESSURE PIPE ............................................ 96 Precaution for Procedure without Cowl Top Cover.. 116
HIGH-PRESSURE PIPE : Removal and Installa- Precautions For Refrigerant System Service ........ 116
tion .......................................................................... 96 Service Equipment ................................................ 119 D
LOW-PRESSURE PIPE ............................................. 97 PREPARATION ......................................... 121

LOW-PRESSURE PIPE : Removal and Installa-
tion .......................................................................... 97 PREPARATION ............................................... 121 E
Special Service Tool .............................................. 121
CONDENSER .....................................................99 Commercial Service Tools ................................... 122
Exploded View ........................................................ 99 Sealant or/and Lubricant ....................................... 123 F
CONDENSER ............................................................ 99 SYSTEM DESCRIPTION ........................... 125
CONDENSER : Removal and Installation ............... 99
COMPONENT PARTS .................................... 125 G
LIQUID TANK .......................................................... 101 Component Parts Location .................................... 125
LIQUID TANK : Removal and Installation ............. 101
SYSTEM .......................................................... 126 H
REFRIGERANT PRESSURE SENSOR .................. 101
System Diagram .................................................... 126
REFRIGERANT PRESSURE SENSOR : Remov-
System Description ................................................ 126
al and Installation .................................................. 101
CONDENSER PIPE ASSEMBLY ............................ 102

BASIC INSPECTION ................................. 128 HA
CONDENSER PIPE ASSEMBLY : Removal and DIAGNOSIS AND REPAIR WORKFLOW ...... 128
Installation ............................................................. 102 Work Flow .............................................................. 128 J
HEATER & COOLING UNIT ASSEMBLY ....... 104 REFRIGERANT ............................................... 130
Exploded View ...................................................... 104 Description ............................................................. 130
HEATER & COOLING UNIT ASSEMBLY ............... 108 Leak Test ............................................................... 130 K
HEATER & COOLING UNIT ASSEMBLY : Re- Recycle Refrigerant ............................................... 132
moval and Installation ........................................... 108 Charge Refrigerant ................................................ 132
L
EXPANSION VALVE ............................................... 110 LUBRICANT .................................................... 134
EXPANSION VALVE : Removal and Installation .. 111 Description ............................................................. 134
Inspection .............................................................. 134
EVAPORATOR ........................................................ 111 Perform Lubricant Return Operation ..................... 134 M
EVAPORATOR : Removal and Installation ........... 111 Lubricant Adjusting Procedure for Components
Replacement Except Compressor ......................... 134
HEATER CORE ....................................................... 112
Lubricant Adjusting Procedure for Compressor N
HEATER CORE : Removal and Installation .......... 112 Replacement ......................................................... 135
SERVICE DATA AND SPECIFICATIONS PERFORMANCE TEST .................................. 136
(SDS) .......................................................... 114 Inspection .............................................................. 136 O
SERVICE DATA AND SPECIFICATIONS SYMPTOM DIAGNOSIS ............................ 138

(SDS) ................................................................ 114 P
Compressor ........................................................... 114 REFRIGERATION SYSTEM SYMPTOMS ...... 138
Lubricant ............................................................... 114 Trouble Diagnosis For Unusual Pressure .............. 138
Refrigerant ............................................................ 114 Symptom Table ..................................................... 138
Engine Idling Speed .............................................. 114
Belt Tension .......................................................... 114 NOISE .............................................................. 140
Symptom Table ..................................................... 140
YS23DDT/YS23DDTT
REMOVAL AND INSTALLATION ............. 141

COMPRESSOR ............................................... 141 REFRIGERANT PRESSURE SENSOR .................. 151
Exploded View .......................................................141 REFRIGERANT PRESSURE SENSOR : Remov-
al and Installation .................................................. 151
COMPRESSOR ........................................................142
COMPRESSOR : Removal and Installation ..........142 CONDENSER PIPE ASSEMBLY ............................ 151
CONDENSER PIPE ASSEMBLY : Removal and
MAGNET CLUTCH ..................................................143 Installation ............................................................. 151
MAGNET CLUTCH : Removal and Installation .....143
Inspection ..............................................................144 HEATER & COOLING UNIT ASSEMBLY ........ 153
Exploded View ...................................................... 153
COOLER PIPE AND HOSE ............................. 145
Exploded View .......................................................145 HEATER & COOLING UNIT ASSEMBLY .............. 157
HEATER & COOLING UNIT ASSEMBLY : Re-
HIGH-PRESSURE FLEXIBLE HOSE ......................145 moval and Installation ........................................... 157
HIGH-PRESSURE FLEXIBLE HOSE : Removal
and Installation ......................................................145 EXPANSION VALVE ............................................... 159
EXPANSION VALVE : Removal and Installation . 160
LOW-PRESSURE FLEXIBLE HOSE .......................146
LOW-PRESSURE FLEXIBLE HOSE : Removal EVAPORATOR ........................................................ 160
and Installation ......................................................146 EVAPORATOR : Removal and Installation ........... 160
HIGH-PRESSURE PIPE ...........................................147 HEATER CORE ....................................................... 161

HIGH-PRESSURE PIPE : Removal and Installa- HEATER CORE : Removal and Installation .......... 161
tion .........................................................................147
SERVICE DATA AND SPECIFICATIONS
LOW-PRESSURE PIPE ...........................................148 (SDS) ......................................................... 163
LOW-PRESSURE PIPE : Removal and Installa-
tion .........................................................................148 SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................ 163
CONDENSER .................................................. 149 Compressor .......................................................... 163
Exploded View .......................................................149 Lubricant ............................................................... 163
CONDENSER ...........................................................149 Refrigerant ............................................................ 163
CONDENSER : Removal and Installation .............149 Engine Idling Speed .............................................. 163
Belt Tension .......................................................... 163
LIQUID TANK ...........................................................150
LIQUID TANK : Removal and Installation ..............150

PRECAUTIONS
< PRECAUTION > [YD25DDTi]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000011671987
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
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 AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: D
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
F
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing HA
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service. J
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000011671988
K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables. L
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position. P
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

PRECAUTIONS
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precautions for Removing Battery Terminal INFOID:0000000011671989
When disconnecting the battery terminal, pay attention to the following.

• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running.
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi-
nal after a lapse of the specified time:
D4D engine : 20 minutes YS23DDT : 4 minutes

HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Precaution for Procedure without Cowl Top Cover INFOID:0000000011671991
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
Precautions For Refrigerant System Service INFOID:0000000011671992
GENERAL REFRIGERANT PRECAUTION

WARNING:

PRECAUTIONS
• Never breathe 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. A
Ventilate work area before resuming service if accidental system discharge occurs. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
• Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to cap-
B
ture the refrigerant each time an air conditioning system is discharged.
• Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or air
conditioning system.
• Never store or heat refrigerant containers above 52°C (126°F). C
• Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm
pail of water if container warming is required.
• Never intentionally drop, puncture, or incinerate refrigerant containers. D
• Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns.
• Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo-
cation.
• Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air condi- E
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.
WORKING WITH HFC-134a (R-134a)
CAUTION: G
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These regrigerants
must never be mixed, even in the smallest amounts. Compressor malfunction is likely occur if the
refrigerants are mixed.
H
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. Compressor malfunction is likely to occur if lubricant other than that specified is used.
• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed: HA
- Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere when
removing refrigerant components from a vehicle.
- Never remove the caps (unseal) until just before connecting the components when installing refrig- J
erant components to a vehicle. Connect all refrigerant loop components as quickly as possible to
minimize the entry of moisture into system.
- Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant.
Lubricant becomes moisture saturated and should not be used without proper sealing. K
- Never allow lubricant (A/C system Oil Type S) to come in contact with styrene foam parts. Damage
may result.
REFRIGERANT CONNECTION L
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
• Expansion valve to evaporator
• Refrigerant pressure sensor to condenser & liquid tank assembly M
WARNING:
Check that 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. N
CAUTION:
Observe the following when replacing or cleaning refrigerant cycle components.
• Store it in the same way at it is when mounted on the car when the compressor is removed. Failure
to do so will cause lubricant to enter the low-pressure chamber. O
• Use always a torque wrench and a back-up wrench when connecting tubes.
• Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes.
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle. P
Never 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.
• Remove thoroughly moisture from the refrigeration system before charging the refrigerant.
• Replace always used O-rings.
• Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to
apply lubricant to threaded portion.

PRECAUTIONS
Name : A/C system Oil Type S

• O-ring must be closely attached to the groove portion of tube.
• Be careful not to damage O-ring and tube when replacing the O-ring.
• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is
installed to tube correctly.
• Perform leakage test and make sure that there is no leakage from connections after connecting line.
Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tighten
connections of seal seat to the specified torque.
RHA861F
COMPRESSOR
CAUTION:
• Plug all openings to prevent moisture and foreign matter from entering.
• Store it in the same way at it is when mounted on the car when the compressor is removed.
• Follow “MAINTENANCE OF LUBRICANT LEVEL IN COMPRESSOR” exactly when replacing or repair-
ing compressor. Refer to HA-26, "Description".
• Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth
moistened with thinner if the surface is contaminated with lubricant.
• Turn the compressor shaft by hand more than five turns in both directions after compressor service
operation. This distributes equally lubricant inside the compressor. Let the engine idle and operate
the compressor for one hour after the compressor is installed.
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet
clutch.
LEAK DETECTION DYE
CAUTION:
• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An
ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages.
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of
the fluorescent dye.
• The fluorescent dye leak detector is not a replacement for an electrical leak detector. The fluorescent
dye leak detector should be used in conjunction with an electrical leak detector to pin-point refriger-
ant leakages.
• Read and follow all manufacture’s operating instructions and precautions prior to performing the
work for the purpose of safety and customer’s satisfaction.
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres-
sor shaft seal should only be repaired after confirming the leakage with an electrical leak detector.
• Remove always any remaining dye from the leakage area after repairs are completed to avoid a mis-
diagnosis during a future service.
• Never allow dye to come into contact with painted body panels or interior components. Clean imme-
diately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for an
extended period of time cannot be removed.
• Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).

PRECAUTIONS
• Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system.
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use A
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C system, or A/C system damage may result.
• The fluorescent properties of the dye remains for three or more years unless a compressor malfunc-
B
tion occurs.
Service Equipment INFOID:0000000011671993
C
RECOVERY/RECYCLING RECHARGING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine. D
ELECTRICAL LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
E
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems.
The vent side of the vacuum pump is exposed to atmospheric pres- F
sure. So the vacuum pump lubricant may migrate out of the pump
into the service hose. This is possible when the pump is switched
OFF after evacuation (vacuuming) and hose is connected to it. G
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as per the following.
• Vacuum pumps usually have a manual isolator valve as part of the
pump. Close this valve to isolate the service hose from the pump. H
• Use a hose equipped with a manual shut-off valve near the pump
end for pumps without an isolator. Close the valve to isolate the
hose from the pump. HA
• Disconnect the hose from the pump if the hose has an automatic
shut-off valve. As long as the hose is connected, the valve is open
and lubricating oil may migrate.
Some one-way valves open when vacuum is applied and close J
under no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
K
RHA270DA L
MANIFOLD GAUGE SET
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- M
vice hoses. Confirm the set has been used only with refrigerant
HFC-134a (R-134a) and specified lubricants.
N
SHA533D
P
SERVICE HOSES

PRECAUTIONS
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must equip positive shut-
off devices (either manual or automatic) near the end of the hoses
opposite to the manifold gauge.
RHA272D
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
the CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
do 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. The hose fitting must
be 1/2″-16 ACME if the scale controls refrigerant flow electronically.
RHA274D
CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale each three month.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset” and “Enter” at the same time.
2. Press “8787”. “A1” is displayed.
3. Remove all weight from the scale.
4. Press “0”, then press “Enter”. “0.00” is 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.
9. Press “6”— the known weight on the scale is displayed.
10. Remove the known weight from the scale. “0.00” is displayed.
11. Press “Shift/Reset” to return the ACR4 to the program mode.
CHARGING CYLINDER
Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve
when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an
electronic scale or of quality recycle/recharge equipment.

PREPARATION
< PREPARATION > [YD25DDTi]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000011671994
B
HFC-134a (R-134a) Service Tool and Equipment

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/ C
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles D
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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and E
compressor malfunction may result.
Tool number
F
(SPX-North America No.) Description
Tool name
KV99106200
Installing pulley
Pulley installer H
S-NT235
HA
Refrigerant dye leak detection
kit
Kit includes: J
UV lamp and UV safety goggles
HFC-134a (R-134a) dye injector
Power supply:
Use with J-41447, 1/4 ounce
DC 12 V (Battery terminal)
bottle K
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
Refrigerant dye cleaner L
ZHA200H
Power supply: M
For checking refrigerant leak when fluores-
cent dye is installed in A/C system
Includes: N
SHA438F
O
Application:
For HFC-134a (R-134a) PAG oil
HFC-134a (R-134a) fluorescent Container:
leak detection dye 1/4 ounce (7.4 cc) bottle P
(Box of 24, 1/4 ounce bottles) (Includes self-adhesive dye identification
labels for affixing to vehicle after charging
system with dye.)
SHA439F

PREPARATION
Tool number
Tool name

For injecting 1/4 ounce of fluorescent leak
detection dye into A/C system
bottle
SHA440F
Refrigerant dye cleaner For cleaning dye spills
SHA441F
Commercial Service Tools INFOID:0000000011671995

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/
or its lubricant.
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
Tool name Description
Recovery/recycling/recharg- Function: Refrigerant recovery, recycling

ing equipment (ACR4) and recharging
RJIA0195E
Power supply:
Electrical leak detector
DC 12 V (Cigarette lighter)
SHA705EB

PREPARATION
A
Identification:
B
• The gauge face indicates HFC-134a (R-
Manifold gauge set (with hos- 134a).
es and couplers) Fitting size: Thread size C
• 1/2″-16 ACME
D
RJIA0196E
Hose color:
• Low-pressure side hose: Blue with black
E
stripe
Service hoses • High-pressure side hose: Red with black
• High-pressure side hose stripe
• Low-pressure side hose • Utility hose: Yellow with black stripe or
• Utility hose F
green with black stripe
Hose fitting to gauge:
S-NT201
• 1/2″-16 ACME
G
Service couplers Hose fitting to service hose: H

• High-pressure side coupler M14 x 1.5 fitting is optional or permanently
• Low-pressure side coupler attached.
HA
S-NT202
J
For measuring of refrigerant
Refrigerant weight scale Fitting size: Thread size
1/2″-16 ACME
K
S-NT200
L
Capacity:
• Air displacement: 4 CFM
Vacuum pump • Micron rating: 20 microns
(Including the isolator valve) • Oil capacity: 482 g (17 oz.) M
Fitting size: Thread size
• 1/2″-16 ACME
S-NT203
N
Sealant or/and Lubricant INFOID:0000000011671996
O
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ P
lubricant.

PREPARATION
Container color: Light blue

Container marking: HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
• Large container 1/2″-16 ACME
S-NT196
Type: Polyalkylene glycol oil (PAG),

type S (DH-PS)
Application:
A/C system Oil Type S (DH-PS)
HFC-134a (R-134a) swash plate com-
pressors
Capacity: 40 m (1.4 Imp fl oz.)
JMIIA1759ZZ

COMPONENT PARTS
< SYSTEM DESCRIPTION > [YD25DDTi]
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000011671997
B
LHD MODELS
C
HA
M
JMIIA4007ZZ
Built-in heater & cooling unit assembly N
No. Component Function

• Refer to HAC-19, "Refrigerant Pressure Sensor". (Automatic air conditioning) O
• Refer to HAC-136, "Refrigerant Pressure Sensor". [Manual air conditioning (Full-elc)]
Refrigerant pressure sensor
• Refer to HAC-225, "Refrigerant Pressure Sensor". [Manual air conditioning & cool (Semi-
elc)]
P
Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant.
Liquid tank Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.
Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant
Compressor
cycle.

COMPONENT PARTS
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by
Expansion valve
drawing function.
The mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from
Evaporator
blower motor. The air is cooled by the heat by evaporation.
RHD MODELS
JSIIA1997ZZ
Built-in heater & cooling unit assembly

• Refer to HAC-19, "Refrigerant Pressure Sensor". (Automatic air conditioning)
elc)]
Compressor
cycle.

COMPONENT PARTS
A
Evaporator
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by
Expansion valve B
drawing function.
HA

SYSTEM
SYSTEM
System Diagram INFOID:0000000011671998
JPIIA1671GB
System Description INFOID:0000000011671999
REFRIGERANT CYCLE
Refrigerant Flow
The refrigerant from the compressor, flows the condenser with liquid tank assembly, the evaporator, and
returns to the compressor. The refrigerant evaporation in the evaporator is controlled by an expansion valve.
Freeze Protection
When evaporator fin temperature is low, compressor stops so that freeze of evaporator can be prevented.
Refer to the following.
• Auto air conditioning: HAC-24, "AUTOMATIC AIR CONDITIONING SYSTEM : Compressor Control".
• Manual air conditioning (Full-elc): HAC-139, "Compressor Control".
• Manual air conditioning & cool (Semi-elc): HAC-227, "Compressor Control".
REFRIGERANT SYSTEM PROTECTION
Refrigerant Pressure Sensor
• The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure
sensor, installed at the outlet pipe assembly. The refrigerant pressure sensor detects the pressure inside the
refrigerant line and sends the voltage signal to the ECM if the system pressure rises above, or falls below
the specifications.
• ECM turns the A/C relay to OFF and stops the compressor when the high-pressure side detected by refriger-
ant pressure sensor is following conditions;
- Approximately 3,120 kPa (31.2 bar, 31.8 kg/cm2, 452 psi) or more (Engine speed is less than 1,500 rpm.)
- Approximately 2,740 kPa (27.4 bar, 27.9 kg/cm2, 397 psi) or more (Engine speed is 1,500 rpm or more.)
- Approximately 140 kPa (1.4 bar, 1.4 kg/cm2, 17 psi) or less
Pressure Relief Valve

SYSTEM
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere A
when the pressure of refrigerant in the system increases to an unusual level [more than 3,800 kPa (38 bar,
38.8 kg/cm2, 551 psi)].
B
HA

DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [YD25DDTi]
BASIC INSPECTION
Work Flow INFOID:0000000011672000
OVERALL SEQUENCE
NNIIA0143GB
DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.

>> GO TO 2.
2.SYMPTOM CHECK A
Check the symptom from the customer's information. Check that any symptom occurs other than the inter-
viewed symptom.
B
Insufficient cooling/heating>>GO TO 3.
Refrigerant leakage>>GO TO 6.
C
Noise >> GO TO 7.
3.CONTROL SYSTEM DIAGNOSIS
Perform the system diagnosis for the A/C control system. Refer to the following. D
• Auto air conditioning: HAC-57, "Work Flow".
• Manual air conditioning (Full-elc): HAC-167, "Work Flow".
• Manual air conditioning & cool (Semi-elc): HAC-257, "Work Flow". E
Is A/C control system normal?
YES >> GO TO 4.
NO >> GO TO 8. F
4.PERFORMANCE TEST
Perform the performance test. Check the operation of each part. Refer to HA-28, "Inspection".
G
>> GO TO 5.
5.TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE H
Diagnose using a manifold gauge whenever system's high and/or low side pressure(s) is/are unusual. Specify
the malfunctioning part. Refer to HA-30, "Symptom Table".
HA
Low refrigerant charge>>GO TO 6.
Except above>>GO TO 8.
6.CHECK REFRIGERANT FOR LEAKAGES J
Check refrigerant for leakages. Specify the malfunctioning part. Refer to HA-22, "Leak Test".
K
>> GO TO 8.
7.TROUBLE DIAGNOSIS FOR NOISE
L
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-32, "Symptom Table".
>> GO TO 8.
M
8.MALFUNCTION PART REPAIR
Repair or replace the malfunctioning part.
N
>> GO TO 9.
9.REPAIR CHECK (OPERATION CHECK) O
Check the operation of each part.
Does it operate normally?
YES >> INSPECTION END P
NO >> GO TO 2.

REFRIGERANT
REFRIGERANT
Description INFOID:0000000011672001
CONNECTION OF SERVICE TOOLS AND EQUIPMENT
JSIIA0258ZZ
Shut-off valve A/C service valve Recovery/recycling recharging

equipment
Vacuum pump Manifold gauge set Refrigerant container (HFC-134a)
Weight scale
Preferred (best) method Alternative method For charging
Leak Test INFOID:0000000011672002
CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE
RJIA3815J
1. Install a fender cover .

2. Wear UV safety goggles provided with refrigerant dye leak detection kit.
3. Connect power cable of UV lamp to positive and negative terminals of the battery .
4. Press UV lamp switch and check A/C system for refrigerant leakage. (Where refrigerant leakage
occurs, fluorescent leak detection dye appears in green color.)

REFRIGERANT
WARNING:
Never look directly into UV lamp light source. A
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Illuminate piping joints from different angles using UV lamp and check that there is no leakage.
B
• Use a mirror in area that is difficult to see to check refrigerant leakage.
• Refrigerant leakage from evaporator can be detected by soaking cotton swab or a similar material with
drain hose water and illuminating it using UV lamp.
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and C
other locations may fluoresce. Be careful not to misidentify leakage.
5. Repair or replace parts where refrigerant leakage occurs and wipe off fluorescent leak detection dye.
NOTE: D
Completely wipe off fluorescent leak detection dye from gaps between parts, screw threads, and others
using a cotton swab or similar materials.
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work. E
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions. F
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and
G
CHECK REFRIGERANT LEAKAGE USING ELECTRICAL LEAK DETECTOR
WARNING:
Never check refrigerant leakage while the engine is running.
H
CAUTION:
Be careful of the following items so that inaccurate checks or misidentifications are avoided.
• Never allow refrigerant vapor, shop chemical vapors, cigarette smoke, or others around the vehicle.
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse HA
when leakage occurs.
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set to A/C service valve. J
3. Check that A/C refrigerant pressure is 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) or more when temperature
is 16°C (61°F) or more. When pressure is lower than the specified value, recycle refrigerant completely
and fill refrigerant to the specified level. K
NOTE:
Leakages may not be detected if A/C refrigerant pressure is 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) or
less when temperature is less than 16°C (61°F). L
4. Clean area where refrigerant leakage check is performed, and check refrigerant leakage along all sur-
faces of pipe connections and A/C system components using electrical leak detector probe.
CAUTION: M
• Continue checking when a leakage is found. Always continue and complete checking along all
pipe connections and A/C system components for additional leakage.
• When a leakage is detected, clean leakage area using compressed air and check again.
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the N
probe surface may not be exposed to water or dirt.
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side. O
• When checking leakage of cooling unit inside, operate blower fan motor for 15 minutes or more at the
maximum fan speed while the engine is stopped, and then insert electrical leak detector probe into drain
hose and hold for 10 minutes or more.
• When disconnecting shut-off valve that is connected to A/C service valve, always evacuate remaining P
refrigerant so that misidentification can be avoided.
5. Repair or replace parts where refrigerant leakage is detected. (Leakage is detected but leakage area is
unknown. GO TO 6.)
6. Start the engine and set A/C control in the following conditions.
• A/C switch ON
• Air flow: VENT (Ventilation)

REFRIGERANT
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold
• Fan speed: Maximum speed set
7. Run the engine at approximately 1,500 rpm for 2 minutes or more.
8. Stop the engine. Check again for refrigerant leakage. GO TO 4.
WARNING:
Never to get burned when the engine is hot.
NOTE:
• Start refrigerant leakage check immediately after the engine is
stopped.
• When refrigerant circulation is stopped, pressure on the low-
pressure side rises gradually, and after this, pressure on the
high-pressure side falls gradually.
• The higher the pressure is, the easier it is to find the refriger-
ant leakage.
SHA839E
Recycle Refrigerant INFOID:0000000011672003
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, or
throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1. Perform lubricant return operation. Refer to HA-26, "Perform Lubricant Return Operation". (If refrigerant or
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is
detected.
2. Check gauge pressure readings of recovery/recycling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose.
NOTE:
Follow manufacturer instructions for the handling or maintenance of the equipment. Never fill the equip-
ment with non-specified refrigerant.
3. Remove A/C service valve cap from the vehicle.
4. Connect recovery/recycling/recharging equipment to A/C service valve.
5. Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
6. Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated to compressor lubri-
cant, etc.
7. Refrigerant recycle operation is complete.
Charge Refrigerant INFOID:0000000011672004
WARNING:
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure my irritate eyes, nose, or throat.

REFRIGERANT
1. Connect recovery/recycling/recharging equipment to the A/C service valve.
2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or A
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced. B
3. Check the airtightness of A/C system for 25 minutes or more. If pressure rises more than the specified
level, charge A/C system with approximately 200 g (0.4 lb) refrigerant and check that there is no refriger-
ant leakage. Refer to HA-22, "Leak Test".
C
CAUTION:
Check the airtightness for 15 minutes or more if the parts are replaced.
4. If parts other than compressor are replaced, fill compressor lubricant according to parts that are replaced.
D
5. Charge the specified amount of refrigerant to A/C system.
6. Check that A/C system operates normally.
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose E
and low-pressure hose of recovery/recycling/recharging equipment.)
8. Install A/C service valve cap.
9. Refrigerant charge is complete. F
HA

LUBRICANT
LUBRICANT
MAINTENANCE OF LUBRICANT LEVEL

The compressor lubricant is circulating in the system together with the refrigerant. It is necessary to fill com-
pressor with lubricant when replacing A/C system parts or when a large amount of refrigerant leakage is
detected. It is important to always maintain lubricant level within the specified level. Otherwise, the following
conditions may occur.
• Insufficient lubricant amount: Stuck compressor
• Excessive lubricant amount: Insufficient cooling (caused by insufficient heat exchange)
Inspection INFOID:0000000011672006
If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.COMPRESSOR OIL JUDGMENT
1. Remove compressor. Refer to HA-34, "COMPRESSOR : Removal and Installation".
2. Sample a compressor oil and judge on the figure.
JSIIA0927GB
Judgement result 1>>Replace compressor only.

Judgement result 2>>Replace compressor and condenser & liquid tank assembly.
Perform Lubricant Return Operation INFOID:0000000011672007
CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera-
tion.
1. Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm
• A/C switch: ON
2. Perform lubricant return operation for approximately 10 minutes.
3. Stop the engine.
4. Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000011672008
Fill with lubricant for the amount that is calculated according to the following conditions.
Example: Lubricant amount to be added when replacing evaporator, condenser and liquid tank [m (Imp fl
oz.)] = 45 (1.6) + 30 (1.1) + 15 (0.5) + α

LUBRICANT
Lubricant amount to be added to A/C system A

Conditions
m (Imp fl oz.)
Replace evaporator 45 (1.6)
Replace condenser 30 (1.1) B
Replace liquid tank 15 (0.5)
Large amount leakage 30 (1.1)
Refrigerant leakage is detected C
Small amount leakage —
Lubricant amount that is recycled together with refrigerant during recycle operation α
D
Lubricant Adjusting Procedure for Compressor Replacement INFOID:0000000011672009
1. Drain lubricant from removed compressor and measure lubricant amount.

E
1. Drain lubricant from high-pressure port and low-pressure
port while rotating magnet clutch.
2. Measure total amount of lubricant that is drained from
removed compressor. F
H
JSIIA1933ZZ
2. Drain lubricant from a new compressor that is calculated accord-

ing to the following conditions. HA
Amount to be drained (A)

[m (Imp fl oz.)] = F − (D + S + R + α) J
F : Lubricant amount that a new compressor con-
tains [150 (5.3)]
D : Lubricant amount that is drained from removed K
compressor
S : Lubricant amount that remains inside of re- JPIIA1455GB
moved compressor [20 (0.7)] L

R : Lubricant amount to be added according to com-
ponents that are removed except compressor
M
α : Lubricant amount that is recycled together with
refrigerant during recycle operation
CAUTION: N
If lubricant amount that is drained from removed compressor is less than 60 m (2.1 Imp fl oz.),
perform calculation by setting “D” as 40 m (1.4 Imp fl oz.).
O
Lubricant amount to be added to A/C system
Conditions
m (Imp fl oz.)
Replace evaporator 45 (1.6) P
Replace condenser 30 (1.1)
Example: Lubricant amount to be drained from a new compressor when replacing compressor, condenser
and liquid tank [m (Imp fl oz.)] [D = 60 (2.1), α = 5 (0.2)]
150 (5.3) − [60 (2.1) + 20 (0.7) + 30 (1.1) + 15 (0.5) + 5 (0.2)] = 20 (0.7)
3. Install compressor and check the operation.

PERFORMANCE TEST
PERFORMANCE TEST
INSPECTION PROCEDURE
1. Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge.
2. Start the engine, and set to the following condition.
Test condition
Surrounding condition Indoors or in the shade (in a well-ventilated place)
Door Closed
Door glass Full open
Vehicle condition
Hood Open
Engine speed Idle speed
Temperature control switch or dial Full cold
A/C switch ON
A/C condition Air outlet VENT (Ventilation)
Intake door position REC (Recirculation)
Fan speed Maximum speed set
3. Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4. Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to-
operating pressure” are within the specified value.
5. When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to HA-30,
"Symptom Table".
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE
Inside air (Recirculating air) at blower assembly inlet

Discharge air temperature from center ventilator
Relative humidity Air temperature °C (°F)
% °C (°F)
20 (68) 4.7 – 6.7 (40 – 44)
25 (77) 8.6 – 11.1 (47 – 52)
50 – 60
30 (86) 12.6 – 15.6 (55 – 60)
35 (95) 19.0 – 22.5 (66 – 73)
20 (68) 6.7 – 8.7 (44 – 48)
25 (77) 11.1 – 13.6 (52 – 56)
60 – 70
30 (86) 15.6 – 18.6 (60 – 65)
35 (95) 22.5 – 26.0 (73 – 79)
AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE

PERFORMANCE TEST
Fresh air A
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
% °C (°F)
909 – 1,112 159 – 194 B
25 (77)
(9.1 – 11.1, 9.2 – 11.3, 131.8 – 161.2) (1.6 – 1.9, 1.6 – 2.0, 23.1 – 28.1)
1,073 – 1,312 211 – 259
30 (86)
(10.7 – 13.1, 10.9 – 13.4, 155.6 – 190.2) (2.1 – 2.6, 2.2 – 2.6, 30.6 – 37.6) C
50 – 70
1,445 – 1,766 247 – 300
35 (95)
(14.5 – 17.7, 14.7 – 18.0, 209.5 – 256.1) (2.5 – 3.0, 2.5 – 3.1, 35.8 – 43.5)
1,650 – 2,017 290 – 355 D
40 (104)
(16.5 – 20.2, 16.8 – 20.6, 239.3 – 292.5) (2.9 – 3.6, 3.0 – 3.6, 42.1 – 51.5)
HA

REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [YD25DDTi]
SYMPTOM DIAGNOSIS
Trouble Diagnosis For Unusual Pressure INFOID:0000000011672011
Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer to
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how-
ever, differs from vehicle to vehicle.
Symptom Table INFOID:0000000011672012
Gauge indication Refrigerant cycle Probable cause Corrective action

Collect all refrigerant, evacuate
The pressure returns to nor-
refrigerant cycle again, and
mal soon after sprinkling wa- Overfilled refrigerant.
then refill it with the specified
ter on condenser.
amount of refrigerant.
Insufficient condenser cooling
performance.
Both high- and low-pressure sides • Poor fan rotation of radiator • Repair or replace malfunc-
are too high. Air flow to condenser is insuf- and condenser. tioning parts.
ficient. • Improper installation of air • Clean and repair condenser
guide. fins.
• Clogged or dirty condenser
fins.
When compressor is stopped,
a high-pressure reading Collect all refrigerant, evacuate
AC359A
quickly drops by approximate- refrigerant cycle again, and
ly 196 kPa (1.96 bar, 2 kg/ Air mixed in refrigerant cycle.
cm2, 28 psi). It then gradually amount of refrigerant.
decreases.
• Low-pressure pipe is cooler
than the outlet of evapora- Expansion valve opened too
tor. much (excessive flow of refrig- Replace expansion valve.
• Low-pressure pipe is frost- erant).
ed.
High-pressure side is excessively
high and low-pressure side is too
low.
High-pressure pipe and upper
Clogged or crushed high-pres-
side of condenser become Repair or replace the malfunc-
sure pipe located between
hot, however, liquid tank does tioning parts.
compressor and condenser.
not become so hot.
AC360A
High-pressure side is too low and

low-pressure side is too high. • The readings of both sides
Malfunction in compressor sys-
become equal soon after
tem (insufficient compressor
compressor operation
pressure operation).
stops. Replace compressor.
• Damage or breakage of
• There is no temperature dif-
valve.
ference between high- and
• Malfunctioning gaskets.
low-pressure sides.
AC356A

A
• The area around evapora-
Clogged expansion valve.
tor outlet does not become
• Breakage of temperature Eliminate foreign material from
cold.
sensor. expansion valve, or replace it.
• The area around evapora- B
• Clogging by foreign material.
tor inlet becomes frosted.
• There is a temperature dif-
Both high- and low-pressure sides ference between the areas
around outlet and inlet Malfunction in inner liquid tank Replace condenser & liquid
C
are too low.
pipes of liquid tank. (clogged strainer). tank assembly.
• Liquid tank becomes frost-
ed. D
Clogged or crushed low-pres- Repair or replace malfunction-
sure pipe. ing parts.
Evaporator becomes frosted. • Intake sensor. Refer to HAC- E
Malfunction in intake sensor or
AC353A 72, "Diagnosis Procedure".
thermo control amp.
• Check thermo control amp.
• Check for leakage.
There is a small temperature
• Collect all refrigerant, evacu-
F
difference between the high • Shortage of refrigerant.
ate refrigerant cycle again,
and low pressure pipes for re- • Leakage of refrigerant.
and then refill it with the spec-
frigerant cycle.
ified amount of refrigerant. G
Low-pressure side sometimes be-
comes negative. • Collect all refrigerant.
• Sometimes the area
• Evacuate refrigerant cycle H
around evaporator outlet • Icing caused by the mixing of
completely, and then refill it
does not become cold. water in cooler cycle.
with the specified amount of
• Sometimes the area • Deteriorated dryer in liquid
refrigerant. At this time, al-
around evaporator inlet is tank.
frosted.
ways replace condenser & HA
liquid tank assembly.
AC354A

NOISE
NOISE
Symptom Noise source Probable cause Corrective action

Wear, breakage, or clogging of foreign Check compressor oil. Re-
Inside of compressor
material in inner parts. fer to HA-26, "Inspection".
Check clearance between
Unusual noise from compressor Magnet clutch Contact of clutch disc with pulley. clutch disc and pulley. Refer
when A/C is ON. to HA-36, "Inspection".
Check bolts for tightness.
Compressor body Loosened compressor mounting bolts. Refer to HA-33, "Exploded
View".
Check the installation condi-
Cooler piping (pipe and Improper installation of clip and brack- tion of the cooler piping. Re-
Unusual noise from cooler piping.
flexible hose) et. fer to HA-37, "Exploded
View".
• Collect all refrigerant,
evacuate refrigerant cycle
Shortage of refrigerant.
again, and then refill it
Unusual noise from expansion with the specified amount
Expansion valve
valve when A/C is ON. of refrigerant.
Eliminate foreign material
Wear, breakage, or clogging of foreign
from expansion valve, or re-
material in inner parts.
place it.
Check belt tension. Refer to
Loosened belt
Unusual noise from belt. — EM-286, "Inspection".
Internal compressor parts get locked Replace compressor.

COMPRESSOR
< REMOVAL AND INSTALLATION > [YD25DDTi]
REMOVAL AND INSTALLATION A

COMPRESSOR
Exploded View INFOID:0000000011672015
B
REMOVAL
C
HA
J
JSIIA1872GB
Alternator & compressor bracket Compressor K

: N·m (kg-m, ft-lb)
DISASSEMBLY L
JMIIA0746GB

COMPRESSOR
Compressor unit Field coil Snap ring

Pulley assembly Snap ring Shim
Clutch disc
COMPRESSOR
COMPRESSOR : Removal and Installation INFOID:0000000011672017
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
26, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy-
cle Refrigerant".
2. Remove front fender protector LH. Refer to EXT-23, "Removal and Installation".
3. Disconnect magnet clutch connector .
JSIIA1902ZZ
4. Remove drive belt. Refer to EM-285, "Removal and Installation".

5. Remove mounting bolt , and then disconnect low-pressure
flexible hose from compressor.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
JSIIA1903ZZ
6. Remove mounting bolt , and then disconnect high-pressure

CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.
JSIIA1904ZZ

COMPRESSOR
7. Remove mounting bolts , and then remove compressor
from the vehicle. A
JSIIA1920ZZ
D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. E
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-27, "Lubricant
Adjusting Procedure for Compressor Replacement".
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test". F
• Check tension of the drive belt after installing compressor. Refer to EM-286, "Inspection".
• For installing alternator & compressor bracket, temporarily
tighten bolts in the order 1→2 (parts shall not be in contact) as
shown in the figure, so that position of bracket may be G
adjusted. Tighten bolts to the specified torque in the order of
3→5, and then tighten bolts to the specified torque in the
order of 1→2. H
HA
JSIIA1906ZZ
J
• For installing compressor, temporarily tighten bolts in the
order of 1→4 as shown in the figure, and then tighten bolts to
the specified torque in the order of 1→4.
K
M
JSIIA1907ZZ
MAGNET CLUTCH
N
MAGNET CLUTCH : Removal and Installation INFOID:0000000011672018
REMOVAL O
1. Fix clutch disc.
2. Remove center bolt, and then remove clutch disc.
3. Remove snap ring using external snap ring pliers. P
4. Position center pulley puller on the end of the drive shaft, and remove pulley assembly using any commer-
cially available pulley puller.
To prevent pulley groove from being deformed, puller claws should be positioned into the edge of the pul-
ley assembly.
5. Disconnect field coil harness from compressor unit.
6. Remove snap ring using external snap ring pliers, and then remove field coil.

COMPRESSOR
INSTALLATION
1. Install field coil .
Be sure to align the coil’s pin with the hole in the compres-
sor’s front head.
2. Connect field coil harness to compressor unit.
JMIIA0575ZZ
3. Install pulley assembly using installer (SST: J-41260) (A) and

a hand press, and then install snap ring using snap ring pli-
ers.
JMIIA0576ZZ
4. Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand.
5. Using holder to prevent clutch disc rotation.
After tightening the bolt, check that the pulley rotates smoothly.
Break-in Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty-times. Break-in operation raises the level of transmitted torque.
CHECK DISC TO PULLEY CLEARANCE

Check the clearance (B) between pulley assembly and clutch disc
along the entire periphery with a feeler gauge (A).
Clearance : Refer to HA-63, "Compressor".

CAUTION:
Replace compressor if specified clearance is not obtained,
replace adjusting spacer and readjust.
SJIA1918E

COOLER PIPE AND HOSE
A
LHD models B
HA
L
JMIIA3999GB
High-pressure pipe O-ring Condenser & liquid tank assembly M

High-pressure flexible hose Compressor Low-pressure pipe bracket
Low-pressure pipe Heater & cooling unit assembly Low-pressure flexible hose
N
: Always replace after every disassembly.
: N·m (kg-m, in-lb)

O

RHD models
JSIIA1890GB
High-pressure pipe O-ring Condenser & liquid tank assembly

High-pressure flexible hose Compressor Low-pressure pipe
Heater & cooling unit assembly Low-pressure flexible hose
HIGH-PRESSURE FLEXIBLE HOSE

HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000011672021
CAUTION:
REMOVAL
cle Refrigerant".
2. Remove front wheel and tire (LH side only). Refer to WT-7, "Removal and Installation".

3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation".
4. Remove mounting bolt , and then disconnect high-pressure A
flexible hose from condenser inlet pipe assembly.
CAUTION:
Cap or wrap the joint of the A/C piping and condenser & liq- B
uid tank assembly with suitable material such as vinyl tape
to avoid the entry of air.
C
JSIIA1908ZZ
D

flexible hose from compressor side. E
CAUTION:
F
JSIIA1904ZZ
H
6. Remove high-pressure flexible hose from the vehicle.
INSTALLATION HA
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test". J
LOW-PRESSURE FLEXIBLE HOSE K

LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000011672022
CAUTION: L
M
REMOVAL
cle Refrigerant". N
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation".
4. Remove mounting bolt , and then disconnect low-pressure O
flexible hose from low-pressure pipe.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- P
JSIIA1909ZZ


CAUTION:
JSIIA1903ZZ
6. Remove low-pressure flexible hose from the vehicle.
INSTALLATION
CAUTION:
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000011672023
CAUTION:
REMOVAL
cle Refrigerant".
2. Remove low-pressure flexible hose. Refer to HA-39, "LOW-PRESSURE FLEXIBLE HOSE : Removal and
Installation".
3. Remove air filter assembly. Refer to EM-292, "Removal and Installation".
4. Remove fuel filter assembly (RHD models). Refer to FL-51, "Removal and Installation".
pipe from expansion valve.
CAUTION:
JSIIA1910ZZ

6. Remove mounting bolt and then disconnect high-pressure
pipe from condenser outlet pipe assembly. A
JSIIA1912ZZ
D
7. Remove fixing clips, and then remove high pressure pipe from vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal. E
CAUTION:
LOW-PRESSURE PIPE
G
LOW-PRESSURE PIPE : Removal and Installation INFOID:0000000011672024
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large H
HA
REMOVAL
cle Refrigerant".
J
2. Remove fuel filter bracket mounting bolt and nut to make work space. (LHD models)
pipe from expansion valve. K
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air. L
JSIIA1914ZZ
N
pipe from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- O
JSIIA1913ZZ

5. Remove low-pressure pipe mounting bracket bolts , and then
remove low-pressure pipe .
: Bracket
JSIIA1924ZZ
INSTALLATION
CAUTION:

CONDENSER
CONDENSER
A
G
JSIIA1891GB
Condenser upper bracket RH O-ring Refrigerant pressure sensor

H
Outlet pipe assembly Condenser Inlet pipe assembly
Condenser lower bracket Bracket Liquid tank
Liquid tank bracket Condenser upper bracket LH HA

J
K
CONDENSER
CONDENSER : Removal and Installation INFOID:0000000011672026
L
REMOVAL
cle Refrigerant". M
2. Remove front grille. Refer to EXT-19, "Removal and Installation".
3. Remove radiator upper seal. Refer to DLK-169, "Removal and Installation" (With Intelligent Key system)
N
or DLK-379, "Removal and Installation" (Without Intelligent Key system).
4. Remove front bumper fascia assembly. Refer to EXT-11, "Removal and Installation".
5. Remove condenser inlet pipe assembly and outlet pipe assembly from the condenser. Refer to HA-46,
O
"CONDENSER PIPE ASSEMBLY : Removal and Installation".
6. Remove AT fluid cooler mounting bolt, and then disengage AT fluid cooler fixing pawls from radiator. Refer
to TM-638, "Exploded View" (with AT fluid cooler).
CAUTION: P
Never damage the core surface of AT fluid cooler.

CONDENSER
7. Remove condenser upper bracket mounting bolt .
JSIIA1915ZZ
8. Remove condenser upper bracket RH by pressing the lock as

shown in the figure.
JSIIA1916ZZ
9. Remove radiator mounting bolts (LH and RH).
JSIIA1917ZZ
10. Lift up radiator, and then remove radiator from radiator mounting rubber.
CAUTION:
Never damage the cooling fan and radiator shroud.
11. Move the radiator to the rear direction to make enough space and take out the condenser assembly
upwards.
CAUTION:
• Never give heavy load to the radiator.
• Never damage the core surface of condenser.
JSIIA1942ZZ

CONDENSER
INSTALLATION
Note the following items, and then install in the reverse order of removal. A
CAUTION:
• Check for leakages when recharging refrigerant. B
LIQUID TANK
C
LIQUID TANK : Removal and Installation INFOID:0000000011672027
REMOVAL D
1. Remove condenser assembly. Refer to HA-43, "CONDENSER : Removal and Installation".
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank.
CAUTION: E
Be sure to clean carefully.
3. Remove mounting bolts , and then remove liquid tank .
CAUTION: F
Cap or wrap the joint of the A/C piping and liquid tank with
JSIIA1919ZZ
INSTALLATION HA
CAUTION:
• Install liquid tank, and then install liquid tank bracket on condenser. J
• Check that liquid tank bracket is securely installed at protrusion of condenser. (Check that liquid
tank bracket does not move to a position below center of liquid tank.)
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to HA-27, "Lubricant
Adjusting Procedure for Compressor Replacement". K
L
REFRIGERANT PRESSURE SENSOR
REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000011672028 M
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy- N
cle Refrigerant".
2. Remove condenser outlet pipe assembly. Refer to HA-46, "CONDENSER PIPE ASSEMBLY : Removal
and Installation". O
3. Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then
remove the refrigerant pressure sensor from the condenser.
CAUTION: P
• Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry
of air.
INSTALLATION
CAUTION:

CONDENSER
CONDENSER PIPE ASSEMBLY
CONDENSER PIPE ASSEMBLY : Removal and Installation INFOID:0000000011672029
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy-
cle Refrigerant".
2. Remove bumper fascia assembly. Refer to EXT-11, "Removal and Installation".
3. Remove mounting bolt , and then disconnect condenser inlet
pipe assembly from high-pressure flexible hose assembly .
CAUTION:
JSIIA1896ZZ

pipe assembly from condenser assembly.
CAUTION:
JSIIA1897ZZ
5. Remove condenser inlet pipe assembly from vehicle.

6. Disconnect the refrigerant pressure sensor connector .
JSIIA1911ZZ
7. Remove mounting bolt , and then disconnect condenser outlet

pipe assembly from high-pressure pipe assembly .
CAUTION:
JSIIA1898ZZ

CONDENSER
pipe assembly from condenser assembly. A
CAUTION:
rial such as vinyl tape to avoid the entry of air. B
JSIIA1899ZZ
D
9. Remove condenser outlet pipe assembly from vehicle.
INSTALLATION
CAUTION:
HA

HEATER & COOLING UNIT ASSEMBLY
REMOVAL
LHD models
JMIIA4038GB
Steering member Instrument stay LH Instrument stay RH

Drain hose Blower unit assembly Heater & cooling unit assembly

RHD models
A
HA
JSIIA1938GB
Heater & cooling unit assembly*1

Blower unit assembly Drain hose J
Cooler unit assembly*2
Instrument stay LH Instrument stay RH Steering member
: N·m (kg-m, ft-lb) K
*1: With air conditioning system

*2: With manual cooler system L
DISASSEMBLY
M
LHD Models

Manual air conditioning (switch type)
JMIIA4035GB
Adapter case Foot door assembly Fan control amp.

Heater & cooling unit case RH Heater pipe cover Evaporator pipe cover
AC cover Foot duct Heater pipe grommet
Heater core O-ring Expansion valve packing
Expansion valve Evaporator insulator Evaporator assembly
Defroster lever Mix adapter Air mix door motor assembly
Mode door motor assembly Mode lever Main link
Ventilator lever Foot link Defroster link
Foot lever Heater & cooling unit case LH Defroster door
Ventilator door Center plate case Defroster seal
Ventilator seal Inner duct case Slide door unit
Sub harness Intake outlet packing Intake sensor assembly
AC drain case Air guide case

A
Manual air conditioning (dial type) B
HA
JMIIA4036GB
N
Adapter case Foot door assembly Inner duct case
Blower fan resistor Sub harness Heater & cooling unit case RH
O
Heater pipe cover Evaporator pipe cover AC cover
Foot duct Thermo control amp. Heater pipe grommet
Heater core O-ring Expansion valve packing P
Air mix gear lever Mix link Mix lever
Main link Ventilator lever Foot link
Defroster lever Defroster link Foot lever
Defroster door Ventilator door Center plate case

Defroster seal Ventilator seal Slide door unit
Air guide case Intake outlet packing AC drain case
Heater & cooling unit case LH
Auto air conditioning (dual type)
JMIIA4037GB
Adapter case Foot door assembly Fan control amp.

Sub harness Heater & cooling unit case RH Mix adapter
Air mix door motor assembly Heater pipe cover Evaporator pipe cover
AC cover Foot duct Heater pipe grommet
Heater core O-ring Expansion valve packing
Aspirator Mode lever Defroster link
Defroster lever Main link Defroster link
Mode door motor assembly Ventilator lever Foot link
Foot lever Defroster door Ventilator door
Center plate case Defroster seal Ventilator seal
Inner duct case Slide door assembly Intake outlet packing
Intake sensor assembly AC drain case Air guide case
Heater & cooling unit case LH

A
RHD Models
B
HA
JSIIA1900GB N
Ventilator seal Defroster seal Ventilator door

Defroster door Center plate case Heater & cooling unit case RH O
Foot lever Defroster link Foot link
Ventilator lever Main link Mode lever
P
Mode door motor assembly Air mix door motor assembly Mix adapter
Defroster lever Evaporator assembly Evaporator insulator
Expansion valve Expansion valve packing O-ring
Heater core Heater pipe grommet Foot duct
AC cover Evaporator pipe cover Heater pipe cover
Heater & cooling unit case LH Intake outlet packing Sub harness

Fan control amp. Adapter case Foot door assembly
Inner duct case Slide door unit Air guide case
AC drain case Intake sensor assembly
Manual air conditioning (dial type)
JSIIA1943GB

Defroster door Center plate case Foot lever
Defroster link Defroster lever Foot link
Ventilator lever Main link Mix lever
Mix link Air mix gear lever Evaporator assembly
Evaporator insulator Expansion valve Expansion valve packing
O-ring Heater core Heater pipe grommet

Thermo control amp. Foot duct AC cover
A
Evaporator pipe cover Heater pipe cover Heater & cooling unit case LH
Sub harness Blower fan resistor Inner duct case
Foot door assembly Adapter case Slide door unit B
Air guide duct Heater & cooling unit case RH AC drain case
Intake outlet packing
: Always replace after every disassembly. C

D
Manual cooler
HA
P
JMIIA4048GB

Ventilator lever Main link Evaporator assembly

O-ring Grommet Thermo control amp.
Foot duct AC cover Evaporator pipe cover
Heater pipe grommet Cooling unit case LH Sub harness
Blower fan resistor Inner duct case Foot door assembly
Adapter case Air guide duct Cooling unit case RH
AC drain case Intake outlet packing
JSIIA1944GB

Foot link Vent lever Mode door motor assembly
Mode lever Main link Defroster lever
Defroster link Mix adapter Air mix door motor assembly
Aspirator Evaporator assembly Evaporator insulator
Air mix door motor assembly Heater & cooling unit case LH Intake outlet packing
Sub harness Fan control amp. Adapter case

Foot door assembly Inner duct case Slide door assembly
A
Heater & cooling unit case RH Air guide case AC drain case
Intake sensor assembly
: Always replace after every disassembly. B
HEATER & COOLING UNIT ASSEMBLY C
HEATER & COOLING UNIT ASSEMBLY : Removal and Installation INFOID:0000000011672031
D
CAUTION:
26, "Perform Lubricant Return Operation". E
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy- F
cle Refrigerant".
2. Drain engine coolant from cooling system. Refer to CO-68, "Inspection".
3. Remove wiper drive assembly. Refer to WW-49, "WIPER DRIVE ASSEMBLY : Removal and Installation" G
(With Intelligent Key system) or WW-105, "WIPER DRIVE ASSEMBLY : Removal and Installation" (With-
out Intelligent Key system).
4. Remove mounting bolt , and then disconnect low-pressure H
pipe and high-pressure pipe from expansion valve.
CAUTION:
with suitable material such as vinyl tape to avoid the entry HA
of air.
JSIIA1925ZZ
K
5. Remove fixing clamps , and then disconnect heater hoses .
(With air conditioning)
CAUTION: L
• Some coolant may spill when heater hoses are discon-
nected.
• Close off the coolant inlet and outlet on the heater pipes M
(2 locations) with shop cloths.
N
JSIIA1927ZZ
6. Remove instrument panel assembly. Refer to IP-14, "Removal and Installation" (LHD models) or IP-39, O
"Removal and Installation" (RHD models).

7. Remove blower mounting bolts .
JSIIA1892ZZ
8. Remove mounting nuts , mounting bolts and then remove

instrument stay . (LH and RH)
JSIIA1928ZZ
9. Disconnect drain hose from heater & cooling (cooler) unit

assembly.
JSIIA1929ZZ
10. Remove mounting bolts of ground wires.
JSIIA1931ZZ
11. Remove all of harness connectors and mounting nuts necessary to allow steering column assembly to be
moved. Refer to ST-17, "Removal and Installation".
12. Move steering column assembly to secure work space.
13. Remove all of harness connectors and clips necessary to allow steering member to be removed. Move
main harness aside and secure work space so that steering member can be easily removed.

14. Remove mounting bolts , and then remove steering member from the vehicle.
A
H
JSIIA1930ZZ
CAUTION:
When removing steering member, 2 workers are required to prevent it from dropping. HA
15. Disconnect the intake door motor and blower motor connectors.
16. Remove mounting screws , and then remove blower unit
J
assembly .
JSIIA1939ZZ
M
17. Remove heater & cooling (cooler) unit assembly from the vehicle.
CAUTION:
When removing heater & cooling unit assembly, 2 workers are required to prevent it from drop- N
ping.
INSTALLATION O
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. P
NOTE:
When filling radiator with engine coolant. Refer to CO-69, "Refilling".
EXPANSION VALVE

EXPANSION VALVE : Removal and Installation INFOID:0000000011672032
CAUTION:
REMOVAL
cle Refrigerant".
CAUTION:
of air.
JSIIA1925ZZ
3. Remove mounting bolts , and then remove expansion valve.

CAUTION:
Cap or wrap the joint of the expansion valve and evaporator
of air.
JSIIA1926ZZ
INSTALLATION
CAUTION:
EVAPORATOR
EVAPORATOR : Removal and Installation INFOID:0000000011672033
CAUTION:
REMOVAL
cle Refrigerant".
2. Remove heater & cooling (cooler) unit assembly. Refer to HA-57, "HEATER & COOLING UNIT ASSEM-
BLY : Removal and Installation".
3. Disassemble heater & cooling (cooler) unit assembly, and then remove evaporator assembly.
4. Disconnect intake sensor or thermo control amp. Refer to HA-48, "Exploded View".
5. Remove expansion valve from evaporator. Refer to HA-48, "Exploded View".
INSTALLATION

CAUTION: A
• When install the intake sensor or thermo control amp., set the same position before replacement.
• Never rotate the bracket insertion part when removing and installing the intake sensor.
B
• Perform lubricant adjusting procedure after installing new evaporator. Refer to HA-26, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
C
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000011672034 D
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-57, "HEATER & COOLING UNIT ASSEMBLY : E
Removal and Installation".
2. Remove heater pipe grommet .
F
JSIIA1941ZZ
HA
3. Remove mounting screws , and then remove heater pipe
cover .
J
L
JSIIA1893ZZ
4. Slide heater core to leftward (as shown in the figure). M
JSIIA1894ZZ P
INSTALLATION
CAUTION:

NOTE:

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi]
SERVICE DATA AND SPECIFICATIONS (SDS) A

Compressor INFOID:0000000011672035
B
VALEO THERMAL SYSTEMS THI make C

Model
DKS-17DT
Type Swash plate
Displacement D
Maximum 175 (10.7)
cm3 (cu in)/rev
Cylinder bore × stroke (Max.)mm (in.) 30.5 (1.20) × 24 (0.94)
Direction of rotation Clockwise (viewed from clutch) E
Drive belt Poly V
Disc to pulley clearance 0.3 – 0.6
Standard F
mm (in) (0.012 – 0.028)
Lubricant INFOID:0000000011672036
Name A/C System Oil Type S (DH-PS)
Capacity Total in system 150 (5.3) H

m (Imp fl oz.) Compressor (service part) charging amount 150 (5.3)
Refrigerant INFOID:0000000011672037
HA
Type HFC-134a (R-134a) J

Capacity
0.50 (1.1)
kg (lb)
K
Engine Idling Speed INFOID:0000000011672038
Refer to EC-754, "General Specification".

L
Belt Tension INFOID:0000000011672039
Refer to EM-286, "Inspection".

M

PRECAUTIONS
< PRECAUTION > [QR25DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
the event of a collision that would result in air bag inflation, all maintenance must be performed by
connectors.
WARNING:
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
battery, and wait at least 3 minutes before performing any service.
INFOID:0000000011013040
CAUTION:
then disconnect both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
OPERATION PROCEDURE
NOTE:
2. Turn the ignition switch to ACC position.

PRECAUTIONS
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
B

• Always use a 12V battery as power source. C
D
D4D engine : 20 minutes YS23DDT : 4 minutes E

M9R engine : 4 minutes ZD30DDTT : 60 seconds F
SEF289H
YD25DDTi : 2 minutes G
NOTE:
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur. H
NOTE: HA
- Driving for 30 minutes or more on a steep slope. J
NOTE: K
NOTE: L
M
windshield. N
P
PIIB3706J

WARNING:

PRECAUTIONS
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant.
• Never store or heat refrigerant containers above 52°C (126°F).
• Never intentionally drop, puncture, or incinerate refrigerant containers.
cation.
• Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air condi-
injury or property damage. Additional health and safety information may be obtained from refriger-
ant manufacturers.
CAUTION:
lowing handling precautions must be observed:
- Never remove the caps (unseal) until just before connecting the components when installing refrig-
Lubricant becomes moisture saturated and should not be used without proper sealing.
may result.
REFRIGERANT CONNECTION
• Refrigerant pressure sensor to condenser & liquid tank assembly
WARNING:
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.
CAUTION:
to do so will cause lubricant to enter the low-pressure chamber.
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle.

PRECAUTIONS
Name : A/C system Oil Type S A

• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is B
C
H
RHA861F
COMPRESSOR HA
CAUTION:
• Follow “MAINTENANCE OF LUBRICANT LEVEL IN COMPRESSOR” exactly when replacing or repair- J
moistened with thinner if the surface is contaminated with lubricant. K
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet L
clutch.
LEAK DETECTION DYE M
CAUTION:
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of N
dye leak detector should be used in conjunction with an electrical leak detector to pin-point refriger- O
ant leakages.
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres- P

PRECAUTIONS
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use
tion occurs.

introduce any refrigerant other than that specified into the machine.
VACUUM PUMP
The vent side of the vacuum pump is exposed to atmospheric pres-
OFF after evacuation (vacuuming) and hose is connected to it.
pump. Close this valve to isolate the service hose from the pump.
hose from the pump.
Some one-way valves open when vacuum is applied and close
RHA270DA
MANIFOLD GAUGE SET

sure the gauge set has 1/2″-16 ACME threaded connections for ser-
SHA533D
SERVICE HOSES

PRECAUTIONS
(colored hose with black stripe). All hoses must equip positive shut- A
B
RHA272D
D
SERVICE COUPLERS
do not properly connect to the CFC-12 (R-12) system. However, if an E
may occur.
F
Clockwise Open
G
RHA273D
REFRIGERANT WEIGHT SCALE H

be 1/2″-16 ACME if the scale controls refrigerant flow electronically. HA
K
RHA274D

Calibrate the scale each three month. L
M
N
6. Enter the known weight using four digits. (Example 10 lb. = 10.00, 10.5 lb. = 10.50) O
9. Press “6”— the known weight on the scale is displayed. P
CHARGING CYLINDER

PREPARATION
< PREPARATION > [QR25DE]
PREPARATION
PREPARATION

or its lubricant.
lubricant.
Tool number
Tool name
KV99106200
Installing pulley
Pulley installer
S-NT235

kit
Kit includes:
Power supply:
bottle
leak detection dye
Refrigerant dye cleaner
ZHA200H
Power supply:
Includes:
SHA438F
Application:
leak detection dye 1/4 ounce (7.4 cc) bottle
system with dye.)
SHA439F

PREPARATION
Tool number
(SPX-North America No.) Description A
Tool name
B
bottle C
SHA440F
Refrigerant dye cleaner For cleaning dye spills E
SHA441F F
G
or its lubricant. H
lubricant.
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid HA
compressor malfunction may result. J
L
M
RJIA0195E N
Power supply:
Electrical leak detector P
SHA705EB

PREPARATION
Identification:
es and couplers) Fitting size: Thread size
• 1/2″-16 ACME
RJIA0196E
Hose color:
stripe
• Utility hose green with black stripe
S-NT201
• 1/2″-16 ACME
Service couplers Hose fitting to service hose:

S-NT202

1/2″-16 ACME
S-NT200
Capacity:
(Including the isolator valve) • Oil capacity: 482 g (17 oz.)
• 1/2″-16 ACME
S-NT203

or its lubricant.
lubricant.

PREPARATION
Tool name Description A

Container marking: HFC-134a (R- B
C
S-NT196
Type: Polyalkylene glycol oil (PAG), D

type S (DH-PS)
Application:
pressors
E
JMIIA1759ZZ
HA

COMPONENT PARTS
< SYSTEM DESCRIPTION > [QR25DE]
SYSTEM DESCRIPTION
COMPONENT PARTS
JMIIA4008ZZ
Component Description
Refrigerant pressure sensor • Refer to HAC-225, "Refrigerant Pressure Sensor". [Manual air conditioning & cool (Semi-
elc)]
Compressor
cycle.
Evaporator
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.

SYSTEM
SYSTEM
A
HA
JPIIA1671GB

J
REFRIGERANT CYCLE
Refrigerant Flow K
Freeze Protection L
• Manual air conditioning (Full-elc): HAC-139, "Compressor Control". M
N
sensor, installed at the outlet pipe assembly. The refrigerant pressure sensor detects the pressure inside the
refrigerant line and sends the voltage signal to the ECM if the system pressure rises above, or falls below O
the specifications.
ant pressure sensor is following conditions; P
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere

SYSTEM
38.8 kg/cm2, 551 psi)].

< BASIC INSPECTION > [QR25DE]
BASIC INSPECTION A
B
OVERALL SEQUENCE
C
HA
P
NNIIA0143GB
DETAILED FLOW

>> GO TO 2.
2.SYMPTOM CHECK
viewed symptom.
Noise >> GO TO 7.
Perform the system diagnosis for the A/C control system. Refer to the following.
• Manual air conditioning & cool (Semi-elc): HAC-257, "Work Flow".
YES >> GO TO 4.
NO >> GO TO 8.
4.PERFORMANCE TEST
>> GO TO 5.
5.TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE

6.CHECK REFRIGERANT FOR LEAKAGES
>> GO TO 8.
>> GO TO 8.
>> GO TO 9.
9.REPAIR CHECK (OPERATION CHECK)
YES >> INSPECTION END
NO >> GO TO 2.

REFRIGERANT
REFRIGERANT
A
CONNECTION OF SERVICE TOOLS AND EQUIPMENT B
JSIIA0258ZZ
H
equipment
HA
Weight scale
J
CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE K
P
RJIA3815J


REFRIGERANT
WARNING:
NOTE:
NOTE:
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work.
WARNING:
NOTE:
WARNING:
CAUTION:
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set to A/C service valve.
and fill refrigerant to the specified level.
NOTE:
less when temperature is less than 16°C (61°F).
CAUTION:
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side.
• When disconnecting shut-off valve that is connected to A/C service valve, always evacuate remaining
unknown. GO TO 6.)
• A/C switch ON

REFRIGERANT
• Temperature setting: Full cold A
8. Stop the engine. Check again for refrigerant leakage. GO TO 4. B
WARNING:
NOTE: C
stopped.
pressure side rises gradually, and after this, pressure on the D
ant leakage. E
F
SHA839E
G
WARNING:
due to insufficient lubrication. H
throat. HA
1. Perform lubricant return operation. Refer to HA-83, "Perform Lubricant Return Operation". (If refrigerant or J
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is K
detected.
exists, recycle refrigerant from high-pressure hose and low-pressure hose. L
NOTE:
3. Remove A/C service valve cap from the vehicle. M
N
cant, etc.
O
WARNING: P

REFRIGERANT
2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced.
CAUTION:
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose
9. Refrigerant charge is complete.

LUBRICANT
LUBRICANT
A
MAINTENANCE OF LUBRICANT LEVEL B

detected. It is important to always maintain lubricant level within the specified level. Otherwise, the following C
D
Inspection INFOID:0000000010585682 E
1.COMPRESSOR OIL JUDGMENT F
G
HA
JSIIA0927GB
J
K
CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera- L
tion.
• Engine speed: Idling to 1,200 rpm M
• A/C switch: ON
• Temperature setting: Full cold N
3. Stop the engine.
O
INFOID:0000000010585684 P
oz.)] = 55 (1.9) + 35 (1.2) + 15 (0.5) + α

LUBRICANT

Conditions
m (Imp fl oz.)
Refrigerant leakage is detected

removed compressor.
JMIIA4001ZZ

ing to the following conditions.

[m (Imp fl oz.)] = F − (D + S + R + α)
tains [180 (6.3)]
D : Lubricant amount that is drained from removed
compressor
moved compressor [20 (0.7)]

CAUTION:

Conditions
m (Imp fl oz.)
180 (6.3) − [60 (2.1) + 20 (0.7) + 35 (1.2) + 15 (0.5) + 5 (0.2)] = 45 (1.6)

PERFORMANCE TEST
PERFORMANCE TEST
A
INSPECTION PROCEDURE B
C
Test condition
Door Closed
D
Vehicle condition
Hood Open
Engine speed Idle speed E
A/C switch ON
F
Fan speed Maximum speed set G
operating pressure” are within the specified value. H
"Symptom Table". HA

J
% °C (°F)
K
20 (68) 4.7 – 6.7 (40 – 44)
25 (77) 8.6 – 11.1 (47 – 52)
50 – 60
30 (86) 12.6 – 15.6 (55 – 60) L
35 (95) 19.0 – 22.5 (66 – 73)
20 (68) 6.7 – 8.7 (44 – 48)
25 (77) 11.1 – 13.6 (52 – 56) M
60 – 70
30 (86) 15.6 – 18.6 (60 – 65)
35 (95) 22.5 – 26.0 (73 – 79)
N

O

PERFORMANCE TEST
Fresh air
% °C (°F)
909 – 1,112 159 – 194
25 (77)
(9.1 – 11.1, 9.2 – 11.3, 131.8 – 161.2) (1.6 – 1.9, 1.6 – 2.0, 23.1 – 28.1)
1,073 – 1,312 211 – 259
30 (86)
(10.7 – 13.1, 10.9 – 13.4, 155.6 – 190.2) (2.1 – 2.6, 2.2 – 2.6, 30.6 – 37.6)
50 – 70
1,445 – 1,766 247 – 300
35 (95)
(14.5 – 17.7, 14.7 – 18.0, 209.5 – 256.1) (2.5 – 3.0, 2.5 – 3.1, 35.8 – 43.5)
1,650 – 2,017 290 – 355
40 (104)
(16.5 – 20.2, 16.8 – 20.6, 239.3 – 292.5) (2.9 – 3.6, 3.0 – 3.6, 42.1 – 51.5)

< SYMPTOM DIAGNOSIS > [QR25DE]
SYMPTOM DIAGNOSIS A
B
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how- C
D

E
ter on condenser.
amount of refrigerant. F
performance.
Air flow to condenser is insuf- and condenser. tioning parts. G
are too high.
guide. fins.
• Clogged or dirty condenser H
fins.
quickly drops by approximate- refrigerant cycle again, and HA
AC359A
decreases. J
• Low-pressure pipe is frost- erant). K
ed.
high and low-pressure side is too L
low.
side of condenser become Repair or replace the malfunc- M
not become so hot.
N
AC360A

low-pressure side is too high. • The readings of both sides O
• Damage or breakage of P
valve.
low-pressure sides.
AC356A

cold.
are too low. around outlet and inlet Malfunction in inner liquid tank Replace condenser & liquid
ed.
Evaporator becomes frosted. • Intake sensor. Refer to HAC-
thermo control amp.
frigerant cycle.
ified amount of refrigerant.
• Evacuate refrigerant cycle
ways replace condenser &
frosted.
AC354A

NOISE
NOISE
A
B
C
D
View".
E
View".
F
Shortage of refrigerant. G
Expansion valve
Eliminate foreign material H
place it.
Check belt tension. Refer to HA
Loosened belt
J

COMPRESSOR
< REMOVAL AND INSTALLATION > [QR25DE]
REMOVAL AND INSTALLATION

COMPRESSOR
REMOVAL
JMIIA4002ZZ
Compressor
DISASSEMBLY
JMIIA0746GB

Clutch disc
COMPRESSOR

COMPRESSOR
A
CAUTION:
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA- B
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy- C
cle Refrigerant".
2. Remove front fender protector LH. Refer to EXT-23, "Removal and Installation".
3. Disconnect magnet clutch connector . D
: Vehicle front
E
JMIIA4012ZZ
G

5. Remove mounting bolt , and then disconnect low-pressure H
CAUTION:
rial such as vinyl tape to avoid the entry of air. HA
: Vehicle front
J
JMIIA4013ZZ K
CAUTION: L
M
: Vehicle front
N
JMIIA4014ZZ
7. Remove mounting bolts , and then remove stay. O
: Vehicle front
P
JMIIA4015ZZ

COMPRESSOR
8. Remove mounting bolts , and then remove compressor from
the vehicle.
: Vehicle front
JMIIA4016ZZ
INSTALLATION
CAUTION:
Adjusting Procedure for Compressor Replacement".
MAGNET CLUTCH
REMOVAL
1. Fix clutch disc.
3. Remove snap ring using external snap ring pliers.
ley assembly.
INSTALLATION
Be sure to align the coil’s pin with the hole in the compres-
sor’s front head.
JMIIA0575ZZ

COMPRESSOR
3. Install pulley assembly using installer (SST: KJ99106200) (A)
and a hand press, and then install snap ring using snap ring A
pliers.
JMIIA0576ZZ
D
4. Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand.
After tightening the bolt, check that the pulley rotates smoothly. E
Break-in Operation
ing and disengaging the clutch about thirty-times. Break-in operation raises the level of transmitted torque. F
G
along the entire periphery with a feeler gauge (A). H

CAUTION: HA
J
SJIA1918E

JMIIA3997GB
High-pressure pipe O-ring Condenser & liquid tank assembly

High-pressure flexible hose Low-pressure flexible hose Compressor
Low-pressure pipe Low-pressure flexible pipe bracket Heater & cooling unit assembly

: Indicates that the part is connected at points with same symbol in actual vehicle.
HIGH-PRESSURE FLEXIBLE HOSE

CAUTION:

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy- A
cle Refrigerant".
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation". B

flexible hose from condenser inlet pipe assembly.
CAUTION: C
Cap or wrap the joint of the A/C piping and condenser with
D
JSIIA1908ZZ
5. Remove mounting bolt , and then disconnect high-pressure F

flexible hose from compressor side.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with G
: Vehicle front
H
JMIIA4014ZZ
HA
6. Remove high-pressure flexible hose from the vehicle.

J
INSTALLATION
CAUTION:
K
L
LOW-PRESSURE FLEXIBLE HOSE
M
CAUTION:
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA- N
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy- O
cle Refrigerant".
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation". P

CAUTION:
JSIIA1909ZZ

CAUTION:
: Vehicle front
JMIIA4013ZZ
INSTALLATION
CAUTION:
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000010490523
CAUTION:
REMOVAL
cle Refrigerant".
2. Remove air cleaner assembly. Refer to EM-292, "Removal and Installation".
3. Disconnect vacuum hose from brake booster. Refer to BR-124, "Removal and Installation".
CAUTION:
JSIIA1910ZZ

5. Remove mounting bolt and then disconnect high-pressure
pipe from condenser outlet pipe assembly . A
JMIIA4018ZZ
D
INSTALLATION
CAUTION:
LOW-PRESSURE PIPE
G
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large H
HA
REMOVAL
cle Refrigerant".
J
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve K
of air.
L
M
JSIIA1914ZZ

pipe from low-pressure flexible hose. N
CAUTION:
rial such as vinyl tape to avoid the entry of air. O
JSIIA1913ZZ

4. Remove low-pressure pipe mounting bracket bolts , and then
remove low-pressure pipe .
: Bracket
JSIIA1924ZZ
INSTALLATION
CAUTION:

CONDENSER
CONDENSER
A
G
JMIIA4010GB
Condenser upper bracket RH Condenser side seal upper Condenser side seal lower
H
Outlet pipe assembly Refrigerant pressure sensor O-ring
Condenser Inlet pipe assembly Condenser lower bracket
Bracket Liquid tank Liquid tank bracket HA
Condenser upper bracket LH Condenser upper seal
J

K
CONDENSER
L
REMOVAL
M
cle Refrigerant".
2. Remove front bumper fascia assembly. Refer to EXT-11, "Removal and Installation". N
3. Remove radiator upper seal. Refer to the following.
• With Intelligent Key system: Refer to DLK-169, "Removal and Installation"
• Without Intelligent Key system: Refer to DLK-169, "Removal and Installation".
O
4. Remove AT fluid cooler mounting bolt, and then disengage AT fluid cooler fixing pawls from radiator (with
AT fluid cooler). Refer to TM-638, "Exploded View".
CAUTION:
Never damage the core surface of AT fluid cooler. P
5. Remove condenser inlet pipe assembly and outlet pipe assembly from the condenser. Refer to HA-102,
"CONDENSER PIPE ASSEMBLY : Removal and Installation".

CONDENSER
JSIIA1915ZZ

JSIIA1916ZZ
8. Remove radiator mounting bolts (LH and RH).
JSIIA1917ZZ
9. Remove front under cover. Refer to EXT-24, "Removal and Installation".

10. Disengage radiator shroud (lower) fixing pawls, and then remove radiator shroud (lower). Refer to CO-16,
"Exploded View".
11. Lift up radiator, and then remove radiator from radiator mounting rubber.
12. Move the radiator to the rear direction to make enough space and take out the condenser assembly
upwards.
JSIIA1942ZZ
CAUTION:

CONDENSER
• Never damage the core surface of condenser. A
INSTALLATION
CAUTION: B
Adjusting Procedure for Components Replacement Except Compressor". C
• Check for leakages when recharging refrigerant.
LIQUID TANK D
E
REMOVAL
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank. F
CAUTION:
3. Remove mounting bolts , and then remove liquid tank . G
CAUTION:
H
HA
JSIIA1919ZZ J
INSTALLATION
CAUTION: K
• Install liquid tank, and then install liquid tank bracket on condenser.
tank bracket does not move to a position below center of liquid tank.) L
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to HA-83, "Lubricant
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test". M

N
REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000010490566
REMOVAL O
cle Refrigerant".
2. Remove condenser outlet pipe assembly. Refer to HA-102, "CONDENSER PIPE ASSEMBLY : Removal P
and Installation".
remove the refrigerant pressure sensor from the condenser.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry
of air.

CONDENSER
INSTALLATION
Note the following item, and then install in the reverse order of removal.
CAUTION:
Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test".
CONDENSER PIPE ASSEMBLY

REMOVAL
cle Refrigerant".
2. Remove bumper fascia assembly. Refer to EXT-11, "Removal and Installation".
pipe assembly from high-pressure flexible hose assembly .
CAUTION:
JSIIA1896ZZ

CAUTION:
JSIIA1897ZZ
5. Remove condenser inlet pipe assembly from vehicle.

6. Disconnect the refrigerant pressure sensor connector .
JSIIA1911ZZ

CONDENSER
pipe assembly from high-pressure pipe assembly . A
CAUTION:
rial such as vinyl tape to avoid the entry of air. B
JMIIA4018ZZ
D
CAUTION: E
G
JSIIA1899ZZ
9. Remove condenser outlet pipe assembly from vehicle.

H
INSTALLATION
CAUTION: HA
J

REMOVAL
JSIIA1938GB
Heater & cooling unit assembly*1

Blower unit assembly Drain hose
Cooler unit assembly*2
Instrument stay LH Instrument stay RH Steering member
*1: With manual air conditioning system

*2: With manual cooler system
DISASSEMBLY

A
HA
L
JSIIA1900GB
Ventilator seal Defroster seal Ventilator door M

Defroster door Center plate case Heater & cooling unit case RH
N
Defroster lever Evaporator assembly Evaporator insulator O
P

Manual air conditioning (dial type)
JSIIA1943GB

Mix link Air mix gear lever Evaporator assembly
Foot door assembly Adapter case Slide door unit

A
: N·m (kg-m, in-lb) B
Manual cooler
C
HA
N
JMIIA4048GB
Ventilator seal Defroster seal Ventilator door O

Ventilator lever Main link Evaporator assembly
P

O-ring Grommet Thermo control amp.
Foot duct AC cover Evaporator pipe cover
Heater pipe grommet Cooling unit case LH Sub harness
Blower fan resistor Inner duct case Foot door assembly

Adapter case Air guide duct Cooling unit case RH
AC drain case Intake outlet packing

CAUTION:
REMOVAL
cle Refrigerant".
2. Drain engine coolant from cooling system. Refer to CO-11, "Draining".
3. Remove wiper drive assembly. Refer to WW-49, "WIPER DRIVE ASSEMBLY : Removal and Installation"
(With Intelligent Key system) or WW-105, "WIPER DRIVE ASSEMBLY : Removal and Installation" (With-
CAUTION:
of air.
JSIIA1925ZZ

(with manual air conditioning)
CAUTION:
nected.
• Close off the coolant inlet and outlet on the heater pipes
JSIIA1927ZZ
6. Remove instrument panel assembly. Refer to IP-14, "Removal and Installation".

JSIIA1892ZZ


instrument stay . (LH and RH) A
JSIIA1928ZZ
D
9. Disconnect drain hose from heater & cooling (cooler) unit
assembly.
E
G
JSIIA1929ZZ
10. Remove mounting bolts of ground wires. H
HA
JSIIA1931ZZ
K
12. Move steering column assembly to secure work space. L
M

JSIIA1930ZZ
CAUTION:
When removing steering member, 2 workers are required to prevent it from dropping.
assembly .
JSIIA1939ZZ
17. Remove heater & cooling (cooler) unit assembly from the vehicle.
CAUTION:
When removing heater & cooling unit assembly, 2 workers are required to prevent it from drop-
ping.
INSTALLATION
CAUTION:
NOTE:
EXPANSION VALVE

A
CAUTION:
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA- B
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy- C
cle Refrigerant".
pipe and high-pressure pipe from expansion valve. D
CAUTION:
with suitable material such as vinyl tape to avoid the entry E
of air.
JSIIA1925ZZ
G
CAUTION:
Cap or wrap the joint of the expansion valve and evaporator H
of air.
HA
J
JSIIA1926ZZ
INSTALLATION
Note the following items, and then install in the reverse order of removal. K
CAUTION:
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test". L
EVAPORATOR
M
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large N
REMOVAL O
cle Refrigerant".
P
2. Remove heater & cooling (cooler) unit assembly. Refer to HA-108, "HEATER & COOLING UNIT ASSEM-
BLY : Removal and Installation".
3. Disassemble heater & cooling (cooler) unit assembly, and then remove evaporator assembly.
INSTALLATION

CAUTION:
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000010491660
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-108, "HEATER & COOLING UNIT ASSEMBLY :
JSIIA1941ZZ

cover .
JSIIA1893ZZ
4. Slide heater core to leftward (as shown in the figure).
JSIIA1894ZZ
INSTALLATION
CAUTION:

NOTE:
When filling radiator with engine coolant. Refer to CO-69, "Refilling". A
HA

< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]

VALEO THERMAL SYSTEMS JAPAN make

Model
DKS-17D
Type Swash plate
Displacement
Maximum 175 (10.7)
cm3 (cu in)/rev
Direction of rotation Clockwise (viewed from clutch)
Drive belt Poly V
Standard
mm (in) (0.012 – 0.024)
Capacity Total in system 180 (6.3)

Type HFC-134a (R-134a)

Capacity
0.50 (1.1)
kg (lb)
Refer to EC-754, "General Specification".

Refer to EM-286, "Inspection".

PRECAUTIONS
< PRECAUTION > [YS23DDT/YS23DDTT]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
WARNING: D
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
F
connectors. G
WARNING: H
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing HA
serious injury.
battery, and wait at least 3 minutes before performing any service. J
INFOID:0000000011991374
K
CAUTION:
then disconnect both battery cables. L
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
OPERATION PROCEDURE
O
NOTE:
2. Turn the ignition switch to ACC position. P

PRECAUTIONS
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock

• Always use a 12V battery as power source.
D4D engine : 20 minutes YS23DDT : 4 minutes

M9R engine : 4 minutes ZD30DDTT : 60 seconds
SEF289H
YD25DDTi : 2 minutes
NOTE:
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
NOTE:
- Driving for 30 minutes or more on a steep slope.
NOTE:
NOTE:
windshield.
PIIB3706J

WARNING:

PRECAUTIONS
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. A
B
• Never store or heat refrigerant containers above 52°C (126°F). C
• Never intentionally drop, puncture, or incinerate refrigerant containers. D
cation.
• Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air condi- E
injury or property damage. Additional health and safety information may be obtained from refriger- F
ant manufacturers.
CAUTION: G
H
lowing handling precautions must be observed: HA
- Never remove the caps (unseal) until just before connecting the components when installing refrig- J
Lubricant becomes moisture saturated and should not be used without proper sealing. K
may result.
REFRIGERANT CONNECTION L
• Refrigerant pressure sensor to condenser & liquid tank assembly M
WARNING:
less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. N
CAUTION:
to do so will cause lubricant to enter the low-pressure chamber. O
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle. P

PRECAUTIONS

• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is
RHA861F
COMPRESSOR
CAUTION:
• Follow “MAINTENANCE OF LUBRICANT LEVEL IN COMPRESSOR” exactly when replacing or repair-
moistened with thinner if the surface is contaminated with lubricant.
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet
clutch.
LEAK DETECTION DYE
CAUTION:
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of
dye leak detector should be used in conjunction with an electrical leak detector to pin-point refriger-
ant leakages.
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres-

PRECAUTIONS
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use A
B
tion occurs.
C
introduce any refrigerant other than that specified into the machine. D
E
VACUUM PUMP
The vent side of the vacuum pump is exposed to atmospheric pres- F
OFF after evacuation (vacuuming) and hose is connected to it. G
pump. Close this valve to isolate the service hose from the pump. H
hose from the pump. HA
Some one-way valves open when vacuum is applied and close J
K
RHA270DA L
MANIFOLD GAUGE SET
sure the gauge set has 1/2″-16 ACME threaded connections for ser- M
N
SHA533D
P
SERVICE HOSES

PRECAUTIONS
(colored hose with black stripe). All hoses must equip positive shut-
RHA272D
SERVICE COUPLERS
do not properly connect to the CFC-12 (R-12) system. However, if an
may occur.

Clockwise Open
RHA273D
REFRIGERANT WEIGHT SCALE

be 1/2″-16 ACME if the scale controls refrigerant flow electronically.
RHA274D

Calibrate the scale each three month.
6. Enter the known weight using four digits. (Example 10 lb. = 10.00, 10.5 lb. = 10.50)
9. Press “6”— the known weight on the scale is displayed.
CHARGING CYLINDER

PREPARATION
< PREPARATION > [YS23DDT/YS23DDTT]
PREPARATION A
PREPARATION
B

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/ C
or its lubricant.
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles D
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and E
Tool number
F
Tool name
KV99106200
Installing pulley
Pulley installer H
S-NT235
HA
kit
Kit includes: J
Power supply:
bottle K
leak detection dye
Refrigerant dye cleaner L
ZHA200H
Power supply: M
Includes: N
SHA438F
O
Application:
leak detection dye 1/4 ounce (7.4 cc) bottle P
system with dye.)
SHA439F

PREPARATION
Tool number
Tool name

bottle
SHA440F
Refrigerant dye cleaner For cleaning dye spills
SHA441F

or its lubricant.
lubricant.

RJIA0195E
Power supply:
Electrical leak detector
SHA705EB

PREPARATION
A
Identification:
B
es and couplers) Fitting size: Thread size C
• 1/2″-16 ACME
D
RJIA0196E
Hose color:
E
stripe
• Utility hose F
green with black stripe
S-NT201
• 1/2″-16 ACME
G
Service couplers Hose fitting to service hose: H

HA
S-NT202
J
1/2″-16 ACME
K
S-NT200
L
Capacity:
(Including the isolator valve) • Oil capacity: 482 g (17 oz.) M
• 1/2″-16 ACME
S-NT203
N
O
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ P
lubricant.

PREPARATION

Container marking: HFC-134a (R-
S-NT196
Type: Polyalkylene glycol oil (PAG),

type S (DH-PS)
Application:
pressors
JMIIA1759ZZ

COMPONENT PARTS
< SYSTEM DESCRIPTION > [YS23DDT/YS23DDTT]
SYSTEM DESCRIPTION A
COMPONENT PARTS
B
HA
JMIIA4009ZZ
M
Component Description N
Compressor
cycle.
• Refer to HAC-19, "Refrigerant Pressure Sensor". [Automatic air conditioning]
O
elc)] P
Evaporator
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.

SYSTEM
SYSTEM
JPIIA1671GB
REFRIGERANT CYCLE
Refrigerant Flow
Freeze Protection
• Automatic air conditioning: HAC-24, "AUTOMATIC AIR CONDITIONING SYSTEM : Compressor Control".
• Manual air conditioning (Full-elc): HAC-139, "Compressor Control".
sensor, installed at the condenser pipe assembly. The refrigerant pressure sensor detects the pressure
inside the refrigerant line and sends the voltage signal to the ECM if the system pressure rises above, or
falls below the specifications.
ant pressure sensor is following conditions;

SYSTEM
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere A
38.8 kg/cm2, 551 psi)].
B
HA

< BASIC INSPECTION > [YS23DDT/YS23DDTT]
BASIC INSPECTION
OVERALL SEQUENCE
NNIIA0143GB
DETAILED FLOW

>> GO TO 2.
2.SYMPTOM CHECK A
viewed symptom.
B
C
Noise >> GO TO 7.
Perform the system diagnosis for the A/C control system. Refer to the following. D
• Automatic air conditioning: HAC-57, "Work Flow".
• Manual air conditioning & cool (Semi-elc): HAC-257, "Work Flow". E
YES >> GO TO 4.
NO >> GO TO 8. F
4.PERFORMANCE TEST
G
>> GO TO 5.
5.TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE H
HA
6.CHECK REFRIGERANT FOR LEAKAGES J
K
>> GO TO 8.
L
>> GO TO 8.
M
N
>> GO TO 9.
9.REPAIR CHECK (OPERATION CHECK) O
YES >> INSPECTION END P
NO >> GO TO 2.

REFRIGERANT
REFRIGERANT
CONNECTION OF SERVICE TOOLS AND EQUIPMENT
JSIIA0258ZZ

equipment
Weight scale
CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE
RJIA3815J


REFRIGERANT
WARNING:
Never look directly into UV lamp light source. A
NOTE:
B
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and C
NOTE: D
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work. E
WARNING:
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions. F
G
WARNING:
H
CAUTION:
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse HA
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set to A/C service valve. J
and fill refrigerant to the specified level. K
NOTE:
less when temperature is less than 16°C (61°F). L
CAUTION: M
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the N
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side. O
• When disconnecting shut-off valve that is connected to A/C service valve, always evacuate remaining P
unknown. GO TO 6.)
• A/C switch ON

REFRIGERANT
8. Stop the engine. Check again for refrigerant leakage. GO TO 4.
WARNING:
NOTE:
stopped.
pressure side rises gradually, and after this, pressure on the
ant leakage.
SHA839E
WARNING:
throat.
1. Perform lubricant return operation. Refer to HA-134, "Perform Lubricant Return Operation". (If refrigerant
or lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is
detected.
exists, recycle refrigerant from high-pressure hose and low-pressure hose.
NOTE:
3. Remove A/C service valve cap from the vehicle.
cant, etc.
WARNING:

REFRIGERANT
2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or A
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced. B
C
CAUTION:
D
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose E
9. Refrigerant charge is complete. F
HA

LUBRICANT
LUBRICANT
MAINTENANCE OF LUBRICANT LEVEL

detected. It is important to always maintain lubricant level within the specified level. Otherwise, the following
1.COMPRESSOR OIL JUDGMENT
JSIIA0927GB

CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera-
tion.
• Engine speed: Idling to 1,200 rpm
• A/C switch: ON
3. Stop the engine.
INFOID:0000000011991393
oz.)] = 45 (1.6) + 30 (1.1) + 15 (0.5) + α

LUBRICANT
Lubricant amount to be added to A/C system A

Conditions
m (Imp fl oz.)
Replace condenser 30 (1.1) B
Refrigerant leakage is detected C
D

E
removed compressor. F
H
JMIIA4003ZZ

ing to the following conditions. HA

[m (Imp fl oz.)] = F − (D + S + R + α) J
tains [150 (5.3)]
D : Lubricant amount that is drained from removed K
compressor
moved compressor [20 (0.7)] L

M
CAUTION: N
O
Conditions
m (Imp fl oz.)
Replace condenser 30 (1.1) P
150 (5.3) − [60 (2.1) + 20 (0.7) + 30 (1.1) + 15 (0.5) + 5 (0.2)] = 20 (0.7)

PERFORMANCE TEST
PERFORMANCE TEST
INSPECTION PROCEDURE
Test condition
Door Closed
Vehicle condition
Hood Open
Engine speed Idle speed
A/C switch ON
Fan speed Maximum speed set
operating pressure” are within the specified value.
"Symptom Table".

% °C (°F)
20 (68) 4.7 – 6.7 (40 – 44)
25 (77) 8.6 – 11.1 (47 – 52)
50 – 60
30 (86) 12.6 – 15.6 (55 – 60)
35 (95) 19.0 – 22.5 (66 – 73)
20 (68) 6.7 – 8.7 (44 – 48)
25 (77) 11.1 – 13.6 (52 – 56)
60 – 70
30 (86) 15.6 – 18.6 (60 – 65)
35 (95) 22.5 – 26.0 (73 – 79)

PERFORMANCE TEST
Fresh air A
% °C (°F)
909 – 1,112 159 – 194 B
25 (77)
(9.1 – 11.1, 9.2 – 11.3, 131.8 – 161.2) (1.6 – 1.9, 1.6 – 2.0, 23.1 – 28.1)
1,073 – 1,312 211 – 259
30 (86)
(10.7 – 13.1, 10.9 – 13.4, 155.6 – 190.2) (2.1 – 2.6, 2.2 – 2.6, 30.6 – 37.6) C
50 – 70
1,445 – 1,766 247 – 300
35 (95)
(14.5 – 17.7, 14.7 – 18.0, 209.5 – 256.1) (2.5 – 3.0, 2.5 – 3.1, 35.8 – 43.5)
1,650 – 2,017 290 – 355 D
40 (104)
(16.5 – 20.2, 16.8 – 20.6, 239.3 – 292.5) (2.9 – 3.6, 3.0 – 3.6, 42.1 – 51.5)
HA

< SYMPTOM DIAGNOSIS > [YS23DDT/YS23DDTT]
SYMPTOM DIAGNOSIS
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how-

ter on condenser.
amount of refrigerant.
performance.
are too high. Air flow to condenser is insuf- and condenser. tioning parts.
guide. fins.
• Clogged or dirty condenser
fins.
AC359A
quickly drops by approximate- refrigerant cycle again, and
decreases.
• Low-pressure pipe is frost- erant).
ed.
high and low-pressure side is too
low.
side of condenser become Repair or replace the malfunc-
not become so hot.
AC360A

low-pressure side is too high. • The readings of both sides
• Damage or breakage of
valve.
low-pressure sides.
AC356A

A
cold.
• The area around evapora- B
around outlet and inlet Malfunction in inner liquid tank Replace condenser & liquid
C
are too low.
ed. D
Evaporator becomes frosted. • Intake sensor. Refer to HAC- E
thermo control amp.
F
frigerant cycle.
ified amount of refrigerant. G
• Evacuate refrigerant cycle H
frosted.
ways replace condenser & HA
AC354A

NOISE
NOISE

View".
View".
Shortage of refrigerant.
Expansion valve
Eliminate foreign material
place it.
Check belt tension. Refer to
Loosened belt

COMPRESSOR
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT]
REMOVAL AND INSTALLATION A

COMPRESSOR
B
REMOVAL
C
HA
J
JMIIA4004GB
Compressor K
DISASSEMBLY L
JMIIA0746GB

COMPRESSOR

Clutch disc
COMPRESSOR
CAUTION:
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant".
2. Remove air cleaner and air duct. Refer to EM-159, "Removal and Installation".
3. Remove air inlet tube. Refer to EM-162, "Removal and Installation".
5. Disconnect magnet clutch connector.
CAUTION:
: Vehicle front
JMIIA4120ZZ

CAUTION:
: Vehicle front
JMIIA4121ZZ
8. Remove mounting bolts , and then remove compressor from

the vehicle.
: Vehicle front
JMIIA4117ZZ

COMPRESSOR
INSTALLATION
Note the following items, and then install in the reverse order of removal. A
CAUTION:
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-135, "Lubri- B
cant Adjusting Procedure for Compressor Replacement".
C
MAGNET CLUTCH
D
REMOVAL
E
1. Fix clutch disc.
3. Remove snap ring using external snap ring pliers.
F
ley assembly. G
H
INSTALLATION
Be sure to align the coil’s pin with the hole in the compres- HA
sor’s front head.
J
JMIIA0575ZZ
L
3. Install pulley assembly using installer (SST: KJ99106200) (A)
and a hand press, and then install snap ring using snap ring
pliers. M
O
JMIIA0576ZZ
4. Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand. P
After tightening the bolt, check that the pulley rotates smoothly.
Break-in Operation
ing and disengaging the clutch about thirty-times. Break-in operation raises the level of transmitted torque.

COMPRESSOR

along the entire periphery with a feeler gauge (A).

CAUTION:
SJIA1918E

A
HA
L
JMIIA3998GB
High-pressure pipe O-ring Condenser & liquid tank assembly M

Compressor Heater & cooling unit assembly Low-pressure pipe
High-pressure flexible hose Low-pressure flexible hose
N

O
: Indicates that the part is connected at points with same symbol in actual vehicle.
HIGH-PRESSURE FLEXIBLE HOSE P
CAUTION:

REMOVAL
CAUTION:
: Vehicle front
JMIIA4120ZZ

flexible hose from condenser pipe assembly.
CAUTION:
JMIIA4123ZZ
INSTALLATION
CAUTION:
LOW-PRESSURE FLEXIBLE HOSE

CAUTION:
REMOVAL

flexible hose from compressor. A
CAUTION:
B
: Vehicle front
JMIIA4121ZZ
D
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- E
G
JMIIA4119ZZ

H
INSTALLATION
CAUTION: HA
J
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000011991406 K
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large L
REMOVAL M
2. Remove low-pressure pipe. Refer to HA-148, "LOW-PRESSURE PIPE : Removal and Installation". N
3. Disconnect high-pressure pipe from expansion valve.
flexible hose and high-pressure pipe from condenser pipe O
assembly.
JMIIA4122ZZ

INSTALLATION
CAUTION:
LOW-PRESSURE PIPE
CAUTION:
REMOVAL
3. Remove engine cover. Refer to EM-157, "Removal and Installation"
5. Remove oil separator. Refer to EM-187, "Removal and Installation"
6. Remove water pipe assembly. Refer to CO-58, "Exploded View".
7. Remove fuel filter bracket to make work space. Refer to FL-29, "Exploded View".
CAUTION:
of air.
JSIIA1914ZZ

pipe from low-pressure flexible hose.
CAUTION:
JMIIA4124ZZ
10. Remove low-pressure pipe bracket mounting bolt, and then remove low-pressure pipe from vehicle.
INSTALLATION
CAUTION:
NOTE:

CONDENSER
CONDENSER
A
G
JMIIA4011GB
Condenser upper bracket RH O-ring Condenser pipe assembly

H
Refrigerant pressure sensor Condenser Condenser lower bracket
Bracket Liquid tank Liquid tank bracket
Condenser upper bracket LH HA

J
CONDENSER K
L
REMOVAL
"Recycle Refrigerant". M
3. Remove radiator core support upper. Refer to the following.
• With Intelligent Key system: Refer to DLK-169, "Removal and Installation" N
4. Remove AT fluid cooler mounting bolt, and then disengage AT fluid cooler fixing pawls from radiator (with
AT fluid cooler). Refer to TM-638, "Exploded View".
O
CAUTION:
Never damage the core surface of AT fluid cooler.
5. Remove condenser pipe assembly from the condenser. Refer to HA-151, "CONDENSER PIPE ASSEM-
BLY : Removal and Installation". P

CONDENSER
JMIIA4194ZZ

JMIIA4195ZZ
8. Move the radiator to the rear direction to make enough space

and take out the condenser assembly upwards.
CAUTION:
• Never damage the core surface of condenser.
JMIIA4196ZZ
INSTALLATION
CAUTION:
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-134, "Lubri-
cant Adjusting Procedure for Components Replacement Except Compressor".
• Check for leakages when recharging refrigerant.
LIQUID TANK
REMOVAL
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank.
CAUTION:

CONDENSER
3. Remove mounting bolts , and then remove liquid tank .
CAUTION: A
B
JSIIA1919ZZ
D
INSTALLATION
CAUTION:
• Install liquid tank, and then install liquid tank bracket on condenser. E
tank bracket does not move to a position below center of liquid tank.)
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to HA-134, "Lubricant F
G

H
REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000011991411
REMOVAL
HA
J
3. Clean refrigerant pressure sensor and its surrounding area, and then remove dust and rust from refriger-
ant pressure sensor.
CAUTION:
Be sure to clean carefully. K
4. Disconnect refrigerant pressure sensor harness connector.
remove the refrigerant pressure sensor from the condenser. L
CAUTION:
Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry
of air. M
INSTALLATION
Note the following item, and then install in the reverse order of removal.
CAUTION: N
Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
CONDENSER PIPE ASSEMBLY O
P
REMOVAL
cle Refrigerant".
3. Remove air guide RH. Refer to the following.
• With Intelligent Key system: Refer to DLK-169, "Removal and Installation".

CONDENSER
4. Disconnect the refrigerant pressure sensor connector.
flexible hose and high-pressure pipe from condenser pipe
assembly.
CAUTION:
JMIIA4122ZZ
6. Remove mounting bolt , and then remove condenser pipe

assembly.
CAUTION:
JMIIA4118ZZ
INSTALLATION
CAUTION:

A
REMOVAL B
HA
JSIIA1938GB
K
Heater & cooling unit assembly Blower unit assembly Drain hose
Instrument stay LH Instrument stay RH Steering member L
M
DISASSEMBLY

JSIIA1900GB

Defroster door Center plate case Heater & cooling unit case RH
Defroster lever Evaporator assembly Evaporator insulator

A
Manual air conditioning (dial type) B
HA
JSIIA1943GB
N
O
Mix link Air mix gear lever Evaporator assembly P

Foot door assembly Adapter case Slide door unit
JSIIA1944GB

Foot link Vent lever Mode door motor assembly
Mode lever Main link Defroster lever
Defroster link Mix adapter Air mix door motor assembly
Aspirator Evaporator assembly Evaporator insulator
Air mix door motor assembly Heater & cooling unit case LH Intake outlet packing
Sub harness Fan control amp. Adapter case
Foot door assembly Inner duct case Slide door assembly
Heater & cooling unit case RH Air guide case AC drain case
Intake sensor assembly

A
HEATER & COOLING UNIT ASSEMBLY B

CAUTION: C
D
REMOVAL
"Recycle Refrigerant". E
3. Remove wiper drive assembly. Refer to WW-49, "WIPER DRIVE ASSEMBLY : Removal and Installation"
(With Intelligent Key system) or WW-105, "WIPER DRIVE ASSEMBLY : Removal and Installation" (With- F
pipe and high-pressure pipe from expansion valve. G
CAUTION:
with suitable material such as vinyl tape to avoid the entry H
of air.
HA
JSIIA1925ZZ
J
CAUTION:
K
nected.
• Close off the coolant inlet and outlet on the heater pipes
L
M
JSIIA1927ZZ
6. Remove instrument panel assembly. Refer to IP-14, "Removal and Installation".

N
JSIIA1892ZZ

instrument stay . (LH and RH)
JSIIA1928ZZ
9. Disconnect drain hose from heater & cooling unit assembly.
JSIIA1929ZZ
10. Remove mounting bolts of ground wires.
JSIIA1931ZZ
12. Move steering column assembly to secure work space.

A
H
JSIIA1930ZZ
CAUTION:
When removing steering member, 2 workers are required to prevent it from dropping. HA
J
assembly .
JSIIA1939ZZ
M
17. Remove heater & cooling unit assembly from the vehicle.
CAUTION:
When removing heater & cooling unit assembly, 2 workers are required to prevent it from drop- N
ping.
INSTALLATION O
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. P
NOTE:
EXPANSION VALVE

CAUTION:
REMOVAL
CAUTION:
of air.
JSIIA1925ZZ

CAUTION:
Cap or wrap the joint of the expansion valve and evaporator
of air.
JSIIA1926ZZ
INSTALLATION
CAUTION:
EVAPORATOR
CAUTION:
REMOVAL
2. Remove heater & cooling unit assembly. Refer to HA-157, "HEATER & COOLING UNIT ASSEMBLY :
3. Disassemble heater & cooling unit assembly, and then remove evaporator assembly.
INSTALLATION

CAUTION: A
B
C
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000011991417 D
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-157, "HEATER & COOLING UNIT ASSEMBLY : E
F
JSIIA1941ZZ
HA
cover .
J
L
JSIIA1893ZZ
4. Slide heater core to leftward (as shown in the figure). M
JSIIA1894ZZ P
INSTALLATION
CAUTION:

NOTE:

< SERVICE DATA AND SPECIFICATIONS (SDS) [YS23DDT/YS23DDTT]
SERVICE DATA AND SPECIFICATIONS (SDS) A

B
VALEO THERMAL SYSTEMS THI make C

Model
DKS-17DT
Type Swash plate
Displacement D
Maximum 175 (10.7)
cm3 (cu in)/rev
Direction of rotation Clockwise (viewed from clutch) E
Drive belt Poly V
Standard F
mm (in) (0.012 – 0.024)
Capacity Total in system 150 (5.3) H

HA
Type HFC-134a (R-134a) J

Capacity
0.50 (1.1)
kg (lb)
K
Refer to EC-1203, "Idle Speed".

L
Refer to EM-261, "Drive Belts".

M

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VENTILATION, HEATER & AIR CONDITIONER

HEATER & AIR CONDITIONING SYSTEM

PREPARATION ..................................................11 NOISE ................................................................ 32 K

Revision: 2015 March HA-1 D23

Revision: 2015 March HA-2 D23

LOW-PRESSURE PIPE ............................................. 97 PREPARATION ......................................... 121

CONDENSER PIPE ASSEMBLY ............................ 102

SERVICE DATA AND SPECIFICATIONS SYMPTOM DIAGNOSIS ............................ 138

Revision: 2015 March HA-3 D23

HIGH-PRESSURE PIPE ...........................................147 HEATER CORE ....................................................... 161

Revision: 2015 March HA-4 D23

Revision: 2015 March HA-5 D23

When disconnecting the battery terminal, pay attention to the following.

D4D engine : 20 minutes YS23DDT : 4 minutes

Precautions For Refrigerant System Service INFOID:0000000011671992

GENERAL REFRIGERANT PRECAUTION

Revision: 2015 March HA-6 D23

Revision: 2015 March HA-7 D23

Name : A/C system Oil Type S

Revision: 2015 March HA-8 D23

Revision: 2015 March HA-9 D23

Shut-off valve rotation A/C service valve

REFRIGERANT WEIGHT SCALE

CALIBRATING ACR4 WEIGHT SCALE

Revision: 2015 March HA-10 D23

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

Revision: 2015 March HA-11 D23

HFC-134a (R-134a) dye injector

Refrigerant dye cleaner For cleaning dye spills

Commercial Service Tools INFOID:0000000011671995

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

Tool name Description

Recovery/recycling/recharg- Function: Refrigerant recovery, recycling

Revision: 2015 March HA-12 D23

Service couplers Hose fitting to service hose: H

Revision: 2015 March HA-13 D23

Tool name Description

Container color: Light blue

Type: Polyalkylene glycol oil (PAG),

Revision: 2015 March HA-14 D23

Built-in heater & cooling unit assembly N

No. Component Function

Revision: 2015 March HA-15 D23

Built-in heater & cooling unit assembly

No. Component Function

Revision: 2015 March HA-16 D23

Revision: 2015 March HA-17 D23

System Description INFOID:0000000011671999

Revision: 2015 March HA-18 D23

Revision: 2015 March HA-19 D23

Revision: 2015 March HA-20 D23

Revision: 2015 March HA-21 D23

CONNECTION OF SERVICE TOOLS AND EQUIPMENT

Shut-off valve A/C service valve Recovery/recycling recharging

Leak Test INFOID:0000000011672002

CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE

1. Install a fender cover .

Revision: 2015 March HA-22 D23

Revision: 2015 March HA-23 D23