Heater & Air Conditioning System: Section
Heater & Air Conditioning System: Section
Heater & Air Conditioning System: Section
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
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
Always observe the following items for preventing accidental activation.
• 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.
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
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.).
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
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.
RHA274D
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000011671994
B
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
DC 12 V (Battery terminal)
For checking refrigerant leak when fluores-
UV lamp and UV safety goggles
cent dye is installed in A/C system
Includes: N
UV lamp and UV safety goggles
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
SHA440F
SHA441F
RJIA0195E
Power supply:
Electrical leak detector
DC 12 V (Cigarette lighter)
SHA705EB
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
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
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/
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ P
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.
S-NT196
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000011671997
B
LHD MODELS
C
HA
M
JMIIA4007ZZ
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.
RHD MODELS
JSIIA1997ZZ
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.
HA
JPIIA1671GB
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
HA
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000011672000
OVERALL SEQUENCE
NNIIA0143GB
DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.
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.
JSIIA0258ZZ
RJIA3815J
SHA839E
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:
• 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 my 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.
HA
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
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
• Fan speed: Maximum speed set
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold
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
H
JSIIA1933ZZ
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
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
SYMPTOM DIAGNOSIS
REFRIGERATION SYSTEM SYMPTOMS
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
AC360A
REMOVAL
C
HA
J
JSIIA1872GB
DISASSEMBLY L
JMIIA0746GB
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
JSIIA1903ZZ
JSIIA1904ZZ
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.
JMIIA0575ZZ
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.
Inspection INFOID:0000000011672019
SJIA1918E
LHD models B
HA
L
JMIIA3999GB
JSIIA1890GB
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 wheel and tire (LH side only). Refer to WT-7, "Removal and Installation".
JSIIA1908ZZ
D
JSIIA1904ZZ
H
6. Remove high-pressure flexible hose from the vehicle.
INSTALLATION HA
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.
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test". J
CAUTION: L
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".
M
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy-
cle Refrigerant". N
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 low-pressure O
flexible hose from low-pressure pipe.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- P
rial such as vinyl tape to avoid the entry of air.
JSIIA1909ZZ
JSIIA1903ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000011672023
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 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".
5. Remove mounting bolt , and then disconnect high-pressure
pipe from expansion valve.
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.
JSIIA1910ZZ
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:
• 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". F
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
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
26, "Perform Lubricant Return Operation".
HA
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy-
cle Refrigerant".
J
2. Remove fuel filter bracket mounting bolt and nut to make work space. (LHD models)
3. Remove mounting bolt , and then disconnect low-pressure
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
4. Remove mounting bolt , and then disconnect low-pressure
pipe from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- O
rial such as vinyl tape to avoid the entry of air.
JSIIA1913ZZ
: Bracket
JSIIA1924ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
G
JSIIA1891GB
K
CONDENSER
CONDENSER : Removal and Installation INFOID:0000000011672026
L
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-24, "Recy-
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.
JSIIA1915ZZ
JSIIA1916ZZ
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
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
suitable material such as vinyl tape to avoid the entry of air.
JSIIA1919ZZ
INSTALLATION HA
Note the following items, and then install in the reverse order of removal.
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
• 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".
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
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
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:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
JSIIA1896ZZ
JSIIA1897ZZ
JSIIA1911ZZ
JSIIA1898ZZ
JSIIA1899ZZ
D
9. Remove condenser outlet pipe assembly from vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal. E
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". F
HA
REMOVAL
LHD models
JMIIA4038GB
HA
JSIIA1938GB
DISASSEMBLY
M
LHD Models
JMIIA4035GB
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
Expansion valve Evaporator insulator Evaporator assembly
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
JMIIA4037GB
RHD Models
B
Manual air conditioning (switch type)
HA
JSIIA1900GB N
JSIIA1943GB
HA
P
JMIIA4048GB
JSIIA1944GB
D
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". 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:
Cap or wrap the joint of the A/C piping and expansion valve
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).
JSIIA1892ZZ
JSIIA1928ZZ
JSIIA1929ZZ
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.
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
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. P
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
NOTE:
When filling radiator with engine coolant. Refer to CO-69, "Refilling".
EXPANSION VALVE
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 mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve.
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.
JSIIA1925ZZ
JSIIA1926ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
EVAPORATOR
EVAPORATOR : Removal and Installation INFOID:0000000011672033
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 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
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
JSIIA1894ZZ P
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.
• Check for leakages when recharging refrigerant. Refer to HA-22, "Leak Test".
Lubricant INFOID:0000000011672036
Refrigerant INFOID:0000000011672037
HA
K
Engine Idling Speed INFOID:0000000011672038
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000011014042
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
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
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “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.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• 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
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.
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000011013040
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.
• 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
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-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position.
(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.
P
PIIB3706J
H
RHA861F
COMPRESSOR HA
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- J
ing compressor. Refer to HA-83, "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. K
• 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 L
clutch.
LEAK DETECTION DYE M
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 N
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- O
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- P
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.).
RHA270DA
SHA533D
SERVICE HOSES
RHA272D
D
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 E
improper connection is attempted, discharging and contamination
may occur.
F
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
G
RHA273D
K
RHA274D
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000010585663
Tool number
(SPX-North America No.) Description
Tool name
KV99106200
Installing pulley
Pulley installer
S-NT235
Power supply:
DC 12 V (Battery terminal)
For checking refrigerant leak when fluores-
UV lamp and UV safety goggles
cent dye is installed in A/C system
Includes:
UV lamp and UV safety goggles
SHA438F
Application:
For HFC-134a (R-134a) PAG oil
HFC-134a (R-134a) fluorescent Container:
leak detection dye 1/4 ounce (7.4 cc) bottle
(Box of 24, 1/4 ounce bottles) (Includes self-adhesive dye identification
labels for affixing to vehicle after charging
system with dye.)
SHA439F
B
HFC-134a (R-134a) dye injector
For injecting 1/4 ounce of fluorescent leak
Use with J-41447, 1/4 ounce
detection dye into A/C system
bottle C
SHA440F
SHA441F F
G
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/
or its lubricant. H
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid HA
mixed use of the refrigerants/lubricant.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result. J
L
Recovery/recycling/recharg- Function: Refrigerant recovery, recycling
ing equipment (ACR4) and recharging
M
RJIA0195E N
Power supply:
Electrical leak detector P
DC 12 V (Cigarette lighter)
SHA705EB
Identification:
• The gauge face indicates HFC-134a (R-
Manifold gauge set (with hos- 134a).
es and couplers) Fitting size: Thread size
• 1/2″-16 ACME
RJIA0196E
Hose color:
• Low-pressure side hose: Blue with black
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 green with black stripe
Hose fitting to gauge:
S-NT201
• 1/2″-16 ACME
S-NT202
S-NT200
Capacity:
• Air displacement: 4 CFM
Vacuum pump • Micron rating: 20 microns
(Including the isolator valve) • Oil capacity: 482 g (17 oz.)
Fitting size: Thread size
• 1/2″-16 ACME
S-NT203
HA
SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location INFOID:0000000010585666
JMIIA4008ZZ
Component Description
• 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)]
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.
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.
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.
HA
JPIIA1671GB
REFRIGERANT CYCLE
Refrigerant Flow K
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 L
When evaporator fin temperature is low, compressor stops so that freeze of evaporator can be prevented.
Refer to the following.
• Manual air conditioning (Full-elc): HAC-139, "Compressor Control". M
• Manual air conditioning & cool (Semi-elc): HAC-227, "Compressor Control".
REFRIGERANT SYSTEM PROTECTION
N
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 O
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; P
- 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
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
BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000010585676
B
OVERALL SEQUENCE
C
HA
P
NNIIA0143GB
DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.
Insufficient cooling/heating>>GO TO 3.
Refrigerant leakage>>GO TO 6.
Noise >> GO TO 7.
3.CONTROL SYSTEM DIAGNOSIS
Perform the system diagnosis for the A/C control system. Refer to the following.
• Manual air conditioning (Full-elc): HAC-167, "Work Flow".
• Manual air conditioning & cool (Semi-elc): HAC-257, "Work Flow".
Is A/C control system normal?
YES >> GO TO 4.
NO >> GO TO 8.
4.PERFORMANCE TEST
Perform the performance test. Check the operation of each part. Refer to HA-85, "Inspection".
>> GO TO 5.
5.TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE
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-87, "Symptom Table".
>> GO TO 8.
7.TROUBLE DIAGNOSIS FOR NOISE
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-89, "Symptom Table".
>> GO TO 8.
8.MALFUNCTION PART REPAIR
Repair or replace the malfunctioning part.
>> GO TO 9.
9.REPAIR CHECK (OPERATION CHECK)
Check the operation of each part.
Does it operate normally?
YES >> INSPECTION END
NO >> GO TO 2.
JSIIA0258ZZ
H
Shut-off valve A/C service valve Recovery/recycling recharging
equipment
Vacuum pump Manifold gauge set Refrigerant container (HFC-134a)
HA
Weight scale
Preferred (best) method Alternative method For charging
J
Leak Test INFOID:0000000010585678
P
RJIA3815J
F
SHA839E
G
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication. H
• 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. HA
• 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-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.
2. Check gauge pressure readings of recovery/recycling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose. L
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. M
4. Connect recovery/recycling/recharging equipment to A/C service valve.
5. Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
N
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.
O
Charge Refrigerant INFOID:0000000010585680
WARNING: P
• 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 my 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.
Inspection INFOID:0000000010585682 E
If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.COMPRESSOR OIL JUDGMENT F
1. Remove compressor. Refer to HA-91, "COMPRESSOR : Removal and Installation".
2. Sample a compressor oil and judge on the figure.
G
HA
JSIIA0927GB
J
Judgement result 1>>Replace compressor only.
Judgement result 2>>Replace compressor and condenser & liquid tank assembly.
K
Perform Lubricant Return Operation INFOID:0000000010585683
CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera- L
tion.
1. Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm M
• A/C switch: ON
• Fan speed: Maximum speed set
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold N
2. Perform lubricant return operation for approximately 10 minutes.
3. Stop the engine.
O
4. Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000010585684 P
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.)] = 55 (1.9) + 35 (1.2) + 15 (0.5) + α
JMIIA4001ZZ
INSPECTION PROCEDURE B
1. Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge.
2. Start the engine, and set to the following condition.
C
Test condition
Surrounding condition Indoors or in the shade (in a well-ventilated place)
Door Closed
D
Door glass Full open
Vehicle condition
Hood Open
Engine speed Idle speed E
Temperature control switch or dial Full cold
A/C switch ON
F
A/C condition Air outlet VENT (Ventilation)
Intake door position REC (Recirculation)
Fan speed Maximum speed set G
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. H
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-87,
"Symptom Table". HA
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE
Fresh air
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
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 A
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000010585671
B
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- C
ever, differs from vehicle to vehicle.
Symptom Table INFOID:0000000010585672
D
N
AC360A
B
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-83, "Inspection".
C
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-93, "Inspection".
D
Check bolts for tightness.
Compressor body Loosened compressor mounting bolts. Refer to HA-90, "Exploded
View".
Check the installation condi-
E
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-94, "Exploded
View".
F
• Check for leakage.
• Collect all refrigerant,
evacuate refrigerant cycle
Shortage of refrigerant. G
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 H
Wear, breakage, or clogging of foreign
from expansion valve, or re-
material in inner parts.
place it.
Check belt tension. Refer to HA
Loosened belt
Unusual noise from belt. — EM-286, "Inspection".
Internal compressor parts get locked Replace compressor.
J
REMOVAL
JMIIA4002ZZ
Compressor
DISASSEMBLY
JMIIA0746GB
COMPRESSOR
A
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- B
83, "Perform Lubricant Return Operation".
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
: Vehicle front
J
JMIIA4013ZZ K
6. Remove mounting bolt , and then disconnect high-pressure
flexible hose from compressor.
CAUTION: L
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.
M
: Vehicle front
N
JMIIA4014ZZ
: Vehicle front
P
JMIIA4015ZZ
: Vehicle front
JMIIA4016ZZ
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.
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-84, "Lubricant
Adjusting Procedure for Compressor Replacement".
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test".
• Check tension of the drive belt after installing compressor. Refer to EM-286, "Inspection".
MAGNET CLUTCH
MAGNET CLUTCH : Removal and Installation INFOID:0000000010599502
REMOVAL
1. Fix clutch disc.
2. Remove center bolt, and then remove clutch disc.
3. Remove snap ring using external snap ring pliers.
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.
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
JMIIA0576ZZ
D
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. E
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. F
Inspection INFOID:0000000010489011
G
CHECK DISC TO PULLEY CLEARANCE
Check the clearance (B) between pulley assembly and clutch disc
along the entire periphery with a feeler gauge (A). H
SJIA1918E
JMIIA3997GB
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-
83, "Perform Lubricant Return Operation".
JSIIA1908ZZ
: Vehicle front
H
JMIIA4014ZZ
HA
L
LOW-PRESSURE FLEXIBLE HOSE
LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000010490522
M
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- N
83, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy- O
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". P
JSIIA1909ZZ
: Vehicle front
JMIIA4013ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test".
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000010490523
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-
83, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy-
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".
4. Remove mounting bolt , and then disconnect high-pressure
pipe from expansion valve.
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.
JSIIA1910ZZ
JMIIA4018ZZ
D
6. 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:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test". F
LOW-PRESSURE PIPE
G
LOW-PRESSURE PIPE : Removal and Installation INFOID:0000000010490524
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large H
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
83, "Perform Lubricant Return Operation".
HA
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy-
cle Refrigerant".
J
2. Remove mounting bolt , and then disconnect low-pressure
pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve K
with suitable material such as vinyl tape to avoid the entry
of air.
L
M
JSIIA1914ZZ
JSIIA1913ZZ
: Bracket
JSIIA1924ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test".
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
: Always replace after every disassembly.
J
: N·m (kg-m, in-lb)
CONDENSER
L
CONDENSER : Removal and Installation INFOID:0000000010490564
REMOVAL
M
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy-
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".
JSIIA1915ZZ
JSIIA1916ZZ
JSIIA1917ZZ
JSIIA1942ZZ
CAUTION:
LIQUID TANK D
E
REMOVAL
1. Remove condenser assembly. Refer to HA-99, "CONDENSER : Removal and Installation".
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank. F
CAUTION:
Be sure to clean carefully.
3. Remove mounting bolts , and then remove liquid tank . G
CAUTION:
Cap or wrap the joint of the A/C piping and liquid tank with
suitable material such as vinyl tape to avoid the entry of air.
H
HA
JSIIA1919ZZ J
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION: K
• Install liquid tank, and then install liquid tank bracket on condenser.
• 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.) L
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to HA-83, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test". M
REMOVAL O
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy-
cle Refrigerant".
2. Remove condenser outlet pipe assembly. Refer to HA-102, "CONDENSER PIPE ASSEMBLY : Removal P
and Installation".
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:
Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry
of air.
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "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:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
JSIIA1896ZZ
JSIIA1897ZZ
JSIIA1911ZZ
JMIIA4018ZZ
D
8. Remove mounting bolt , and then disconnect condenser outlet
pipe assembly from condenser assembly.
CAUTION: E
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
G
JSIIA1899ZZ
REMOVAL
JSIIA1938GB
DISASSEMBLY
HA
L
JSIIA1900GB
JSIIA1943GB
Manual cooler
C
HA
N
JMIIA4048GB
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-
83, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy-
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-
out Intelligent Key system).
4. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve.
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.
JSIIA1925ZZ
JSIIA1927ZZ
JSIIA1892ZZ
JSIIA1928ZZ
D
9. Disconnect drain hose from heater & cooling (cooler) unit
assembly.
E
G
JSIIA1929ZZ
HA
JSIIA1931ZZ
K
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. L
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.
M
JSIIA1930ZZ
CAUTION:
When removing steering member, 2 workers are required to prevent it from dropping.
15. Disconnect the intake door motor and blower motor connectors.
16. Remove mounting screws , and then remove blower unit
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
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.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test".
NOTE:
When filling radiator with engine coolant. Refer to CO-12, "Refilling".
EXPANSION VALVE
A
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- B
83, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy- C
cle Refrigerant".
2. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve. D
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 E
of air.
JSIIA1925ZZ
G
3. Remove mounting bolts , and then remove expansion valve.
CAUTION:
Cap or wrap the joint of the expansion valve and evaporator H
with suitable material such as vinyl tape to avoid the entry
of air.
HA
J
JSIIA1926ZZ
INSTALLATION
Note the following items, and then install in the reverse order of removal. K
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test". L
EVAPORATOR
M
EVAPORATOR : Removal and Installation INFOID:0000000010491659
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large N
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
83, "Perform Lubricant Return Operation".
REMOVAL O
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-81, "Recy-
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.
4. Disconnect intake sensor or thermo control amp. Refer to HA-104, "Exploded View".
5. Remove expansion valve from evaporator. Refer to HA-104, "Exploded View".
INSTALLATION
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000010491660
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-108, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
2. Remove heater pipe grommet .
JSIIA1941ZZ
JSIIA1893ZZ
JSIIA1894ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-79, "Leak Test".
HA
Lubricant INFOID:0000000010491759
Refrigerant INFOID:0000000010491760
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000011991373
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
Always observe the following items for preventing accidental activation.
• 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:0000000011991374
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.
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.
PIIB3706J
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-134, "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.).
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
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.
RHA274D
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000011991379
B
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
DC 12 V (Battery terminal)
For checking refrigerant leak when fluores-
UV lamp and UV safety goggles
cent dye is installed in A/C system
Includes: N
UV lamp and UV safety goggles
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
SHA440F
SHA441F
RJIA0195E
Power supply:
Electrical leak detector
DC 12 V (Cigarette lighter)
SHA705EB
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
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:0000000011991381
O
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/
or its lubricant.
• Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ P
lubricant.
• Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles
refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid
mixed use of the refrigerants/lubricant.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.
S-NT196
SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000011991382
B
HA
JMIIA4009ZZ
M
Component Description N
Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant
Compressor
cycle.
• 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.
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.
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.
JPIIA1671GB
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.
• Automatic 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 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.
• 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
HA
BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000011991385
OVERALL SEQUENCE
NNIIA0143GB
DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.
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
• Automatic 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-136, "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-138, "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-130, "Leak Test".
K
>> GO TO 8.
7.TROUBLE DIAGNOSIS FOR NOISE
L
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-140, "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.
JSIIA0258ZZ
RJIA3815J
SHA839E
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-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.
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:0000000011991389
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 my 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.
HA
Inspection INFOID:0000000011991391
If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.COMPRESSOR OIL JUDGMENT
1. Remove compressor. Refer to HA-142, "COMPRESSOR : Removal and Installation".
2. Sample a compressor oil and judge on the figure.
JSIIA0927GB
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
• Fan speed: Maximum speed set
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold
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:0000000011991393
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
H
JMIIA4003ZZ
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-138,
"Symptom Table".
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE
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
SYMPTOM DIAGNOSIS
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000011991396
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:0000000011991397
AC360A
REMOVAL
C
HA
J
JMIIA4004GB
Compressor K
: N·m (kg-m, ft-lb)
DISASSEMBLY L
JMIIA0746GB
COMPRESSOR
COMPRESSOR : Removal and Installation INFOID:0000000011991400
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-
134, "Perform Lubricant Return Operation".
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".
4. Remove drive belt. Refer to EM-158, "Removal and Installation".
5. Disconnect magnet clutch connector.
6. Remove mounting bolt , and then disconnect high-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.
: Vehicle front
JMIIA4120ZZ
: Vehicle front
JMIIA4121ZZ
: Vehicle front
JMIIA4117ZZ
MAGNET CLUTCH
MAGNET CLUTCH : Removal and Installation INFOID:0000000011991401
D
REMOVAL
E
1. Fix clutch disc.
2. Remove center bolt, and then remove clutch disc.
3. Remove snap ring using external snap ring pliers.
F
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. G
5. Disconnect field coil harness from compressor unit.
6. Remove snap ring using external snap ring pliers, and then remove field coil.
H
INSTALLATION
1. Install field coil .
Be sure to align the coil’s pin with the hole in the compres- HA
sor’s front head.
2. Connect field coil harness to compressor unit.
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
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.
SJIA1918E
HA
L
JMIIA3998GB
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-
134, "Perform Lubricant Return Operation".
: Vehicle front
JMIIA4120ZZ
JMIIA4123ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
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-
134, "Perform Lubricant Return Operation".
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".
JMIIA4121ZZ
D
5. Remove mounting bolt , and then disconnect low-pressure
flexible hose from low-pressure pipe.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- E
rial such as vinyl tape to avoid the entry of air.
G
JMIIA4119ZZ
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large L
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
134, "Perform Lubricant Return Operation".
REMOVAL M
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant".
2. Remove low-pressure pipe. Refer to HA-148, "LOW-PRESSURE PIPE : Removal and Installation". N
3. Disconnect high-pressure pipe from expansion valve.
4. Remove mounting bolt , and then disconnect high-pressure
flexible hose and high-pressure pipe from condenser pipe O
assembly.
JMIIA4122ZZ
5. Remove fixing clips, and then remove high pressure pipe from vehicle.
LOW-PRESSURE PIPE
LOW-PRESSURE PIPE : Removal and Installation INFOID:0000000011991407
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-
134, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant".
2. Drain engine coolant from cooling system. Refer to CO-11, "Draining".
3. Remove engine cover. Refer to EM-157, "Removal and Installation"
4. Remove air cleaner and air duct. Refer to EM-159, "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".
8. Remove mounting bolt , and then disconnect low-pressure
pipe from expansion valve.
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.
JSIIA1914ZZ
JMIIA4124ZZ
10. Remove low-pressure pipe bracket mounting bolt, and then remove low-pressure pipe from vehicle.
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.
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
NOTE:
When filling radiator with engine coolant. Refer to CO-12, "Refilling".
G
JMIIA4011GB
CONDENSER K
L
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant". M
2. Remove front grille. Refer to EXT-19, "Removal and Installation".
3. Remove radiator core support upper. Refer to the following.
• With Intelligent Key system: Refer to DLK-169, "Removal and Installation" N
• Without Intelligent Key system: Refer to DLK-169, "Removal and Installation".
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
JMIIA4194ZZ
JMIIA4195ZZ
JMIIA4196ZZ
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.
• 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
LIQUID TANK : Removal and Installation INFOID:0000000011991410
REMOVAL
1. Remove condenser assembly. Refer to HA-149, "CONDENSER : Removal and Installation".
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank.
CAUTION:
Be sure to clean carefully.
JSIIA1919ZZ
D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Install liquid tank, and then install liquid tank bracket on condenser. E
• 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-134, "Lubricant F
Adjusting Procedure for Components Replacement Except Compressor".
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
G
REMOVAL
HA
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant".
2. Remove front grille. Refer to EXT-19, "Removal and Installation".
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.
5. 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. 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".
P
REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132, "Recy-
cle Refrigerant".
2. Remove front grille. Refer to EXT-11, "Removal and Installation".
3. Remove air guide RH. Refer to the following.
• With Intelligent Key system: Refer to DLK-169, "Removal and Installation".
JMIIA4122ZZ
JMIIA4118ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
REMOVAL B
HA
JSIIA1938GB
K
Heater & cooling unit assembly Blower unit assembly Drain hose
Instrument stay LH Instrument stay RH Steering member L
: N·m (kg-m, ft-lb)
M
DISASSEMBLY
JSIIA1900GB
HA
JSIIA1943GB
N
Ventilator seal Defroster seal Ventilator door
Defroster door Center plate case Foot lever
O
Defroster link Defroster lever Foot link
Ventilator lever Main link Mix lever
Mix link Air mix gear lever Evaporator assembly P
Evaporator insulator Expansion valve Expansion valve packing
O-ring Heater core Heater pipe grommet
Thermo control amp. Foot duct AC cover
Evaporator pipe cover Heater pipe cover Heater & cooling unit case LH
Sub harness Blower fan resistor Inner duct case
JSIIA1944GB
CAUTION: C
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-
134, "Perform Lubricant Return Operation".
D
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant". E
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- F
out Intelligent Key system).
4. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve. G
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 H
of air.
HA
JSIIA1925ZZ
J
5. Remove fixing clamps , and then disconnect heater hoses .
CAUTION:
• Some coolant may spill when heater hoses are discon-
K
nected.
• Close off the coolant inlet and outlet on the heater pipes
(2 locations) with shop cloths.
L
M
JSIIA1927ZZ
JSIIA1892ZZ
JSIIA1928ZZ
JSIIA1929ZZ
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.
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 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
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. P
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
NOTE:
When filling radiator with engine coolant. Refer to CO-12, "Refilling".
EXPANSION VALVE
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-
134, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant".
2. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve.
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.
JSIIA1925ZZ
JSIIA1926ZZ
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.
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
EVAPORATOR
EVAPORATOR : Removal and Installation INFOID:0000000011991416
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-
134, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-132,
"Recycle Refrigerant".
2. Remove heater & cooling unit assembly. Refer to HA-157, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
3. Disassemble heater & cooling unit assembly, and then remove evaporator assembly.
4. Disconnect intake sensor or thermo control amp. Refer to HA-153, "Exploded View".
5. Remove expansion valve from evaporator. Refer to HA-153, "Exploded View".
INSTALLATION
REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-157, "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
JSIIA1894ZZ P
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.
• Check for leakages when recharging refrigerant. Refer to HA-130, "Leak Test".
Lubricant INFOID:0000000011991419
Refrigerant INFOID:0000000011991420
HA
K
Engine Idling Speed INFOID:0000000011991421