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VENTILATION, HEATER & AIR CONDITIONER

HEATER & AIR CONDITIONING SYSTEM
SECTION HA B

E
CONTENTS
BASIC INSPECTION ................................... 3
. Special Service Tool ...............................................22
. F
Commercial Service Tool .......................................25
.
DIAGNOSIS AND REPAIR WORKFLOW ......... 3
. Sealant or/and Lubricant ........................................25
.
Work Flow ................................................................ 3
. G
ON-VEHICLE MAINTENANCE ................... 26
.
FUNCTION DIAGNOSIS .............................. 4
.
REFRIGERANT ................................................. 26
REFRIGERATION SYSTEM .............................. 4
. Collection and Charge ............................................26
. H
System Diagram ....................................................... 4
.
System Description .................................................. 4
. LUBRICANT ...................................................... 30
Component Parts Location ....................................... 5
. Maintenance of Lubricant Quantity .........................30 .
HA
Component Description ............................................ 6
. Lubricant Adjusting Procedure for Components
Replacement Except Compressor ..........................30 .
SYMPTOM DIAGNOSIS .............................. 7
. Lubricant Adjusting Procedure for Compressor
Replacement ..........................................................31
. J
REFRIGERATION SYSTEM SYMPTOMS ......... 7
.
Trouble Diagnosis For Unusual Pressure ................ 7 . REFRIGERATION SYSTEM ............................. 33
Symptom Table ........................................................ 7
. Inspection ...............................................................33
. K
Performance Chart .................................................33 .
PRECAUTION ............................................. 11
. Refrigerant Leakages .............................................34 .
PRECAUTIONS .................................................11
. FLUORESCENT LEAK DETECTOR ................ 35 L
Precaution for Supplemental Restraint System Inspection ...............................................................35
.
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................ 11
. ELECTRICAL LEAK DETECTOR .................... 36
M
Precaution Necessary for Steering Wheel Rota- Inspection ...............................................................36
.
tion after Battery Disconnect .................................. 11 .
Precaution for Procedure without Cowl Top Cover 12 .... ON-VEHICLE REPAIR ................................ 39
.
Precautions For Xenon Headlamp Service ............ 12 . N
COMPRESSOR ................................................. 39
Working with HFC-134a (R-134a) .......................... 12 .
Exploded View ........................................................39
.
General Refrigerant Precaution ............................. 13 .
Removal and Installation ........................................39 .
Refrigerant Connection .......................................... 13. O
Inspection ...............................................................40
.
Service Equipment ................................................. 17
.
LOW-PRESSURE FLEXIBLE HOSE ................ 41
COMPRESSOR .................................................20
.
Exploded View ........................................................41
. P
General Precautions .............................................. 20
.
Removal and Installation ........................................41
.
LEAK DETECTION DYE ...................................21
.
HIGH-PRESSURE FLEXIBLE HOSE ............... 43
General Precautions .............................................. 21
.
Exploded View ........................................................43
.
PREPARATION .......................................... 22
. Removal and Installation ........................................43
.

PREPARATION .................................................22
. HIGH-PRESSURE PIPE 1 ................................. 45

Revision: 2007 November HA-1 2008 EX35
Exploded View ....................................................... 45
. REFRIGERANT PRESSURE SENSOR ........... 58
.
Removal and Installation ....................................... 45
. Exploded View ....................................................... 58
.
Removal and Installation ........................................ 58
.
LOW-PRESSURE PIPE 2 ................................. 48
.
Exploded View ....................................................... 48
. EVAPORATOR ................................................. 59
.
Removal and Installation ....................................... 48
. Exploded View ....................................................... 59
.
Removal and Installation ........................................ 60
.
LOW-PRESSURE PIPE 1 AND HIGH-PRES-
SURE PIPE 2 .................................................... 50
. EXPANSION VALVE ........................................ 61
.
Exploded View ....................................................... 50
. Exploded View ....................................................... 61
.
Removal and Installation ....................................... 50
. Removal and Installation ........................................ 62
.

CONDENSER ................................................... 53
. SERVICE DATA AND SPECIFICATIONS
Exploded View ....................................................... 53
. (SDS) .......................................................... 63
Removal and Installation ....................................... 53
.
SERVICE DATA AND SPECIFICATIONS
CONDENSER PIPE ASSEMBLY ..................... 55
. (SDS) ................................................................ 63
.
Exploded View ....................................................... 55
. Compressor ........................................................... 63
.
Removal and Installation ....................................... 55
. Lubricant ................................................................ 63
.
LIQUID TANK ................................................... 57
. Refrigerant ............................................................. 63
.
Engine Idling Speed ............................................... 63 .
Exploded View ....................................................... 57
.
Belt Tension ........................................................... 63
.
Removal and Installation ....................................... 57
.

Revision: 2007 November HA-2 2008 EX35
DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000003545446
B

DETAILED FLOW
1.LISTEN TO CUSTOMER COMPLAINT C
Listen to customer complaint. (Get detailed information about the conditions and environment when the symp-
tom occurs.)
D
>> GO TO 2.
2.VERIFY THE SYMPTOM WITH OPERATIONAL CHECK E
Verify the symptom with operational check. Refer to HAC-6, "WITHOUT LEFT AND RIGHT VENTILATION
TEMPERATURE SEPARATELY CONTROL SYSTEM : Description & Inspection" (Without left and right venti-
lation temperature separately control system) or HAC-11, "WITH LEFT AND RIGHT VENTILATION TEMPER- F
ATURE SEPARATELY CONTROL SYSTEM : Description & Inspection" (With left and right ventilation
temperature separately control system).
G
>> GO TO 3.
3.GO TO APPROPRIATE TROUBLE DIAGNOSIS
H
Go to appropriate trouble diagnosis (Refer to HAC-132, "Diagnosis Chart By Symptom" below).

>> GO TO 4.
HA
4.REPAIR OR REPLACE
Repair or replace the specific parts.
J
>> GO TO 5.
5.FINAL CHECK K
Final check.
Is the inspection result normal?
YES >> CHECK OUT L
NO >> GO TO 3.

Revision: 2007 November HA-3 2008 EX35
REFRIGERATION SYSTEM
< FUNCTION DIAGNOSIS >
FUNCTION DIAGNOSIS
REFRIGERATION SYSTEM
System Diagram INFOID:0000000003545447

RJIA1552E

System Description INFOID:0000000003545448

REFRIGERANT CYCLE
Refrigerant Flow
The refrigerant flows from the compressor, through the condenser with liquid tank, through the evaporator, and
back to the compressor. The refrigerant evaporation in the evaporator is controlled by an externally equalized
expansion valve, located inside the evaporator case.
Freeze Protection
To prevent evaporator from freezing up, the evaporator air temperature is monitored, and the voltage signal to
the unified meter and A/C amp. makes the A/C relay go OFF and stop the compressor.
REFRIGERANT SYSTEM PROTECTION
Refrigerant Pressure Sensor
The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sen-
sor, located on the liquid tank. 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 makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side
detected by refrigerant pressure sensor is over approximately 3,119 kPa (31.8 kg/cm2, 452 psi), or below
approximately 118 kPa (1.2 kg/cm2, 17 psi).
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
when the pressure of refrigerant in the system increases to an unusual level [more than 3,628 kPa (37 kg/cm2,
526 psi)].

Revision: 2007 November HA-4 2008 EX35
REFRIGERATION SYSTEM
< FUNCTION DIAGNOSIS >
Component Parts Location INFOID:0000000003545449

JPIIA0713ZZ

L
1. Refrigerant pressure sensor 2. Liquid tank 3. Condenser
4. Compressor
M

Revision: 2007 November HA-5 2008 EX35
REFRIGERATION SYSTEM
< FUNCTION DIAGNOSIS >

JPIIA0714ZZ

1. Expansion valve 2. Evaporator 3. Blower motor

Component Description INFOID:0000000003545450

Component Description
Compressor Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant cycle.
Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant.
Liquid tank Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.
Refrigerant pressure sensor Refer to EC-471, "Description".
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by drawing
Expansion valve
function.
The mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from blower
Evaporator
motor. The air is cooled by the heat by evaporation.
Takes in air in the vehicle or fresh outside air, provides it forcedly to the air conditioner, and conveys
Blower motor
it inside the vehicle.

Revision: 2007 November HA-6 2008 EX35
REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS >
SYMPTOM DIAGNOSIS A
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000003545451
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:0000000003545452
D

Gauge indication Refrigerant cycle Probable cause Corrective action
E
The pressure returns to nor-
Excessive refrigerant charge in Reduce refrigerant until speci-
mal is reduced soon after wa-
refrigeration cycle. fied pressure is obtained.
ter is splashed on condenser.
Insufficient condenser cooling F
performance.

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