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VENTILATION, HEATER & AIR CONDITIONER
A
HEATER & AIR CONDITIONING SYSTEM
SECTION HA B
C
D
E
CONTENTS
BASIC INSPECTION ................................... 3
. Service Equipment .................................................20
. F
DIAGNOSIS AND REPAIR WORKFLOW ......... 3
. REFRIGERANT ................................................. 22
Work Flow ................................................................ 3
. Description ..............................................................22
.
G
Leak Test ................................................................22
.
SYSTEM DESCRIPTION ............................. 5
. Recycle Refrigerant ................................................24.
Charge Refrigerant .................................................24.
REFRIGERATION SYSTEM .............................. 5
. H
System Diagram ....................................................... 5
. LUBRICANT ...................................................... 26
System Description .................................................. 5
. Description ..............................................................26
.
Component Parts Location ....................................... 6
. Inspection ...............................................................26
. HA
Component Description ............................................ 6
. Perform Lubricant Return Operation ......................26 .
Lubricant Adjusting Procedure for Components
SYMPTOM DIAGNOSIS .............................. 8
. Replacement Except Compressor ..........................26 .
Lubricant Adjusting Procedure for Compressor J
REFRIGERATION SYSTEM SYMPTOMS ......... 8
. Replacement ..........................................................27
.
Trouble Diagnosis For Unusual Pressure ................ 8 .
Symptom Table ........................................................ 8
. PERFORMANCE TEST .................................... 29 K
Inspection ...............................................................29
.
NOISE ................................................................10
.
Symptom Table ...................................................... 10
. REMOVAL AND INSTALLATION .............. 31
.
L
PRECAUTION ............................................. 11
. COMPRESSOR ................................................. 31
Exploded View ........................................................31
.
PRECAUTIONS .................................................11
. Removal and Installation ........................................31 .
Precaution for Supplemental Restraint System M
Inspection ...............................................................32
.
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................ 11
. COOLER PIPE AND HOSE .............................. 33
Precaution Necessary for Steering Wheel Rota- Exploded View ........................................................33
. N
tion after Battery Disconnect .................................. 11 .
Precaution for Procedure without Cowl Top Cover 12 .... HIGH-PRESSURE FLEXIBLE HOSE .......................33 .
Precautions For Refrigerant System Service ......... 12 . HIGH-PRESSURE FLEXIBLE HOSE : Removal
O
and Installation .......................................................33
.
PREPARATION .......................................... 16
.
LOW-PRESSURE FLEXIBLE HOSE ........................34 .
PREPARATION .................................................16
. LOW-PRESSURE FLEXIBLE HOSE : Removal P
Special Service Tool .............................................. 16
. and Installation .......................................................34
.
Commercial Service Tool ....................................... 18
.
Sealant or/and Lubricant ........................................ 18
. HIGH-PRESSURE PIPE ...........................................35 .
HIGH-PRESSURE PIPE : Removal and Installa-
PERIODIC MAINTENANCE ........................ 20
. tion ..........................................................................35
.
DESCRIPTION ..................................................20
. CONDENSER .................................................... 37
Revision: 2009 March HA-1 2009 Z12
Exploded View ....................................................... 37
. EVAPORATOR : Removal and Installation ............ 48
.
CONDENSER ........................................................... 37
. HEATER CORE ........................................................ 48
.
CONDENSER : Removal and Installation ............. 37 . HEATER CORE : Removal and Installation ........... 48 .
LIQUID TANK ........................................................... 38
. EXPANSION VALVE ........................................ 49
.
LIQUID TANK : Removal and Installation .............. 38 . Exploded View ....................................................... 49
.
Removal and Installation ........................................ 49
.
REFRIGERANT PRESSURE SENSOR ................... 39 .
REFRIGERANT PRESSURE SENSOR : Remov- SERVICE DATA AND SPECIFICATIONS
al and Installation ................................................... 39
. (SDS) .......................................................... 51
A/C UNIT ASSEMBLY ...................................... 40
. SERVICE DATA AND SPECIFICATIONS
Exploded View (Automatic Air Conditioner) ........... 40
.
(SDS) ................................................................ 51
.
Exploded View (Manual Air Conditioner) ............... 42
.
Compressor ........................................................... 51
.
Exploded View (Manual Heater) ............................ 44
.
Lubricant ................................................................ 51
.
A/C UNIT ASSEMBLY ............................................. 45
. Refrigerant ............................................................. 51
.
A/C UNIT ASSEMBLY : Removal and Installation... 46 Engine Idling Speed ............................................... 51 .
Belt Tension ........................................................... 51
.
EVAPORATOR ........................................................ 48
.
Revision: 2009 March HA-2 2009 Z12
DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000004932772
B
OVERALL SEQUENCE
C
D
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F
G
H
HA
J
K
L
M
N
O
P
NNIIA0143GB
DETAILED FLOW
1.INTERVIEW FOR MALFUNCTION
Interview the symptom to the customer.
Revision: 2009 March HA-3 2009 Z12
DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION >
>> GO TO 2.
2.SYMPTOM CHECK
Check the symptom from the customer's information. Check that any symptom occurs other than the inter-
viewed symptom.
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 HAC-6, "Work Flow" (AUTOMATIC AIR
CONDITIONER) or HAC-155, "Work Flow" (MANUAL AIR CONDITIONER).
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-29, "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-8, "Symptom Table".
Low refrigerant charge>>GO TO 6.
Except above>>GO TO 8.
6.CHECK REFRIGERANT FOR LEAKAGES
Check refrigerant for leakages. Specify the malfunctioning part. Refer to HA-22, "Leak Test".
>> GO TO 8.
7.TROUBLE DIAGNOSIS FOR NOISE
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-10, "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.
Revision: 2009 March HA-4 2009 Z12
REFRIGERATION SYSTEM
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION A
REFRIGERATION SYSTEM
System Diagram INFOID:0000000004932773
B
C
D
E
F
G
H
HA
JPIIA1671GB
J
System Description INFOID:0000000004932774
REFRIGERANT CYCLE
K
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 L
expansion valve, located inside the evaporator case.
Freeze Protection
M
Automatic air conditioner
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