HVAC System Troubleshooting & Testing: Removal & Installation Honda Civic IX

Removal

Note. If accidental system discharge occurs, ventilate the work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure. To avoid damage to the radiator, cover it with cardboard when removing any of fan shroud.

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1. Glove Box - Move Lower the glove box (A).
2. R-134a Refrigerant Recovery/Recycling/Charging Station - Connection Connect an R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.
3. A/C Refrigerant - Recovery Recover the refrigerant from the A/C system. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging.
4. Battery Terminal - Disconnection Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode. Disconnect and isolate the negative cable with the battery sensor (A) from the battery. NOTE: Always disconnect the negative side first. To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal. Do not disconnect the battery sensor from the negative terminal (C). Disconnect the positive cable (D) from the battery.
5. Radiator Mounting Bracket, Upper Both Remove the radiator mount upper brackets/cushions (A), and the A/C condenser upper mount brackets (B).
6. Bulkhead - Removal Disconnect the connectors (A). Remove the harness clamps (B). Remove the bulkhead (A).
7. A/C Condenser Fan Shroud Assembly Remove the A/C condenser fan shroud assembly (A).
8. Drive Belt Move the auto-tensioner (A) counterclockwise to relieve tension from the drive belt (B). Remove the drive belt.
9. Alternator Disconnect the connector and the cable. Remove the harness connector (A) and the harness clamps (B). Remove the alternator.
10. A/C Compressor Assembly Disconnect the suction hose (A) and the discharge hose (B). NOTE: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. Remove the A/C compressor (A). NOTE: Be careful not to damage the radiator fins when removing the A/C compressor.

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1. A/C Compressor Clutch - Check Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set. Inspect the friction surfaces and the compressor shaft hub for excess oil. If excess oil is present, and it is not from the engine or power steering system, then the compressor shaft seal is leaking. Replace the A/C compressor. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Also check for grease leakage from the bearing. Replace the clutch set with a new one if it is noisy, has excessive play/drag, or has bearing grease contamination on the clutch faces. NOTE: The rotor pulley and the armature plate were mated at the factory by a burnishing operation. Always replace the rotor pulley and the plate as a set. Replacing only one part of the clutch set will cause clutch slippage. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance. Clearance: 0.35-0.65 mm (0.014-0.025 in) NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. USA and Canada models: Check for continuity between the A/C compressor clutch connector terminals No. 1 and No. 3. If there is no continuity, replace the thermal protector. NOTE: The thermal protector will have no continuity above about 252 to 262 °F (122 to 128 °C). When the temperature drops below about 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. Mexico models: Disconnect the connector (A). Mexico models: Check the thermal protector for continuity. If there is no continuity, replace the thermal protector. NOTE: The thermal protector will have no continuity above about 252 to 262 °F (122 to 128 °C). When the temperature drops below about 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. USA and Canada models: Disconnect the connector (A). Measure the resistance of the field coil. If resistance is not within specifications, replace the field coil. Field Coil Resistance: 3.35-3.65 ohms at 68 °F (20 °C)

Installation

Note. If an accidental system discharge occurs, ventilate the work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure. Inspect the A/C lines for any signs of contamination. If you're installing a new A/C compressor, you must calculate the amount of refrigerant oil to be removed from it. A new A/C compressor comes with a full charge of oil. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Use only PAG refrigerant oil (SP-10) for HFC-134a A/C systems. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Be careful not to damage the radiator fins when installing the A/C compressor, the alternator or the A/C condenser fan shroud.

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1. A/C Compressor Assembly Install the A/C compressor (A). NOTE: Be careful not to damage the radiator fins when removing the A/C compressor. Remove the plugs or caps. Connect the suction hose (A) with a new O-ring (B) that is lubricated with clean refrigerant oil. Connect the discharge hose (C) with a new O-ring (D) that is lubricated with clean refrigerant oil.
2. Alternator Install the alternator. Connect the connector and the cable. Make sure the crimped side of the ring terminal faces away from the alternator when you connect it. Install the harness connector (A) and the harness clamps (B).
3. Drive Belt Move the auto-tensioner (A) counterclockwise. Install the drive belt (B).
4. A/C Condenser Fan Shroud Assembly Install the A/C condenser fan shroud assembly (A).
5. Bulkhead - Installation Install the bulkhead (A). Install the harness clamps (A). Connect the connectors (B).
6. Radiator Mounting Bracket, Upper Both Install the radiator mount upper bracket/cushion (A), and the brackets (B).
7. Battery Terminal - Reconnection NOTE: If the battery performs abnormally, test the battery. Clean the battery terminals. Connect the positive cable (A) to the battery. NOTE: Always connect the positive side first. Connect the negative cable and the battery sensor (B) to the battery. NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal. Apply multipurpose grease to the terminals to prevent corrosion.
8. A/C System Evacuation Evacuate the system. The vacuum pump should run for a minimum of 30 minutes to eliminate all moisture from the system. When the suction gauge reads -93.3 kPa (-700 mmHg, -27.55 inHg) for at least 30 minutes, close all valves, and turn off the vacuum pump. If the suction gauge dose not reach approximately -93.3 kPa (-700 mmHg, -27.55 inHg) in 15 minutes, there is probably a large leak in the system. Partially charge the system, and check for leaks.
9. A/C Refrigerant - Charging Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the A/C compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station. Refrigerant Capacity: 375 to 425 g 13.2 to 15.0 oz 0.375 to 0.425 kg 0.827 to 0.937 lbs
10. A/C Refrigerant - Leak Check Leak Detector Usage Tips (Refer to the Operator's Manual for complete operating instructions) Position the vehicle in a wind-free work area. This will aid in detecting small leaks. When using the leak detector for the first time, allow it to warm up for 2 minutes with the probe in a clean atmosphere. This lets the temperature sensor in the detector stabilize. The calibration check should be done in the "Search 2" mode. Once that is done, the other check modes do not need calibrating. When leak checking through the HVAC module drain hose, avoid drawing water into the probe. Water can damage the internal pump and sensor. Avoid creasing the flexible probe extension. Creases can restrict air flow and give false readings. Because the detector recalibrates itself for ambient gases, it may be necessary to move the detector away from the leak to clear the sensor. Once the sensor has cleared, recheck the suspected leak. When removing the clear probe tip, be careful not to lose the flow ball. R-134a is heavier than air; always check below and to the sides of all potential leak sources. Halogen leak detectors are sensitive to chemicals: windshield washing solutions, solvents/cleaners, and some vehicle adhesives. Keep these chemicals out of the area when doing leak detection. Fluorescent Dye Usage Tips Use only Tracer-Stick single dose fluorescent dye capsules from Tracerline®. Other dyes contain solvents that may contaminate the refrigerant oil, leading to component failure. Adding excessive amounts of dye can damage the A/C compressor. PAG oil is water soluble, so condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain. After checking and repairing leaks, thoroughly clean any residual dye from the areas where leaks were found. Use GLO-AWAY dye cleaner, from Tracerline®, and hot water to remove the dye (follow the instructions on the bottle). Residual dye stains can cause misdiagnosis of any future A/C system leaks. If any refrigerant dye contacts an exterior paint surface, remove it by doing this: Carefully wash the affected surfaces to remove any dirt, and to prevent paint scratching. Mix water and isopropyl alcohol in a 50/50 mixture. Soak a soft 100 % cotton towel with the water/alcohol mixture, and place the cloth on the affected areas to remove the dye. After removing the dye with the water/alcohol-soaked cloth, carefully wash the affected areas, and check that there is no remaining dye. With the engine OFF, use a halogen leak detector first to detect the leak source. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test the following areas of the system for leaks: Possible Leak Area Diagnostic Procedure with the Leak Detector Notes Service ports Check the service ports with caps installed If the detector "sniffs" a leak, use fluorescent dye to confirm it When capping the service ports, ensure that the seals on the port caps are in place, and that the caps are tight. The caps are used as the final seals in the system A/C condenser If the detector "sniffs" a leak, use fluorescent dye to confirm it Check for joints or connections coated with oily dust Check for damaged and corroded areas Check all fittings, couplings, brazed/welded areas and areas around attachment points Move the probe slowly (1 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak If you detect a leak, blow compressed air over the area, then recheck for leaks. For large leaks, clearing the area with compressed air may help you pinpoint the leak source Evaporator Check at the evaporator drain hose Check at the passenger's side vent and turn the blower on low speed A/C lines Wiggle the rubber hoses when checking crimped metal ends If the detector "sniffs" a leak, use fluorescent dye to confirm it Check all fittings, couplings, pressure switches, brazed/welded areas, and areas around attachment points on A/C lines and components Check for damaged and corroded areas Move the probe slowly (1 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak Close the quick coupler valves, then disconnect the quick couplers from the vehicle service ports. Attach the universal connect set, from the Optimax Jr. Leak Detection Kit, to the service valve fitting. Close the control valve (the black knob on the connect set). Attach the charging station low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the charging station vacuum pump, then close the quick coupler valve. Detach the universal connect set, and install a Tracer-Stick® dye capsule between the connect set and the service valve fitting (see the manufacturer's instructions for more detail). Attach the quick coupler on the universal connect set to the low pressure service port on the vehicle. Open the charging station low pressure hose quick coupler valve, but do not open the control valve. Start the engine, and set the A/C system to maximum cooling. Open the control valve to let refrigerant and the dye enter the A/C system through the low pressure service port. Close the control valve when the Tracer-Stick® dye capsule is empty. Run the engine and A/C system for 15 minutes to thoroughly circulate the dye. Then shut the engine off, and inspect the following areas of the system for leaks: NOTE: Check for leaks in a dark work area, and use the UV light and the special glasses from the leak check kit. Other UV lights may not work well with the Tracer-Stick® dye. Small leaks may take up to 1 week of vehicle operation (with normal A/C use) to become visible. Possible Leak Area Diagnostic Procedure with Fluorescent Dye Service ports If a leak is found, replace the cap/O-ring seal or A/C line as needed A/C lines Use a permanent marker pen to circle the leak area If a leak is found, remove and replace the A/C line A/C condenser If a leak is found, remove the A/C condenser Determine whether leak is in the A/C condenser or the receiver/dryer Use a permanent marker pen to circle the leak area Replace either the receiver/dryer, or the A/C condenser, depending upon which is leaking A/C compressor Check for leaks at all of the A/C compressor joints, the clutch center, the A/C compressor front housing bolts, and the scroll bolts on the back of the A/C compressor If a leak is found, use a permanent marker pen to circle the leak area If the A/C compressor relief valve appears to be leaking, determine whether the leak is coming from the relief valve, or the joint between the A/C compressor casing and the valve. If the leak is from the relief valve, check the A/C system pressures, and refer to the pressure test table in the A/C system test. If the leak is from the casing/valve joint, replace the A/C compressor relief valve If the leak is coming from the suction hose and/or discharge hose fittings on the A/C compressor, clean the A/C fittings and replace the suction/discharge fitting O-rings For all other A/C compressor leaks, remove and replace the A/C compressor Evaporator Start checking for evaporator leaks by illuminating the evaporator drain tube area If a leak is found, remove the evaporator core Determine whether leak is from evaporator or expansion valve Use a permanent marker pen to circle leak area Replace the expansion valve, or the evaporator core, depending upon which is leaking
11. A/C System - Test Insert a thermometer (A) in the center vent. Place a hygro-thermometer (B) near the blower unit's recirculation inlet duct. Test conditions: Move the vehicle out of direct sunlight and let it cool down to the surrounding (ambient) temperature. If necessary, wash the vehicle to cool it down more quickly. The blower intake temperature must be at least 68 °F (20 °C). Open the hood. Open the front doors. Start the engine. Set the temperature control dial or temperature control button to MAX COOL, the mode control button to VENT, and the recirculation control button to RECIRCULATE. Set the A/C button on and the fan control dial or fan control button to Max. Run the engine at 1, 500 RPM. No driver or passengers in vehicle. Inspect the A/C components for the following conditions: A/C compressor clutch not engaged. Abnormal frost areas. Unusual noises. If you observe any of these conditions, refer to the Symptom Troubleshooting Index. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the center vent, the blower intake temperature near the blower unit, and the discharge (high) and suction (low) pressures on the A/C gauges. To complete the vent (delivery)/blower intake temperature chart: Mark the vent (delivery) temperature on the vertical line. Mark the blower intake temperature on the bottom line. Draw a vertical line from the blower intake temperature mark. Draw a horizontal line from the vent (delivery) temperature mark until it intersects the vertical line. NOTE: The vent (delivery) temperature and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection. To complete the high side (discharge) pressure/blower intake temperature chart: Mark the high side (discharge) pressure on the vertical line. Mark the blower intake temperature on the bottom line. Draw a vertical line from the blower intake temperature mark. Draw a horizontal line from the high side (discharge) pressure mark until it intersects the vertical line. NOTE: The high side (discharge) pressure and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection. To complete the low side (suction) pressure/blower intake temperature chart: Mark the low side (suction) pressure along the vertical line. Mark the blower intake temperature along the bottom line. Draw a vertical line from the blower intake temperature mark. Draw a horizontal line from the low side (suction) pressure mark until it intersects the vertical line. NOTE: The low side (suction) pressure and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.
12. Glove Box - Move Install the glove box (A).

Note. If accidental system discharge occurs, ventilate the work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure. To avoid damage to the radiator, cover it with cardboard when removing any of fan shroud.

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1. Glove Box - Move Lower the glove box (A).
2. R-134a Refrigerant Recovery/Recycling/Charging Station - Connection Connect an R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.
3. A/C Refrigerant - Recovery Recover the refrigerant from the A/C system. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging.
4. Battery Terminal - Disconnection Make sure the ignition switch is in LOCK (0), or the vehicle ignition in the OFF mode. Disconnect and isolate the negative cable with the battery sensor (A) from the battery. NOTE: Always disconnect the negative side first. To protect the battery sensor connector (B) from damage, do not hold it when removing the negative terminal. Do not disconnect the battery sensor from the negative terminal (C). Disconnect the positive cable (D) from the battery.
5. Radiator Mounting Bracket, Upper Both Remove the radiator mount upper brackets/cushions (A), and the A/C condenser upper mount brackets (B).
6. Bulkhead - Removal Disconnect the connectors (A). Remove the harness clamps (B). Remove the bulkhead (A).
7. A/C Condenser Fan Shroud Assembly Remove the A/C condenser fan shroud assembly (A).
8. Drive Belt Move the auto-tensioner (A) using the belt tension release tool in the direction of the arrow to relieve tension from the drive belt, then remove the drive belt.
9. A/C Compressor Assembly Remove the bolt (A). Disconnect the connector (A). Disconnect the suction hose (B) and the discharge hose (C). NOTE: Plug or cap the lines immediately after disconnecting them to avoid moisture and dust contamination. Remove the A/C compressor (A). NOTE: Be careful not to damage the radiator fins when removing the A/C compressor.

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1. A/C Compressor Clutch - Check Check the armature plate for discoloration, peeling, or other damage. If there is damage, replace the clutch set. Inspect the friction surfaces and the compressor shaft hub for excess oil. If excess oil is present, and it is not from the engine or power steering system, then the compressor shaft seal is leaking. Replace the A/C compressor. Check the rotor pulley bearing play and drag by rotating the rotor pulley by hand. Also check for grease leakage from the bearing. Replace the clutch set with a new one if it is noisy, has excessive play/drag, or has bearing grease contamination on the clutch faces. NOTE: The rotor pulley and the armature plate were mated at the factory by a burnishing operation. Always replace the rotor pulley and the plate as a set. Replacing only one part of the clutch set will cause clutch slippage. Measure the clearance between the rotor pulley (A) and the armature plate (B) all the way around. If the clearance is not within specified limits, remove the armature plate and add or remove shims as needed to increase or decrease clearance. Clearance: 0.35-0.65 mm (0.014-0.025 in) NOTE: The shims are available in four thicknesses: 0.1 mm, 0.2 mm, 0.4 mm, and 0.5 mm. USA and Canada models: Check for continuity between the A/C compressor clutch connector terminals No. 2 and No. 3. If there is no continuity, replace the thermal protector. NOTE: The thermal protector will have no continuity above about 252 to 262 °F (122 to 128 °C). When the temperature drops below about 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. USA and Canada models Mexico models: Disconnect the connector (A). Mexico models: Check the thermal protector for continuity. If there is no continuity, replace the thermal protector. NOTE: The thermal protector will have no continuity above 252 to 262 °F (122 to 128 °C). When the temperature drops below 241 to 219 °F (116 to 104 °C), the thermal protector will have continuity. Mexico models USA and Canada models: Disconnect the connector (A). Measure the resistance of the field coil. If resistance is not within specifications, replace the field coil. Field Coil Resistance: 3.15-3.45 ohms at 68 °F (20 °C)

Note. If an accidental system discharge occurs, ventilate the work area before resuming service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.5 oz) per year or better. Do not install an A/C compressor into a system unless you are completely sure that the system is free of contamination. Installing the A/C compressor into a contaminated system can result in premature A/C compressor failure. Inspect the A/C lines for any signs of contamination. If you're installing a new A/C compressor, you must calculate the amount of refrigerant oil to be removed from it. A new A/C compressor comes with a full charge of oil. Replace the O-rings with new ones at each fitting, and apply a thin coat of refrigerant oil before installing them. Be sure to use the correct O-rings for HFC-134a (R-134a) to avoid leakage. Use only PAG refrigerant oil (SP-10) for HFC-134a A/C systems. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if the refrigerant oil contacts the paint, wash it off immediately. Be careful not to damage the radiator fins when installing the A/C compressor, the alternator or the A/C condenser fan shroud.

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1. A/C Refrigerant Oil - Replacement Recommended PAG oil: SP-10 P/N 38897-P13-A01AH: 120 mL (4 fl.oz) It is important to have the correct amount of refrigerant oil in the A/C system to ensure proper lubrication of the A/C compressor. Too little oil damages the A/C compressor; too much oil reduces the cooling capacity of the system, and can produce high vent temperatures. To avoid contamination, do not return the oil to the container once dispensed, and never mix it with other refrigerant oils. Immediately after using the oil, reinstall the cap on the container, and seal it to avoid moisture absorption. Do not spill the refrigerant oil on the vehicle; it may damage the paint; if it gets on the paint, wash it off immediately. Add the recommended refrigerant oil in the amount listed if you replace any of the following parts. A/C condenser (including Receiver/Dryer) 50 mL (1 2/3 fl.oz) A/C condenser (including Dryer Desiccant) 50 mL (1 2/3 fl.oz) Evaporator 40 mL (1 1/3 fl.oz) Line or hose 10 mL (1/3 fl.oz) Receiver/Dryer (4-door) 10 mL (1/3 fl.oz) Dryer desiccant (2-door) 10 mL (1/3 fl.oz) Leakage repair 25 mL (5/6 fl.oz) A/C compressor Since the oil separator is equipped inside the A/C compressor for this vehicle, oil drainage is unnecessary at the time of A/C compressor replacement.
2. A/C Compressor Assembly Install the A/C compressor (A). NOTE: Be careful not to damage the radiator fins when removing the A/C compressor. Remove the plugs or caps. Connect the suction hose (A) with a new O-ring (B) that is lubricated with clean refrigerant oil. Connect the discharge hose (C) with a new O-ring (D) that is lubricated with clean refrigerant oil. Connect the connector (E). Install the bolt (A).
3. Drive Belt Install the drive belt.
4. A/C Condenser Fan Shroud Assembly Install the A/C condenser fan shroud assembly (A).
5. Bulkhead - Installation Install the bulkhead (A). Install the harness clamps (A). Connect the connectors (B).
6. Radiator Mounting Bracket, Upper Both Install the radiator mount upper bracket/cushion (A), and the brackets (B).
7. Battery Terminal - Reconnection NOTE: If the battery performs abnormally, test the battery. Clean the battery terminals. Connect the positive cable (A) to the battery. NOTE: Always connect the positive side first. Connect the negative cable and the battery sensor (B) to the battery. NOTE: To protect the battery sensor connector (C) from damage, do not hold it when installing the negative terminal. Apply multipurpose grease to the terminals to prevent corrosion.
8. A/C Refrigerant - Recovery Recover the refrigerant from the A/C system. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging.
9. R-134a Refrigerant Recovery/Recycling/Charging Station - Connection Connect an R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.
10. A/C System Evacuation Evacuate the system. The vacuum pump should run for a minimum of 30 minutes to eliminate all moisture from the system. When the suction gauge reads -93.3 kPa (-700 mmHg, -27.55 inHg) for at least 30 minutes, close all valves, and turn off the vacuum pump. If the suction gauge dose not reach approximately -93.3 kPa (-700 mmHg, -27.55 inHg) in 15 minutes, there is probably a large leak in the system. Partially charge the system, and check for leaks.
11. A/C Refrigerant - Charging Charge the system with the specified amount of R-134a refrigerant. Do not overcharge the system; the A/C compressor will be damaged. Select the appropriate units of measure for your refrigerant charging station. Refrigerant Capacity: 375 to 425 g 13.2 to 15.0 oz 0.375 to 0.425 kg 0.827 to 0.937 lbs
12. A/C Refrigerant - Leak Check Leak Detector Usage Tips (Refer to the Operator's Manual for complete operating instructions) Position the vehicle in a wind-free work area. This will aid in detecting small leaks. When using the leak detector for the first time, allow it to warm up for 2 minutes with the probe in a clean atmosphere. This lets the temperature sensor in the detector stabilize. The calibration check should be done in the "Search 2" mode. Once that is done, the other check modes do not need calibrating. When leak checking through the HVAC module drain hose, avoid drawing water into the probe. Water can damage the internal pump and sensor. Avoid creasing the flexible probe extension. Creases can restrict air flow and give false readings. Because the detector recalibrates itself for ambient gases, it may be necessary to move the detector away from the leak to clear the sensor. Once the sensor has cleared, recheck the suspected leak. When removing the clear probe tip, be careful not to lose the flow ball. R-134a is heavier than air; always check below and to the sides of all potential leak sources. Halogen leak detectors are sensitive to chemicals: windshield washing solutions, solvents/cleaners, and some vehicle adhesives. Keep these chemicals out of the area when doing leak detection. Fluorescent Dye Usage Tips Use only Tracer-Stick single dose fluorescent dye capsules from Tracerline®. Other dyes contain solvents that may contaminate the refrigerant oil, leading to component failure. Adding excessive amounts of dye can damage the A/C compressor. PAG oil is water soluble, so condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain. After checking and repairing leaks, thoroughly clean any residual dye from the areas where leaks were found. Use GLO-AWAY dye cleaner, from Tracerline®, and hot water to remove the dye (follow the instructions on the bottle). Residual dye stains can cause misdiagnosis of any future A/C system leaks. If any refrigerant dye contacts an exterior paint surface, remove it by doing this: Carefully wash the affected surfaces to remove any dirt, and to prevent paint scratching. Mix water and isopropyl alcohol in a 50/50 mixture. Soak a soft 100 % cotton towel with the water/alcohol mixture, and place the cloth on the affected areas to remove the dye. After removing the dye with the water/alcohol-soaked cloth, carefully wash the affected areas, and check that there is no remaining dye. With the engine OFF, use a halogen leak detector first to detect the leak source. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test the following areas of the system for leaks: Possible Leak Area Diagnostic Procedure with the Leak Detector Notes Service ports Check the service ports with caps installed If the detector "sniffs" a leak, use fluorescent dye to confirm it When capping the service ports, ensure that the seals on the port caps are in place, and that the caps are tight. The caps are used as the final seals in the system A/C condenser If the detector "sniffs" a leak, use fluorescent dye to confirm it Check for joints or connections coated with oily dust Check for damaged and corroded areas Check all fittings, couplings, brazed/welded areas and areas around attachment points Move the probe slowly (1 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak If you detect a leak, blow compressed air over the area, then recheck for leaks. For large leaks, clearing the area with compressed air may help you pinpoint the leak source Evaporator Check at the evaporator drain hose Check at the passenger's side vent and turn the blower on low speed A/C lines Wiggle the rubber hoses when checking crimped metal ends If the detector "sniffs" a leak, use fluorescent dye to confirm it Check all fittings, couplings, pressure switches, brazed/welded areas, and areas around attachment points on A/C lines and components Check for damaged and corroded areas Move the probe slowly (1 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak Close the quick coupler valves, then disconnect the quick couplers from the vehicle service ports. Attach the universal connect set, from the Optimax Jr. Leak Detection Kit, to the service valve fitting. Close the control valve (the black knob on the connect set). Attach the charging station low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the charging station vacuum pump, then close the quick coupler valve. Detach the universal connect set, and install a Tracer-Stick® dye capsule between the connect set and the service valve fitting (see the manufacturer's instructions for more detail). Attach the quick coupler on the universal connect set to the low pressure service port on the vehicle. Open the charging station low pressure hose quick coupler valve, but do not open the control valve. Start the engine, and set the A/C system to maximum cooling. Open the control valve to let refrigerant and the dye enter the A/C system through the low pressure service port. Close the control valve when the Tracer-Stick® dye capsule is empty. Run the engine and A/C system for 15 minutes to thoroughly circulate the dye. Then shut the engine off, and inspect the following areas of the system for leaks: NOTE: Check for leaks in a dark work area, and use the UV light and the special glasses from the leak check kit. Other UV lights may not work well with the Tracer-Stick® dye. Small leaks may take up to 1 week of vehicle operation (with normal A/C use) to become visible. Possible Leak Area Diagnostic Procedure with Fluorescent Dye Service ports If a leak is found, replace the cap/O-ring seal or A/C line as needed A/C lines Use a permanent marker pen to circle the leak area If a leak is found, remove and replace the A/C line A/C condenser If a leak is found, remove the A/C condenser Determine whether leak is in the A/C condenser or the receiver/dryer Use a permanent marker pen to circle the leak area Replace either the receiver/dryer, or the A/C condenser, depending upon which is leaking A/C compressor Check for leaks at all of the A/C compressor joints, the clutch center, the A/C compressor front housing bolts, and the scroll bolts on the back of the A/C compressor If a leak is found, use a permanent marker pen to circle the leak area If the A/C compressor relief valve appears to be leaking, determine whether the leak is coming from the relief valve, or the joint between the A/C compressor casing and the valve. If the leak is from the relief valve, check the A/C system pressures, and refer to the pressure test table in the A/C system test. If the leak is from the casing/valve joint, replace the A/C compressor relief valve If the leak is coming from the suction hose and/or discharge hose fittings on the A/C compressor, clean the A/C fittings and replace the suction/discharge fitting O-rings For all other A/C compressor leaks, remove and replace the A/C compressor Evaporator Start checking for evaporator leaks by illuminating the evaporator drain tube area If a leak is found, remove the evaporator core Determine whether leak is from evaporator or expansion valve Use a permanent marker pen to circle leak area Replace the expansion valve, or the evaporator core, depending upon which is leaking
13. A/C System - Test Insert a thermometer (A) in the center vent. Place a hygro-thermometer (B) near the blower unit's recirculation inlet duct. Test conditions: Move the vehicle out of direct sunlight and let it cool down to the surrounding (ambient) temperature. If necessary, wash the vehicle to cool it down more quickly. The blower intake temperature must be at least 68 °F (20 °C). Open the hood. Open the front doors. Start the engine. Set the temperature control dial or temperature control button to MAX COOL, the mode control button to VENT, and the recirculation control button to RECIRCULATE. Set the A/C button on and the fan control dial or fan control button to Max. Run the engine at 1, 500 RPM. No driver or passengers in vehicle. Inspect the A/C components for the following conditions: A/C compressor clutch not engaged. Abnormal frost areas. Unusual noises. If you observe any of these conditions, refer to the Symptom Troubleshooting Index. After running the air conditioning for 10 minutes under the above test conditions, read the delivery temperature from the thermometer in the center vent, the blower intake temperature near the blower unit, and the discharge (high) and suction (low) pressures on the A/C gauges. To complete the vent (delivery)/blower intake temperature chart: Mark the vent (delivery) temperature on the vertical line. Mark the blower intake temperature on the bottom line. Draw a vertical line from the blower intake temperature mark. Draw a horizontal line from the vent (delivery) temperature mark until it intersects the vertical line. NOTE: The vent (delivery) temperature and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection. To complete the high side (discharge) pressure/blower intake temperature chart: Mark the high side (discharge) pressure on the vertical line. Mark the blower intake temperature on the bottom line. Draw a vertical line from the blower intake temperature mark. Draw a horizontal line from the high side (discharge) pressure mark until it intersects the vertical line. NOTE: The high side (discharge) pressure and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection. To complete the low side (suction) pressure/blower intake temperature chart: Mark the low side (suction) pressure along the vertical line. Mark the blower intake temperature along the bottom line. Draw a vertical line from the blower intake temperature mark. Draw a horizontal line from the low side (suction) pressure mark until it intersects the vertical line. NOTE: The low side (suction) pressure and blower intake temperature should intersect in the shaded area. Any measurements outside the line may indicate the need for further inspection.
14. Glove Box - Move Install the glove box (A).

Scheme 98

Note. It is normal for the A/C compressor to turn off under certain conditions, such as low idle, high engine coolant temperature, or hard acceleration. Do not use this troubleshooting procedure if the fans are also inoperative with the A/C on. Refer to the symptom troubleshooting index. Before doing any symptom troubleshooting, check for PGM-FI DTCs. See HOW TO TROUBLESHOOT THE A/T SYSTEM , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (K24Z7) , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18A9) or HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18Z1) .

Scheme 99

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Scheme 104

1. Fuses check: 1. Check the following fuses. Fuse No. A25 (7.5 A) Location Under-hood fuse/relay box Is the fuse OK? YES: Go to step 2. NO: Replace the fuse. If the fuse blows again, repair a short to ground in the No. A25 (7.5 A) fuse circuit.
2. Climate control system check: 1. Connect the HDS to the DLC. 2. Start the engine. 3. Set the A/C button and the fan control dial to ON. 4. Using the HDS, check the under following conditions: Engine speed between 700 and 800 RPM (K24Z7 engine) Engine speed between 620 and 820 RPM (except K24Z7 engine) ECT sensor 2 between 176-212 °F (80-100 °C) TP sensor about 0.5 V at idle 5. Using the HDS, confirm the following value in the PGM-FI Data List at idle. A/C Pressure Sensor 196-3, 138 kPa (2.00-32.00 kgf/cm 2 ) (28.4-455.1 psi) Are all the values within specifications? YES: Go to step 3. NO: Go to the «A/C SYSTEM TEST RESULT»(ref-614127-S23891236372014050700000) .
3. Climate control system check: 1. Using the HDS, confirm the following values in the PGM-FI Data List at idle. A/C SWITCH ON A/C CLUTCH ON Are all the values within specifications? YES: Go to step 4. NO: A/C switch is OFF, go to the «A/C SIGNAL CIRCUIT TROUBLESHOOTING»(ref-614127-S11163944412014050700000) . NO: A/C SWITCH is ON and A/C CLUTCH is OFF, Update the ECM/PCM See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE if it does not have the latest software, or substitute a known-good ECM (K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE or ECM/PCM (except K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE , and recheck.
4. A/C compressor clutch relay check: 1. Turn the ignition switch to LOCK (0). 2. Remove the A/C compressor clutch relay from the under-hood fuse/relay box, and test it See «POWER RELAY TEST (EXCEPT NATURAL GAS MODELS)»(ref-614103-S35184897672014050700000) or «POWER RELAY TEST (NATURAL GAS MODELS)»(ref-614103-S26004828472014050700000) . Is the relay OK? YES: Go to step 5. NO: Replace the A/C compressor clutch relay.
5. Open wire check (+B_MG_CLUTCH line): 1. Measure the voltage between test points 1 and 2. Test condition IG LOCK (0) A/C compressor clutch relay: disconnected Test circuit +B_MG_CLUTCH Test point 1 A/C compressor clutch relay 4P socket terminal No. 1 (GRN) (Built into the under-hood fuse/relay box) Test point 2 Body ground Is there battery voltage? YES: The +B_MG_CLUTCH wire is OK. Go to step 6. NO: An open in the +B_MG_CLUTCH wire. Replace the under-hood fuse/relay box.
6. Determine possible failure area (A/C compressor clutch relay switch side circuit, A/C compressor clutch relay coil side circuit): 1. Connect terminals 1 and 2 with a jumper wire. Terminal 1 A/C compressor clutch relay 4P socket terminal No. 1 (GRN) (Built into the under-hood fuse/relay box) Terminal 2 A/C compressor clutch relay 4P socket terminal No. 2 (PUR) (Built into the under-hood fuse/relay box) Does the A/C compressor clutch click? YES: Go to step 7. NO: Go to step 9 .
7. Open wire check (IG2_A/C line): 1. Disconnect the jumper wire. 2. Turn the ignition switch to ON (II). 3. Measure the voltage between test points 1 and 2. Test condition IG ON (II) A/C compressor clutch relay: disconnected Test circuit IG2_A/C Test point 1 A/C compressor clutch relay 4P socket terminal No. 7 (BRN) (Built into the under-hood fuse/relay box) Test point 2 Body ground Is there battery voltage? YES: The IG2_A/C wire is OK. Go to step 8. NO: Repair an open in the wire between the under-dash fuse/relay box No. B22 (7.5 A) fuse and the A/C compressor clutch relay.
8. Open wire check (A/C_MG_CLUTCH_RLY_CL- line): 1. Turn the ignition switch to LOCK (0). 2. Reinstall the A/C compressor clutch relay. 3. Jump the SCS line with the HDS. NOTE: This step must be done to protect the ECM/PCM from damage. 4. Disconnect the following connector. ECM/PCM connector A (49P) 5. Connect terminals 1 and 2 with a jumper wire. Terminal 1 ECM/PCM connector A (49P) terminal No. 12 (RED) Terminal 2 Body ground Does the A/C compressor clutch click? YES: Replace the ECM See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE or the ECM/PCM See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE . NO: Repair an open in the wire between the A/C compressor clutch relay and the ECM/PCM.
9. Open wire check (A/C MG CLUTCH/AC MG CLUTCH line (K24Z7 engine) or A/C_MG_CLUTCH line (except K24Z7 engine)): 1. Disconnect the jumper wire. 2. Disconnect the following connector. A/C compressor clutch 3P connector 3. Check for continuity between test points 1 and 2. K24Z7 engine Test condition IG LOCK (0) A/C compressor clutch relay: disconnected A/C compressor clutch 3P connector: disconnected Test circuit A/C MG CLUTCH/AC MG CLUTCH Test point 1 A/C compressor clutch relay 4P socket terminal No. 2 (PUR) (Built into the under-hood fuse/relay box) Test point 2 A/C compressor clutch 3P connector terminal No. 1 (BLU) Except K24Z7 engine Test condition IG LOCK (0) A/C compressor clutch relay: disconnected A/C compressor clutch 3P connector: disconnected Test circuit A/C_MG_CLUTCH Test point 1 A/C compressor clutch relay 4P socket terminal No. 2 (PUR) (Built into the under-hood fuse/relay box) Test point 2 A/C compressor clutch 3P connector terminal No. 2 (BLU/RED) Is there continuity? YES: The A/C MG CLUTCH/AC MG CLUTCH wire (K24Z7 engine) or A/C_MG_CLUTCH wire (except K24Z7 engine) is OK. Check the A/C compressor clutch clearance and the A/C compressor clutch field coil See «A/C COMPRESSOR CLUTCH CHECK (EXCEPT K24Z7)»(ref-614127-S41717679172014050700000) or «A/C COMPRESSOR CLUTCH CHECK (K24Z7)»(ref-614127-S21239616452014050700000) . Repair as needed. NO: Repair an open in the wire between the A/C compressor clutch relay and the A/C compressor clutch.

Scheme 105

Note. It is normal for the A/C compressor to turn off under certain conditions, such as low idle, high engine coolant temperature, or hard acceleration. Do not use this troubleshooting procedure if the fans are also inoperative with the A/C on. Refer to the symptom troubleshooting index. Before doing symptom troubleshooting, check for PGM-FI DTCs. See HOW TO TROUBLESHOOT THE A/T SYSTEM , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (K24Z7) , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18A9) or HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18Z1) .

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Scheme 111

1. Fuses check: 1. Check the following fuses. Fuse No. A25 (7.5 A) Location Under-hood fuse/relay box Fuse No. B22 (7.5 A) Location Under-dash fuse/relay box Are the fuses OK? YES: Go to step 2. NO: Replace the fuse(s). If the fuse(s) blows again, repair a short to ground in the No. A25 (7.5 A) fuse and/or the No. B22 (7.5 A) fuse circuit.
2. A/C pressure check: 1. Connect the HDS to the DLC. 2. Start the engine. 3. Set the A/C button and the fan control dial to ON. 4. Using the HDS, check the under following conditions: Engine speed between 700 and 800 RPM (K24Z7 engine) Engine speed between 620 and 820 RPM (except K24Z7 engine) ECT sensor 2 more than 199 °F (93 °C) TP sensor about 0.5 V at idle 5. Using the HDS, confirm the following value in the PGM-FI Data List at idle. A/C Pressure Sensor 196-3, 138 kPa (2.00-32.00 kgf/cm 2 ) (28.4-455.1 psi) Is the value within specifications? YES: Go to step 3. NO: Go to the «A/C SYSTEM TEST RESULT»(ref-614127-S23891236372014050700000) .
3. HVAC control system check: 1. Using the HDS, confirm the following values in the PGM-FI Data List at idle. A/C Switch ON A/C Clutch ON Are all the values within specifications? YES: Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM (K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE or ECM/PCM (except K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE and recheck. NO: A/C switch is OFF, go to the «A/C SIGNAL CIRCUIT TROUBLESHOOTING»(ref-614127-S11163944412014050700000) . NO: A/C switch is ON and A/C clutch is OFF, go to step 4.
4. A/C compressor clutch relay check: 1. Turn the ignition switch to LOCK (0). 2. Remove the A/C compressor clutch relay from the under-hood fuse/relay box, and test it See «POWER RELAY TEST (EXCEPT NATURAL GAS MODELS)»(ref-614103-S35184897672014050700000) or «POWER RELAY TEST (NATURAL GAS MODELS)»(ref-614103-S26004828472014050700000) . Is the relay OK? YES: Go to step 5. NO: Replace the A/C compressor clutch relay
5. Open wire check (+B_MG_CLUTCH line): 1. Measure the voltage between test points 1 and 2. Test condition IG LOCK (0) A/C compressor clutch relay: disconnected Test circuit +B_MG_CLUTCH Test point 1 A/C compressor clutch relay 4P socket No. 1 (GRN) (Built into the under-hood fuse/relay box) Test point 2 Body ground Is there battery voltage? YES: The +B_MG_CLUTCH wire is OK. Go to step 6. NO: Repair an open in the +B_MG_CLUTCH wire.
6. Determine possible failure area (A/C compressor clutch relay switch side circuit, A/C compressor clutch relay coil side circuit): 1. Connect terminals A and B with a jumper wire. Terminal A A/C compressor clutch relay 4P socket No. 1 (GRN) (Built into the under-hood fuse/relay box) Terminal B A/C compressor clutch relay 4P socket No. 2 (PUR) (Built into the under-hood fuse/relay box) Does the A/C compressor clutch click? YES: Go to step 7. NO: Go to step 9 .
7. Open wire check (IG2_A/C line): 1. Disconnect the jumper wire. 2. Turn the ignition switch to ON (II). 3. Measure the voltage between test points 1 and 2. Test condition IG ON (II) A/C compressor clutch relay: disconnected Test circuit IG2_A/C Test point 1 A/C compressor clutch relay 4P socket No. 7 (BRN) (Built into the under-hood fuse/relay box) Test point 2 Body ground Is there battery voltage? YES: The IG2_A/C wire is OK. Go to step 8. NO: Repair an open or high resistance in the IG2_A/C wire between the under-dash fuse/relay box No. B22 (7.5 A) fuse and the A/C compressor clutch relay.
8. Open wire check (A/C_MG_CLUTCH_RLY_CL- line): 1. Turn the ignition switch to LOCK (0). 2. Reinstall the A/C compressor clutch relay. 3. Jump the SCS line with the HDS. NOTE: This step must be done to protect the ECM/PCM from damage. 4. Disconnect the following connector. ECM/PCM connector A (49P) 5. Connect terminals A and B with a jumper wire. Terminal A ECM/PCM connector A (49P) No. 12 (RED) Terminal B Body ground 6. Turn the ignition switch to ON (II). Does the A/C compressor clutch click? YES: Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM (K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE or ECM/PCM (except K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE and recheck. NO: Repair an open or high resistance in the wire between the A/C compressor clutch relay and the ECM/PCM.
9. Open wire check (A/C_MG_CLUTCH line): 1. Disconnect the jumper wire. 2. Disconnect the following connector. A/C compressor clutch 3P connector 3. Check for continuity between test points 1 and 2. K24Z7 engine Test condition IG LOCK (0) A/C compressor clutch relay: disconnected A/C compressor clutch 3P connector: disconnected Test circuit A/C_MG_CLUTCH Test point 1 A/C compressor clutch relay 4P socket No. 2 (PUR) (Built into the under-hood fuse/relay box) Test point 2 A/C compressor clutch 3P connector No. 1 (BLU) Except K24Z7 engine Test condition IG LOCK (0) A/C compressor clutch relay: disconnected A/C compressor clutch 3P connector: disconnected Test circuit A/C_MG_CLUTCH Test point 1 A/C compressor clutch relay 4P socket No. 2 (PUR) (Built into the under-hood fuse/relay box) Test point 2 A/C compressor clutch 3P connector No. 2 (BLU/RED) Is there continuity? YES: The A/C_MG_CLUTCH wire is OK. Check the A/C compressor clutch clearance See «A/C COMPRESSOR CLUTCH CHECK (EXCEPT K24Z7)»(ref-614127-S41717679172014050700000) or «A/C COMPRESSOR CLUTCH CHECK (K24Z7)»(ref-614127-S21239616452014050700000) and the A/C compressor clutch field coil See «A/C COMPRESSOR CLUTCH OVERHAUL (EXCEPT K24Z7)»(ref-614160-S12040273132014050700000) or «A/C COMPRESSOR CLUTCH OVERHAUL (K24Z7)»(ref-614160-S36804723572014050700000) . Repair as needed. NO: Repair an open or high resistance in the wire between the A/C compressor clutch relay and the A/C compressor clutch.

Scheme 112

Note. Do not use this troubleshooting procedure if the A/C compressor is inoperative. Refer to the symptom troubleshooting index. If A/C refrigerant pressure is abnormal, the radiator fans are controlled based only on engine coolant temperature. Before doing symptom troubleshooting, check for PGM-FI DTCs. See HOW TO TROUBLESHOOT THE A/T SYSTEM , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (K24Z7) , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18A9) or HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18Z1) .

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Scheme 117

1. Fuse check: 1. Check the following fuses. Fuse No. A2-10 (20 A) Location Under-hood fuse/relay box Fuse No. A11 (7.5 A) Location Under-hood fuse/relay box Are the fuses OK? YES: Go to step 2. NO: Replace the fuse(s), and recheck. If the fuse blows again, check for a short in the No. A2-10 (20 A) fuse and/or the No. A11 (7.5 A) fuse circuits.
2. A/C condenser fan relay check: 1. Remove the A/C condenser fan relay from the under-hood fuse/relay box, and test it See «POWER RELAY TEST (EXCEPT NATURAL GAS MODELS)»(ref-614103-S35184897672014050700000) or «POWER RELAY TEST (NATURAL GAS MODELS)»(ref-614103-S26004828472014050700000) . Is the relay OK? YES: Go to step 3. NO: Replace the A/C condenser fan relay.
3. Open wire check (+B_SUB_FAN line): 1. Measure the voltage between test points 1 and 2. Test condition IG LOCK (0) A/C compressor clutch relay: disconnected Test circuit +B_SUB_FAN Test point 1 A/C condenser fan relay 4P socket No. 1 Test point 2 Body ground Is there battery voltage? YES: The +B_SUB_FAN wire is OK. Go to step 4. NO: An open in the +B_SUB_FAN wire. Replace the under-hood fuse/relay box.
4. SUB FAN MOTOR line check: 1. Connect terminals A and B with a jumper wire. Terminal A A/C condenser fan relay 4P socket No. 1 Terminal B A/C condenser fan relay 4P socket No. 2 (BLU) Does the A/C condenser fan run on high? YES: The +B_SUB_FAN/SUB_FAN_MOTOR wires are OK. Go to step 5. NO: An open in the +B_SUB_FAN wire. Replace the under-hood fuse/relay box.
5. A/C condenser fan relay coil side power circuit check: 1. Disconnect the jumper wire. 2. Turn the ignition switch to ON (II). 3. Measure the voltage between test points 1 and 2. Test condition IG ON (II) A/C compressor clutch relay: disconnected Test circuit SUB_FAN_DIODE- Test point 1 A/C condenser fan relay 4P socket No. 3 (PNK) Test point 2 Body ground Is there battery voltage? YES: No. A11 (7.5 A) fuse wire is OK. Go to step 6. NO: Go to step 7 .
6. Open wire check (FAN_HI_SIGNAL line): 1. Turn the ignition switch to LOCK (0). 2. Reinstall the A/C condenser fan relay. 3. Jump the SCS line with the HDS. NOTE: This step must be done to protect the ECM/PCM from damage. 4. Disconnect the following connector. ECM/PCM connector A (49P) 5. Connect terminals A and B with a jumper wire. Terminal A ECM/PCM connector A (49P) No. 16 (GRY) Terminal B Body ground Terminal A ECM/PCM connector A (49P) No. 20 (LT BLU) Terminal B Body ground 6. Turn the ignition switch to ON (II). Does the A/C condenser fan run on high? YES: Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM (K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE or ECM/PCM (except K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE and recheck. NO: Repair an open in the wire between the A/C condenser fan relay and the ECM/PCM.
7. A/C diode A check: 1. Turn the ignition switch to LOCK (0). 2. Using the diode setting on a DVOM, check for current flow in both directions between A/C diode A terminals No. 1 and No. 2. Is there current flow in only one direction? YES: An open in the No. A11 (7.5 A) fuse circuit wire. Replace the under-hood fuse/relay box. NO: Replace A/C diode A.

Scheme 118

Note. Do not use this troubleshooting procedure if the A/C compressor is inoperative. Refer to the symptom troubleshooting index. If A/C refrigerant pressure is abnormal, the radiator fans are controlled based only on engine coolant temperature. Before doing symptom troubleshooting, check for PGM-FI DTCs. See HOW TO TROUBLESHOOT THE A/T SYSTEM , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (K24Z7) , HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18A9) or HOW TO TROUBLESHOOT THE FUEL AND EMISSIONS SYSTEMS (R18Z1) .

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Scheme 123

1. Fuse check: 1. Check the following fuses. Fuse No. A2-10 (20 A) Location Under-hood fuse/relay box Fuse No. A11 (7.5 A) Location Under-hood fuse/relay box Are the fuses OK? YES: Go to step 2. NO: Replace the fuse(s), and recheck. If the fuse(s) blows again, check for a short in the No. A2-10 (20 A) fuse and/or the No. A11 (7.5 A) fuse circuits.
2. A/C condenser fan relay check: 1. Remove the A/C condenser fan relay from the under-hood fuse/relay box, and test it See «POWER RELAY TEST (EXCEPT NATURAL GAS MODELS)»(ref-614103-S35184897672014050700000) or «POWER RELAY TEST (NATURAL GAS MODELS)»(ref-614103-S26004828472014050700000) . Is the relay OK? YES: Go to step 3. NO: Replace the A/C condenser fan relay.
3. Open wire check (+B_SUB_FAN line): 1. Measure the voltage between test points 1 and 2. Test condition IG LOCK (0) A/C condenser fan relay: disconnected Test circuit +B_SUB_FAN Test point 1 A/C condenser fan relay 4P socket No. 1 Test point 2 Body ground Is there battery voltage? YES: The +B_SUB_FAN wire is OK. Go to step 4. NO: An open in the +B_SUB_FAN wire. Replace the under-hood fuse/relay box.
4. SUB FAN MOTOR line check: 1. Connect terminals A and B with a jumper wire. Terminal A A/C condenser fan relay 4P socket No. 1 Terminal B A/C condenser fan relay 4P socket No. 2 (BLU) Does the A/C condenser fan run on high? YES: The +B_SUB_FAN/SUB_FAN_MOTOR wires are OK. Go to step 5. NO: An open in the +B_SUB_FAN wire. Replace the under-hood fuse/relay box.
5. A/C condenser fan relay coil side power circuit check: 1. Disconnect the jumper wire. 2. Turn the ignition switch to ON (II). 3. Measure the voltage between test points 1 and 2. Test condition IG ON (II) A/C condenser fan relay: disconnected Test circuit SUB_FAN_DIODE- Test point 1 A/C condenser fan relay 4P socket No. 3 (PNK) Test point 2 Body ground Is there battery voltage? YES: No. A11 (7.5 A) fuse wire is OK. Go to step 6. NO: Go to step 7 .
6. Open wire check (FAN_HI_SIGNAL line): 1. Turn the ignition switch to LOCK (0). 2. Reinstall the A/C condenser fan relay. 3. Jump the SCS line with the HDS. NOTE: This step must be done to protect the ECM/PCM from damage. 4. Disconnect the following connector. ECM/PCM connector A (49P) 5. Connect terminals A and B with a jumper wire. Terminal A ECM/PCM connector A (49P) No. 16 (GRY) Terminal B Body ground Terminal A ECM/PCM connector A (49P) No. 20 (LT BLU) Terminal B Body ground 6. Turn the ignition switch to ON (II). Does the A/C condenser fan run on high? YES: Update the ECM/PCM if it does not have the latest software, or substitute a known-good ECM (K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE or ECM/PCM (except K24Z7 engine) See «ECM REMOVAL AND INSTALLATION (K24Z7)»(ref-614093-S42243049962014050700000) , «ECM/PCM REMOVAL AND INSTALLATION (Except K24Z7 and R18Z1 (CVT))»(ref-614093-S04499420502014050700000) or ECM/PCM UPDATE and recheck. NO: Repair an open in the wire between the A/C condenser fan relay and the ECM/PCM.
7. A/C diode A check: 1. Turn the ignition switch to LOCK (0). 2. Using the diode setting on a DVOM, check for current flow in both directions between A/C diode A terminals No. 1 and No. 2. Is there current flow in only one direction? YES: An open in No. A11 (7.5 A) fuse circuit wire. Replace the under-hood fuse/relay box. NO: Replace A/C diode A.