Automatic Air Conditioner: Other Nissan Armada I

PRECAUTIONS FOR SUPPLEMENTAL RESTRAINT SYSTEM (SRS) "AIR BAG" AND "SEAT BELT PRE-TENSIONER"

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. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.

Information necessary to service the system safely is included in SUPPLEMENTAL RESTRAINT SYSTEM and SEAT BELTS articles.

PRECAUTIONS FOR WORKING WITH HFC-134A (R-134A)

CONTAMINATED REFRIGERANT

If a refrigerant other than pure HFC-134a (R-134a) is identified in a vehicle, your options are

1. Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere.
2. Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply.
3. Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred.
4. If you choose to perform the repair, recover the refrigerant using only dedicated equipment and containers. Do not recover contaminated refrigerant into your existing service equipment. If your facility does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended.
5. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact NISSAN Customer Affairs for further assistance.

GENERAL REFRIGERANT PRECAUTIONS

PRECAUTIONS FOR LEAK DETECTION DYE

1. The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks.
2. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye.
3. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector (J-41995).
4. For your safety and the customer's satisfaction, read and follow all manufacturer's operating instructions and precautions prior to performing work.
5. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).
6. Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service.
7. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed .
8. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).
9. Do not use more than one refrigerant dye bottle (1/4 ounce / 7.4 cc) per A/C system.
10. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C systems or CFC-12 (R-12) leak detection dye in HFC-134a (R-134a) A/C systems or A/C system damage may result.
11. The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure occurs.

PRECAUTIONS FOR REFRIGERANT CONNECTION

A new type refrigerant connection has been introduced to all refrigerant lines except the following locations.

1. Expansion valve to cooling unit
2. Evaporator pipes to evaporator (inside cooling unit)
3. Refrigerant pressure sensor

Scheme 169

1. The O-ring has been relocated. It has also been provided with a groove for proper installation. This reduces the possibility of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics.
2. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections.

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PRECAUTIONS FOR SERVICING COMPRESSOR

1. Plug all openings to prevent moisture and foreign matter from entering.
2. When the compressor is removed, store it in the same position as it is when mounted on the car.
3. When replacing or repairing compressor, follow "Maintenance of Lubricant Quantity in Compressor" exactly. Refer to «MAINTENANCE OF LUBRICANT QUANTITY IN COMPRESSOR»(ref-233307-S12720044522006052500000) .
4. Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with lubricant, wipe it off by using a clean waste cloth moistened with thinner.
5. After compressor service operation, turn the compressor shaft by hand more than 5 turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for 1 hour.
6. After replacing the compressor magnet clutch, apply voltage to the new one and check for normal operation. Refer to «REMOVAL AND INSTALLATION FOR COMPRESSOR CLUTCH»(ref-233307-S06674210492006052500000)

RECOVERY/RECYCLING EQUIPMENT

Follow the manufacturer's instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR

Follow the manufacturer's instructions for tester operation and tester maintenance.

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 pressure 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.

To prevent this migration, use a manual valve situated near the hose-to-pump connection, as follows.

1. Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump.
2. For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump.
3. If the hose has an automatic shut off valve, disconnect the hose from the pump: 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 under a no vacuum condition. Such valves may restrict the pump's ability to pull a deep vacuum and are not recommended.

Scheme 174

MANIFOLD GAUGE SET

Be certain that the gauge face indicates HFC-134a (R-134a or 134a). Make sure the gauge set has 1/2"-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) along with specified lubricant.

Scheme 175

SERVICE HOSES

Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut-off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.

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SERVICE COUPLERS

Never attempt to connect HFC-134a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. If an improper connection is attempted, discharging and contamination may occur.

SERVICE COUPLERS REFERENCE DATA

Scheme 177

REFRIGERANT WEIGHT SCALE

Verify that no refrigerant other than HFC134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2"-16 ACME.

Scheme 178

CHARGING CYLINDER

Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder's top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment.

SPECIAL SERVICE TOOLS

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Scheme 179

HFC-134A (R-134A) SERVICE TOOLS AND EQUIPMENT

Never mix HFC-134a (R-134a) refrigerant and/or the specified lubricant with CFC- 12 (R-12) refrigerant and/or the lubricant.

Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant.

Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles 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.

Adapters that convert one size fitting to another must never be used refrigerant/lubricant contamination will occur and compressor failure will result.

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REFRIGERANT FLOW

The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, through the front and rear evaporators, and back to the compressor. The refrigerant evaporation through the evaporator coils are controlled by front and rear externally equalized expansion valves, located inside the front and rear evaporator cases.

REFRIGERANT PRESSURE SENSOR

The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends a voltage signal to the ECM. The ECM de-energizes the A/C relay to disengage the magnetic compressor clutch when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm 2 , 398 psi), or below about 120 kPa (1.22 kg/cm 2 , 17.4 psi).

PRESSURE RELIEF VALVE

The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an abnormal level [more than 2,990 kPa (30.5 kg/cm 2 , 433.6 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere.

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LUBRICANT

Name: NISSAN A/C System Lubricant Type S (DH-PS) or equivalent

Part number: KLH00-PAGS0

CHECKING AND ADJUSTING

Start the engine and set the following conditions

Test Condition

1. Engine speed: Idling to 1,200 rpm
2. A/C switch: On
3. Blower speed: Max. position
4. Temp. control: Optional [Set so that intake air temperature is 25° to 30°C (77° to 86°F)]
5. Intake position: Recirculation
6. Perform lubricant return operation for about ten minutes

Adjust the lubricant quantity according to the following table.

AIR MIX DOORS CONTROL

The air mix doors are automatically controlled so that in-vehicle temperature is maintained at a predetermined value by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

BLOWER SPEED CONTROL

Blower speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position.

When AUTO switch is pressed, the blower motor starts to gradually increase air flow volume (if required).

When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

INTAKE DOOR CONTROL

The intake door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and by the ON-OFF operation of the compressor.

MODE DOOR CONTROL

The mode door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload.

DEFROSTER DOOR CONTROL

The defroster door is controlled by: Turning the defroster dial to front defroster.

Scheme 187

When A/C switch or DEF switch is pressed, front air control inputs compressor ON signal to BCM.

BCM sends compressor ON signal to ECM, via CAN communication line.

ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant pressure sensor signal, throttle angle sensor, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to IPDM E/R, via CAN communication line.

Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor.

DISPLAY SCREEN

Displays the operational status of the system.

AUTO SWITCH

1. The compressor, intake door, air mix doors, outlet doors and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.
2. When pressing AUTO switch, air inlet, air outlet, blower speed, and discharge air temperature are automatically controlled.

TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL) (DRIVER SIDE)

Increases or decreases the set temperature.

TEMPERATURE CONTROL DIAL (TEMPERATURE CONTROL) (PASSENGER SIDE)

Increases or decreases the set temperature.

TEMPERATURE CONTROL DIAL (TEMPERATURE AND MODE CONTROL) (REAR)

Increases or decreases the set temperature. The mode also changes from foot at full hot setting, to foot/vent mid-range (warm) setting, and then to panel on full cold setting.

RECIRCULATION () SWITCH

1. When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.
2. When REC switch is turned OFF, or when compressor is turned from ON to OFF, REC switch is automatically turned OFF. REC mode can be re-entered by pressing REC switch again.
3. REC switch is not operated when DEF switch is turned ON, or at the D/F position.

DEFROSTER (DEF) SWITCH

Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.

REAR WINDOW DEFOGGER SWITCH

When switch is ON, rear window is defogged.

OFF SWITCH

The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot (75% foot and 25% defrost) position.

A/C SWITCH

The compressor is ON or OFF.

(Pressing the A/C switch when the AUTO switch is ON will turn off the A/C switch and compressor.)

MODE SWITCH (FRONT)

Controls the air discharge outlets.

FRONT BLOWER CONTROL DIAL

Manually control the blower speed. Seven speeds are available for manual control (as shown on the display screen).

Scheme 188

TEMPERATURE CONTROL DIAL (TEMPERATURE AND MODE CONTROL)

The temperature increases or decreases the set temperature. The mode also changes from foot at full hot setting, to foot/vent at mid-range (warm) setting, and then to vent at full cold setting.

REAR BLOWER CONTROL DIAL

When the rear blower switch (front) is in the OFF position, the rear blower motor cannot operate.

When the rear blower switch (front) is in the REAR position, it allows the rear blower switch (rear) to control the rear blower motor speed. In any other position (1-4), the rear blower switch (front) controls the rear blower motor speed regardless of the rear blower switch (rear) position.

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CONSULT-II FUNCTION (HVAC)

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

DIAGNOSTIC MODE DESCRIPTION

DISPLAY ITEM LIST

DISPLAY ITEM LIST

DISPLAY ITEM LIST

*: DENT is displayed when MODE switch is between selections.

CONSULT-II FUNCTION (BCM)

CONSULT-II can display each diagnostic item using the diagnostic test modes shown following.

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DISPLAY ITEM LIST

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*1 OPERATIONAL CHECK (FRONT) or OPERATIONAL CHECK (REAR) .

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FRONT AIR CONTROL TERMINALS AND REFERENCE VALUE

Measure voltage between each terminal and ground by following Terminals and Reference Value for front air control.

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CHECKING BLOWER

1. Press the AUTO switch. Blower should operate on low speed. The blower symbol should have one blade lit (on display).
2. Turn the front blower control dial again, and continue checking blower speed and blower symbol until all speeds are checked.
3. Leave blower on MAX speed.

If NG, go to trouble diagnosis procedure for DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR .

If OK, continue with next check.

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1. Press MODE switch four times and the DEF switch.
2. Each position indicator should change shape (on display).
3. Confirm that discharge air comes out according to the air distribution table. Refer to «DISCHARGE AIR FLOW»(ref-233307-S21528205632006052500000) .

Mode door position is checked in the next step.

If NG, go to trouble diagnosis procedure for MODE DOOR MOTOR CIRCUIT .

If OK, continue the check.

Note. Confirm that the compressor clutch is engaged (sound or visual inspection) and intake door position is at fresh when the DEF or D/F is selected.

Scheme 210

CHECKING RECIRCULATION

1. Press recirculation (***) switch one time. Recirculation indicator should illuminate.
2. Press recirculation (***) switch one more time. Recirculation indicator should go off.
3. Listen for intake door position change (blower sound should change slightly).

If NG, go to trouble diagnosis procedure for INTAKE DOOR MOTOR CIRCUIT .

If OK, continue the check.

Note. Confirm that the compressor clutch is engaged (sound or visual inspection) and intake door position is at fresh when the DEF or D/F is selected.

Scheme 211

CHECKING TEMPERATURE DECREASE

1. Rotate temperature control dial (driver side or passenger side) counterclockwise until 16°C (60°F) is displayed.
2. Check for cold air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation. If OK, go to trouble diagnosis procedure for INSUFFICIENT COOLING . If air mix door motor appears to be malfunctioning, go to DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER) or DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (PASSENGER) .

If OK, continue the check.

Scheme 212

CHECKING TEMPERATURE INCREASE

1. Rotate temperature control dial clockwise (driver side or passenger side) until 32°C (90°F) is displayed.
2. Check for hot air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation. If OK, go to trouble diagnosis procedure for INSUFFICIENT HEATING . If air mix door motor appears to be malfunctioning, go to DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER) or DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (PASSENGER) .

If OK, continue with next check.

Scheme 213

CHECK A/C SWITCH

1. Press A/C switch when AUTO switch is ON, or in manual mode.
2. A/C switch indicator will turn ON. Confirm that the compressor clutch engages (sound or visual inspection).

If NG, go to trouble diagnosis procedure for MAGNET CLUTCH CIRCUIT .

If OK, continue with next check.

Scheme 214

CHECKING AUTO MODE

1. Press AUTO switch.
2. Display should indicate AUTO. If ambient temperature is warm, and selected temperature is cool, confirm that the compressor clutch engages (sound or visual inspection). (Discharge air and blower speed will depend on ambient, in-vehicle, and set temperatures.)

If NG, go to trouble diagnosis procedure for POWER SUPPLY AND GROUND CIRCUIT FOR FRONT AIR CONTROL , then if necessary, trouble diagnosis procedure for MAGNET CLUTCH CIRCUIT .

Scheme 215

If all operational checks are OK (symptom cannot be duplicated), go to malfunction Simulation Tests and perform tests as outlined to simulate driving conditions environment. If symptom appears. Refer to HOW TO PERFORM TROUBLE DIAGNOSIS FOR QUICK AND ACCURATE REPAIR , SYMPTOM TABLE and perform applicable trouble diagnosis procedures.

1. Turn the rear blower control dial to switch position "1". Blower should operate on low speed.
2. Turn the rear blower control dial counterclockwise to switch position "2", "3", and "4" until all speeds are checked.
3. Leave blower on MAX speed.

If NG, go to trouble diagnosis procedure for REAR BLOWER MOTOR CIRCUIT .

If OK, continue the check.

Scheme 216

1. Rotate temperature and mode dial fully counterclockwise.
2. Check for cold air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation if OK, go to trouble diagnosis procedure for INSUFFICIENT COOLING . If air mix door motor appears to be malfunctioning, go to DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR) .

If OK, continue the check.

Scheme 217

1. Rotate temperature and mode dial clockwise.
2. Check for hot air at appropriate discharge air outlets.

If NG, listen for sound of air mix door motor operation. If OK, go to trouble diagnosis procedure for INSUFFICIENT HEATING . If air mix door motor appears to be malfunctioning, go to DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR) .

If OK, continue the check.

Scheme 218

POWER SUPPLY AND GROUND CIRCUIT FOR FRONT AIR CONTROL

SYMPTOM: A/C system does not come on.

Scheme 219

*1 POWER SUPPLY AND GROUND CIRCUIT FOR FRONT AIR CONTROL

*2 OPERATIONAL CHECK (FRONT) or OPERATIONAL CHECK (REAR)

FRONT AIR CONTROL

The front air control has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motors, mode door motor, intake door motor, defroster door motor, blower motor and compressor are then controlled.

The front air control is unitized with control mechanisms. When the various switches and temperature dials are operated, data is input to the front air control.

Self-diagnostic functions are also built into the front air control to provide quick check of malfunctions in the auto air conditioner system.

Scheme 220

POTENTIO TEMPERATURE CONTROL (PTC)

There are two PTCs (passenger and driver) built into the front air control. They can be set at an interval of 0.5°C (1.0°F) in the 16°C (60°F) to 32°C (90°F) temperature range by rotating the temperature dial. The set temperature is displayed.

Scheme 221

MODE DOOR MOTOR CIRCUIT

SYMPTOM

1. Air outlet does not change.
2. Mode door motor does not operate normally.

Scheme 222

*1 DISCHARGE AIR FLOW

*2 OPERATIONAL CHECK (FRONT)

*3 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*4 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*5 DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR

COMPONENT PARTS

Mode door control system components are

1. Front air control
2. Mode door motor
3. PBR (built into mode door motor)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

MODE DOOR MOTOR

The mode door motor is attached to the heater & cooling unit. It rotates so that air is discharged from the outlet as indicated by the front air control. Motor rotation is conveyed to a link which activates the mode door.

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1. CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 92 or DTC B2588 is present. Refer to «A/C SYSTEM SELF-DIAGNOSIS FUNCTION»(ref-233307-S17035136932006052500000) . YES or NO YES: GO TO 2 . NO: GO TO 3 .
2. CHECK POWER SUPPLY AND GROUND CIRCUITS FOR MODE DOOR MOTOR Turn ignition switch OFF. Disconnect front air control connector and mode door motor connector. Check continuity between front air control harness connector M49 terminal 5 (BR/W) and mode door motor harness connector M142 terminal 5 (BR/W) and between front air control harness connector M49 terminal 6 (P/L) and mode door motor harness connector M142 terminal 6 (P/L). 5 - 5: Continuity should exist. 6 - 6: Continuity should exist. OK or NG OK: Replace mode door motor. Refer to «MODE DOOR MOTOR»(ref-233307-S01888053192006052500000) NG: Repair or replace harness as necessary.
3. CHECK PBR REFERENCE SIGNAL VOLTAGE Disconnect the mode door motor connector. Turn ignition switch ON. Check voltage between mode door motor harness connector M142 terminal 3 (Y) and ground. 3 - Ground: Approx. 5 V OK or NG OK: GO TO 5 . NG: GO TO 4 .
4. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN MODE DOOR AND FRONT AIR CONTROL Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between mode door motor harness connector M142 terminal 3 (Y) and front air control harness connector M49 terminal 2 (Y). 3 - 2: Continuity should exist. OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: Repair or replace harness as necessary.
5. CHECK PBR GROUND REFERENCE CIRCUIT Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between mode door motor harness connector M142 terminal 1 (P) and front air control harness connector M49 terminal 15 (P). 1 - 15: Continuity should exist. OK or NG OK: GO TO 6 . NG: Repair or replace harness as necessary.
6. CHECK PBR FEEDBACK SIGNAL Reconnect the front air control connector and mode door motor connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 16 (GR) and ground. Press mode switch through all modes. 16 - Ground: Approx. 0 - 5 V OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: GO TO 7 .
7. CHECK PBR FEEDBACK CIRCUIT Turn ignition switch OFF. Disconnect the mode door motor connector and front air control harness connector. Check continuity between mode door motor harness connector M142 terminal 2 (GR) and front air control harness connector M49 terminal 16 (GR). 2 - 16: Continuity should exist. OK or NG OK: Replace mode door motor. Refer to «MODE DOOR MOTOR»(ref-233307-S01888053192006052500000) . NG: Repair or replace harness as necessary.

AIR MIX DOOR MOTOR CIRCUIT

SYMPTOM

1. Discharge air temperature does not change.
2. Air mix door motor does not operate.

Scheme 230

*1 OPERATIONAL CHECK (FRONT) or OPERATIONAL CHECK (REAR)

*2 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*3 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*4 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (DRIVER)

*5 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (PASSENGER)

*6 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR)

Air mix door control system components are

1. Front air control.
2. Air mix door motors (Driver, Passenger, and rear)
3. PBR (built-into air mix door motors)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

AIR MIX DOOR MOTORS

The driver and front passenger air mix door motors are attached to the front heater & cooling unit. The rear air mix door motor is attached to the rear heater & cooling unit. These motors rotate so that the air mix door is opened or closed to a position set by the front (or rear) air control. Motor rotation is then conveyed through a shaft and the air mix door position is then fed back to the front air control by the PBR built into the air mix door motors.

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1. CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 22 or DTC B2577 is present. Refer to «A/C SYSTEM SELF-DIAGNOSIS FUNCTION»(ref-233307-S17035136932006052500000) . YES or NO YES: GO TO 2 . NO: GO TO 3 .
2. CHECK POWER SUPPLY CIRCUITS FOR AIR MIX DOOR MOTOR (DRIVER) Turn ignition switch OFF. Disconnect front air control connector and air mix door motor (Driver) connector. Check continuity between front air control harness connector M49 terminal 3 (W/G) and 4 (G) and air mix door motor (driver) harness connector M147 terminal 1 (W/G) and 6 (G). 3 - 1: Continuity should exist. 4 - 6: Continuity should exist. OK or NG OK: Replace air mix door motor (Driver). Refer to «FRONT AIR MIX DOOR MOTOR (DRIVER)»(ref-233307-S41729755362006052500000) . NG: Repair or replace harness as necessary.
3. CHECK PBR REFERENCE SIGNAL VOLTAGE Turn ignition switch OFF. Disconnect the air mix door motor (Driver) connector. Turn ignition switch ON. Check voltage between air mix door motor (Driver) harness connector M147 terminal 3 (Y) and ground. 3 - Ground: Approx. 5 V OK or NG OK: GO TO 5 . NG: GO TO 4 .
4. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN AIR MIX DOOR MOTOR (DRIVER) AND FRONT AIR CONTROL Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between air mix door motor (Driver) harness connector M147 terminal 3 (Y) and front air control harness connector M49 terminal 2 (Y). 3 - 2: Continuity should exist. OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: Repair or replace harness as necessary.
5. CHECK PBR GROUND REFERENCE CIRCUIT Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between air mix door motor (Driver) harness connector M147 terminal 2 (P) and front air control harness connector M49 terminal 15 (P). 2 - 15: Continuity should exist. OK or NG OK: GO TO 6 . NG: Repair or replace harness as necessary.
6. CHECK PBR FEEDBACK SIGNAL Reconnect the front air control connector and air mix door motor (Driver) connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 18 (SB) and ground. Rotate Driver temperature control dial through complete range. 18 - Ground: Approx. 0 V - 5 V OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: GO TO 7 .
7. CHECK PBR FEEDBACK CIRCUIT Turn ignition switch OFF. Disconnect the air mix door motor (Driver) connector and front air control connector. Check continuity between air mix door motor (Driver) harness connector M147 terminal 4 (SB) and front air control harness connector M49 terminal 18 (SB). 4 - 18 Continuity should exist. OK or NG OK: Replace air mix door motor (Driver). Refer to «FRONT AIR MIX DOOR MOTOR (DRIVER)»(ref-233307-S41729755362006052500000) . NG: Repair or replace harness as necessary.

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Scheme 245

1. CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 12 or DTC B2574 is present. Refer to «A/C SYSTEM SELF-DIAGNOSIS FUNCTION»(ref-233307-S17035136932006052500000) . YES or NO YES: GO TO 2 . NO: GO TO 3 .
2. CHECK POWER SUPPLY CIRCUIT FOR AIR MIX DOOR MOTOR (PASSENGER) Turn ignition switch OFF. Disconnect front air control connector and air mix door motor (Passenger) connector. Check continuity between front air control harness connector M50 terminal 36 (G/W) and 37 (L) and air mix door motor (Passenger) harness connector M143 terminal 1 (G/W) and 6 (L). 36 - 1 Continuity should exist. 37 - 6 Continuity should exist. OK or NG OK: Replace air mix door motor (Passenger). Refer to «FRONT AIR MIX DOOR MOTOR (PASSENGER)»(ref-233307-S08861096492006052500000) NG: Repair or replace harness as necessary.
3. CHECK PBR REFERENCE SIGNAL VOLTAGE Turn ignition switch OFF. Disconnect the air mix door motor (Passenger) connector. Turn ignition switch ON. Check voltage between air mix door motor (Passenger) harness connector M143 terminal 3 (Y) and ground. 3 - Ground: Approx. 5 V OK or NG OK: GO TO 5 . NG: GO TO 4 .
4. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN AIR MIX DOOR (PASSENGER) AND FRONT AIR CONTROL Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between air mix door motor (Passenger) harness connector M143 terminal 3 (Y) and front air control harness connector M49 terminal 2 (Y). 3 - 2 Continuity should exist. OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: Repair or replace harness as necessary.
5. CHECK PBR GROUND REFERENCE CIRCUIT Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between air mix door motor (Passenger) harness connector M143 terminal 2 (P) and front air control harness connector M49 terminal 15 (P). 2 - 15 Continuity should exist. OK or NG OK: GO TO 6 . NG: Repair or replace harness as necessary.
6. CHECK PBR FEEDBACK SIGNAL Reconnect the front air control connector and air mix door motor (Passenger) connector. Turn ignition switch ON. Check voltage between front air control harness connector M50 terminal 41 (R/W) and ground. Rotate Passenger temperature control dial through complete range. 41 - Ground: Approx. 0 - 5 V OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: GO TO 7 .
7. CHECK PBR FEEDBACK CIRCUIT Turn ignition switch OFF. Disconnect the air mix door motor (Passenger) connector and front air control connector. Check continuity between air mix door motor (Passenger) harness connector M143 terminal 4 (R/W) and front air control harness connector M50 terminal 41 (R/W). 4 - 41: Continuity should exist. OK or NG OK: Replace air mix door motor (Passenger). Refer to «FRONT AIR MIX DOOR MOTOR (PASSENGER)»(ref-233307-S08861096492006052500000) NG: Repair or replace harness as necessary.

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

1. CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 38 or DTC B257A is present. Refer to «A/C SYSTEM SELF-DIAGNOSIS FUNCTION»(ref-233307-S17035136932006052500000) . YES or NO YES: GO TO 2 . NO: GO TO 3 .
2. CHECK POWER SUPPLY CIRCUIT FOR AIR MIX DOOR MOTOR (REAR) Turn ignition switch OFF. Disconnect front air control connector and air mix door motor (Rear) connector. Check continuity between front air control harness connector M50 terminal 27 (GR/R) and air mix door motor (rear) harness connector B155 terminal 1 (GR/R) and between front air control harness connector M50 terminal 28 (L/Y) and air mix door motor (rear) harness connector B155 terminal 6 (L/Y). 27 - 1 Continuity should exist. 28 - 6 Continuity should exist. OK or NG OK: Replace air mix door motor (Rear). Refer to «REAR AIR MIX DOOR MOTOR»(ref-233307-S33338756132006052500000) . NG: Repair or replace harness as necessary.
3. CHECK PBR REFERENCE SIGNAL VOLTAGE Turn ignition switch OFF. Disconnect the air mix door motor (Rear) connector. Turn ignition switch ON. Check voltage between air mix door motor (Rear) harness connector B155 terminal 3 (Y) and ground. 3 - Ground: Approx. 5 V OK or NG OK: GO TO 5 . NG: GO TO 4 .
4. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN AIR MIX DOOR MOTOR (REAR) AND FRONT AIR CONTROL Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between air mix door motor (Rear) harness connector B155 terminal 3 (Y) and front air control harness connector M49 terminal 2 (Y). 3 - 2 Continuity should exist. OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: Repair or replace harness as necessary.
5. CHECK PBR GROUND REFERENCE CIRCUIT Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between air mix door motor (Rear) harness connector B155 terminal 2 (P) and front air control harness connector M49 terminal 15 (P). 2 - 15 Continuity should exist. OK or NG OK: GO TO 6 . NG: Repair or replace harness as necessary.
6. CHECK PBR FEEDBACK SIGNAL Reconnect the front air control connector and air mix door motor (Rear) connector. Turn ignition switch ON. Check voltage between front air control harness connector M50 terminal 42 (R/Y) and ground. Rotate rear temperature control dial through complete range. 42 - Ground: Approx. 0 - 5 V OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: GO TO 7 .
7. CHECK PBR FEEDBACK CIRCUIT Turn ignition switch OFF. Disconnect the air mix door motor (Rear) connector and front air control connector. Check continuity between air mix door motor (Rear) harness connector B155 terminal 4 (R/Y) and front air control harness connector M50 terminal 42 (R/Y). 4 - 42 Continuity should exist. OK or NG OK: Replace air mix door motor (Rear) «REAR AIR MIX DOOR MOTOR»(ref-233307-S33338756132006052500000) . NG: Repair or replace harness as necessary.

INTAKE DOOR MOTOR CIRCUIT

SYMPTOM

1. Intake door does not change.
2. Intake door motor does not operate normally.

Scheme 252

*1 OPERATIONAL CHECK (FRONT)

*2 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*3 SELF-DIAGNOSIS CODE CHART

Intake door control system components are

1. Front air control
2. Intake door motor
3. In-vehicle sensor
4. Ambient sensor
5. Optical sensor
6. Intake sensor

INTAKE DOOR MOTOR

The intake door motor is attached to the intake unit. It rotates so that air is drawn from inlets set by the front air control. Motor rotation is conveyed to a lever which activates the intake door.

Scheme 253

Scheme 254

1. CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 82 or DTC B2586 is present. Refer to «A/C SYSTEM SELF-DIAGNOSIS FUNCTION»(ref-233307-S17035136932006052500000) . YES or NO YES: GO TO 2 . NO: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) .
2. CHECK POWER SUPPLY CIRCUIT FOR INTAKE DOOR MOTOR Turn ignition switch OFF. 2. Disconnect front air control connector and intake door motor connector. Check continuity between front air control harness connector M49 terminal 7 (O) and intake door motor harness connector M58 terminal 1 (O) and between front air control harness connector M49 terminal 8 (G/B) and intake door motor harness connector M58 terminal 6 (G/B). 7 - 1 Continuity should exist. 8 - 6 Continuity should exist. OK or NG OK: Replace intake door motor. Refer to «INTAKE DOOR MOTOR»(ref-233307-S29562276922006052500000) . NG: Repair or replace harness as necessary.

Defroster door control system components are

1. Front air control
2. Defroster door motor
3. PBR (Built into defroster door motor)
4. In-vehicle sensor
5. Ambient sensor
6. Optical sensor
7. Intake sensor

DEFROSTER DOOR MOTOR

The defroster door motor is attached to the front heater & cooling unit. The front air control sends a voltage to rotate to the defroster door directing the air flow either to the defroster ducts, or to the floor ducts, depending on which way the voltage and ground are applied to the motor leads. Motor rotation is conveyed to a lever which activates the defroster door.

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

1. CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 62 on DTC B2583 is present. Refer to «A/C SYSTEM SELF-DIAGNOSIS FUNCTION»(ref-233307-S17035136932006052500000) . YES or NO YES: GO TO 2 . NO: GO TO 3 .
2. CHECK POWER SUPPLY CIRCUIT FOR DEFROSTER DOOR MOTOR Turn ignition switch OFF. Disconnect front air control connector and defroster door motor connector. Check continuity between front air control harness connector M49 terminal 19 (LG) and defroster door motor connector M144 terminal 1 (LG) and between front air control harness connector M49 terminal 20 (P/B) and defroster door motor connector M144 terminal 6 (P/B). 19 - 1: Continuity should exist. 20 - 6: Continuity should exist. OK or NG OK: Replace defroster door motor. Refer to «REMOVAL AND INSTALLATION»(ref-233307-S36596054932006052500000) . NG: Repair or replace harness as necessary.
3. CHECK PBR REFERENCE SIGNAL VOLTAGE Disconnect the defroster door motor harness connector. Turn ignition switch ON. Check voltage between defroster door motor harness connector M144 terminal 3 (Y) and ground. 3 - Ground: Approx. 5 V. OK or NG OK: GO TO 5 . NG: GO TO 4 .
4. CHECK PBR REFERENCE VOLTAGE CIRCUIT BETWEEN DEFROSTER DOOR MOTOR AND FRONT AIR CONTROL Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between defroster door motor harness connector M144 terminal 3 (Y) and front air control harness connector M49 terminal 2 (Y). 3 - 2: Continuity should exist. OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: Repair or replace harness as necessary.
5. CHECK PBR GROUND REFERENCE CIRCUIT Turn ignition switch OFF. Disconnect the front air control connector. Check continuity between defroster door motor harness connector M144 terminal 2 (P) and front air control harness connector M49 terminal 15 (P). 2 - 15: Continuity should exist. OK or NG OK: GO TO 6 . NG: Repair or replace harness as necessary.
6. CHECK PBR FEEDBACK SIGNAL Reconnect the front air control connector and defroster door motor connector. Turn ignition switch ON. Check voltage between front air control harness connector M49 terminal 25 (LG/B) and ground. Change mode between floor, defroster, and panel. 25 - Ground: Approx. 0 - 5 V OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: GO TO 7 .
7. CHECK PBR FEEDBACK CIRCUIT Turn ignition switch OFF. Disconnect the defroster door motor connector and front air control connector. Check continuity between defroster door motor harness connector M144 terminal 4 (LG/B) and front air control harness connector M49 terminal 25 (LG/B). 4 - 25: Continuity should exist. OK or NG OK: Replace defroster door motor. Refer to «REMOVAL AND INSTALLATION»(ref-233307-S36596054932006052500000) . NG: Repair or replace harness as necessary.

FRONT BLOWER MOTOR CIRCUIT

SYMPTOM

1. Blower motor operation is malfunctioning.
2. Blower motor operation is malfunctioning under cold starting conditions.

Scheme 262

*1 OPERATIONAL CHECK (FRONT)

*2 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*3 SELF-DIAGNOSIS CODE CHART

*4 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR

*5 DTC P0117, P0118 ECT SENSOR

*6 SYMPTOM TABLE

Blower speed control system components are

1. Front air control
2. In-vehicle sensor
3. Ambient sensor
4. Optical sensor
5. Intake sensor

Scheme 263

AUTOMATIC MODE

In the automatic mode, the blower motor speed is calculated by the front air control and variable blower control based on input from the in-vehicle sensor, optical sensor, intake sensor and ambient sensor, and potentio temperature control (PTC).

When the air flow is increased, the blower motor speed is adjusted gradually to prevent a sudden increase in air flow.

In addition to manual air flow control and the usual automatic air flow control, starting air flow control, low water temperature starting control and high passenger compartment temperature starting control are available.

STARTING BLOWER SPEED CONTROL

Start up from cold soak condition (Automatic mode).

In a cold start up condition where the engine coolant temperature is below 50°C (122°F), the blower will not operate at blower speed 1 for a short period of time (up to 210 seconds). The exact start delay time varies depending on the ambient and engine coolant temperatures.

In the most extreme case (very low ambient temperature) the blower starting delay will be 210 seconds as described above. After the coolant temperature reaches 50°C (122°F), or the 210 seconds has elapsed, the blower speed will increase to the objective blower speed.

Start up from usual operating or hot soak condition (Automatic mode).

The blower will begin operation momentarily after the AUTO switch is pushed. The blower speed will gradually rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective blower speed).

BLOWER SPEED COMPENSATION - SUNLOAD

When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low speed. The speed will vary depending on the sunload. During conditions of low or no sunload, the blower operates at low speed. During high sunload conditions, the front air control causes the blower speed to increase.

Scheme 264

VARIABLE BLOWER CONTROL

The variable blower control is located on the cooling unit. The variable blower control receives a gate voltage from the front air control to steplessly maintain the blower motor voltage in the 0 to 5 volt range (approx.).

Scheme 265

FRONT BLOWER MOTOR RELAY

Check continuity between terminals by supplying 12 volts and ground to coil side terminals of relay.

Scheme 266

FRONT BLOWER MOTOR

Confirm smooth rotation of the blower motor.

Scheme 267

1. Ensure that there are no foreign particles inside the blower unit.
2. Apply 12 volts to terminal + and ground to terminal - and verify that the motor operates freely and quietly.

REAR BLOWER MOTOR CIRCUIT

SYMPTOM

1. Blower motor operation is malfunctioning.

Scheme 268

*1 OPERATIONAL CHECK (REAR)

*2 REAR BLOWER SWITCH (REAR) CIRCUIT

*3 SYMPTOM TABLE

Rear blower speed control system components are

1. Front air control
2. Rear blower switch (front)
3. Rear air control
4. Rear blower motor resistor
5. Rear blower motor
6. Rear blower motor relay

Scheme 269

REAR BLOWER CONTROL

When the rear blower control dial (front) is in the OFF position, the rear blower motor cannot operate. When the rear blower control dial (front) is in the REAR position, it allows the rear blower switch (rear) to control the rear blower motor speed. In any other position (1-4), the rear blower switch (front) controls the rear blower motor speed regardless of the rear blower switch (rear) position.

REAR BLOWER SWITCH (REAR) CIRCUIT

SYMPTOM

1. Rear blower motor does not rotate when rear blower switch (front) is set to REAR position and the rear blower switch (rear) is set at 1-4 speed.

Scheme 270

1. CHECK REAR BLOWER MOTOR OPERATION Blower motor rotates normally when rear blower control dial (front) is set at 1 - 4 speed. OK or NG OK: GO TO 2 . NG: Refer to «TROUBLE DIAGNOSIS PROCEDURE FOR REAR BLOWER MOTOR (1 - 4 SPEED)»(ref-233307-S12290247722006052500000) .
2. CHECK REAR BLOWER SWITCH (FRONT) Refer to «REAR BLOWER SWITCH (FRONT)»(ref-233307-S33328533222006052500000) . OK or NG OK: GO TO 3 . NG: Replace rear blower switch (front).
3. CHECK REAR AIR CONTROL Refer to «REAR BLOWER SWITCH (REAR) CIRCUIT»(ref-233307-S20046062592006052500000) . OK or NG OK: GO TO 4 . NG: Replace rear blower switch (rear). Refer to «REAR AIR CONTROL»(ref-233307-S00740902282006052500000) .
4. CHECK CIRCUIT CONTINUITY Turn ignition switch OFF. Disconnect rear blower switch (front) connector and rear air control connector. Check continuity between rear blower switch (front) harness connector M52 terminal 2 (BR) and rear blower switch (rear) harness connector R208 terminal 10 (BR). 2 - 10: Continuity should exist. OK or NG OK: Inspection End. NG: Repair harness or connector.

REAR BLOWER MOTOR RELAY

Check circuit continuity between terminals by supplying 12 volts and ground to coil side terminals of relays.

Scheme 271

REAR BLOWER SWITCH (REAR)

Check continuity between terminals at each switch position.

Scheme 272

REAR BLOWER SWITCH (FRONT)

Check continuity between terminals at each switch position.

Scheme 273

REAR BLOWER MOTOR

Check that there are no foreign particles inside the intake unit. Apply 12 volts to terminal 2 and ground to terminal 1 and ensure that the blower motor rotates freely and quietly.

Scheme 274

REAR BLOWER MOTOR RESISTOR

Check continuity between terminals. There will be resistance, but there should not be an open or short between any two terminals.

Scheme 275

REAR AIR CONTROL CIRCUIT

SYMPTOM

1. Temperature cannot be adjusted from the rear air control.

Scheme 276

*1 OPERATIONAL CHECK (REAR) or OPERATIONAL CHECK (FRONT)

*2 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*3 SELF-DIAGNOSIS CODE CHART

*4 DIAGNOSTIC PROCEDURE FOR REAR AIR CONTROL

*5 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR)

Rear air control system components are

1. Front air control
2. Rear air control
3. Air mix door motor (rear)
4. Rear blower motor relay
5. Rear blower motor resistor
6. Rear blower motor

Scheme 277

REAR AIR CONTROL

When the rear blower switch (front) (integral to the front air control) is in the REAR position the rear blower motor speeds and the rear temperature and mode are controlled by the rear blower switch (rear) and the rear temperature switch (rear) (both integral to the rear air control).

MAGNET CLUTCH CIRCUIT

SYMPTOM: Magnet clutch does not engage.

Scheme 278

*1 OPERATIONAL CHECK (FRONT)

*2 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*3 SELF-DIAGNOSIS CODE CHART

*4 AMBIENT SENSOR CIRCUIT

*5 INTAKE SENSOR CIRCUIT

LOW TEMPERATURE PROTECTION CONTROL

The front air control will turn the compressor ON or OFF as determined by a signal detected by the intake sensor and the ambient sensor.

When intake air temperature is higher than the preset value, the compressor turns ON. The compressor turns OFF when intake air temperature is lower than the preset value. That preset value is dependent on the ambient temperature, refer to AMBIENT TEMPERATURE REFERENCE .

AMBIENT TEMPERATURE REFERENCE

The refrigerant pressure sensor is attached to the condenser.

Scheme 279

INSUFFICIENT COOLING

SYMPTOM: Insufficient cooling

Scheme 280

*1 OPERATIONAL CHECK (FRONT)

*2 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*3 SELF-DIAGNOSIS CODE CHART

*4 SYSTEM DESCRIPTION

*5 CONTAMINATED REFRIGERANT

*6 PERFORMANCE TEST DIAGNOSES

*7 TEST READING

*8 CHECKING DRIVE BELTS

*9 WATER VALVE CIRCUIT

Scheme 281

*1 PERFORMANCE CHART

*2 PERFORMANCE CHART

*3 TROUBLE DIAGNOSES FOR UNUSUAL PRESSURE

*4 AIR MIX DOOR MOTOR CIRCUIT

Scheme 282

*1 REMOVAL AND INSTALLATION FOR COMPRESSOR CLUTCH

*2 FRONT BLOWER MOTOR CIRCUIT

*3 CHECKING DRIVE BELTS

INSUFFICIENT HEATING

SYMPTOM: Insufficient heating

Scheme 283

*1 OPERATIONAL CHECK (FRONT) or OPERATIONAL CHECK (REAR)

*2 AIR MIX DOOR MOTOR CIRCUIT

*3 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*4 SELF-DIAGNOSIS CODE CHART

*5 FRONT BLOWER MOTOR CIRCUIT

*6 DTC P0117, P0118 ECT SENSOR

CHANGING ENGINE COOLANT

WATER VALVE CIRCUIT

MEMORY FUNCTION

SYMPTOM: Memory function does not operate.

Scheme 284

*1 POWER SUPPLY AND GROUND CIRCUIT FOR FRONT AIR CONTROL

*2 OPERATIONAL CHECK (FRONT)

*3 A/C SYSTEM SELF-DIAGNOSIS FUNCTION

*4 SELF-DIAGNOSIS CODE CHART

WATER VALVE

The water valve cuts the flow of engine coolant to the front and rear heater cores to allow for maximum cooling during A/C operation. It is controlled by the front air control throughout the water valve relay.

Scheme 285

Scheme 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

Scheme 291

Scheme 292

1. CHECK WATER VALVE RELAY POWER INPUT CIRCUITS Turn ignition switch OFF. Disconnect water valve relay connector M7. Check voltage between water valve relay harness connector terminals and ground. OK or NG OK: GO TO 2 . NG: Repair harness or connector.
2. CHECK WATER VALVE CONTROL Turn ignition switch ON. Select MAX A/C with mode switch. Check continuity between water valve relay harness connector M7 terminal 1 (W/G) and ground, as MAX A/C is switched OFF and ON. OK or NG OK: GO TO 4 . NG: GO TO 3 .
3. CHECK WATER VALVE CONTROL OUTPUT CIRCUIT Turn ignition switch OFF. Disconnect front air control connector M50. Check continuity between water valve relay harness connector M7 terminal 1 (W/G) and front air control harness connector M50 terminal 29 (W/G). 1 - 29: Continuity should exist. Check continuity between water valve relay harness connector M7 terminal 1 (W/G) and ground. 1 - Ground: Continuity should not exist. OK or NG OK: Replace front air control. Refer to «FRONT AIR CONTROL»(ref-233307-S38951088582006052500000) . NG: Repair harness or connector.
4. CHECK WATER VALVE RELAY Check water valve relay. Refer to «WATER VALVE RELAY»(ref-233307-S19483517202006052500000) . OK or NG OK: GO TO 5 NG: Replace water valve relay.
5. CHECK WATER VALVE GROUND CIRCUIT Turn ignition switch OFF. Disconnect water valve connector F68. Check continuity between water valve harness connector F68 terminal - (B) and ground. (-) - Ground: Continuity should exist. OK or NG OK: GO TO 6 . NG: Repair harness or connector.
6. CHECK WATER VALVE POWER CIRCUIT Check continuity between water valve relay connector terminal 5 (Y/L) and water valve connector F68 terminal + (Y/L) 5 - +: Continuity should exist. Check continuity between water valve relay harness connector M7 terminal 5 (Y/L) and ground. 5 - Ground: Continuity should not exist. OK or NG OK: Replace water valve. NG: Repair harness or connector.

WATER VALVE RELAY

Check continuity between terminals by supplying 12 volts and ground to coil side terminals of relay.

Scheme 293

AMBIENT SENSOR

The ambient sensor is attached on the radiator core support (left side). It detects ambient temperature and converts it into a resistance value which is then input into the front air control.

Scheme 294

AMBIENT TEMPERATURE INPUT PROCESS

The front air control includes a processing circuit for the ambient sensor input. However, when the temperature detected by the ambient sensor increases quickly, the processing circuit retards the front air control function. It only allows the front air control to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds.

This prevents constant adjustments due to momentary conditions, such as stopping after high speed driving. Although the actual ambient temperature has not changed, the temperature detected by the ambient sensor will increase. This is because the heat from the engine compartment can radiate to the front grille area, location of the ambient sensor.

After disconnecting ambient sensor connector E1, measure resistance between terminals 1 and 2 at sensor component side, using the TEMPERATURE RESISTANCE REFERENCE .

TEMPERATURE RESISTANCE REFERENCE

If NG, replace ambient sensor.

Scheme 295

IN-VEHICLE SENSOR

The in-vehicle sensor is located on instrument lower driver panel. It converts variations in temperature of passenger compartment air (drawn in through the integrated fan) into a resistance value. It is then input into the front air control.

Scheme 296

Scheme 297

After disconnecting in-vehicle sensor connector M32, measure resistance between terminals 1 and 4 at sensor component side, using the table below.

TEMPERATURE RESISTANCE REFERENCE

If NG, replace in-vehicle sensor.

Scheme 298

OPTICAL INPUT PROCESS

The front air control includes a processing circuit which averages the variations in detected sunload over a period of time. This prevents adjustments in the ATC system operation due to small or quick variations in detected sunload.

For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the optical sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly after entering a long tunnel, the system will recognize the change in sunload, and the system will react accordingly.

INTAKE SENSOR

The intake sensor is located on the heater & cooling unit. It converts temperature of air after it passes through the evaporator into a resistance value which is then input to the front air control.

Scheme 299

After disconnecting intake sensor connector, measure resistance between terminals 1 and 2 at sensor harness side, using the TEMPERATURE RESISTANCE REFERENCE .

TEMPERATURE RESISTANCE REFERENCE

If NG, replace intake sensor.

Scheme 300

Scheme 301

1. Remove the five control knobs from the front air control unit.
2. Remove the cluster lid C. Refer to «CLUSTER LID C»(ref-233304-S22806159032006052500000) .
3. Remove the four screws securing the front air control unit to cluster lid C.
4. Remove the front air control unit.

FUNCTION

The air inside the passenger compartment is filtered by the in-cabin microfilters when the heater or A/C controls are set on either the recirculation or fresh mode. The two in-cabin microfilters are located in the front heater and cooling unit assembly. The rear heater and cooling unit assembly only draws in air from the passenger compartment to recirculate into the passenger compartment, so the rear heater and cooling unit assembly is not equipped with in-cabin microfilters.

Scheme 302

CLUTCH DISC

If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley.

Scheme 303

PULLEY

Check the appearance of the pulley assembly. If contact surface of pulley shows signs of excessive grooving, replace clutch disc and pulley. The contact surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

COIL

Check magnet coil for loose connections or any cracked insulation.

Scheme 304

Scheme 305

Scheme 306

Scheme 307

Scheme 308

1. Install the magnet coil. CAUTION: Be sure to align the magnet coil pin with the hole in the compressor front head.
2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install the snap ring using snap ring pliers. Tool number: - (J-38873-A)
4. Install the clutch disc on the compressor shaft, together with the original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc from turning and tighten the bolt to specification. Tool number: J-44614 CAUTION: After tightening the clutch pulley bolt, check that the clutch pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc (Scheme 308) Clutch disc-to-pulley clearance: 0.3 - 0.6 mm (0.012-0.024 in)
7. If the specified clearance is not obtained, replace the adjusting spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer to «DRIVE BELTS»(ref-233240-S28365612942006052500000)
10. Install the engine under cover and the splash shield.

CHECKING FOR REFRIGERANT LEAKS

Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage, and corrosion. Any A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector (J-41995) or fluorescent dye leak detector (J-42220).

If any dye is observed using a fluorescent dye leak detector (J-42220), confirm the leak using a electronic refrigerant leak detector (J-41995). It is possible that the dye is from a prior leak that was repaired and not properly cleaned.

When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections.

When searching for refrigerant leaks using an electronic refrigerant leak detector (J-41995), move the probe along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the component.

CHECKING SYSTEM FOR LEAKS USING THE FLUORESCENT DYE LEAK DETECTOR

1. Check the A/C system for leaks using the fluorescent dye leak detector and safety goggles (J-42220) in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly leak (tubes, core or expansion valve).
2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, then inspect the shop rag or cloth with the fluorescent dye leak detector (J-42220) for dye residue.
3. After the leak is repaired, remove any residual dye using refrigerant dye cleaner (J-43872) to prevent future misdiagnosis.
4. Perform a system performance check and then verify the leak repair using a electronic refrigerant leak detector (J-41995). NOTE: Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. Do not allow the sensor tip of the electronic refrigerant leak detector (J-41995) to contact with any substance. This can also cause false readings and may damage the detector.

DYE INJECTION

Note. This procedure is only necessary when recharging the system or when the compressor has seized and must be replaced.

1. Check the A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm 2 , 50 psi).
2. Pour one bottle 7.4 cc (1/4 ounce) of the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) into the HFC-134a (R-134a) dye injector (J-41459). CAUTION: If repairing the A/C system or replacing a component, pour the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) directly into the open system connection and proceed with the service procedures.
3. Connect the refrigerant dye injector (J-41459) to the low-pressure service valve.
4. Start the engine and switch the A/C system ON.
5. When the A/C system is operating (compressor running), inject one bottle 7.4 cc (1/4 ounce) of HFC-134a (R-134a) fluorescent leak detection dye (J-41447) through the low-pressure service valve using HFC-134a (R-134a) dye injector (J- 41459). Refer to .
6. With the engine still running, disconnect the HFC-134a (R-134a) dye injector (J-41459) from the low-pressure service valve.
7. Operate the A/C system for a minimum of 20 minutes to mix the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) with the A/C system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the HFC-134a (R-134a) fluorescent leak detection dye to penetrate an A/C system leak and become visible.

PRECAUTIONS FOR HANDLING LEAK DETECTOR

Note. When performing a refrigerant leak check, use a electronic refrigerant leak detector (J-41995) or equivalent. Ensure that the electronic refrigerant leak detector (J-41995) is calibrated and set properly according to the manufacturer's operating instructions.

The electronic refrigerant leak detector (J-41995) is a delicate device. To use the leak detector properly, read the manufacturer's operating instructions and perform any specified maintenance.

Scheme 309

Scheme 310

Scheme 311

Scheme 312

1. Position the probe approximately 5 mm (3/16 in) away from the point to be checked (Scheme 312)
2. When checking for leaks, circle each fitting completely with the probe (Scheme 313)
3. Move the probe along each component at a speed of approximately 25-50 mm (1 - 2 in)/second see scheme 314

CHECKING PROCEDURE

Note. To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle. Perform the leak test in a calm area (low air/wind movement) so that the leaking refrigerant is not dispersed.

Scheme 313

1. Turn the engine OFF.
2. Connect the manifold gauge set (J-39183-C) to the A/C service ports. Refer to «SETTING OF SERVICE TOOLS AND EQUIPMENT»(ref-233307-S36671724992006052500000).
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm 2, 50 psi) above a temperature of 16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. Refer to «HFC-134A (R-134A) SERVICE PROCEDURE»(ref-233307-S01487896662006052500000) NOTE: At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm 2, 50 psi) pressure.
4. Perform the leak test from the high-pressure side (front A/C compressor discharge "a" to evaporator inlet "f" or rear piping connection "l") to the low- pressure side (front A/C evaporator drain hose "g" to shaft seal "k" and rear A/C evaporator drain hose "o" to piping connection "r"). Refer to «COMPONENTS»(ref-233307-S05252121782006052500000). Clean the component to be checked and carefully move the electronic refrigerant leak detector probe completely around the following connections and components. Check the compressor shaft seal Check the high and low-pressure pipe and hose fittings, relief valve, and compressor shaft seal Check the liquid tank Check the refrigerant pressure sensor Check all around the service valves. Check that the service valve caps are screwed tightly on the service valves (to prevent leaks). NOTE: After removing manifold gauge set (J-39183-C) from the service valves, wipe any residue from the service valves to prevent any false readings by the electronic refrigerant leak detector (J-41995). Evaporator With engine OFF, turn blower fan on "High" for at least 15 seconds to dissipate any refrigerant trace in the heater and cooling unit assembly. Wait a minimum of 10 minutes accumulation time (refer to for actual wait time) before inserting the electronic refrigerant leak detector probe into the heater and cooling unit assembly drain hose. NOTE: Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose.
5. If a leak is detected, verify at least once by blowing compressed air into the area of the suspected leak, then repeat the leak check.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components and connections.
7. If no leaks are found, perform steps 8 - 11.
8. Start the engine.
9. Set the heater A/C controls as follows: NOTE: For the automatic system, turn OFF the automatic controls and set the heater A/C controls manually. A/C switch to ON Air flow to VENT mode Intake position to RECIRCULATION mode Temperature to MAX cold Blower speed to HIGH
10. Run the engine at 1,500 rpm for at least 2 minutes.
11. Turn the engine OFF and perform the leak check again following steps 4 through 6 above. Refrigerant leaks should be checked immediately after turning the engine OFF. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after the refrigerant circulation stops and pressure on the low pressure side will gradually rise see scheme 315 Some leaks are more easily detected when the pressure is high.
12. Before connecting the recovery/recycling recharging equipment to the vehicle, check the recovery/recycling recharging equipment gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover the refrigerant from the equipment lines and then check the refrigerant purity.
13. Confirm refrigerant purity in supply tank using recovery/recycling recharging equipment and refrigerant identifier equipment (J-41810-NI).
14. Confirm the refrigerant purity in the vehicle's A/C system using recovery/recycling recharging equipment and refrigerant identifier equipment (J-41810-NI).
15. Discharge the A/C system using recovery/recycling recharging equipment. Repair the leaking fitting or component as necessary.
16. Evacuate and recharge the A/C system and perform the leak test to confirm that there are no refrigerant leaks.
17. Conduct the Operational Check to ensure system works properly. Refer to «OPERATIONAL CHECK (FRONT)»(ref-233307-S37942830662006052500000) and «OPERATIONAL CHECK (REAR)»(ref-233307-S08418955132006052500000).

COMPRESSOR

COMPRESSOR SPECIFICATION

LUBRICANT SPECIFICATION

REFRIGERANT

REFRIGERANT SPECIFICATION

ENGINE IDLING SPEED

Refer to IDLE SPEED AND IGNITION TIMING CHECK

BELT TENSION

Refer to CHECKING DRIVE BELTS