ATC
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AUTOMATIC AIR CONDITIONER J AIR CONDITIONER SECTION ATC AUTOMATIC AIR CONDITIONER A B C D E CONTENTS PRECAUTIONS .......................................................... 5 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 5 Precautions for Working with HFC-134a (R-134a)..... 5 CONTAMINATED REFRIGERANT ....................... 5 General Refrigerant Precautions .............................. 7 Lubricant Precautions .............................................. 7 Precautions for Refrigerant Connection ................... 8 ABOUT ONE-TOUCH JOINT ................................ 8 FEATURES OF NEW TYPE REFRIGERANT CONNECTION .................................................... 10 O-RING AND REFRIGERANT CONNECTION....11 Precautions for Servicing Compressor ................... 13 Precautions for Service Equipment ........................ 13 RECOVERY/RECYCLING EQUIPMENT ............ 13 ELECTRONIC LEAK DETECTOR ...................... 13 VACUUM PUMP ................................................. 14 MANIFOLD GAUGE SET .................................... 14 SERVICE HOSES ............................................... 14 SERVICE COUPLERS ........................................ 15 REFRIGERANT WEIGHT SCALE ...................... 15 CALIBRATING ACR4 WEIGHT SCALE .............. 15 CHARGING CYLINDER ...................................... 15 Precautions for Leak Detection Dye ....................... 16 IDENTIFICATION ................................................ 16 IDENTIFICATION LABEL FOR VEHICLE ........... 16 Wiring Diagrams and Trouble Diagnosis ................ 16 PREPARATION ......................................................... 17 Special Service Tools ............................................. 17 HFC-134a (R-134a) Service Tools and Equipment... 18 Commercial Service Tools ...................................... 20 REFRIGERATION SYSTEM ..................................... 21 Refrigerant Cycle ................................................... 21 REFRIGERANT FLOW ....................................... 21 FREEZE PROTECTION ..................................... 21 Refrigerant System Protection ............................... 21 REFRIGERANT PRESSURE SENSOR ............. 21 PRESSURE RELIEF VALVE ............................... 21 V-6 Variable Displacement Compressor ................. 22 Revision; 2004 April GENERAL INFORMATION ................................. 22 DESCRIPTION .................................................... 23 Component Layout ................................................. 26 LUBRICANT .............................................................. 27 Maintenance of Lubricant Quantity in Compressor... 27 LUBRICANT ........................................................ 27 LUBRICANT RETURN OPERATION .................. 27 LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR .................................................. 28 LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT ....................... 29 AIR CONDITIONER CONTROL ............................... 30 Description of Air Conditioner LAN Control System... 30 System Construction .............................................. 30 OPERATION ........................................................ 30 TRANSMISSION DATA AND TRANSMISSION ORDER ............................................................... 31 AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) ..................................... 32 FAN SPEED CONTROL ...................................... 32 INTAKE DOOR CONTROL ................................. 32 OUTLET DOOR CONTROL ................................ 32 MAGNET CLUTCH CONTROL ........................... 32 SELF-DIAGNOSTIC SYSTEM ............................ 32 Description of Control System ................................ 33 Control Operation ................................................... 33 DISPLAY SCREEN .............................................. 34 AUTO SWITCH ................................................... 34 TEMPERATURE SWITCH (POTENTIO TEMPERATURE CONTROL) (DRIVER SIDE) ........... 34 TEMPERATURE SWITCH (POTENTIO TEMPERATURE CONTROL) (PASSENGER SIDE)... 34 RECIRCULATION (REC) SWITCH ..................... 34 FRESH (FRE) SWITCH ...................................... 34 DEFROSTER (DEF) SWITCH ............................. 34 REAR WINDOW DEFOGGER SWITCH ............. 34 OFF SWITCH ...................................................... 34 A/C SWITCH ....................................................... 34 MODE SWITCH .................................................. 34 ATC-1 2003 FX F G H I ATC K L M FAN SWITCH ...................................................... 34 DUAL SWITCH (WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM) .......................................... 34 Fail-safe Function ................................................... 35 Discharge Air Flow ................................................. 36 System Description ................................................. 37 SWITCHES AND THEIR CONTROL FUNCTION... 37 CAN Communication System Description .............. 38 CAN Communication Unit ....................................... 38 TYPE 1/TYPE2 .................................................... 39 TYPE 3 ................................................................ 42 TYPE 4/TYPE5 .................................................... 45 TYPE 6 ................................................................ 48 TROUBLE DIAGNOSIS ............................................ 52 CONSULT-II ............................................................ 52 CONSULT-II BASIC OPERATION ....................... 52 DATA MONITOR .................................................. 53 How to Perform Trouble Diagnosis for Quick and Accurate Repair ...................................................... 54 WORK FLOW ...................................................... 54 SYMPTOM TABLE .............................................. 54 Component Parts and Harness Connector Location... 56 ENGINE COMPARTMENT .................................. 56 PASSENGER COMPARTMENT .......................... 57 Schematic ............................................................... 58 Wiring Diagram —A/C— ......................................... 59 Auto Amp. Terminals and Reference Value ............ 64 PIN CONNECTOR TERMINAL LAYOUT ............ 64 TERMINALS AND REFERENCE VALUE FOR UNIFIED METER AND A/C AMP. ........................ 64 Self-diagnosis Function .......................................... 66 DESCRIPTION .................................................... 66 FUNCTION CONFIRMATION PROCEDURE ...... 67 AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER ........................................... 73 AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER ........................................... 74 AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION ................................................. 74 Operational Check .................................................. 75 CHECKING MEMORY FUNCTION ..................... 75 CHECKING BLOWER ......................................... 75 CHECKING DISCHARGE AIR ............................ 75 CHECKING RECIRCULATION ............................ 76 CHECKING TEMPERATURE DECREASE ......... 76 CHECKING TEMPERATURE INCREASE .......... 76 CHECK A/C SWITCH .......................................... 76 CHECKING AUTO MODE ................................... 77 Power Supply and Ground Circuit for Auto Amp. ... 77 INSPECTION FLOW ........................................... 77 COMPONENT DESCRIPTION ............................ 78 DIAGNOSTIC PROCEDURE FOR A/C SYSTEM... 78 LAN System Circuit ................................................ 80 DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT .................................................................... 80 Mode Door Motor Circuit ........................................ 83 INSPECTION FLOW ........................................... 83 SYSTEM DESCRIPTION .................................... 84 Revision; 2004 April COMPONENT DESCRIPTION ............................85 DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR ....................................................85 Air Mix Door Motor Circuit .......................................86 INSPECTION FLOW ............................................86 SYSTEM DESCRIPTION .....................................87 COMPONENT DESCRIPTION ............................88 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR ..................................................................88 Air Mix Door Motor PBR Circuit ..............................88 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR PBR ..........................................................88 Intake Door Motor Circuit ........................................89 INSPECTION FLOW ............................................89 SYSTEM DESCRIPTION .....................................90 COMPONENT DESCRIPTION ............................91 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR ....................................................91 Blower Motor Circuit ................................................92 INSPECTION FLOW ............................................92 SYSTEM DESCRIPTION .....................................93 COMPONENT DESCRIPTION ............................94 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR ................................................................94 COMPONENT INSPECTION ...............................97 Magnet Clutch Circuit ..............................................98 INSPECTION FLOW ............................................98 SYSTEM DESCRIPTION .....................................99 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH ..............................................................99 COMPONENT INSPECTION ............................. 103 Insufficient Cooling ................................................ 104 INSPECTION FLOW .......................................... 104 PERFORMANCE TEST DIAGNOSES .............. 105 PERFORMANCE CHART .................................. 107 TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE ................................................................. 108 DIAGNOSTIC PROCEDURE FOR INSUFFICIENT COOLING ............................................... 110 Insufficient Heating ............................................... 112 INSPECTION FLOW .......................................... 112 Noise ..................................................................... 113 INSPECTION FLOW .......................................... 113 Self-diagnosis ....................................................... 114 INSPECTION FLOW .......................................... 114 Memory Function .................................................. 115 INSPECTION FLOW .......................................... 115 Ambient Sensor Circuit ......................................... 116 COMPONENT DESCRIPTION .......................... 116 AMBIENT TEMPERATURE INPUT PROCESS . 116 DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR ............................................................ 116 COMPONENT INSPECTION ............................. 118 In-vehicle Sensor Circuit ....................................... 119 COMPONENT DESCRIPTION .......................... 119 DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR ............................................................ 120 COMPONENT INSPECTION ............................. 121 Sunload Sensor Circuit ......................................... 122 ATC-2 2003 FX COMPONENT DESCRIPTION ......................... 122 SUNLOAD INPUT PROCESS .......................... 122 DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR ........................................................... 122 COMPONENT INSPECTION ............................ 124 Intake Sensor Circuit ............................................ 125 COMPONENT DESCRIPTION ......................... 125 DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR .................................................................. 125 COMPONENT INSPECTION ............................ 126 CONTROLLER ....................................................... 127 Removal and Installation of A/C and AV Switch ... 127 REMOVAL ......................................................... 127 INSTALLATION ................................................. 127 AUTO AMP ............................................................. 128 Removal and Installation of Unified Meter and A/C Amp. ..................................................................... 128 REMOVAL ......................................................... 128 INSTALLATION ................................................. 128 AMBIENT SENSOR ................................................ 129 Removal and Installation ...................................... 129 REMOVAL ......................................................... 129 INSTALLATION ................................................. 129 IN-VEHICLE SENSOR ............................................ 130 Removal and Installation ...................................... 130 REMOVAL ......................................................... 130 INSTALLATION ................................................. 130 SUNLOAD SENSOR .............................................. 131 Removal and Installation ...................................... 131 REMOVAL ......................................................... 131 INSTALLATION ................................................. 131 INTAKE SENSOR ................................................... 132 Removal and Installation ...................................... 132 REMOVAL ......................................................... 132 INSTALLATION ................................................. 133 BLOWER UNIT ....................................................... 134 Removal and Installation ...................................... 134 REMOVAL ......................................................... 134 INSTALLATION ................................................. 134 Disassembly and Assembly ................................. 135 BLOWER MOTOR .................................................. 136 Removal and Installation ...................................... 136 REMOVAL ......................................................... 136 INSTALLATION ................................................. 136 INTAKE DOOR MOTOR ......................................... 137 Removal and Installation ...................................... 137 REMOVAL ......................................................... 137 INSTALLATION ................................................. 137 HEATER & COOLING UNIT ASSEMBLY .............. 138 Removal and Installation ...................................... 138 REMOVAL ......................................................... 138 INSTALLATION ................................................. 139 Disassembly and Assembly ................................. 140 MODE DOOR MOTOR ........................................... 142 Removal and Installation ...................................... 142 REMOVAL ......................................................... 142 INSTALLATION ................................................. 142 Revision; 2004 April AIR MIX DOOR MOTOR ......................................... 143 Removal and Installation ...................................... 143 REMOVAL ......................................................... 143 INSTALLATION ................................................. 143 HEATER CORE ....................................................... 144 Removal and Installation ...................................... 144 REMOVAL ......................................................... 144 INSTALLATION ................................................. 144 DUCTS AND GRILLES ........................................... 145 Removal and Installation ...................................... 145 REMOVAL ......................................................... 145 INSTALLATION ................................................. 148 REFRIGERANT LINES ........................................... 149 HFC-134a (R-134a) Service Procedure ............... 149 SETTING OF SERVICE TOOLS AND EQUIPMENT ................................................................ 149 Components ......................................................... 151 VK45DE ............................................................. 151 VQ35DE ............................................................ 152 Removal and Installation of Compressor .............. 152 REMOVAL ......................................................... 152 INSTALLATION ................................................. 154 Removal and Installation of Compressor Clutch . 155 REMOVAL ......................................................... 155 INSTALLATION ................................................. 157 Removal and Installation of Low-pressure Flexible Hose ..................................................................... 159 REMOVAL ......................................................... 159 INSTALLATION ................................................. 160 Removal and Installation of High-pressure Flexible Hose ..................................................................... 160 REMOVAL ......................................................... 160 INSTALLATION ................................................. 161 Removal and Installation of Low-pressure Pipe 1 (Engine Compartment) ......................................... 161 REMOVAL ......................................................... 161 INSTALLATION ................................................. 162 Removal and Installation of High-pressure Pipe 1 and 2 (Engine Compartment) ............................... 162 REMOVAL ......................................................... 162 INSTALLATION ................................................. 163 Removal and Installation of Low-pressure Pipe 2 and High-pressure Pipe 3 ..................................... 163 REMOVAL ......................................................... 163 INSTALLATION ................................................. 164 Removal and Installation of Liquid Tank ............... 165 REMOVAL ......................................................... 165 INSTALLATION ................................................. 165 Removal and Installation of Condenser ................ 166 REMOVAL ......................................................... 166 INSTALLATION ................................................. 166 Removal and Installation of Refrigerant Pressure Sensor .................................................................. 167 REMOVAL ......................................................... 167 INSTALLATION ................................................. 167 Removal and Installation of Evaporator ................ 167 REMOVAL ......................................................... 167 INSTALLATION ................................................. 167 Removal and Installation of Expansion Valve ....... 169 ATC-3 2003 FX A B C D E F G H I ATC K L M REMOVAL ......................................................... 169 INSTALLATION .................................................. 169 Checking for Refrigerant Leaks ............................ 170 Checking System for Leaks Using the Fluorescent Leak Detector ....................................................... 170 Dye Injection ......................................................... 170 Electronic Refrigerant Leak Detector .................... 171 PRECAUTIONS FOR HANDLING LEAK Revision; 2004 April DETECTOR ....................................................... 171 CHECKING PROCEDURE ................................ 172 SERVICE DATA AND SPECIFICATIONS (SDS) .... 174 Compressor .......................................................... 174 Lubricant ............................................................... 174 Refrigerant ............................................................ 174 Engine Idling Speed .............................................. 174 Belt Tension .......................................................... 174 ATC-4 2003 FX PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A AJS001BM 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 the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions for Working with HFC-134a (R-134a) B C D E F G AJS0013V WARNING: ● CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants H are mixed and compressor malfunction is likely to occur, refer to “CONTAMINATED REFRIGERANT” below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500-INF) and Refrigerant I Identifier. ● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. ATC ● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: – When removing refrigerant components from a vehicle, immediately cap (seal) the component to K minimize the entry of moisture from the atmosphere. – When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possi- L ble to minimize the entry of moisture into system. – Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. M – Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting requirements of SAE J2210 [HFC-134a (R-134a) recycling equipment], or J2209 [HFC-134a (R134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. – Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result. CONTAMINATED REFRIGERANT If a refrigerant other than pure HFC-134a ( R-134a) is identified in a vehicle, your options are: ● Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into the atmosphere. ● Explain that recovery of the contaminated refrigerant could damage your service equipment and refrigerant supply. ● Suggest the customer return the vehicle to the location of previous service where the contamination may have occurred. Revision; 2004 April ATC-5 2003 FX PRECAUTIONS ● ● 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. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Customer Affairs for further assistance. Revision; 2004 April ATC-6 2003 FX PRECAUTIONS General Refrigerant Precautions AJS0013W WARNING: ● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. ● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. ● Do not store or heat refrigerant containers above 52°C (125°F). ● Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water. ● Do not intentionally drop, puncture, or incinerate refrigerant containers. ● Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. ● Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. ● Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. Lubricant Precautions ● ● – – – ● ● AJS0013X A B C D E F G Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following H handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. I When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. ATC Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from the A/C system, using certified service equipment meeting require- K ments of SAE J2210 [HFC-134a (R-134a) recycling equipment], or J2209 [HFC-134a (R-134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. L Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts. Damage may result. M Revision; 2004 April ATC-7 2003 FX PRECAUTIONS Precautions for Refrigerant Connection AJS0013Y A new type refrigerant connection has been introduced to all refrigerant lines except the following location. ● Expansion valve to evaporator ● Refrigerant pressure sensor to condenser ABOUT ONE-TOUCH JOINT Description One-touch joints are pipe joints which do not require tools during piping connection. Unlike conventional connection methods using union nuts and flanges, controlling tightening torque at connection point is not necessary. ● When removing a pipe joint, use a disconnector. COMPONENT PARTS ● ● RJIA0970E FUNCTIONS OF COMPONENT PARTS ● Retains O-rings. ● Retains garter spring in cage. Pipe (Male side) Garter spring Anchors female side piping. Indicator ring When connection is made properly, this is ejected from male-side piping. (This part is no longer necessary after connection.) O-ring Seals connection point. (Not reusable) ● Seals connection by compressing O-rings. ● Anchors piping connection using flare and garter spring. Pipe (Female side) NOTE: ● Garter spring cannot be removed from cage of male-side piping. ● Indicator ring remains near piping connection point, however, this is not a malfunction. (This is to check piping connection during factory assembly.) Revision; 2004 April ATC-8 2003 FX PRECAUTIONS REMOVAL A B C D E F SJIA0106E 1. 2. 3. Clean piping connection point, and set a disconnector. Slide disconnector in axial direction of piping, and stretch garter spring with tapered point of disconnector. Slide disconnector farther so that inside diameter of garter spring becomes larger than outside diameter of female-side piping flare. Then male-side piping can be disconnected. INSTALLATION G H I ATC K L M SJIA0107E 1. 2. 3. Clean piping connection points, and insert male-side piping into female-side piping. Push inserted male-side piping harder so that female-side piping flare stretches garter spring. If inside diameter of garter spring becomes larger than outside diameter of female-side piping flare, garter spring seats on flare. Then, it fits in between male-side piping cage and female-side piping flare to anchor piping connection point. NOTICE: When garter spring seats on flare, and fits in between male-side piping cage and female-side piping flare, it clicks. CAUTION: ● Female-side piping connection point is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert it in axial direction. ● Insert piping securely until a click is heard. Revision; 2004 April ATC-9 2003 FX PRECAUTIONS After piping connection is completed, pull male-side piping by hand to make sure connection does not come loose. NOTE: One-touch joint connection is used in points below. ● Low-pressure pipe 1 to low-pressure pipe 2 (O-ring size: 16) ● High-pressure pipe 1 to high-pressure pipe 2 (O-ring size: 8) ● High-pressure pipe 2 to high-pressure pipe 3 (O-ring size: 8) ● Low-pressure flexible hose to low-pressure pipe 1 (O-ring size: 16) ● Condenser to high-pressure flexible hose (O-ring size: 12) ● Condenser to high-pressure pipe 1 (O-ring size: 8) ● FEATURES OF NEW TYPE REFRIGERANT CONNECTION ● ● The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance 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. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. SHA815E Revision; 2004 April ATC-10 2003 FX PRECAUTIONS O-RING AND REFRIGERANT CONNECTION VK45DE A B C D E F G H I RJIA1954E VQ35DE ATC K L M RJIA1955E Revision; 2004 April ATC-11 2003 FX PRECAUTIONS CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection. O-Ring Part Numbers and Specifications Connection type New Piping connection point Part number QTY O-ring size Low-pressure pipe 1 to low-pressure pipe 2 (One-touch joint) 92473 N8221 2 16 Low-pressure pipe 2 to expansion valve 92473 N8210 1 16 High-pressure pipe 1 to high-pressure pipe 2 (One-touch joint) 92471 N8221 2 8 High-pressure pipe 3 to expansion valve 92471 N8210 1 8 High-pressure pipe 2 to high-pressure pipe 3 (One-touch joint) 92471 N8221 2 8 Condenser to high-pressure flexible hose (One-touch joint) 92472 N8221 2 12 Condenser to high-pressure pipe 1 (One-touch joint) 92471 N8221 2 8 Low-pressure flexible hose to low-pressure pipe 1 (One-touch joint) 92473 N8221 2 16 Compressor to low-pressure flexible hose 92474 N8210 1 19 Compressor to high-pressure flexible hose 92472 N8210 1 12 Inlet Liquid tank to condenser pipe Outlet Refrigerant pressure sensor to condenser Former Expansion valve to evaporator 1 92471 N8210 1 8 J2476 89956 1 10 Inlet 92475 71L00 1 12 Outlet 92475 72L00 1 16 WARNING: Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: When replacing or cleaning refrigerant cycle components, observe the following. ● When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low-pressure chamber. ● When connecting tubes, always use a torque wrench and a back-up wrench. ● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. ● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operation. Do not remove the seal caps of pipes and other components until just before required for connection. ● Allow components stored in cool areas to warm to working area temperature before removing seal caps. This prevents condensation from forming inside A/C components. ● Thoroughly remove moisture from the refrigeration system before charging the refrigerant. ● Always replace used O-rings. ● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0 ● O-ring must be closely attached to dented portion of tube. ● When replacing the O-ring, be careful not to damage O-ring and tube. ● Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. Revision; 2004 April ATC-12 2003 FX PRECAUTIONS ● After connecting line, perform leak test and make sure that there is no leakage from connections. When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. A B C D E F G RHA861F Precautions for Servicing Compressor ● ● ● ● ● ● AJS0013Z H Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in CompresI sor” exactly. Refer to ATC-27, "Maintenance of Lubricant Quantity in Compressor" . 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. ATC After compressor service operation, turn the compressor shaft by hand more than five 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 one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for usual K operation. Precautions for Service Equipment AJS00140 RECOVERY/RECYCLING EQUIPMENT Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine. ELECTRONIC LEAK DETECTOR Be certain to follow the manufacturer′s instructions for tester operation and tester maintenance. Revision; 2004 April ATC-13 2003 FX L M PRECAUTIONS 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 placed near the hoseto-pump connection, as follows. ● Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. ● 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. ● 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. RHA270DA MANIFOLD GAUGE SET Be certain that the gauge face indicates HFC-134a (R-134a or 134a). Be 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) and specified lubricants. SHA533D 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. RHA272D Revision; 2004 April ATC-14 2003 FX PRECAUTIONS SERVICE COUPLERS A Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut-off valve rotation B A/C service valve Clockwise Open Counterclockwise Close C RHA273D D REFRIGERANT WEIGHT SCALE Verify that no refrigerant other than HFC-134a (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. E F G RHA274D H CALIBRATING ACR4 WEIGHT SCALE Calibrate the scale every three months. I To calibrate the weight scale on the ACR4 (J-39500-INF): 1. Press Shift/Reset and Enter at the same time. 2. Press 8787 . “A1 ” will be displayed. ATC 3. Remove all weight from the scale. 4. Press 0 , then press Enter . “0.00 ” will be displayed and change to “A2 ”. 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb.) on the center K of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb. = 10.00, 10.5 lb. = 10.50) 7. Press Enter — the display returns to the vacuum mode. L 8. Press Shift/Reset and Enter at the same time. 9. Press 6 — the known weight on the scale is displayed. 10. Remove the known weight from the scale. “0.00 ” will be displayed. M 11. Press Shift/Reset to return the ACR4 to the program mode. 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. Revision; 2004 April ATC-15 2003 FX PRECAUTIONS Precautions for Leak Detection Dye ● ● ● ● ● ● ● ● ● ● ● AJS00141 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. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye. 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 to (J41995) pin-point refrigerant leaks. For your safety and your customer′s satisfaction, read and follow all manufacture′s operating instructions and precautions prior to performing the work. 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). Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. 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. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system. 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 system or CFC-12 (R-12) leak detector dye in HFC-134a (R-134a) A/C systems or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs. IDENTIFICATION NOTE: Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label. IDENTIFICATION LABEL FOR VEHICLE Vehicles with factory installed fluorescent dye have this identification label on the front side of hood. SHA436FA Wiring Diagrams and Trouble Diagnosis AJS00142 When you read wiring diagrams, refer to the following: ● GI-15, "How to Read Wiring Diagrams" in GI section. ● PG-4, "Wiring Diagram - POWER -" in PG section. When you perform trouble diagnosis, refer to the following: ● GI-11, "How to Follow Trouble Diagnoses" in GI section. ● GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident" in GI section. Revision; 2004 April ATC-16 2003 FX PREPARATION PREPARATION Special Service Tools PFP:00002 A AJS00143 The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here. B Tool number (Kent-Moore No.) Tool name Description C KV99106100 (J-41260) Clutch disc wrench D E S-NT232 Removing shaft nut and clutch disc F G RJIA0194E KV99232340 (J-38874) or KV992T0001 (-) Clutch disc puller H Removing clutch disc I S-NT376 KV99106200 (J-41261) Pulley installer ATC Installing pulley K S-NT235 92530 89908 (for high-pressure pipe 1) (-) 92530 89912 (for high-pressure flexible hose) (-) 92530 89916 (for low-pressure pipe 1 and low-pressure flexible hose) (-) Disconnector tool set (J-45815) Revision; 2004 April L M Disconnect one-touch joint connection SJIA0285E ATC-17 2003 FX PREPARATION HFC-134a (R-134a) Service Tools and Equipment AJS00144 Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/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 malfunction will result. Tool number (Kent-Moore No.) Tool name Description Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size HFC-134a (R-134a) refrigerant ● Large container 1/2″ -16 ACME S-NT196 Type: Poly alkylene glycol oil (PAG), type S (DH-PS) Application: HFC-134a (R-134a) swash plate compressors (Nissan only) Lubricity: 40 m (1.4 US fl oz., 1.4 Imp fl oz.) KLH00-PAGS0 (-) Nissan A/C System Oil Type S (DH-PS) S-NT197 (J-39500-INF) Recovery/Recycling/ Recharging equipment (ACR4) Function: Refrigerant Recovery and Recycling and Recharging RJIA0195E Power supply: (J-41995) Electrical leak detector ● DC 12V (Cigarette lighter) AHA281A Revision; 2004 April ATC-18 2003 FX PREPARATION Tool number (Kent-Moore No.) Tool name A Description (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) Refrigerant dye injector (J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) (J-43872) Refrigerant dye cleaner B C Power supply: DC 12V (Battery terminal) D ZHA200H E Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system Includes: UV lamp and UV safety goggles (J-42220) UV lamp and UV safety goggles SHA438F Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.) (J-41447) HFC-134a (R-134a) Fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) F G H I SHA439F ATC (J-41459) HFC-134a (R-134a) Dye injector Use with J-41447, 1/4 ounce bottle For injecting 1/4 ounce of fluorescent leak detection dye into A/C system K SHA440F L (J-43872) Refrigerant dye cleaner M For cleaning dye spills SHA441F Identification: (J-39183) Manifold gauge set (with hoses and couplers) ● ● The gauge face indicates HFC-134a (R-134a). Fitting size: Thread size 1/2″ -16 ACME RJIA0196E Revision; 2004 April ATC-19 2003 FX PREPARATION Tool number (Kent-Moore No.) Tool name Description Service hoses Hose color: High-pressure side hose (J-39501-72) ● Low hose: Blue with black stripe ● High hose: Red with black stripe ● Low-pressure side hose (J-39502-72) ● ● Utility hose (J-39476-72) Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: ● S-NT201 ● 1/2″ -16 ACME Service couplers ● ● Hose fitting to service hose: High-pressure side coupler (J-39500-20) ● Low-pressure side coupler (J-39500-24) M14 x 1.5 fitting is optional or permanently attached. S-NT202 For measuring of refrigerant Fitting size: Thread size (J-39650) Refrigerant weight scale ● 1/2″ -16 ACME S-NT200 Capacity: (J-39649) Vacuum pump (Including the isolator valve) ● Air displacement: 4 CFM ● Micron rating: 20 microns ● Oil capacity: 482 g (17 oz.) Fitting size: Thread size ● S-NT203 1/2″ -16 ACME Commercial Service Tools AJS00145 Tool name Description Refrigerant identifier equipment Checking for refrigerant purity and system contamination RJIA0197E Power tool Loosening bolts and nuts PBIC0190E Revision; 2004 April ATC-20 2003 FX REFRIGERATION SYSTEM REFRIGERATION SYSTEM Refrigerant Cycle PFP:KA990 A AJS00146 REFRIGERANT FLOW The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case. FREEZE PROTECTION B C Under usual operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore, temperature is controlled by the compressor to prevent freeze up. Refrigerant System Protection AJS00147 D REFRIGERANT PRESSURE SENSOR The refrigerant system is protected against excessively high- or low-pressure 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 the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm2 , 398 psi), or below about 134 kPa (1.4 kg/cm2 , 20 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 unusual level [more than 3,727 kPa (38 kg/cm2 , 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. E F G H I ATC K L M RJIA0849E Revision; 2004 April ATC-21 2003 FX REFRIGERATION SYSTEM V-6 Variable Displacement Compressor AJS001BE GENERAL INFORMATION 1. 2. 3. 4. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable compressor do not drop too far below 5°C (41°F) when: Evaporator intake air temperature is less than 20°C (68°F). Engine is running at speeds less than 1,500 rpm. This is because the V-6 compressor provides a means of “capacity” control. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the wobble (swash) plate has changed and is not a malfunction. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor. Revision; 2004 April ATC-22 2003 FX REFRIGERATION SYSTEM DESCRIPTION General A The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the wobble (swash) plate allows the piston′s stroke to change so that refrigerant discharge can be continuously changed from 14.5 to 184 cm3 (0.885 to 11.228 cu. in). B C D E F G H I ATC K L M RJIA1260E Revision; 2004 April ATC-23 2003 FX REFRIGERATION SYSTEM Operation 1. – • • • – • • • – 2. Operation Control Valve By changing high-pressure valve lift amount, built-in compressor control valve executes the following: Controls high-pressure valve discharge amount. Changes crankcase pressure in compressor. Changes angle of wobble (swash) plate. Amount of high-pressure valve loft is determined by factors below. Low-pressure applied to diaphragm Spring load of set spring Balance of magnetic force generated in magnet coil Electronic control valve (ECV) magnet coil receives electric signal (duty control) from auto amplifier. Then, magnetic force generated by electric current is changed to control high-pressure valve lift amount. Maximum Cooling High-pressure valve is closed by magnetic force generated by electric signal sent from automatic amplifier. At this time, cylinder moves full stroke due to pressure balance between inside crankcase (Pc) and suction line (Ps). Under this condition, the wobble (swash) plate is set to the maximum stroke position. RJIA0851E 3. – – Capacity Control When no electric signal is sent from automatic amplifier (current: OFF), high-pressure valve is opened by spring force. Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high-pressure enters the crankcase. The force acts around the journal pin near the wobble (swash) plate, and is generated by the pressure difference before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the wobble (swash) plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure Revision; 2004 April ATC-24 2003 FX REFRIGERATION SYSTEM increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the wobble (swash) plate. A B C D E F RJIA0852E G H I ATC K L M Revision; 2004 April ATC-25 2003 FX REFRIGERATION SYSTEM Component Layout AJS00148 RJIA1956E Revision; 2004 April ATC-26 2003 FX LUBRICANT LUBRICANT Maintenance of Lubricant Quantity in Compressor PFP:KLG00 A AJS00149 The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large gas leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: ● Lack of lubricant: May lead to a seized compressor ● Excessive lubricant: Inadequate cooling (thermal exchange interference) B C LUBRICANT Name Part number D : NISSAN A/C System Oil Type S : KLH00-PAGS0 E LUBRICANT RETURN OPERATION Adjust the lubricant quantity according to the test group shown below. 1. CHECK LUBRICANT RETURN OPERATION F Can lubricant return operation be performed? ● A/C system works properly. ● There is no evidence of a large amount of lubricant leakage. YES or NO YES >> GO TO 2. NO >> GO TO 3. G H 2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS: I 1. Start engine, and set the following conditions: – Test condition Engine speed: Idling to 1,200 rpm A/C switch: ON Blower speed: Max. position Temp. control: Optional [Set so that intake air temperature is 25 to 30°C (77 to 86°F).] Intake position: Recirculation (REC) 2. Perform lubricant return operation for about 10 minutes. 3. Stop engine. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation. ATC K L M >> GO TO 3. 3. CHECK COMPRESSOR Should the compressor be replaced? YES >> GO TO ATC-29, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" . NO >> GO TO 4. Revision; 2004 April ATC-27 2003 FX LUBRICANT 4. CHECK ANY PART Is there any part to be replaced? (Evaporator, condenser, liquid tank or in case there is evidence of a large amount of lubricant leakage.) YES >> GO TO ATC-28, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR" . NO >> Carry out the A/C performance test. LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added Lubricant to be added to system Part replaced m Amount of lubricant (US fl oz., Imp fl oz.) Remarks Evaporator 75 (2.5, 2.6) - Condenser 35 (1.2, 1.2) - Liquid tank 10 (0.3, 0.4) - 30 (1.0, 1.1) Large leak - Small leak *1 In case of refrigerant leak *1: If refrigerant leak is small, no addition of lubricant is needed. Revision; 2004 April ATC-28 2003 FX LUBRICANT LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines. Connect ACR4 to vehicle. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. If NG, refer to ATC-5, "CONTAMINATED REFRIGERANT" . Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. If NG, refer to ATC5, "CONTAMINATED REFRIGERANT" . Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling equipment. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount of lubricant drained. Drain the lubricant from the new compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor through the suction port opening. If the liquid tank also needs to be replaced, add an additional 5 m (0.2 US fl oz., 0.2 Imp fl oz.) of lubricant at this time. Do not add this 5 m (0.2 US fl oz., 0.2 Imp fl oz.) of lubricant if only replacing the compressor. A B C D E F G H I ATC K L M RHA065DD Revision; 2004 April ATC-29 2003 FX AIR CONDITIONER CONTROL AIR CONDITIONER CONTROL Description of Air Conditioner LAN Control System PFP:27500 AJS0014A The LAN (Local Area Network) system consists of unified meter and A/C amp., mode door motor, air mix door motor and intake door motor. A configuration of these components is shown in the diagram below. SJIA0262E System Construction AJS0014B A small network is constructed between the unified meter and A/C amp., air mix door motor, mode door motor and intake door motor. The unified meter and A/C amp. and motors are connected by data transmission lines and motor power supply lines. The LAN network is built through the ground circuits of the each door motor. Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted through the data transmission lines connecting the unified meter and A/C amp. and each door motor. The following functions are contained in LCUs built into the air mix door motor, mode door motor and intake door motor. ● Address ● Motor opening angle signals ● Data transmission ● Motor stop and drive decision ● Opening angle sensor (PBR function) ● Comparison ● Decision (Unified meter and A/C amp. indicated value and motor opening angle comparison) RJIA1747E OPERATION The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp. sends mode door, air mix door and intake door opening angle data to the mode door motor LCU, air mix door motor LCU and intake door motor LCU. The mode door motor, air mix door motor and intake door motor read their respective signals according to the address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/COLD, DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection data is returned to the unified meter and A/C amp. Revision; 2004 April ATC-30 2003 FX AIR CONDITIONER CONTROL A B C RJIA1748E D TRANSMISSION DATA AND TRANSMISSION ORDER Unified meter and A/C amp. data is transmitted consecutively to each of the door motors following the form shown in figure below. E Start: Initial compulsory signal sent to each of the door motors. Address: Data sent from the unified meter and A/C amp. is selected according to data-based decisions made by the air mix door motor, mode door motor and intake door motor. If the addresses are identical, the opening angle data and error check signals are received by the door motor F LCUs. The LCUs then make the appropriate error decision. If the opening angle data is usual, door control begins. If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon G the corrected opening angle data. Opening angle: Data that shows the indicated door opening angle of each door motor. H Error check: Procedure by which sent and received data is checked for errors. Error data is then compiled. The error check prevents corrupted data from being used by the air mix door motor, mode door motor and intake door motor. Error data can be related to the following symptoms. I ● Unusual electrical frequency ● Poor electrical connections ● Signal leakage from transmission lines ATC ● Signal level fluctuation Stop signal: At the end of each transmission, a stop operation, in-operation, or internal error message is delivered to the K unified meter and A/C amp. This completes one data transmission and control cycle. L M RJIA1749E Revision; 2004 April ATC-31 2003 FX AIR CONDITIONER CONTROL AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) The air mix door is 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. FAN SPEED CONTROL Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position. When pressing AUTO switch, the blower motor starts to gradually increase air flow volume. When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing. INTAKE DOOR CONTROL The intake doors are automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor. OUTLET DOOR CONTROL The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload. MAGNET CLUTCH CONTROL RJIA1957E When A/C switch or DEF switch is pressed, unified meter and A/C amp. 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, 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. When sending compressor ON signal to IPDM E/R via CAN communication line, ECM simultaneously sends compressor feedback signal to unified meter and A/C amp. via CAN communication line. Unified meter and A/C amp, then, uses input compressor feedback signal to control air inlet. SELF-DIAGNOSTIC SYSTEM The self-diagnostic system is built into the unified meter and A/C amp. to quickly locate the cause of symptoms. Revision; 2004 April ATC-32 2003 FX AIR CONDITIONER CONTROL Description of Control System AJS0014C The control system consists of input sensors, switches, the unified meter and A/C amp. (microcomputer) and outputs. The relationship of these components is shown in the figure below: A B C D E F G H I ATC K RJIA1958E Control Operation AJS0014D L M RJIA1959E Revision; 2004 April ATC-33 2003 FX AIR CONDITIONER CONTROL DISPLAY SCREEN Displays the operational status of the system. AUTO SWITCH ● ● The compressor, intake doors, 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. When pressing AUTO switch, air inlet, air outlet, fan speed, and discharge air temperature are automatically controlled. TEMPERATURE SWITCH (POTENTIO TEMPERATURE CONTROL) (DRIVER SIDE) Increases or decreases the set temperature. TEMPERATURE SWITCH (POTENTIO TEMPERATURE CONTROL) (PASSENGER SIDE) ● ● Increases or decreases the set temperature. When the temperature switch is pressed, the dual switch indicator will automatically illuminate. RECIRCULATION (REC) SWITCH ● ● ● ● When REC switch is ON, REC switch indicator turns ON, and air inlet is fixed to REC. When REC switch is ON and is pressed for approximately 1.5 seconds or longer, REC and FRE switch indicators blink twice. Then, automatic control mode is entered. Inlet status is displayed even during automatically controlled. When FRE switch is turned ON, or when compressor is turned from ON to OFF, REC switch is automatically turned OFF (fixed to FRE mode). REC mode can be re-entered by pressing REC switch again. REC switch is not operated when DEF switch is turned ON, or at the D/F position. FRESH (FRE) SWITCH ● ● ● When FRE switch is ON, FRE switch indicator turns ON, and air inlet is fixed to FRE. When FRE switch is ON and is pressed for approximately 1.5 seconds or longer, REC and FRE switch indicators blink twice. Then, automatic control mode is entered. Inlet status is displayed even during automatically controlled. When REC switch is turned ON, FRE switch is automatically turned OFF (fixed to REC mode). FRE mode can be re-entered by pressing FRE switch again. DEFROSTER (DEF) SWITCH Positions the air outlet doors to the defrost position. Also positions the intake doors to the fresh air position. REAR WINDOW DEFOGGER SWITCH When illumination is ON, rear window is defogged. OFF SWITCH The compressor and blower are OFF, the intake doors are set to the fresh 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 Controls the air discharge outlets. FAN SWITCH Manually control the blower speed. Seven speeds are available for manual control (as shown on the display screen). DUAL SWITCH (WITH LEFT AND RIGHT VENTILATION TEMPERATURE SEPARATELY CONTROL SYSTEM) ● ● When the DUAL switch indicator is not illuminated and the DUAL switch is pressed, the driver-side setting temperature and passenger-side setting temperature can each be set independently. When the DUAL switch indicator is illuminated and the DUAL switch is pressed, the driver-side setting temperature is applied to both sides. Revision; 2004 April ATC-34 2003 FX AIR CONDITIONER CONTROL Fail-safe Function ● – – – – – AJS0014E If a communication error exists between unified meter and A/C amp. and A/C and Audio controller for 30 seconds or longer, air conditioner is controlled under following conditions: Compressor: ON Air outlet: AUTO Air inlet: FRE (Fresh) Blower fan speed: AUTO Set temperature: Setting before communication error occurs. A B C D E F G H I ATC K L M Revision; 2004 April ATC-35 2003 FX AIR CONDITIONER CONTROL Discharge Air Flow AJS0014F RJIA1960E Revision; 2004 April ATC-36 2003 FX AIR CONDITIONER CONTROL System Description AJS0014G A SWITCHES AND THEIR CONTROL FUNCTION B C D E F G H I RJIA1961E ATC K L M RJIA1962E Revision; 2004 April ATC-37 2003 FX AIR CONDITIONER CONTROL CAN Communication System Description AJS0014H CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit AJS001C4 Body type Wagon Axle Engine 2WD AWD VQ35DE VQ35DE/VK45DE Transmission A/T Brake control VDC Navigation system × × Low tire pressure warning system × × ICC system × × Intelligent Key system × × × Automatic drive positioner × × × CAN communication unit ECM × × × × × × TCM × × × × × × Display unit × × × × Display control unit × Low tire pressure warning control unit × × × × AWD control unit × × ICC unit × × Intelligent Key unit × × Data link connector × × × × × × BCM × × × × × × Steering angle sensor × × × × × × Unified meter and A/C amp. × × × × × × × × × × × × × × × × × × × × × ICC sensor ABS actuator and electric unit (control unit) Driver seat control unit IPDM E/R CAN communication type × ATC-39, "TYPE 1/ TYPE2" ATC-42, "TYPE 3" × × ATC-45, "TYPE 4/ TYPE5" ATC-48, "TYPE 6" ×: Applicable Revision; 2004 April ATC-38 2003 FX AIR CONDITIONER CONTROL TYPE 1/TYPE2 System Diagram ● A Type1 B C D E F SKIA6171E ● Type2 G H I ATC K L SKIA6172E Input/output Signal Chart T: Transmit R: Receive ECM TCM Display unit Engine speed signal T R R Engine status signal T Engine coolant temperature signal T R A/T self-diagnosis signal R T Accelerator pedal position signal T R Closed throttle position signal T R Wide open throttle position signal T R Signals Revision; 2004 April BCM Steering angle sensor Unified meter and A/ C amp. ABS actuator and electric unit (control unit) R R Driver seat control unit IPDM E/R R R R ATC-39 2003 FX M AIR CONDITIONER CONTROL Signals Battery voltage signal ECM TCM T R Display unit BCM Steering angle sensor Unified meter and A/ C amp. ABS actuator and electric unit (control unit) Driver seat control unit Key switch signal T R Ignition switch signal T R P range signal T Stop lamp switch signal R R IPDM E/R R R T ABS operation signal R T TCS operation signal R T VDC operation signal R T Fuel consumption monitor signal T Input shaft revolution signal R T R R Output shaft revolution signal R T A/C switch signal R A/C compressor request signal T R A/C relay status signal R T A/C compressor feedback signal T Blower fan motor switch signal R T R T A/C control signal T R R T Cooling fan speed request signal T R Cooling fan speed signal R T Position light request signal R Low beam request signal Low beam status signal R R T R R T High beam request signal High beam status signal T T R R R T Front fog light request signal T R Day time running light request signal T R Turn LED burnout status signal R T R Vehicle speed signal R R R Sleep wake up signal Door switch signal R T R T R T R R R R R T R Turn indicator signal T R Key fob ID signal T R Key fob door unlock signal T R R Oil pressure switch signal Buzzer output signal Fuel level sensor signal Fuel level low warning signal Revision; 2004 April R T T R T R T R ATC-40 T 2003 FX AIR CONDITIONER CONTROL Signals ECM TCM ASCD operation signal T R ASCD OD cancel request T R Display unit BCM Steering angle sensor Unified meter and A/ C amp. ABS actuator and electric unit (control unit) A Driver seat control unit IPDM E/R C Front wiper request signal T R Front wiper stop position signal R T Rear window defogger switch signal T R R T Hood switch signal R T Theft warning horn request signal T R Horn chirp signal T R Rear window defogger control signal R R Steering angle sensor signal T R T VDC OFF indicator lamp signal R T SLIP indicator lamp signal R T Brake warning lamp signal R T T R E F G H R A/T CHECK indicator lamp signal T R A/T position indicator lamp signal T R A/T shift schedule change demand signal R Manual mode signal R T Not manual mode signal R T Manual mode shift up signal R T Manual mode shift down signal R T Manual mode indicator signal T R Distance to empty signal D R ABS warning lamp signal System setting signal B I T R Hand brake switch ATC K L T R T M Revision; 2004 April ATC-41 2003 FX AIR CONDITIONER CONTROL TYPE 3 System Diagram ● Type3 SKIA6173E Input/output Signal Chart T: Transmit R: Receive Low tire pressure warning control unit ECM TCM Display control unit Engine speed signal T R R Engine status signal T Engine coolant temperature signal T R A/T self-diagnosis signal R T Accelerator pedal position signal T R R Closed throttle position signal T R R Wide open throttle position signal T R Battery voltage signal T R Signals ICC unit Intelligent Key unit BCM R Steeri ng angle sensor Unified meter and A/C amp. R ICC sensor ABS actuator and electric unit (control unit) Driver seat control unit R R R R R Key switch signal T R Ignition switch signal T R P range signal T Stop lamp switch signal R R R R R T ABS operation signal R R T TCS operation signal R R T VDC operation signal R R T Fuel consumption monitor signal T Revision; 2004 April IPDM E/R R R ATC-42 2003 FX AIR CONDITIONER CONTROL Signals ECM TCM Display control unit Low tire pressure warning control unit ICC unit Intelligent Key unit BCM Steeri ng angle sensor Unified meter and A/C amp. ICC sensor ABS actuator and electric unit (control unit) A Driver seat control unit IPDM E/R C Input shaft revolution signal R T R Output shaft revolution signal R T R A/C switch signal R A/C compressor request signal T R A/C relay status signal R T A/C compressor feedback signal T Blower fan motor switch signal R D T Cooling fan speed signal R Position light request signal R T R R T H T T R R T T High beam request signal T R T Front fog light request signal T Day time running light request signal T R Turn LED burnout status signal R T Vehicle speed signal R R R Sleep wake up signal L M T R T T R R R R R R R T R R T R Turn indicator signal T R Key fob ID signal T R Key fob door unlock signal T R Door switch signal R R Oil pressure switch signal Buzzer output signal T T Revision; 2004 April ATC-43 K R R R ATC R R R I R R R F G T Low beam request signal High beam status signal E R A/C control signal Low beam status signal B T T R T R R R 2003 FX AIR CONDITIONER CONTROL Signals Fuel level sensor signal ECM ICC unit Intelligent Key unit BCM Steeri ng angle sensor R Fuel level low warning signal ICC operation signal TCM Display control unit Low tire pressure warning control unit Unified meter and A/C amp. ICC sensor ABS actuator and electric unit (control unit) Driver seat control unit IPDM E/R T R T R T Front wiper request signal T R Front wiper stop position signal R T Rear window defogger switch signal T R R T Hood switch signal R T Theft warning horn request signal T R Horn chirp signal T R Rear window defogger control signal R R R Steering angle sensor signal T Tire pressure signal Tire pressure data signal T R R R T ABS warning lamp signal R R T VDC OFF indicator lamp signal R R T SLIP indicator lamp signal R T Brake warning lamp signal R T System setting signal T Distance to empty signal R R R T Hand brake switch signal R Door lock/unlock request signal T R Door lock/unlock status signal R T Starter permission signal T R Back door open request signal T R Power window open request signal T R Alarm request signal T R Key warning signal T ICC sensor signal R ICC warning lamp signal T Revision; 2004 April ATC-44 T R T R 2003 FX AIR CONDITIONER CONTROL Signals ECM TCM ICC system display signal Display control unit Low tire pressure warning control unit ICC unit Intelligent Key unit BCM T Steeri ng angle sensor Unified meter and A/C amp. A Driver seat control unit IPDM E/R T Steering switch signal T ASCD operation signal T R ASCD OD cancel request T R ICC OD cancel request R R C R R R R E F T A/T CHECK indicator lamp signal T A/T position indicator lamp signal T A/T shift schedule change demand signal R Manual mode signal R T Not manual mode signal R T Manual mode shift up signal R T Manual mode shift down signal R T Manual mode indicator signal T R G R H T R I ATC R T K R L TYPE 4/TYPE5 System Diagram ● Type4 M SKIA6174E Revision; 2004 April B D Current gear position signal Ignition knob switch signal ICC sensor ABS actuator and electric unit (control unit) ATC-45 2003 FX AIR CONDITIONER CONTROL ● Type5 SKIA6175E Input/output Signal Chart T: Transmit R: Receive Signals ECM TCM A/T self-diagnosis signal R T ABS operation signal R TCS operation signal R VDC operation signal R Stop lamp switch signal Battery voltage signal Display unit BCM Steering angle sensor Unified meter and A/ C amp. R Driver seat control unit T R T R T R Key switch signal T R Ignition switch signal T R P range signal Closed throttle position signal T T IPDM E/R T R T AWD control unit ABS actuator and electric unit (control unit) R R R R Wide open throttle position signal T R Engine speed signal T R Engine status signal T Engine coolant temperature signal T R Accelerator pedal position signal T R Fuel consumption monitor signal T Input shaft revolution signal R T Output shaft revolution signal R T A/C switch signal R A/C compressor request signal T R A/C relay status signal R T A/C compressor feedback signal T Revision; 2004 April R R R R R R R R R R T R ATC-46 2003 FX AIR CONDITIONER CONTROL Signals Blower fan motor switch signal ECM TCM AWD control unit R T R R T R T D R R T T R T Front fog light request signal T Day time running light request signal T R Turn LED burnout status signal R T R R R R H T R T R R R T R R R Turn indicator signal T R Key fob ID signal T R Key fob door unlock signal T R Sleep wake up signal R R Oil pressure switch signal Buzzer output signal R T R R Fuel level low warning signal T Front wiper request signal T R Front wiper stop position signal R T Rear window defogger switch signal T R R T Hood switch signal R T Theft warning horn request signal T R Horn chirp signal T R Rear window defogger control signal R R Steering angle sensor signal T R ABS warning lamp signal R T VDC OFF indicator lamp signal R T SLIP indicator lamp signal R T Brake warning lamp signal R T System setting signal T AWD warning lamp signal Revision; 2004 April R T ATC-47 K L T R I ATC T T G T R Fuel level sensor signal F R R Door switch signal E R R R B C T High beam request signal Vehicle speed signal IPDM E/R T Low beam request signal High beam status signal Driver seat control unit R Position light request signal Low beam status signal BCM Steering angle sensor A T A/C control signal Cooling fan speed signal Display unit Unified meter and A/ C amp. ABS actuator and electric unit (control unit) R R 2003 FX M AIR CONDITIONER CONTROL Signals ECM TCM Display unit AWD lock indicator lamp signal AWD control unit BCM T Distance to empty signal T R ASCD OD cancel request T R Driver seat control unit IPDM E/R T R ASCD operation signal Unified meter and A/ C amp. R R Hand brake switch signal Steering angle sensor ABS actuator and electric unit (control unit) R T A/T CHECK indicator lamp signal T R A/T position indicator lamp signal T R A/T shift schedule change demand signal R Manual mode signal R T T Not manual mode signal R T Manual mode shift up signal R T Manual mode shift down signal R T Manual mode indicator signal T R TYPE 6 System Diagram ● Type6 SKIA6176E Revision; 2004 April ATC-48 2003 FX AIR CONDITIONER CONTROL Input/output Signal Chart T: Transmit R: Receive Signals ECM A/T self-diagnosis signal R ABS operation signal R TCS operation signal R VDC operation signal R Stop lamp switch signal Battery voltage signal TCM Display control unit AWD control unit ICC unit Intelligen t Key unit BCM Stee ring angl e sensor Unified mete r and A/C amp. ICC sensor Driv er seat control unit R R R T R T R R R E T T F R T R Ignition switch signal T R T R R R R T R Wide open throttle position signal T R Engine speed signal T R Engine status signal T Engine coolant temperature signal T R Accelerator pedal position signal T R Fuel consumption monitor signal T A/T self-diagnosis signal R T Input shaft revolution signal R T R Output shaft revolution signal R T R A/C switch signal R A/C compressor request signal T R A/C relay status signal R T A/C compressor feedback signal T Blower fan motor switch signal R Cooling fan speed signal R R R R R R I R R ATC R R K R L M T R T T R R T T R T R T R R R T High beam request signal Revision; 2004 April R R Low beam request signal Low beam status signal H R Position light request signal G R Closed throttle position signal A/C control signal C D Key switch signal P range signal A B IPD M E/ R T R T Low tire pressure warn ing control unit ABS actuator and electric unit (control unit) T ATC-49 R R 2003 FX AIR CONDITIONER CONTROL Signals High beam status signal ECM TCM Display control unit Low tire pressure warn ing control unit AWD control unit ICC unit Intelligen t Key unit BCM Stee ring angl e sensor Unified mete r and A/C amp. Driv er seat control unit R T Day time running light request signal T R Turn LED burnout status signal R T R R R R R R R R Sleep wake up signal T Door switch signal R R T R T R R T R R R R R R R T Key fob ID signal T R Key fob door unlock signal T R R Oil pressure switch signal Buzzer output signal T T R T R T R T Fuel level sensor signal ICC operation signal R R Fuel level low warning signal IPD M E/ R T Front fog light request signal Vehicle speed signal ICC sensor ABS actuator and electric unit (control unit) T R T R T Front wiper request signal T R Front wiper stop position signal R T Rear window defogger switch signal T R R T Hood switch signal R T Theft warning horn request signal T R Horn chirp signal T Rear window defogger control signal R R R Steering angle sensor signal Tire pressure signal Tire pressure data signal R T T R R R T ABS warning lamp signal R R T VDC OFF indicator lamp signal R R T R T SLIP indicator lamp signal Revision; 2004 April ATC-50 2003 FX AIR CONDITIONER CONTROL Signals ECM TCM Display control unit Low tire pressure warn ing control unit AWD control unit ICC unit Intelligen t Key unit BCM Brake warning lamp signal Stee ring angl e sensor Unified mete r and A/C amp. R System setting signal T R AWD lock indicator lamp signal T R R Hand brake switch signal IPD M E/ R B C R T Distance to empty signal A Driv er seat control unit T R AWD warning lamp signal D E T R R T F Door lock/unlock request signal T R Door lock/unlock status signal R T Starter permission signal T R Back door open request signal T R Power window open request signal T R Alarm request signal T R Key warning signal T G H I R ICC sensor signal R ICC warning lamp signal T R ICC system display signal T R Current gear position signal T Steering switch signal T ASCD operation signal T R ASCD OD cancel request T R ICC OD cancel request R R T R ATC K R R L T A/T CHECK indicator lamp signal T R A/T position indicator lamp signal T R A/T shift schedule change demand signal R Manual mode signal R M T T Not manual mode signal R T Manual mode shift up signal R T Manual mode shift down signal R T Manual mode indicator signal T R Ignition knob switch signal Revision; 2004 April ICC sensor ABS actuator and electric unit (control unit) T ATC-51 R 2003 FX TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS CONSULT-II PFP:00004 AJS0014J CONSULT-II executes the following functions by combining data reception and command transmission via the communication line from BCM data monitor display. System part BCM Check item, diagnosis mode Data monitor Description Displays BCM input data in real time. CONSULT-II BASIC OPERATION CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the ignition switch ON. PBIB1503E 2. Touch “START (NISSAN BASED VHCL)”. SKIA3098E 3. Touch “BCM” on “SELECT SYSTEM” screen. If “BCM” is not indicated, go to GI-40, "CONSULT-II Data Link Connector (DLC) Circuit" . SKIA5036E Revision; 2004 April ATC-52 2003 FX TROUBLE DIAGNOSIS DATA MONITOR Operation Procedure 1. A Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen. B C D SJIA0303E 2. E Touch “DATA MONITOR” on “SELECT DIAG MODE” screen. F G H SJIA0304E 3. Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on “DATA MONITOR” screen. All signals Monitors all the items. Selection from menu Selects and monitors the individual item selected. 4. 5. 6. I ATC Touch “START”. When “SELECTION FROM MENU” is selected, touch items to be monitored. When “ALL SIGNALS” is selected, all the items will be monitored. Touch “RECORD” while monitoring, then the status of the monitored item can be recorded. To stop recording, touch “STOP”. K RJIA1111E L Display Item List Monitor item name “operation or unit” M Contents IGN ON SW “ON/OFF” Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal. FAN ON SIG “ON/OFF” Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal. AIR COND SW “ON/OFF” Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal. Revision; 2004 April ATC-53 2003 FX TROUBLE DIAGNOSIS How to Perform Trouble Diagnosis for Quick and Accurate Repair AJS0014K WORK FLOW SHA900E *1 ATC-75, "Operational Check" SYMPTOM TABLE Symptom A/C system does not come on. Reference Page Go to Trouble Diagnosis Procedure for A/C System. ● Go to Integrated Display System. ● Go to Navigation System. A/C system cannot be controlled. Air outlet does not change. Mode door motor does not operate normally. ATC-77, "Power Supply and Ground Circuit for Auto Amp." AV-89, "A/C and AV Switch Self-Diagnosis Function" (Without navigation system) or AV-170, "A/C and AV Switch Self-Diagnosis Function" (With navigation system) Go to Trouble Diagnosis Procedure for Mode Door Motor. (LAN) ATC-83, "Mode Door Motor Circuit" Go to Trouble Diagnosis Procedure for Air Mix Door Motor. (LAN) ATC-86, "Air Mix Door Motor Circuit" Go to Trouble Diagnosis Procedure for Intake Door Motor. (LAN) ATC-89, "Intake Door Motor Circuit" Discharge air temperature does not change. Air mix door motor does not operate normally. Intake door does not change. Intake door motor does not operate normally. Blower motor operation is malfunctioning. Blower motor operation is malfunctioning under out of starting fan speed control. Go to Trouble Diagnosis Procedure for Blower Motor. ATC-92, "Blower Motor Circuit" Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. ATC-98, "Magnet Clutch Circuit" Go to Trouble Diagnosis Procedure for Insufficient Cooling. ATC-104, "Insufficient Cooling" Insufficient cooling Go to Diagnostic Procedure for Insufficient Cooling. ATC-110, "DIAGNOSTIC PROCEDURE FOR INSUFFICIENT COOLING" Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating. ATC-112, "Insufficient Heating" Noise Go to Trouble Diagnosis Procedure for Noise. ATC-113, "Noise" Revision; 2004 April ATC-54 2003 FX TROUBLE DIAGNOSIS Symptom Reference Page Self-diagnosis cannot be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis. Memory function does not operate. Go to Trouble Diagnosis Procedure for Memory Function. ATC-114, "Self-diagnosis" ATC-115, "Memory Function" A B C D E F G H I ATC K L M Revision; 2004 April ATC-55 2003 FX TROUBLE DIAGNOSIS Component Parts and Harness Connector Location AJS0014L ENGINE COMPARTMENT RJIA1963E Revision; 2004 April ATC-56 2003 FX TROUBLE DIAGNOSIS PASSENGER COMPARTMENT A B C D E F G H I ATC K L M RJIA1964E Revision; 2004 April ATC-57 2003 FX TROUBLE DIAGNOSIS Schematic AJS0014M TJWM0051E Revision; 2004 April ATC-58 2003 FX TROUBLE DIAGNOSIS Wiring Diagram —A/C— AJS0014N A B C D E F G H I ATC K L M TJWM0052E Revision; 2004 April ATC-59 2003 FX TROUBLE DIAGNOSIS TJWM0053E Revision; 2004 April ATC-60 2003 FX TROUBLE DIAGNOSIS A B C D E F G H I ATC K L M TJWM0054E Revision; 2004 April ATC-61 2003 FX TROUBLE DIAGNOSIS TJWM0055E Revision; 2004 April ATC-62 2003 FX TROUBLE DIAGNOSIS A B C D E F G H I ATC K L M TJWM0056E Revision; 2004 April ATC-63 2003 FX TROUBLE DIAGNOSIS Auto Amp. Terminals and Reference Value AJS0014O Measure voltage between each terminal and ground by following Terminals and Reference Value for unified meter and A/C amp. RJIA1965E PIN CONNECTOR TERMINAL LAYOUT RJIA1966E TERMINALS AND REFERENCE VALUE FOR UNIFIED METER AND A/C AMP. Terminal No. Wire color 1 L Item CAN H CAN L Ignition switch Condition Voltage (V) - - - 11 R - - 21 R/W Power supply for BATT OFF - Battery voltage - 22 G/R Power supply for IGN ON - Battery voltage 29 B Ground (Power) ON - Approx. 0 30 B Ground ON - Approx. 0 35 LG/R Power supply for ACC ON - Battery voltage 39 Y Ambient sensor - - - 40 BR/W In-vehicle sensor - - - 41 P Intake sensor - - 42 R/Y Compressor ON signal ON 43 G/B A/C LAN signal ON - A/C switch: ON Approx. 0 A/C switch: OFF Approx. 5 - HAK0652D 45 PU/W ECV (Electric Control Valve) signal ON - RJIA1606E Revision; 2004 April ATC-64 2003 FX TROUBLE DIAGNOSIS Voltage (V) Ignition switch Condition Power supply for IGN2 ON - Battery voltage W/G Sensor ground ON - Approx. 0 LG Sunload sensor - - Terminal No. Wire color 46 L/W 49 50 Item A B - C 53 G Blower motor control signal ACC or ON Blower speed: 1st step D SJIA0116J 54 Y/R 57 BR/Y Power supply for each door motor Blower motor ON signal ON ACC or ON - Battery voltage A/C switch: ON (Blower motor operate) Approx. 0 A/C switch: OFF Approx. 5 E F G H I ATC K L M Revision; 2004 April ATC-65 2003 FX TROUBLE DIAGNOSIS Self-diagnosis Function AJS0014P DESCRIPTION The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch ON) and pressing “OFF” switch for at least 5 seconds. The “OFF” switch must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be canceled by either pressing AUTO switch or turning the ignition switch OFF. Shifting from one step to another is accomplished by means of pressing temperature switch (driver side), as required. Additionally shifting from STEP-5 to AUXILIARY MECHANISM is accomplished by means of pressing (fan) switch (UP). RJIA1967E Revision; 2004 April ATC-66 2003 FX TROUBLE DIAGNOSIS FUNCTION CONFIRMATION PROCEDURE A 1. SET IN SELF-DIAGNOSTIC MODE 1. 2. Turn ignition switch ON. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned ON.), press OFF switch for at least 5 seconds. CAUTION: ● If battery voltage drops below 12V during diagnosis STEP-3, actuator speed becomes slower and as a result, the system may generate an error even when operation is usual. To avoid this, start engine before performing this diagnosis. ● Former STEP-1 (LEDs and display screen are checked) does not exist in this self-diagnosis function. B C D E >> GO TO 2. 2. STEP-2: SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT F Does code No. 20 appear on the display? YES >> GO TO 3. NO >> GO TO 13. G H I RJIA0219E 3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP-3 ATC Press temperature (UP) switch (driver side). Advance to self-diagnosis STEP-3? YES >> GO TO 4. NO >> 1. Malfunctioning temperature switch. 2. Replace A/C and AV switch. K L 4. CHECK TO RETURN SELF-DIAGNOSIS STEP-2 Press temperature (DOWN) switch (driver side). Return to self-diagnosis STEP-2? YES >> GO TO 5. NO >> 1. Malfunctioning temperature switch. 2. Replace A/C and AV switch. Revision; 2004 April ATC-67 M 2003 FX TROUBLE DIAGNOSIS 5. STEP-3: MODE DOOR AND INTAKE DOOR POSITIONS ARE CHECKED Press temperature (UP) switch (driver side). Does code No. 30 appear on the display? YES >> GO TO 6. NO >> GO TO 14. RJIA0220E 6. STEP-4: OPERATION OF EACH DOOR MOTOR IS CHECKED 1. 2. Press temperature (UP) switch (driver side). Press DEF switch. Code No. of each door motor test is indicated on the display. >> GO TO 7. RJIA1968E Revision; 2004 April ATC-68 2003 FX TROUBLE DIAGNOSIS 7. CHECK ACTUATORS A Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage and compressor operation. B C D SJIA0302E E 41 42 43 44 45 46 Mode door position VENT B/L 1 B/L 2 FOOT*1 D/F DEF Intake door position REC REC 20%FRE FRE FRE FRE Air mix door position FULL COLD FULL COLD FULL HOT FULL HOT FULL HOT FULL HOT Blower fan duty ratio 37% 91% 65% 65% 65% 91% Compressor ON ON OFF OFF ON ON 100% 100% 0% 0% 50% 100% Electronic control valve (ECV) duty ratio F G H Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation. I *1: FOOT position during automatic control. Refer to ATC-74, "AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER" . OK or NG ATC OK >> GO TO 8. NG >> ● Air outlet does not change. Go to Mode Door Motor Circuit. Refer to ATC-83, "Mode Door Motor Circuit" . K ● Intake door does not change. Go to Intake Door Motor Circuit. Refer to ATC-89, "Intake Door Motor Circuit" . ● Blower motor operation is malfunctioning. L Go to Blower Motor Circuit. Refer to ATC-92, "Blower Motor Circuit" . ● Magnet clutch does not engage. Go to Magnet Clutch Circuit. Refer to ATC-98, "Magnet Clutch Circuit" . M ● Discharge air temperature does not change. Go to Air Mix Door Motor Circuit. Refer to ATC-86, "Air Mix Door Motor Circuit" . 8. STEP-5: TEMPERATURE OF EACH SENSOR IS CHECKED 1. 2. Press temperature (UP) switch (driver side). Code No. 51 appears on the display. >> GO TO 9. Revision; 2004 April ATC-69 2003 FX TROUBLE DIAGNOSIS 9. CHECK AMBIENT SENSOR Press (DEF) switch one time. Temperature detected by ambient sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 10. NG >> Go to Ambient Sensor Circuit. Refer to ATC-116, "Ambient Sensor Circuit" . RJIA0223E 10. CHECK IN-VEHICLE SENSOR Press (DEF) switch a second time. Temperature detected by invehicle sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 11. NG >> Go to In-vehicle Sensor Circuit. Refer to ATC-119, "Invehicle Sensor Circuit" . RJIA1271E 11. CHECK INTAKE SENSOR Press (DEF) switch a third time. Temperature detected by intake sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 12. NG >> Go to Intake Sensor Circuit. Refer to ATC-125, "Intake Sensor Circuit" . RJIA1272E 12. CHECK CAN COMMUNICATION ERROR 1. 2. Press (REC) switch. CAN communication error between unified meter and A/C amp. and DISPLAY UNIT or DISPLAY CONTROL UNIT is detected. OK or NG OK >> 1. Turn ignition switch OFF or AUTO switch ON. 2. INSPECTION END NG >> Go to CAN communication. Refer to BCS-27, "CAN Communication Inspection Using CONSULT-II (SelfDiagnosis)" . ● Unified meter and A/C amp. - DISPLAY UNIT ● Unified meter and A/C amp. - DISPLAY CONTROL UNIT Revision; 2004 April ATC-70 RJIA1969E 2003 FX TROUBLE DIAGNOSIS 13. CHECK MALFUNCTIONING SENSOR A Refer to the following chart for malfunctioning code No. (If two or more sensors malfunction, corresponding code Nos. blink respectively twice.) *1: Perform self-diagnosis STEP-2 under sunshine. When performing indoors, aim a light (more than 60W) at sunload sensor, otherwise Code No. 25 will indicate despite that sunload sensor is functioning properly. Code No. Malfunctioning sensor (Including circuits) C Reference page 21 / −21 Ambient sensor *2 22 / −22 In-vehicle sensor *3 24 / −24 Intake sensor *4 25 / −25 Sunload sensor *1 *5 26 / −26 Air mix door motor PBR (Driver side) 27 / −27 Air mix door motor PBR (Passenger side) B D E *6 *2: ATC-116, "DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR" . *3: ATC-120, "DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR" . *4: ATC-125, "DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR" . *5: ATC-122, "DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR" . *6: ATC-80, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . F G H I ATC RJIA0227E K >> INSPECTION END L M Revision; 2004 April ATC-71 2003 FX TROUBLE DIAGNOSIS 14. CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH Mode or (and) intake door motor PBR (s) is (are) malfunctioning. Code No. *1 *2 Mode or intake door position 31 VENT 32 B/L 1 33 B/L 2 34 FOOT*3 35 D/F 36 DEF 37 FRE 38 20% FRE 39 REC Reference page Mode door motor *4 Intake door motor *5 (If two or more mode or intake doors are out of order, corresponding code numbers blink respectively twice.) *1: If mode door motor harness connector is disconnected, the following display pattern will appear. 31→32→33→34→35→36→Return to 31 *2: If intake door motor harness connector is disconnected, the following display pattern will appear. 37→38→39→Return to 37 *3: FOOT position during automatic control. Refer to ATC-74, "AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER" . *4:ATC-83, "Mode Door Motor Circuit" . *5:ATC-89, "Intake Door Motor Circuit" . RJIA0228E >> INSPECTION END Revision; 2004 April ATC-72 2003 FX TROUBLE DIAGNOSIS AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER The trimmer compensates for differences in range of ±3°C (±6°F) between temperature setting (displayed digitally) and temperature felt by driver. Operating procedures for this trimmer are as follows: ● Begin Self-diagnosis STEP-5 mode. Refer to ATC-66, "Self-diagnosis Function" . ● Press fan (UP) switch to set system in auxiliary mode. ● Display shows 61 in auxiliary mechanism. It takes approximately 3 seconds. ● Press temperature switch (driver side) as desired. Temperature will change at a rate of 0.5°C (1.0°F) each time a switch is pressed. CAUTION: A decimal point is not indicated when the display shows “°C”. A B C D E F G H I ATC K L M RJIA1970E When battery cable is disconnected, trimmer operation is canceled. Temperature set becomes that of initial condition, i.e. 0°C (0°F). Revision; 2004 April ATC-73 2003 FX TROUBLE DIAGNOSIS AUXILIARY MECHANISM: FOOT POSITION SETTING TRIMMER Wind distribution ratio in FOOT mode can be set. Operating procedures for this trimmer are as follows: ● Begin Self-diagnosis STEP-5 mode. Refer to ATC-66, "Self-diagnosis Function" . ● Press fan (UP) switch to set system in auxiliary mode. ● Display shows 61 in auxiliary mechanism. It takes approximately 3 seconds. ● Press the mode switch as desired. RJIA1971E AUXILIARY MECHANISM: INLET PORT MEMORY FUNCTION When ignition key is turned from OFF to ON, inlet port can be set to AUTO or manual. Operating procedures for this trimmer are as follows: ● Begin Self-diagnosis STEP-5 mode. Refer to ATC-66, "Self-diagnosis Function" . ● Press fan (UP) switch to set system in auxiliary mode. ● Display shows 61 in auxiliary mechanism. It takes approximately 3 seconds. ● Press the recirculation (REC) and fresh (FRE) switch as desired. Switch LED status of REC/FRE switch REC FRE Revision; 2004 April Setting status ON Manual REC status is memorized. (Initial setting) OFF AUTO control ON Manual FRE status is memorized. OFF AUTO control (Initial setting) ATC-74 Setting changeover method REC SW: ON FRE SW: ON 2003 FX TROUBLE DIAGNOSIS Operational Check AJS0014Q A The purpose of the operational check is to confirm that the system operates properly. Conditions : Engine running and at usual operating temperature B CHECKING MEMORY FUNCTION 1. 2. 3. 4. 5. 6. Set the temperature to 32°C (90°F). Press OFF switch. Turn ignition switch OFF. Turn ignition switch ON. Press the AUTO switch. Confirm that the set temperature remains at previous temperature. 7. Press OFF switch. If NG, go to trouble diagnosis procedure for ATC-115, "Memory Function" . If OK, continue with next check. C D E RJIA1972E F CHECKING BLOWER 1. Press fan (UP) switch. Blower should operate on low speed. The fan symbol should have one blade lit. 2. Press fan (UP) switch again, and continue checking blower speed and fan symbol until all speeds are checked. 3. Leave blower on MAX speed. If NG, go to trouble diagnosis procedure for ATC-94, "DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR" . If OK, continue with next check. G H I RJIA1973E ATC CHECKING DISCHARGE AIR 1. 2. Press MODE switch and DEF switch. Each position indicator should change shape. K L M RJIA1974E 3. Confirm that discharge air comes out according to the air distribution table. Refer to ATC-36, "Discharge Air Flow" . If NG, go to trouble diagnosis procedure for ATC-83, "Mode Door Motor Circuit" . If OK, continue with next 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. SJIA0302E Revision; 2004 April ATC-75 2003 FX TROUBLE DIAGNOSIS CHECKING RECIRCULATION 1. Press recirculation (REC) switch one time. Recirculation indicator should illuminate. 2. Press fresh (FRE) switch one time. Fresh indicator should illuminate. 3. Listen for intake door position change (you should hear blower sound change slightly). If NG, go to trouble diagnosis procedure for ATC-89, "Intake Door Motor Circuit" . If OK, continue with next 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. RJIA1978E CHECKING TEMPERATURE DECREASE 1. Press temperature (DOWN) switch (driver side) until 18°C (60°F) is displayed. 2. Check for cold air at discharge air outlets. If NG, go to trouble diagnosis procedure for ATC-104, "Insufficient Cooling" . If OK, continue with next check. RJIA1976E CHECKING TEMPERATURE INCREASE 1. Press temperature (UP) switch (driver side) until 32°C (90°F) is displayed. 2. Check for hot air at discharge air outlets. If NG, go to trouble diagnosis procedure for ATC-112, "Insufficient Heating" . If OK, continue with next check. RJIA1977E CHECK A/C SWITCH 1. 2. Press AUTO switch and A/C switch. 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 ATC-98, "Magnet Clutch Circuit" . If OK, continue with next check. RJIA1975E Revision; 2004 April ATC-76 2003 FX TROUBLE DIAGNOSIS CHECKING AUTO MODE Press AUTO switch and A/C switch. Display should indicate AUTO. ● 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 ATC-77, "Power Supply and Ground Circuit for Auto Amp." , then if necessary, trouble diagnosis procedure for ATC-98, "Magnet Clutch Circuit" . If all operational checks are OK (symptom cannot be duplicated), go to malfunction Simulation Tests in GI-27, "How to Perform Efficient Diagnosis for an Electrical Incident" and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to ATC-54, "SYMPTOM TABLE" and perform applicable trouble diagnosis procedures. A 1. 2. B C RJIA1979E D E Power Supply and Ground Circuit for Auto Amp. AJS001BF SYMPTOM: A/C system does not come on. F INSPECTION FLOW G H I ATC K L M RJIA1980E *1 ATC-78, "DIAGNOSTIC PROCEDURE FOR A/C SYSTEM". *4 AV-170, "A/C and AV Switch SelfDiagnosis Function". Revision; 2004 April *2 ATC-75, "Operational Check". ATC-77 *3 AV-89, "A/C and AV Switch SelfDiagnosis Function". 2003 FX TROUBLE DIAGNOSIS COMPONENT DESCRIPTION Unified Meter and A/C Amp. (Automatic Amplifier) The unified meter and A/C amp. has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motor, mode door motor, intake door motor, blower motor and compressor are then controlled. The unified meter and A/C amp. is unitized with control mechanisms. When the various switches and temperature switch are operated, data is input to the unified meter and A/C amp. from the DISPLAY UNIT/DISPLAY CONTROL UNIT using CAN communication. Self-diagnostic functions are also built into unified meter and A/C amp. to provide quick check of malfunctions in the auto air conditioner system. RJIA1965E Potentio Temperature Control (PTC) The PTC is built into the A/C and AV switch. It can be set at an interval of 0.5°C (1.0°F) in the 18°C (60°F) to 32°C (90°F) temperature range by pressing temperature switch. The set temperature is displayed. RJIA1982E DIAGNOSTIC PROCEDURE FOR A/C SYSTEM SYMPTOM: A/C system does not come on. RJIA1983E Revision; 2004 April ATC-78 2003 FX TROUBLE DIAGNOSIS 1. CHECK POWER SUPPLY CIRCUIT FOR UNIFIED METER AND A/C AMP. 1. 2. A Disconnect unified meter and A/C amp. connector. Check voltage between unified meter and A/C amp. harness connector M56 terminals 21 (R/W), 22 (G/R) and 35 (LG/R), unified meter and A/C amp. harness connector M57 terminal 46 (L/ W) and ground. Terminals B C Ignition switch position (+) Auto amp. connector Terminal No. (wire color) M56 21 (R/W) (-) OFF ACC ON Battery voltage Battery voltage Battery voltage Approx. 0V Approx. 0V Battery voltage D RJIA1984E M56 22 (G/R) M56 35 (LG/R) Approx. 0V Battery voltage Battery voltage M57 46 (L/W) Approx. 0V Battery voltage Battery voltage Ground E F G OK or NG OK >> GO TO 2. NG >> Check 10A and 15A fuses [Nos. 6, 10, 11, 12 and 19, located in the fuse block (J/B)]. Refer to PG98, "FUSE BLOCK - JUNCTION BOX (J/B)" . ● If fuses are OK, check harness for open circuit. Repair or replace as necessary. ● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace as necessary. 2. CHECK GROUND CIRCUIT FOR UNIFIED METER AND A/C AMP. 1. 2. I ATC Turn ignition switch OFF. Check continuity between unified meter and A/C amp. harness connector M56 terminal 29 (B), 30 (B) and ground. 29, 30 – Ground H K : Continuity should exist. OK or NG OK >> Replace unified meter and A/C amp. NG >> Repair harness or connector. L M RJIA1985E Revision; 2004 April ATC-79 2003 FX TROUBLE DIAGNOSIS LAN System Circuit AJS0014S SYMPTOM: Mode door motor, intake door motor and/or air mix door motor(s) does not operate normally. RJIA1775E DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT 1. CHECK POWER SUPPLY FOR UNIFIED METER AND A/C AMP. 1. 2. Turn ignition switch ON. Check voltage between unified meter and A/C amp. harness connector M57 terminal 54 (Y/R) and ground. 54 – Ground : Battery voltage OK or NG OK >> GO TO 2. NG >> Replace unified meter and A/C amp. RJIA1986E 2. CHECK SIGNAL FOR UNIFIED METER AND A/C AMP. Confirm A/C LAN signal between unified meter and A/C amp. harness connector M57 terminal 43 (G/B) and ground using an oscilloscope. Terminals (+) Auto amp. connector Terminal No. (wire color) (−) Voltage RJIA1987E M57 43 (G/B) Ground HAK0652D OK or NG OK >> GO TO 3. NG >> Replace unified meter and A/C amp. Revision; 2004 April ATC-80 2003 FX TROUBLE DIAGNOSIS 3. CHECK POWER SUPPLY FOR MOTOR A Check voltage between mode door motor harness connector M258 terminal 1 (G), driver side air mix door motor harness connector M252 terminal 1 (G), passenger side air mix door motor harness connector M257 terminal 1 (G), intake door motor harness connector M253 terminal 1 (G) and ground. 1 – Ground B : Battery voltage C OK or NG OK >> GO TO 4. NG >> Repair harness or connector. D RJIA1988E 4. CHECK SIGNAL FOR MOTOR E Confirm A/C LAN signal between mode door motor harness connector M258 terminal 3 (L), driver side air mix door motor harness connector M252 terminal 3 (L), passenger side air mix door motor harness connector M257 terminal 3 (L), intake door motor harness connector M253 terminal 3 (G/B) and ground using an oscilloscope. F G Terminals (+) Connector Terminal No. (wire color) Mode M258 3 (L) Air mix (Driver side) M252 3 (L) Air mix (Passenger side) M257 Door motor Voltage H (−) RJIA1989E I ATC Ground 3 (L) K HAK0652D Intake M253 3 (L) OK or NG OK >> GO TO 5. NG >> Repair harness or connector. L 5. CHECK MOTOR GROUND CIRCUIT M 1. 2. 3. Turn ignition switch OFF. Disconnect door motor connector. Check continuity between mode door motor harness connector M258 terminal 2 (B), driver side air mix door motor harness connector M252 terminal 2 (B), passenger side air mix door motor harness connector M257 terminal 2 (B), intake door motor harness connector M253 terminal 2 (B) and ground. 2 – Ground : Continuity should exist. OK or NG OK >> GO TO 6. NG >> Repair harness or connector. Revision; 2004 April RJIA1990E ATC-81 2003 FX TROUBLE DIAGNOSIS 6. CHECK MOTOR OPERATION Disconnect and reconnect the motor connector and confirm the motor operation. OK or NG OK >> (Return to operate normally.) ● Poor contact in motor connector NG >> (Does not operate normally.) ● GO TO 7. 7. CHECK MODE DOOR MOTOR OPERATION 1. Disconnect mode door motor and air mix door motor (driver side, passenger side) connector. 2. Reconnect mode door motor connector and confirm the mode door motor operation. OK or NG OK >> (Mode door motor operates normally.) ● GO TO 8. NG >> (Mode door motor does not operate normally.) ● Replace mode door motor. 8. CHECK AIR MIX DOOR MOTOR OPERATION 1. 2. Disconnect mode door motor connector. Reconnect air mix door motor connector (driver side, passenger side) and confirm the air mix door motor operation. OK or NG OK >> (Air mix door motor operates normally.) ● GO TO 9. NG >> (Air mix door motor does not operate normally.) ● GO TO 10. 9. CHECK INTAKE DOOR MOTOR OPERATION 1. Disconnect air mix door motor connector (driver side, passenger side). 2. Reconnect intake door motor connector and confirm the intake door motor operation. OK or NG OK >> (Intake door motor operates normally.) ● Replace unified meter and A/C amp. NG >> (Intake door motor does not operate normally.) ● Replace intake door motor. 10. CHECK AIR MIX DOOR MOTOR OPERATION 1. Disconnect air mix door motor (driver side) connector. 2. Confirm the air mix door motor (passenger side) operation. OK or NG OK >> (Air mix door motor operates normally.) ● Replace driver side air mix door motor. NG >> (Air mix door motor does not operate normally.) ● Replace passenger side air mix door motor. Revision; 2004 April ATC-82 2003 FX TROUBLE DIAGNOSIS Mode Door Motor Circuit AJS0014T A SYMPTOM: ● Air outlet does not change. ● Mode door motor does not operate normally. B INSPECTION FLOW C D E F G H I ATC K L M RJIA1991E *1 ATC-36, "Discharge Air Flow". *4 *7 ATC-75, "Operational Check". *3 ATC-125, "Intake Sensor Circuit" *5 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 4 to 6. ATC-116, "Ambient Sensor Circuit". *6 ATC-119, "In-vehicle Sensor Circuit". ATC-122, "Sunload Sensor Circuit". ATC-86, "Air Mix Door Motor Circuit". *9 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *10 ATC-80, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT". Revision; 2004 April *2 *8 *11 ATC-142, "MODE DOOR MOTOR". *12 ATC-54, "SYMPTOM TABLE". ATC-83 2003 FX TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts Mode door control system components are: ● Unified meter and A/C amp. ● Mode door motor (LCU) ● A/C LAN system (PBR built-in mode door motor and air mix door motor) ● In-vehicle sensor ● Ambient sensor ● Sunload sensor ● Intake sensor System Operation The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp. sends air mix door, mode door and intake door opening angle data to the air mix door motor LCU, mode door motor LCU and intake door motor LCU. The air mix door motor, mode door motor and intake door motor read their respective signals according to the address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection data is returned to the unified meter and A/C amp. RJIA1777E Revision; 2004 April ATC-84 2003 FX TROUBLE DIAGNOSIS Mode Door Control Specification A B C RJIA1778E D COMPONENT DESCRIPTION Mode Door Motor E The mode door motor is attached to the heater & cooling unit. It rotates so that air is discharged from the outlet set by the unified meter and A/C amp. Motor rotation is conveyed to a link which activates the mode door. F G H RJIA0890E DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR SYMPTOM: Mode door motor does not operate normally. Perform diagnostic procedure for ATC-80, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . I ATC K L M Revision; 2004 April ATC-85 2003 FX TROUBLE DIAGNOSIS Air Mix Door Motor Circuit AJS0014U SYMPTOM: ● Discharge air temperature does not change. ● Air mix door motor does not operate. INSPECTION FLOW RJIA1992E *1 *2 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 4 to 6. ATC-116, "Ambient Sensor Circuit". *3 ATC-119, "In-vehicle Sensor Circuit". *4 ATC-122, "Sunload Sensor Circuit" *5 ATC-88, "Air Mix Door Motor PBR Circuit". *6 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *7 ATC-80, "LAN System Circuit". *8 ATC-88, "COMPONENT DESCRIP- *9 TION". *10 ATC-75, "Operational Check". Revision; 2004 April *11 ATC-54, "SYMPTOM TABLE". ATC-86 ATC-143, "AIR MIX DOOR MOTOR". *12 ATC-125, "Intake Sensor Circuit". 2003 FX TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts A Air mix door control system components are: ● Unified meter and A/C amp. ● Air mix door motor (LCU) ● A/C LAN system (PBR built-in mode door motor and air mix door motor) ● In-vehicle sensor ● Ambient sensor ● Sunload sensor ● Intake sensor B C D System Operation The unified meter and A/C amp. receives data from each of the sensors. The unified meter and A/C amp. sends air mix door, mode door and intake door motor opening angle data to the air mix door motor LCU, mode door motor LCU and intake door motor LCU. The air mix door motor, mode door motor and intake door motor read their respective signals according to the address signal. Opening angle indication signals received from the unified meter and A/C amp. and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/COLD or DEFROST/VENT or FRESH/RECIRCULATION operation is selected. The new selection data is returned to the unified meter and A/C amp. E F G H I ATC K L RJIA1781E M Air Mix Door Control Specification RJIA1782E Revision; 2004 April ATC-87 2003 FX TROUBLE DIAGNOSIS COMPONENT DESCRIPTION Air Mix Door Motor The air mix door motor is attached to the heater & cooling unit. It rotates so that the air mix door is opened or closed to a position set by the unified meter and A/C amp. Motor rotation is then conveyed through a shaft and the air mix door position is then fed back to the unified meter and A/C amp. by PBR built-in air mix door motor. RJIA0893E RJIA0894E DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR Perform diagnostic procedure for ATC-80, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . Air Mix Door Motor PBR Circuit AJS0014V SYMPTOM: ● Discharge air temperature does not change. ● PBR circuit is open or shorted. DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR PBR Perform diagnostic procedure for ATC-80, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . Revision; 2004 April ATC-88 2003 FX TROUBLE DIAGNOSIS Intake Door Motor Circuit AJS0014W A SYMPTOM: ● Intake door does not change. ● Intake door motor does not operate normally. B INSPECTION FLOW C D E F G H I ATC K L M RJIA1993E *1 *2 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 4 to 6. ATC-116, "Ambient Sensor Circuit". *3 ATC-119, "In-vehicle Sensor Circuit". *4 ATC-122, "Sunload Sensor Circuit". *5 ATC-88, "Air Mix Door Motor PBR Circuit". *6 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *7 ATC-80, "LAN System Circuit". *8 ATC-137, "INTAKE DOOR MOTOR". *9 ATC-75, "Operational Check". *10 ATC-54, "SYMPTOM TABLE". Revision; 2004 April *11 ATC-125, "Intake Sensor Circuit". ATC-89 2003 FX TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts Intake door control system components are: ● Unified meter and A/C amp. ● Intake door motor (LCU) ● A/C LAN system (PBR built-in mode motor and air mix door motor) ● In-vehicle sensor ● Ambient sensor ● Sunload sensor ● Intake sensor System Operation The intake door control determines intake door position based on the ambient temperature, the intake air temperature and the in-vehicle temperature. When the DEFROST, or OFF switches are pushed or A/C switch is OFF, the unified meter and A/C amp. sets the intake door at the FRESH position. RJIA1786E Intake Door Control Specification RJIA1787E Revision; 2004 April ATC-90 2003 FX TROUBLE DIAGNOSIS COMPONENT DESCRIPTION Intake Door Motor A The intake door motor is attached to the intake unit. It rotates so that air is drawn from inlets set by the unified meter and A/C amp. Motor rotation is conveyed to a lever which activates the intake door. B C D RJIA0897E DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR E SYMPTOM: Intake door motor does not operate normally. Perform diagnostic procedure for ATC-80, "DIAGNOSTIC PROCEDURE FOR LAN CIRCUIT" . F G H I ATC K L M Revision; 2004 April ATC-91 2003 FX TROUBLE DIAGNOSIS Blower Motor Circuit AJS0014X SYMPTOM: ● Blower motor operation is malfunctioning. ● Blower motor operation is malfunctioning under out of starting fan speed control. INSPECTION FLOW RJIA1994E *1 ATC-75, "Operational Check". *2 ATC-125, "Intake Sensor Circuit". *3 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No.4. *4 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No.6. *5 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No.13. *6 ATC-94, "DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR". *7 ATC-54, "SYMPTOM TABLE". *8 ATC-116, "Ambient Sensor Circuit". *9 ATC-119, "In-vehicle Sensor Circuit". *10 ATC-122, "Sunload Sensor Circuit". Revision; 2004 April *11 EC-197, "DTC P0117, P0118 ECT SENSOR" (VQ35DE) or EC-845, "DTC P0117, P0118 ECT SENSOR" (VK45DE). ATC-92 2003 FX TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts A Fan speed control system components are: ● Unified meter and A/C amp. ● A/C LAN system (PBR built-in mode door motor and air mix door motor) ● In-vehicle sensor ● Ambient sensor ● Sunload sensor ● Intake sensor B C D System Operation E F G H I RJIA1995E ATC Automatic Mode In the automatic mode, the blower motor speed is calculated by the unified meter and A/C amp. based on input from the PBR, in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. When the air flow is increased, the duty ratio of the blower fan motor′s drive signal is changed at 8%/sec. 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. K L M Revision; 2004 April ATC-93 2003 FX TROUBLE DIAGNOSIS Starting Fan Speed Control Start Up From COLD SOAK Condition (Automatic mode) In a cold start up condition where the engine coolant temperature is below 56°C (133°F), the blower will not operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and engine coolant temperature. In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above 56°C (133°F), at which time the blower speed will increase to the objective speed. Start Up From Usual 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 low speed will vary depending on the sunload. During conditions of low or no sunload, the blower low speed is usual low speed (duty ratio 25%). During high sunload conditions, the display and A/C auto amp. causes the blower speed to increase (duty ratio 49%). Fan Speed Control Specification RJIA1996E COMPONENT DESCRIPTION Brush-less Motor The blower motor utilizes a brush-less motor with a rotating magnet. Quietness is improved over previous motors where the brush was the point of contact and the coil rotated. ZHA152H DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR SYMPTOM: Blower motor operation is malfunctioning under starting fan speed control. SJIA0266E Revision; 2004 April ATC-94 2003 FX TROUBLE DIAGNOSIS 1. CHECK POWER SUPPLY FOR BLOWER MOTOR 1. 2. 3. A Disconnect blower motor connector. Turn ignition switch ON. Check voltage between blower motor harness connector M78 terminal 1 (L/W) and ground. 1 – Ground B : Battery voltage C OK or NG OK >> GO TO 2. NG >> Check power supply circuit and 15A fuses [Nos. 10 and 11, located in the fuse block (J/B)]. Refer to PG-98, RJIA1997E "FUSE BLOCK - JUNCTION BOX (J/B)" . ● If OK, check for open circuit in wiring harness. Repair or replace as necessary. ● If NG, replace fuse and check wiring harness for short circuit. Repair or replace as necessary. 2. CHECK BLOWER MOTOR GROUND CIRCUIT 1. 2. E F Turn ignition switch OFF. Check continuity between blower motor harness connector M78 terminal 3 (B) and ground. 3 – Ground D G : Continuity should exist. OK or NG OK >> GO TO 3. NG >> Repair harness or connector. H I RJIA1998E 3. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND UNIFIED METER AND A/C AMP. 1. 2. Disconnect unified meter and A/C amp. connector. Check continuity between blower motor harness connector M78 terminal 2 (G) and unified meter and A/C amp. harness connector M57 terminal 53 (G). 2 – 53 K : Continuity should exist. L OK or NG OK >> GO TO 4. NG >> Repair harness or connector. M RJIA1999E Revision; 2004 April ATC ATC-95 2003 FX TROUBLE DIAGNOSIS 4. CHECK UNIFIED METER AND A/C AMP. OUTPUT SIGNAL 1. 2. 3. Reconnect blower motor connector and unified meter and A/C amp. connector. Turn ignition switch ON. Vary the fan speed between Lo and Hi and confirm the duty ratios between blower motor harness connector M78 terminal 2 (G) and ground using an oscilloscope. Usual No. 2 terminal drive signal duty ratios are shown in the table below. RJIA2000E RJIA2001E OK or NG OK >> GO TO 5. NG >> Replace unified meter and A/C amp. 5. CHECK BLOWER MOTOR DRIVE SIGNAL If the fan air flow does not change, usual No. 2 (G) terminal drive signal duty ratios are shown in the table above. OK or NG OK >> Replace blower motor. NG >> INSPECTION END Revision; 2004 April ATC-96 2003 FX TROUBLE DIAGNOSIS COMPONENT INSPECTION Blower Motor A Confirm smooth rotation of the blower motor. ● Ensure that there are no foreign particles inside the blower unit. B C D RJIA0905E E F G H I ATC K L M Revision; 2004 April ATC-97 2003 FX TROUBLE DIAGNOSIS Magnet Clutch Circuit AJS0014Y SYMPTOM: Magnet clutch does not engage. INSPECTION FLOW RJIA2002E *1 ATC-125, "Intake Sensor Circuit". *2 ATC-116, "Ambient Sensor Circuit". *3 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *4 ATC-98, "Magnet Clutch Circuit". *5 ATC-108, "TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE". *6 ATC-75, "Operational Check". *7 ATC-67, "FUNCTION CONFIRMA*8 TION PROCEDURE", see No. 4 to 6. Revision; 2004 April ATC-54, "SYMPTOM TABLE". ATC-98 2003 FX TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Unified meter and A/C amp. controls compressor operation by ambient temperature, intake air temperature and signal from ECM. Low Temperature Protection Control Unified meter and A/C amp. will turn the compressor ON or OFF as determined by a signal detected by ambient sensor and intake sensor. When ambient temperature is higher than −2°C (28°F), the compressor turns ON. The compressor turns OFF when ambient temperature is lower than −5°C (23°F). A B C D E RHA094GB F When intake air temperature is higher than 1°C (34°F), the compressor turns ON. The compressor turns OFF when intake air temperature is lower than −5°C (23°F). G H I SJIA0267E DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH ATC SYMPTOM: Magnet clutch does not engage when A/C switch is ON. K L M RJIA2003E 1. CHECK INTAKE SENSOR CIRCUIT Check intake sensor. Refer to ATC-67, "FUNCTION CONFIRMATION PROCEDURE" , see No. 11. OK or NG OK >> GO TO 2. NG >> Malfunctioning intake sensor: Refer to ATC-125, "Intake Sensor Circuit" . Revision; 2004 April ATC-99 2003 FX TROUBLE DIAGNOSIS 2. PERFORM AUTO ACTIVE TEST Refer to PG-39, "Auto Active Test" . Does the magnet clutch operate? YES >> ● WITH CONSULT-II GO TO 5. WITHOUT CONSULT-II GO TO 6. >> Check 10A fuse (No. 79, located in IPDM E/R), and GO TO 3. ● NO 3. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector and compressor (magnet clutch) connector. Check continuity between IPDM E/R harness connector E8 terminal 33 (L) and compressor harness connector F2 terminal 1 (L). 33 – 1 : Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair harness or connector. RJIA2004E 4. CHECK MAGNET CLUTCH CIRCUIT Check for operation sound when applying battery voltage direct current to terminal. OK or NG OK >> Replace IPDM E/R. NG >> Replace magnet clutch. Refer to ATC-155, "Removal and Installation of Compressor Clutch" . RJIA2005E 5. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL Check compressor ON/OFF signal. Refer to ATC-52, "CONSULT-II" . A/C SW ON A/C SW OFF : AIR COND SW ON : AIR COND SW OFF OK or NG OK >> GO TO 8. NG >> GO TO 6. RJIA1111E Revision; 2004 April ATC-100 2003 FX TROUBLE DIAGNOSIS 6. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND UNIFIED METER AND A/C AMP. 1. 2. 3. A Turn ignition switch OFF. Disconnect BCM connector and unified meter and A/C amp. connector. Check continuity between BCM harness connector M3 terminal 27 (R/Y) and unified meter and A/C amp. harness connector M57 terminal 42 (R/Y). 27 – 42 B C : Continuity should exist. OK or NG OK >> GO TO 7. NG >> Repair harness or connector. D RJIA2006E 7. CHECK VOLTAGE FOR UNIFIED METER AND A/C AMP. (COMPRESSOR ON SIGNAL) 1. 2. 3. E Reconnect BCM connector and unified meter and A/C amp. connector. Turn ignition switch ON. Check voltage between unified meter and A/C amp. harness connector M57 terminal 42 (R/Y) and ground. F G Terminals (+) Auto amp. connector M57 Terminal No. (wire color) 42 (R/Y) (−) Condition Voltage A/C switch: ON Approx. 0V A/C switch: OFF Approx. 5V H RJIA2007E Ground I OK or NG OK >> GO TO 8. NG-1 >> If the voltage is approx. 5V when A/C switch is ON: Replace unified meter and A/C amp. NG-2 >> If the voltage is approx. 0V when A/C switch is OFF: Replace BCM. ATC K L M Revision; 2004 April ATC-101 2003 FX TROUBLE DIAGNOSIS 8. CHECK REFRIGERANT PRESSURE SENSOR 1. 2. 1. 2. WITH CONSULT-II Start the engine. Check voltage of refrigerant pressure sensor. Refer to EC-138, "CONSULT-II Reference Value in Data Monitor" (VQ35DE) or EC-780, "CONSULT-II Reference Value in Data Monitor" (VK45DE). WITHOUT CONSULT-II Start the engine. Check voltage between ECM harness connector F101 terminal 70 (L/R) and ground. RJIA2008E Terminals (+) ECM connector Terminal No. (wire color) (−) F101 70 (L/R) Ground OK or NG OK >> ● Condition Voltage A/C switch: ON Approx. 0.36 - 3.88V WITH CONSULT-II GO TO 9. WITHOUT CONSULT-II GO TO 10. >> Refer to EC-1288, "REFRIGERANT PRESSURE SENSOR" . ● NG 9. CHECK BCM INPUT (FAN ON) SIGNAL Check FAN ON/OFF signal. Refer to ATC-52, "CONSULT-II" . FAN SW ON FAN SW OFF :FAN ON SIG ON :FAN ON SIG OFF OK or NG OK >> GO TO 12. NG >> GO TO 10. RJIA1111E 10. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector and unified meter and A/C amp. connector. Check continuity between BCM harness connector M3 terminal 28 (BR/Y) and unified meter and A/C amp. harness connector M57 terminal 57 (BR/Y). 28 – 57 : Continuity should exist. OK or NG OK >> GO TO 11. NG >> Repair harness or connector. Revision; 2004 April RJIA2009E ATC-102 2003 FX TROUBLE DIAGNOSIS 11. CHECK VOLTAGE FOR UNIFIED METER AND A/C AMP. (FAN ON SIGNAL) 1. 2. 3. A Reconnect BCM connector and unified meter and A/C amp. connector. Turn ignition switch ON. Check voltage between unified meter and A/C amp. harness connector M57 terminal 57 (BR/Y) and ground. B C Terminals (+) Auto amp. connector M57 Terminal No. (wire color) 57 (BR/Y) (-) Condition Voltage D RJIA2010E Ground A/C switch: ON Blower motor operates Approx. 0V A/C switch: OFF Approx. 5V E OK or NG OK >> GO TO 12. NG-1 >> If the voltage is approx. 5V when blower motor is ON: Replace unified meter and A/C amp. NG-2 >> If the voltage is approx. 0V when blower motor is OFF: Replace BCM. Refer to BCS-28, "Removal and Installation of BCM" . 12. CHECK CAN COMMUNICATION F G H Check CAN communication. Refer to BCS-27, "CAN Communication Inspection Using CONSULT-II (SelfDiagnosis)" . I ● BCM – ECM ● ECM – IPDM E/R ● ECM – Unified meter and A/C amp. ATC OK or NG OK >> INSPECTION END NG >> Repair or replace malfunctioning part(s). K COMPONENT INSPECTION Refrigerant Pressure Sensor The refrigerant pressure sensor is attached to the condenser. L M RJIA2011E Revision; 2004 April ATC-103 2003 FX TROUBLE DIAGNOSIS Insufficient Cooling AJS0014Z SYMPTOM: Insufficient cooling INSPECTION FLOW RJIA2012E *1 *2 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 4 to 6. ATC-86, "Air Mix Door Motor Circuit". *3 *4 ATC-73, "AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER". *5 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *6 ATC-80, "LAN System Circuit". *7 ATC-92, "Blower Motor Circuit". *8 ATC-98, "Magnet Clutch Circuit". *9 ATC-105, "PERFORMANCE TEST DIAGNOSES". Revision; 2004 April ATC-104 ATC-107, "Test Reading". 2003 FX TROUBLE DIAGNOSIS *10 ATC-75, "Operational Check". *11 ATC-5, "CONTAMINATED REFRIGERANT" *12 EM-15, "Checking Drive Belts" (VQ35DE) or EM-167, "Checking Drive Belts" (VK45DE). *13 EC-480, "SYSTEM DESCRIPTION" (VQ35DE) or EC-1142, "System Description" (VK45DE). A B PERFORMANCE TEST DIAGNOSES C D E F G H I ATC K L M RJIA1601E Revision; 2004 April ATC-105 2003 FX TROUBLE DIAGNOSIS *1 ATC-107, "PERFORMANCE CHART". *4 ATC-86, "Air Mix Door Motor Circuit". *2 ATC-107, "PERFORMANCE CHART". *3 ATC-108, "TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE". RJIA1595E *1 ATC-155, "Removal and Installation of Compressor Clutch". Revision; 2004 April *2 ATC-92, "Blower Motor Circuit". ATC-106 *3 EM-15, "Checking Drive Belts" (VQ35DE) or EM-167, "Checking Drive Belts" (VK45DE). 2003 FX TROUBLE DIAGNOSIS PERFORMANCE CHART Test Condition A Testing must be performed as follows: Vehicle location Indoors or in the shade (in a well-ventilated place) Doors Closed Door window Open Hood Open TEMP. Max. COLD Mode switch B C (Ventilation) set Recirculation (REC) switch D (Recirculation) set Max. speed set Fan (blower) speed Engine speed E Idle speed Operate the air conditioning system for 10 minutes before taking measurements. Test Reading F Recirculating-to-discharge Air Temperature Table Inside air (Recirculating air) at blower assembly inlet Relative humidity % Discharge air temperature at center ventilator °C (°F) Air temperature °C (°F) 20 (68) 11.2 - 13.2 (52 - 56) 25 (77) 12.2 - 14.8 (54 - 59) 30 (86) 15.5 - 18.6 (60 - 65) 35 (95) 21.0 - 24.5 (70 - 76) 40 (104) 28.7 - 32.6 (84 - 91) 20 (68) 13.2 - 15.2 (56 - 59) 25 (77) 14.8 - 17.3 (59 - 63) 30 (86) 18.6 - 21.6 (65 - 71) 35 (95) 24.5 - 28.0 (76 - 82) 40 (104) 32.6 - 36.5 (91 - 98) 50 - 60 60 - 70 G H I ATC K Ambient Air Temperature-to-operating Pressure Table Ambient air Relative humidity % 50 - 70 Revision; 2004 April L High-pressure (Discharge side) Low-pressure (Suction side) Air temperature °C (°F) kPa (kg/cm2 , psi) kPa (kg/cm2 , psi) 20 (68) 961 - 1,167 (9.8 - 11.9, 139 - 169) 216 - 265 (2.2 - 2.7, 31 - 38) 25 (77) 1,108 - 1,353 (11.3 - 13.8, 161 - 196) 230 - 281 (2.3 - 2.9, 33 - 41) 30 (86) 1,275 - 1,549 (13.0 - 15.8, 185 - 225) 261 - 320 (2.7 - 3.3, 38 - 46) 35 (95) 1,549 - 1,893 (15.8 - 19.3, 225 - 274) 297 - 364 (3.0 - 3.7, 43 - 53) 40 (104) 1,814 - 2,216 (18.5 - 22.6, 263 - 321) 357 - 435 (3.6 - 4.4, 52 - 63) M ATC-107 2003 FX TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE Whenever system′s high and/or low side pressure is unusual, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperatureto-operating pressure table). Both High- and Low-pressure Sides are Too High Gauge indication Refrigerant cycle Pressure is reduced soon after water is splashed on condenser. Air suction by cooling fan is insufficient. Probable cause Excessive refrigerant charge in refrigeration cycle Insufficient condenser cooling performance ↓ 1. Condenser fins are clogged. Corrective action Reduce refrigerant until specified pressure is obtained. ● Clean condenser. ● Check and repair cooling fan as necessary. 2. Improper fan rotation of cooling fan Both high- and low-pressure sides are too high. ● Low-pressure pipe is not cold. ● When compressor is stopped high-pressure value quickly drops by approximately 196 kPa (2 kg/cm2 , 28 psi). It then decreases gradually thereafter. AC359A Engine tends to overheat. ● ● An area of the low-pressure pipe is colder than areas near the evaporator outlet. Plates are sometimes covered with frost. Poor heat exchange in condenser (After compressor operation stops, high pressure decreases too slowly.) ↓ Air in refrigeration cycle Evacuate repeatedly and recharge system. Engine cooling systems malfunction. Check and repair each engine cooling system. ● Excessive liquid refrigerant on low-pressure side ● Excessive refrigerant discharge flow ● Expansion valve is open a little compared with the specification. Replace expansion valve. ↓ Improper expansion valve adjustment High-pressure Side is Too High and Low-pressure Side is Too Low Gauge indication Refrigerant cycle Probable cause Corrective action High-pressure side is too high and low-pressure side is too low. Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. ● Check and repair or replace malfunctioning parts. ● Check lubricant for contamination. AC360A Revision; 2004 April ATC-108 2003 FX TROUBLE DIAGNOSIS High-pressure Side is Too Low and Low-pressure Side is Too High Gauge indication High-pressure side is too low and low-pressure side is too high. Refrigerant cycle Probable cause High- and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. ↓ Damaged inside compressor packings No temperature difference between high- and low-pressure sides Compressor pressure operation is improper. ↓ Damaged inside compressor packings. AC356A Corrective action Replace compressor. A B C Replace compressor. D Both High- and Low-pressure Sides are Too Low Gauge indication Refrigerant cycle ● ● ● ● ● Both high- and low-pressure sides are too low. There is a big temperature difference between receiver drier outlet and inlet. Outlet temperature is extremely low. Liquid tank inside is slightly clogged. Corrective action ● Replace liquid tank. ● Check lubricant for contamination. Liquid tank inlet and expansion valve are frosted. Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. Expansion valve inlet may be frosted. There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted. High-pressure pipe located between receiver drier and expansion valve is clogged. ● Check and repair malfunctioning parts. ● Check lubricant for contamination. Low refrigerant charge ↓ Leaking fittings or components Expansion valve closes a little compared with the specification. ↓ 1. Improper expansion valve adjustment Check refrigerant for leaks. Refer to ATC-170, "Checking for Refrigerant Leaks" . Air flow volume is not enough or is too low. Revision; 2004 April F ● Remove foreign particles by using compressed air. ● Check lubricant for contamination. 2. Malfunctioning expansion valve Low-pressure pipe is clogged or crushed. ● Check and repair malfunctioning parts. ● Check lubricant for contamination. ● Check intake sensor circuit. Refer to ATC-125, "Intake Sensor Circuit" . ● Replace compressor. Evaporator is frozen. ATC-109 H I ATC K 3. Outlet and inlet may be clogged. An area of the low-pressure pipe is colder than areas near the evaporator outlet. E G Temperature difference occurs somewhere in highpressure side. Expansion valve and liquid tank are warm or only cool when touched. AC353A Probable cause 2003 FX L M TROUBLE DIAGNOSIS Low-pressure Side Sometimes Becomes Negative Gauge indication Low-pressure side sometimes becomes negative. Refrigerant cycle ● ● AC354A Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted. Probable cause Refrigerant does not discharge cyclically. ↓ Moisture is frozen at expansion valve outlet and inlet. ↓ Water is mixed with refrigerant. Corrective action ● Drain water from refrigerant or replace refrigerant. ● Replace liquid tank. Low-pressure Side Becomes Negative Gauge indication Refrigerant cycle Probable cause Corrective action Leave the system at rest until no frost is present. Start it again to check whether or not the malfunction is caused by water or foreign particles. ● If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. ● If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). ● If either of the above methods cannot correct the malfunction, replace expansion valve. ● Replace liquid tank. ● Check lubricant for contamination. Low-pressure side becomes negative. Liquid tank or front/rear side of expansion valve′s pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. ↓ Expansion valve or liquid tank is frosted. AC362A DIAGNOSTIC PROCEDURE FOR INSUFFICIENT COOLING SYMPTOM: Insufficient cooling 1. CHECK POWER SUPPLY FOR ECV (ELECTRONIC CONTROL VALVE) 1. 2. 3. Disconnect compressor (ECV) connector. Turn ignition switch ON. Check voltage between compressor harness connector F6 terminal 2 (G) and ground. 2 – ground : Battery voltage OK or NG OK >> GO TO 2. NG >> Check power supply circuit and 10A fuse [No. 12, located in the fuse block (J/B)]. Refer to PG-98, "FUSE BLOCK - JUNCTION BOX (J/B)" . Revision; 2004 April ATC-110 RJIA2294E 2003 FX TROUBLE DIAGNOSIS 2. CHECK ECV CONTROL SIGNAL 1. 2. 3. 4. 5. A Turn ignition switch OFF. Reconnect compressor (ECV) connector. Perform self-diagnosis. Refer to ATC-66, "Self-diagnosis Function" . Set in self-diagnosis STEP-45. Refer to ATC-67, "FUNCTION CONFIRMATION PROCEDURE" . Confirm the unified meter and A/C amp. harness connector M57 terminal 45 (PU/W) duty ratio using an oscilloscope. B C D RJIA2295E E F G RJIA1475E OK or NG OK >> Replace compressor. NG >> GO TO 3. H I 3. CHECK CIRCUIT CONTINUITY BETWEEN ECV AND UNIFIED METER AND A/C AMP. 1. 2. 3. ATC Turn ignition switch OFF. Disconnect compressor (ECV) and unified meter and A/C amp. connector. Check continuity between compressor (ECV) harness connector F6 terminal 3 (PU) and unified meter and A/C amp. harness connector M57 terminal 45 (PU/W). 3 – 45 K L : Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair harness or connector. RJIA2296E 4. CHECK ECV Check continuity between compressor (ECV) connector F6 terminals 2 and 3. 2–3 : Continuity should exist. OK or NG OK >> Replace unified meter and A/C amp. NG >> Replace compressor. RJIA2297E Revision; 2004 April ATC-111 2003 FX M TROUBLE DIAGNOSIS Insufficient Heating AJS00150 SYMPTOM: Insufficient heating INSPECTION FLOW RJIA2013E *1 ATC-75, "Operational Check". *2 ATC-86, "Air Mix Door Motor Circuit". *3 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 4 to 6. *4 ATC-67, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *5 ATC-80, "LAN System Circuit". *6 ATC-92, "Blower Motor Circuit". *7 EC-197, "DTC P0117, P0118 ECT SENSOR" (VQ35DE) or EC-845, "DTC P0117, P0118 ECT SENSOR" (VK45DE). *8 CO-11, "Changing Engine Coolant" (VQ35DE) or CO-35, "Changing Engine Coolant" (VK45DE). *9 CO-15, "Checking Radiator Cap" (VQ35DE) or CO-40, "Checking Radiator Cap" (VK45DE). Revision; 2004 April ATC-112 2003 FX TROUBLE DIAGNOSIS Noise AJS00151 A SYMPTOM: Noise INSPECTION FLOW B C D E F G H I ATC K L M RJIA1596E Revision; 2004 April ATC-113 2003 FX TROUBLE DIAGNOSIS *1 Compressor Clutch, ATC-155, "REMOVAL" . *2 Compressor Clutch, ATC-157, "INSTALLATION" . *4 ATC-75, "Operational Check". *5 EM-15, "Checking Drive Belts" (VQ35DE) or EM-167, "Checking Drive Belts" (VK45DE). *3 ATC-27, "Maintenance of Lubricant Quantity in Compressor". Self-diagnosis AJS00152 SYMPTOM: Self-diagnosis cannot be performed. INSPECTION FLOW RJIA2014E *1 ATC-77, "Power Supply and Ground Circuit for Auto Amp.". *2 ATC-116, "Ambient Sensor Circuit". *3 ATC-119, "In-vehicle Sensor Circuit". *4 ATC-122, "Sunload Sensor Circuit". *5 ATC-125, "Intake Sensor Circuit". *6 ATC-88, "Air Mix Door Motor PBR Circuit". *7 ATC-75, "Operational Check". *8 ATC-54, "SYMPTOM TABLE". Revision; 2004 April ATC-114 2003 FX TROUBLE DIAGNOSIS Memory Function AJS00153 A SYMPTOM: Memory function does not operate. INSPECTION FLOW B C D E F G H I ATC K RJIA2015E *1 ATC-77, "Power Supply and Ground Circuit for Auto Amp.". *2 ATC-75, "Operational Check". *3 ATC-67, "FUNCTION CONFIRMATION PROCEDURE". L M Revision; 2004 April ATC-115 2003 FX TROUBLE DIAGNOSIS Ambient Sensor Circuit AJS00154 COMPONENT DESCRIPTION Ambient Sensor The ambient sensor is attached on the hood lock stay. It detects ambient temperature and converts it into a resistance value which is then input into the unified meter and A/C amp. RJIA2016E AMBIENT TEMPERATURE INPUT PROCESS The unified meter and A/C amp. 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 unified meter and A/C amp. function. It only allows the unified meter and A/C amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds. As an example, consider stopping for a cup of coffee 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. DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR SYMPTOM: Ambient sensor circuit is open or shorted. (21 or − 21 is indicated on unified meter and A/C amp. As a result of performing Self-diagnosis STEP-2.) RJIA1461E 1. CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND 1. 2. 3. Disconnect ambient sensor connector. Turn ignition switch ON. Check voltage between ambient sensor harness connector E34 terminal 1 (Y) and ground. 1 – Ground : Approx. 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. RJIA2017E Revision; 2004 April ATC-116 2003 FX TROUBLE DIAGNOSIS 2. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between ambient sensor harness connector E34 terminal 2 (W) and unified meter and A/C amp. harness connector M57 terminal 49 (W/G). 2 – 49 B C : Continuity should exist. OK or NG OK >> GO TO 3. NG >> Repair harness or connector. A D RJIA2018E 3. CHECK AMBIENT SENSOR E Refer to ATC-118, "Ambient Sensor" . OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace ambient sensor. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. F G H 4. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. 1 – 39 4. I Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between ambient sensor harness connector E34 terminal 1 (Y) and unified meter and A/C amp. harness connector M57 terminal 39 (Y). ATC : Continuity should exist. K Check continuity between ambient sensor harness connector E34 terminal 1 (Y) and ground. 1 – Ground : Continuity should not exist. RJIA2019E OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP -2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. Revision; 2004 April ATC-117 2003 FX L M TROUBLE DIAGNOSIS COMPONENT INSPECTION Ambient Sensor After disconnecting ambient sensor connector, measure resistance between terminals 2 and 1 at sensor harness side, using the table below. Temperature °C (°F) Resistance kΩ −15 (5) 12.73 −10 (14) 9.92 −5 (23) 7.80 0 (32) 6.19 5 (41) 4.95 10 (50) 3.99 15 (59) 3.24 20 (68) 2.65 25 (77) 2.19 30 (86) 1.81 35 (95) 1.51 40 (104) 1.27 45 (113) 1.07 RJIA2020E If NG, replace ambient sensor. Revision; 2004 April ATC-118 2003 FX TROUBLE DIAGNOSIS In-vehicle Sensor Circuit AJS00155 A COMPONENT DESCRIPTION In-vehicle Sensor The in-vehicle sensor is located on instrument driver lower panel. It converts variations in temperature of compartment air drawn from the aspirator into a resistance value. It is then input into the unified meter and A/C amp. B C D RJIA2021E Aspirator The aspirator is located on driver′s side of heater & cooling unit. It produces vacuum pressure due to air discharged from the heater & cooling unit, continuously taking compartment air in the aspirator. E F G H RJIA0921E I ATC K L RJIA1804E M Revision; 2004 April ATC-119 2003 FX TROUBLE DIAGNOSIS DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR SYMPTOM: In-vehicle sensor circuit is open or shorted. (22 or −22 is indicated on unified meter and A/C amp. as a result of performing Self-diagnosis STEP-2.) RJIA1452E 1. CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND 1. 2. 3. Disconnect in-vehicle sensor connector. Turn ignition switch ON. Check voltage between in-vehicle sensor harness connector M46 terminal 1 (BR/W) and ground. 1 – Ground : Approx. 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. RJIA2022E 2. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between in-vehicle sensor harness connector M46 terminal 2 (W/G) and unified meter and A/C amp. harness connector M57 terminal 49 (W/G). 2 – 49 : Continuity should exist. OK or NG OK >> GO TO 3. NG >> Repair harness or connector. RJIA2023E 3. CHECK IN-VEHICLE SENSOR Refer to ATC-121, "In-vehicle Sensor" . OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace in-vehicle sensor. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. Revision; 2004 April ATC-120 2003 FX TROUBLE DIAGNOSIS 4. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between in-vehicle sensor harness connector M46 terminal 1 (BR/W) and unified meter and A/C amp. harness connector M57 terminal 40 (BR/W). 1 – 40 4. B C : Continuity should exist. Check continuity between in-vehicle sensor harness connector M46 terminal 1 (BR/W) and ground. 1 – Ground A : Continuity should not exist. D RJIA2024E OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. E COMPONENT INSPECTION In-vehicle Sensor G After disconnecting in-vehicle sensor connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below. H Temperature °C (°F) Resistance kΩ −15 (5) 12.73 −10 (14) 9.92 −5 (23) 7.80 0 (32) 6.19 5 (41) 4.95 10 (50) 3.99 15 (59) 3.24 20 (68) 2.65 25 (77) 2.19 30 (86) 1.81 35 (95) 1.51 40 (104) 1.27 45 (113) 1.07 I ATC K L M RJIA2025E If NG, replace in-vehicle sensor. Revision; 2004 April F ATC-121 2003 FX TROUBLE DIAGNOSIS Sunload Sensor Circuit AJS00156 COMPONENT DESCRIPTION Sunload Sensor The sunload sensor is located on the passenger side front defroster grille. It detects sunload entering through windshield by means of a photo diode. The sensor converts the sunload into a current value which is then input into the unified meter and A/C amp. RJIA2026E SUNLOAD INPUT PROCESS The unified meter and A/C amp. also includes a processing circuit which averages the variations in detected sunload over a period of time. This prevents drastic swings 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 sunload 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. DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR SYMPTOM: Sunload sensor circuit is open or shorted. (25 or −25 is indicated on unified meter and A/C amp. as a result of performing Self-diagnosis STEP-2.) RJIA1455E 1. CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND 1. 2. 3. Disconnect sunload sensor connector. Turn ignition switch ON. Check voltage between sunload sensor harness connector M87 terminal 1 (LG) and ground. 1 – Ground : Approx. 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. RJIA2027E Revision; 2004 April ATC-122 2003 FX TROUBLE DIAGNOSIS 2. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between sunload sensor harness connector M87 terminal 2 (W/G) and unified meter and A/C amp. harness connector M57 terminal 49 (W/G). 2 – 49 B C : Continuity should exist. OK or NG OK >> GO TO 3. NG >> Repair harness or connector. A D RJIA2028E 3. CHECK SUNLOAD SENSOR E Refer to ATC-124, "Sunload Sensor" . OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace sunload sensor. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. F G H 4. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. 1 – 50 4. I Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between sunload sensor harness connector M87 terminal 1 (LG) and display and A/C auto amp. harness connector M57 terminal 50 (LG). ATC : Continuity should exist. K Check continuity between sunload sensor harness connector M87 terminal 1 (LG) and ground. 1 – Ground : Continuity should not exist. RJIA2029E OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. Revision; 2004 April ATC-123 2003 FX L M TROUBLE DIAGNOSIS COMPONENT INSPECTION Sunload Sensor Measure voltage between unified meter and A/C amp. harness connector M57 terminal 50 (LG) and ground. If NG, replace sunload sensor. RJIA2030E ● When checking sunload sensor, select a place where sun shines directly on it. SHA930E Revision; 2004 April ATC-124 2003 FX TROUBLE DIAGNOSIS Intake Sensor Circuit AJS00157 A COMPONENT DESCRIPTION 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 unified meter and A/C amp. B C D RJIA0928E DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR SYMPTOM: Intake sensor circuit is open or shorted. (24 or −24 is indicated on unified meter and A/C amp. as a result of performing Self-diagnosis STEP-2.) E F G H RJIA1458E I 1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND 1. 2. 3. ATC Disconnect intake sensor connector. Turn ignition switch ON. Check voltage between intake sensor harness connector M254 terminal 2 (R) and ground. 2 – Ground K : Approx. 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. L RJIA2031E 2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between intake sensor harness connector M254 terminal 1 (W) and unified meter and A/C amp. harness connector M57 terminal 49 (W/G). 1 – 49 : Continuity should exist. OK or NG OK >> GO TO 3. NG >> Repair harness or connector. Revision; 2004 April RJIA2032E ATC-125 2003 FX M TROUBLE DIAGNOSIS 3. CHECK INTAKE SENSOR Refer to ATC-126, "Intake Sensor" . OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace intake sensor. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. 4. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND UNIFIED METER AND A/C AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect unified meter and A/C amp. connector. Check continuity between intake sensor harness connector M254 terminal 2 (R) and unified meter and A/C amp. harness connector M57 terminal 41 (P). 2 – 41 4. : Continuity should exist. Check continuity between intake sensor harness connector M254 terminal 2 (R) and ground. 2 – Ground : Continuity should not exist. RJIA2033E OK or NG OK >> 1. Replace unified meter and A/C amp. 2. Go to self-diagnosis ATC-67, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. COMPONENT INSPECTION Intake Sensor After disconnecting intake sensor connector, measure resistance between terminals 1 and 2 at sensor harness side, using the table below. Temperature °C (°F) Resistance kΩ −15 (5) 12.34 −10 (14) 9.62 −5 (23) 7.56 0 (32) 6.00 5 (41) 4.80 10 (50) 3.87 15 (59) 3.15 20 (68) 2.57 25 (77) 2.12 30 (86) 1.76 35 (95) 1.47 40 (104) 1.23 45 (113) 1.04 RJIA2034E If NG, replace intake sensor. Revision; 2004 April ATC-126 2003 FX CONTROLLER CONTROLLER Removal and Installation of A/C and AV Switch PFP:27500 A AJS001BN REMOVAL Refer to AV-43, "Removal and Installation for A/C and AV Switch" . B INSTALLATION Installation is basically the reverse order of removal. C D E F G H I ATC K L M Revision; 2004 April ATC-127 2003 FX AUTO AMP AUTO AMP Removal and Installation of Unified Meter and A/C Amp. PFP:27760 AJS00159 REMOVAL 1. 2. Remove the audio unit. Refer to AV-42, "Removal and Installation of Audio Unit" . Remove the fixing screws, then remove the unified meter and A/ C amp. RJIA2035E INSTALLATION Installation is basically the reverse order of removal. Revision; 2004 April ATC-128 2003 FX AMBIENT SENSOR AMBIENT SENSOR Removal and Installation PFP:27722 A AJS0015A REMOVAL 1. 2. Remove front grille. Refer to EI-23, "FRONT GRILLE" . Disconnect ambient sensor connector, then remove it. B C D RJIA2016E E INSTALLATION Installation is basically the reverse order of removal. F G H I ATC K L M Revision; 2004 April ATC-129 2003 FX IN-VEHICLE SENSOR IN-VEHICLE SENSOR Removal and Installation PFP:27720 AJS0015B REMOVAL 1. 2. Remove instrument driver lower panel. Refer to IP-11, "Removal and Installation" . Remove in-vehicle sensor. RJIA2036E INSTALLATION Installation is basically the reverse order of removal. Revision; 2004 April ATC-130 2003 FX SUNLOAD SENSOR SUNLOAD SENSOR Removal and Installation PFP:27721 A AJS0015C REMOVAL 1. 2. Remove front defroster grille (right side). Refer to IP-11, "Removal and Installation" . Disconnect sunload sensor connector, then remove sunload sensor. B C D RJIA2026E E INSTALLATION Installation is basically the reverse order of removal. F G H I ATC K L M Revision; 2004 April ATC-131 2003 FX INTAKE SENSOR INTAKE SENSOR Removal and Installation PFP:27723 AJS0015D REMOVAL 1. 2. 3. 4. 5. 6. a. b. c. 7. Set the temperature at 18°C (60°F), and then disconnect the battery negative cable. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant. Remove cowl top cover. Refer to EI-24, "COWL TOP" . Remove high-pressure pipe 2 mounting clip. Remove low-pressure flexible hose bracket mounting bolts. Disconnect evaporator-side one-touch joints. Set a disconnector (High-pressure side: 92530-89908, Lowpressure side: 92530-89916) on A/C piping. Slide a disconnector toward vehicle front until it clicks. Slide A/C piping toward vehicle front and disconnect it. CAUTION: Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere. Remove blower unit. Refer to ATC-134, "BLOWER UNIT" . RJIA2037E 8. Remove air mix door motor (Passenger side), mode door motor and evaporator cover. RJIA0940E 9. Remove the mounting bolt, then remove the low-pressure pipe 2 and high-pressure pipe 3. CAUTION: Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere. RJIA2038E 10. Slide the evaporator to passenger side, then remove the intake sensor. RJIA0928E Revision; 2004 April ATC-132 2003 FX INTAKE SENSOR INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones. Before installing, apply compressor oil to them. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. A B C D E F G H I ATC K L M Revision; 2004 April ATC-133 2003 FX BLOWER UNIT BLOWER UNIT Removal and Installation PFP:27200 AJS0015E REMOVAL 1. 2. 3. 4. Remove instrument passenger lower panel. Refer to IP-11, "Removal and Installation" . Remove ECM with bracket attached. Disconnect intake door motor connector and blower fan motor connector. Remove harness clip from blower unit. RJIA2039E 5. 6. Remove mounting bolt and screws (2), from blower unit. CAUTION: Move blower unit rightward, and remove locating pin (1) and joint. Then remove blower unit downward. Remove blower unit. RJIA0943E INSTALLATION Installation is basically the reverse order of removal. CAUTION: Make sure locating pin (1) and joint are securely inserted. Revision; 2004 April ATC-134 2003 FX BLOWER UNIT Disassembly and Assembly AJS0015F A B C D E F G H I RJIA2240E 1. Adapter 4. Intake lower case 7. Intake door lever 2 10. Intake door lever 3 13. Intake door 1 2. Intake upper case 3. Filter cover 5. Blower fan motor assembly 6. Motor cover 8. Intake door motor 9. Intake door link 11. Intake door 2 12. Intake door lever 1 14. Intake bell mouth ATC K L M Revision; 2004 April ATC-135 2003 FX BLOWER MOTOR BLOWER MOTOR Removal and Installation PFP:27226 AJS0015G REMOVAL 1. 2. 3. Remove instrument lower cover. Refer to IP-11, "Removal and Installation" . Disconnect blower motor connector. Remove screws from blower motor, then remove it. RJIA2239E INSTALLATION Installation is basically the reverse order of removal. Revision; 2004 April ATC-136 2003 FX INTAKE DOOR MOTOR INTAKE DOOR MOTOR Removal and Installation PFP:27730 A AJS0015H REMOVAL 1. 2. Remove blower unit. Refer to ATC-134, "BLOWER UNIT" . Remove intake door motor from the blower unit. B C D RJIA0947E E INSTALLATION Installation is basically the reverse order of removal. F G H I ATC K L M Revision; 2004 April ATC-137 2003 FX HEATER & COOLING UNIT ASSEMBLY HEATER & COOLING UNIT ASSEMBLY Removal and Installation PFP:27110 AJS0015J REMOVAL 1. 2. 3. 4. 5. 6. a. b. c. 7. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant. Drain coolant from cooling system. Refer to CO-11, "Changing Engine Coolant" (VQ35DE) or CO-35, "Changing Engine Coolant" (VK45DE). Remove cowl top cover. Refer to EI-24, "COWL TOP" . Remove high-pressure pipe 2 mounting clip. Remove low-pressure flexible hose bracket mounting bolts. Disconnect evaporator-side one touch joint. Set a disconnector (High-pressure side: 92530-89908, Lowpressure side: 92530-89916) on A/C piping. Slide a disconnector toward vehicle front until it clicks. Slide A/C piping toward vehicle front and disconnect it. CAUTION: Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere. Remove electronic control throttle assembly (VQ35DE). Refer to EM-19, "INTAKE MANIFOLD COLLECTOR" . RJIA2037E 8. 9. Disconnect two heater hoses from heater core. Remove instrument panel assembly. Refer to IP-11, "Removal and Installation" . 10. Remove blower unit. Refer to ATC-134, "BLOWER UNIT" . RJIA2041E RJIA2077E 11. Remove instrument stays (driver side and passenger side). RJIA2042E Revision; 2004 April ATC-138 2003 FX HEATER & COOLING UNIT ASSEMBLY A B C D E F RJIA2043E 12. 13. 14. 15. 16. Remove ventilator ducts, defroster nozzle and ducts. Remove steering member mounting bolts, nut and harness clips. Remove mounting screws from heater & cooling unit. Disconnect drain hose. Remove the steering member, and then remove heater & cooling unit. G H I ATC RJIA2044E INSTALLATION K Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new one, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to check that piping does not come off. ● When recharging refrigerant, check for leaks. NOTE: ● When filling radiator with coolant, refer to CO-11, "Changing Engine Coolant" (VQ35DE) or CO-35, "Changing Engine Coolant" (VK45DE). ● Recharge the refrigerant. Heater & cooling unit mounting bolt Tightening torque : 6.8 N·m (0.69 kg-m, 60 in - lb) Steering member mounting nut and bolt Tightening torque : 12 N·m (1.2 kg-m, 9 ft - lb) Revision; 2004 April ATC-139 2003 FX L M HEATER & COOLING UNIT ASSEMBLY Disassembly and Assembly AJS0015K RJIA2045E 1. Heater pipe grommet 2. Heater core 3. Heater pipe cover 4. Aspirator 5. Aspirator hose 6. Air mix door motor (driver side) 7. Air mix door (slide door) 8. Max. cool door link 9. Max. cool door lever 10. Ventilator door lever 11. Ventilator door link 12. Air mix door motor (passenger side) 13. Intake sensor bracket 14. Intake sensor 15. Foot duct (right) 16. Evaporator cover 17. Evaporator cover adaptor 18. Heater pipe bracket Revision; 2004 April ATC-140 2003 FX HEATER & COOLING UNIT ASSEMBLY 19. Insulator 20. Heater case (right) 21. Low-pressure pipe 2 22. High-pressure pipe 3 23. Expansion valve 24. Evaporator 25. Heater case (left) 26. Foot duct (left) 27. Center case 28. Max. cool door (left) 29. Ventilator door 30. Side link 31. Mode door motor 32. Defroster door 33. Max. cool door (right) 34. Defroster door lever 35. Defroster door link A B C D E F G H I ATC K L M Revision; 2004 April ATC-141 2003 FX MODE DOOR MOTOR MODE DOOR MOTOR Removal and Installation PFP:27731 AJS0015L REMOVAL 1. 2. 3. Remove blower unit. Refer to ATC-134, "BLOWER UNIT" . Remove mounting screws from mode door motor. Disconnect mode door connector, and then remove mode door motor. RJIA0954E INSTALLATION Installation is basically the reverse order of removal. Revision; 2004 April ATC-142 2003 FX AIR MIX DOOR MOTOR AIR MIX DOOR MOTOR Removal and Installation PFP:27732 A AJS0015M REMOVAL Driver Side 1. 2. 3. 4. B Set the temperature at 18°C (60°F), and then disconnect the battery negative cable. Remove instrument lower driver panel. Refer to IP-11, "Removal and Installation" . Remove air mix door motor. Disconnect air mix door motor connector. C D E RJIA0956E F Passenger Side 1. 2. 3. 4. Set the temperature at 18°C (60°F), and then disconnect the battery negative cable. Remove blower unit. Refer to ATC-134, "BLOWER UNIT" . Remove air mix door motor. Disconnect air mix door motor connector. G H I ATC RJIA0955E INSTALLATION K Installation is basically the reverse order of removal. L M Revision; 2004 April ATC-143 2003 FX HEATER CORE HEATER CORE Removal and Installation PFP:27140 AJS0015N REMOVAL 1. 2. 3. 4. 5. Remove heater & cooling unit. Refer to ATC-138, "HEATER & COOLING UNIT ASSEMBLY" . Remove foot duct (left). Refer to ATC-148, "Removal of Foot Ducts" . Remove heater pipe cover. Remove heater pipe support and heater pipe grommet. Slide heater core to driver side. RJIA2046E INSTALLATION Installation is basically the reverse order of removal. Revision; 2004 April ATC-144 2003 FX DUCTS AND GRILLES DUCTS AND GRILLES Removal and Installation PFP:27860 A AJS0015O REMOVAL B C D E F G RJIA2047E 1. Defroster nozzle 2. Side defroster duct (left) 3. Side ventilator duct (left) 4. Instrument panel 5. Side ventilation (left) 6. Center ventilator grille (left) 7. Center ventilator grille (right) 8. Side ventilation (right) 9. Center ventilator duct (right) 10. Side ventilator duct (right) 11. Side defroster duct (right) H 12. Center ventilator duct I 13. Center ventilator duct (left) Removal of Center Ventilator Grille 1. 2. Remove cluster lid C. Refer to IP-11, "Removal and Installation" . Remove center ventilator grille. ATC K L M RJIA2048E Removal of Side Ventilation 1. Remove side ventilation. Refer to IP-11, "Removal and Installation" . Removal of Rear Ventilator Grille 1. 2. Remove center pillar lower garnish. Refer to EI-37, "Removal and Installation" . Remove mounting clips, then remove rear ventilator grille. RJIA2050E Revision; 2004 April ATC-145 2003 FX DUCTS AND GRILLES Removal of Defroster Nozzle, Ducts and Ventilator Ducts 1. 2. 3. 4. 5. 6. Remove instrument panel assembly. Refer to IP-11, "Removal and Installation" . Remove side defroster ducts, using power tools. Remove defroster nozzle, using power tools. Remove center ventilator duct (right and left). Remove side ventilator ducts. Remove center ventilator duct. RJIA2051E Revision; 2004 April ATC-146 2003 FX DUCTS AND GRILLES Removal of Rear Ventilator Ducts 1. 2. A Remove center console. Refer to IP-11, "Removal and Installation" . Slide rear ventilator duct 2 toward vehicle front, then remove it. B C D E F G RJIA2052E 3. 4. Remove floor carpet. Refer to EI-40, "Removal and Installation" . Remove rear ventilator duct 3 mounting clips, then remove rear ventilator duct 3. H I ATC K L M RJIA2053E 5. 6. 7. Remove instrument panel assembly. Refer to IP-11, "Removal and Installation" . Remove rear ventilator duct 1 with center floor duct attached. Remove rear ventilator duct 1 from center floor duct. RJIA2054E Revision; 2004 April ATC-147 2003 FX DUCTS AND GRILLES Removal of Foot Ducts 1. 2. Remove heater & cooling unit. Refer to ATC-138, "HEATER & COOLING UNIT ASSEMBLY" . Remove evaporator cover, and then remove foot duct (passenger side). RJIA0962E Removal of Floor Ducts 1. 2. 3. Remove floor carpet. Refer to EI-40, "Removal and Installation" . Remove mounting clips from side floor ducts. Remove side floor ducts. RJIA2055E 4. 5. 6. Remove instrument panel assembly. Refer to IP-11, "Removal and Installation" . Remove center floor duct with rear ventilator duct 1 attached. Remove center floor duct from rear ventilator duct 1. RJIA2054E INSTALLATION Installation is basically the reverse order of removal. Revision; 2004 April ATC-148 2003 FX REFRIGERANT LINES REFRIGERANT LINES HFC-134a (R-134a) Service Procedure PFP:92600 A AJS0015P SETTING OF SERVICE TOOLS AND EQUIPMENT Discharging Refrigerant B WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of SAE J2210 [HFC-134a (R-134a) recycling equipment] or J2201 [HFC-134a (R-134a) recovery equipment]. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. C D E F G H I SHA179FD ATC Evacuating System and Charging Refrigerant K L M SHA180FD Revision; 2004 April ATC-149 2003 FX REFRIGERANT LINES RJIA1878E *1 ATC-27, "LUBRICANT RETURN OPERATION" *2 ATC-170, "Checking for Refrigerant Leaks" *4 ATC-105, "PERFORMANCE TEST DIAGNOSES" *5 ATC-5, "CONTAMINATED REFRIGERANT" Revision; 2004 April ATC-150 *3 ATC-172, "CHECKING PROCEDURE" 2003 FX REFRIGERANT LINES Components AJS0015Q A Refer to ATC-8, "Precautions for Refrigerant Connection" . VK45DE B C D E F G H I ATC K RJIA2056E L M Revision; 2004 April ATC-151 2003 FX REFRIGERANT LINES VQ35DE RJIA2057E Removal and Installation of Compressor AJS0015R REMOVAL VK45DE RJIA2244E Revision; 2004 April ATC-152 2003 FX REFRIGERANT LINES VQ35DE A B C D E F RJIA2245E 1. 2. 3. 4. 5. 6. G Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove the air cleaner and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" (VQ35DE) or EM170, "AIR CLEANER AND AIR DUCT" (VK45DE). H Remove front engine undercover, using power tools. Remove cooling fan shroud (lower). Refer to CO-38, "RADIATOR" (VK45DE). Remove mounting nuts from low-pressure flexible hose and I high-pressure flexible hose. CAUTION: Cap or wrap the joint of the pipe with suitable material such ATC as vinyl tape to avoid the entry of air. Remove high-pressure flexible hose. Refer to ATC-160, "Removal and Installation of High-pressure Flexible Hose" K (VK45DE). RJIA2058E L M RJIA2059E 7. 8. 9. Disconnect compressor (magnet clutch and ECV) connectors. Remove the A/C compressor belt. Refer to EM-15, "DRIVE BELTS" (VQ35DE) or EM-167, "DRIVE BELTS" (VK45DE). Remove mounting bolt from radiator hose bracket (VK45DE). Revision; 2004 April ATC-153 2003 FX REFRIGERANT LINES 10. Remove mounting bolts from compressor, using power tools. 11. Remove compressor from downward (VK45DE). RJIA2060E 12. Remove compressor from downward (VQ35DE). RJIA2061E INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace the O-ring of the low-pressure flexible hose, high-pressure pipe and high-pressure flexible hose with a new one, then apply compressor oil to it when installing it. ● When recharging refrigerant, check for leaks. Bolts mounting the idler pulley bracket Tightening torque : 28.0 N·m (2.9 kg-m, 21 ft-lb) Revision; 2004 April ATC-154 2003 FX REFRIGERANT LINES Removal and Installation of Compressor Clutch AJS001C8 A REMOVAL Overhaul 1. When removing center bolt, hold clutch disc with wrench. B C D RHA136EB E F G H RHA399FA 2. Remove the clutch disc using the clutch disc puller. I ATC K RHA124FA L 3. Remove the snap ring using external snap ring pliers. M RHA138E Revision; 2004 April ATC-155 2003 FX REFRIGERANT LINES 4. Position the center pulley puller on the end of the drive shaft, and remove the pulley assembly using any commercially available pulley puller. To prevent the pulley groove from being deformed, the puller claws should be positioned into the edge of the pulley assembly. RHA139E 5. Remove the field coil harness clip using a pair of pliers. RHA125F 6. Remove the snap ring using external snap ring pliers. RHA145E Inspection Clutch disc If the contact surface shows signs of damage due to excessive heat, replace clutch disc and pulley. Pulley Check the appearance of the pulley assembly. If the contact surface of pulley sows 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. RHA126F Coil Check coil for loose connection or cracked insulation. Revision; 2004 April ATC-156 2003 FX REFRIGERANT LINES INSTALLATION 1. 2. A Install the field coil. Be sure to align the coil′s pin with the hole in the compressor′s front head. Install the field coil harness clip using a screwdriver. B C RHA142E 3. Install the pulley assembly using the installer and a hand press, and then install the snap ring using snap ring pliers. D E F G RHA143E 4. H Install the clutch disc on the drive shaft, together with the original shim(s). Press the clutch disc down by hand. I ATC K RHA127F 5. Using the holder to prevent clutch disc rotation, tighten the bolt to 14 N·m (1.4 kg-m, 10 ft-lb) torque. After tightening the bolt, make sure the pulley rotates smoothly. L M RHA086E Revision; 2004 April ATC-157 2003 FX REFRIGERANT LINES 6. Check clearance around the entire periphery of clutch disc. Disc to pulley clearance : 0.25 - 0.6 mm (0.010 - 0.024 in) If the specified clearance is not obtained, replace adjusting spacer and readjust. RJIA0965E Break-in Operation When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engaging and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque. Revision; 2004 April ATC-158 2003 FX REFRIGERANT LINES Removal and Installation of Low-pressure Flexible Hose AJS001BG A REMOVAL 1. 2. 3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove the air cleaner and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" (VQ35DE) or EM170, "AIR CLEANER AND AIR DUCT" (VK45DE). Remove mounting bolt for low-pressure flexible hose bracket. B C D E RJIA2062E 4. a. b. c. Disconnect one-touch joint between low-pressure flexible hose and low-pressure pipe 1. Set a disconnector (92530-89916) on A/C piping. Slide a disconnector toward vehicle front until it clicks. Slide A/C piping toward vehicle front and disconnect it. F G H RJIA2069E 5. 6. 7. Remove mounting nut from low-pressure flexible hose. Remove low-pressure flexible hose. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove low-pressure pipe (VK45DE). I ATC K L RJIA2063E M RJIA2064E Revision; 2004 April ATC-159 2003 FX REFRIGERANT LINES INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new one, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to check that piping does not come off. ● When recharging refrigerant, check for leaks. Bolt mounting the low-pressure flexible hose bracket Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) Removal and Installation of High-pressure Flexible Hose AJS0015U REMOVAL 1. 2. 3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove the air cleaner and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" (VQ35DE) or EM170, "AIR CLEANER AND AIR DUCT" (VK45DE). Remove mounting bolt for high-pressure flexible hose bracket. RJIA2065E 4. a. b. c. Disconnect one-touch joint between high-pressure flexible hose and condenser. Set a disconnector (92530-89912) on A/C piping. Slide a disconnector upward until it clicks. Slide A/C piping upward and disconnect it. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. RJIA2066E 5. Remove mounting nut for high-pressure flexible hose (compressor side), and then remove high-pressure flexible hose. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. RJIA2067E Revision; 2004 April ATC-160 2003 FX REFRIGERANT LINES INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. ● When recharging refrigerant, check for leaks. Bolt mounting the high-pressure flexible hose bracket Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) Removal and Installation of Low-pressure Pipe 1 (Engine Compartment) A B C D E AJS0015V REMOVAL 1. 2. 3. F Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove cowl top cover. Refer to EI-24, "COWL TOP" . Remove mounting bolt for low-pressure pipe 1 bracket and lowpressure flexible hose bracket. G H I RJIA2068E 4. a. b. c. Disconnect one-touch joints. Set a disconnector (92530-89916) on A/C piping. Slide a disconnector toward vehicle front until it clicks. Slide A/C piping toward vehicle front and disconnect it. ATC K L M RJIA2069E 5. Remove low-pressure pipe 1. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. RJIA2037E Revision; 2004 April ATC-161 2003 FX REFRIGERANT LINES INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. ● When recharging refrigerant, check for leaks. Bolts mounting the low-pressure pipe 1 bracket and low-pressure flexible hose bracket Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) Removal and Installation of High-pressure Pipe 1 and 2 (Engine Compartment) AJS001BH REMOVAL 1. 2. 3. 4. 5. 6. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove front wiper motor and linkage. Refer to WW-44, "Removal and Installation of Front Wiper Motor and Linkage" . Remove the air cleaner and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" (VQ35DE) or EM170, "AIR CLEANER AND AIR DUCT" (VK45DE). Remove low-pressure pipe 1. Refer to ATC-161, "Removal and Installation of Low-pressure Pipe 1 (Engine Compartment)" . Remove high-pressure flexible hose and low-pressure flexible hose. Refer to ATC-160, "Removal and Installation of High-pressure Flexible Hose" and ATC-159, "Removal and Installation of Low-pressure Flexible Hose" . Remove high-pressure pipe 1 and 2 from clips. RJIA2070E 7. a. b. c. Disconnect one-touch joint between condenser and high-pressure pipe 1. Set a disconnector (92530-89908) on A/C piping. Slide a disconnector upward until it clicks. Slide A/C piping upward and disconnect it. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. RJIA2071E Revision; 2004 April ATC-162 2003 FX REFRIGERANT LINES 8. a. b. c. 9. Disconnect one-touch joint between high-pressure pipe 1 and 2. Set a disconnector (92530-89908) on A/C piping. Slide a disconnector toward vehicle rear until it clicks. Slide A/C piping toward vehicle rear and disconnect it. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove high-pressure pipe 1. A B C RJIA2072E D 10. a. b. c. 11. Disconnect one-touch joint between high-pressure pipe 2 and 3. Set a disconnector (92530-89908) on A/C piping. Slide a disconnector toward vehicle front until it clicks. Slide A/C piping toward vehicle front and disconnect it. Remove the high-pressure pipe 2. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. E F G RJIA2073E INSTALLATION H Installation is basically the reverse order of removal. CAUTION: ● Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when I installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ATC ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. K ● When recharging refrigerant, check for leaks. Removal and Installation of Low-pressure Pipe 2 and High-pressure Pipe 3 AJS001BI REMOVAL 1. 2. 3. 4. L Set the temperature at 18°C (60°F), and then disconnect the battery negative cable. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove cowl top cover. Refer to EI-24, "COWL TOP" . Remove mounting bolts for low-pressure pipe 1 bracket and lowpressure flexible hose bracket. M RJIA2068E Revision; 2004 April ATC-163 2003 FX REFRIGERANT LINES 5. Remove high-pressure pipe 1 from vehicle clips. RJIA2070E 6. a. b. c. 7. Disconnect one-touch joints. Set a disconnector (High-pressure side: 92530-89908, Lowpressure side: 92530-89916) on A/C piping. Slide a disconnector toward vehicle front until it clicks. Slide A/C piping toward vehicle front and disconnect it. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove blower unit. Refer to ATC-134, "BLOWER UNIT" . RJIA2037E 8. Remove air mix door motor (passenger side), mode door motor and evaporator cover. RJIA0940E 9. Remove mounting bolt, then, remove low-pressure pipe 2 and high-pressure pipe 3. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. RJIA2038E INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. ● When recharging refrigerant, check for leaks. Revision; 2004 April ATC-164 2003 FX REFRIGERANT LINES Bolts mounting low-pressure pipe 1 bracket and low-pressure flexible hose bracket Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) Removal and Installation of Liquid Tank A AJS0015Y REMOVAL 1. 2. 3. 4. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove front grille. Refer to EI-23, "FRONT GRILLE" . Clean liquid tank and its surrounding area, and remove dirt and rust from tank. CAUTION: Be sure to clean carefully. Remove mounting bolts for liquid tank and power steering oil cooler. B C D E F G H I RJIA2074E 5. 6. Lift liquid tank upwards. Remove bracket from protruding part of condenser. Slide liquid tank upward, then remove liquid tank. ATC K L M RJIA0672E INSTALLATION Install liquid tank, and then install liquid tank bracket on condenser. CAUTION: ● Make sure liquid tank bracket is securely installed at protrusion of condenser. (Make sure liquid tank bracket does not move to a position below center of liquid tank.) ● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it. ● When recharging refrigerant, check for leaks. RJIA0673E Revision; 2004 April ATC-165 2003 FX REFRIGERANT LINES Removal and Installation of Condenser AJS0015Z REMOVAL 1. 2. 3. 4. 5. 6. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove the air cleaner and air duct. Refer to EM-17, "AIR CLEANER AND AIR DUCT" (VQ35DE) or EM170, "AIR CLEANER AND AIR DUCT" (VK45DE). Remove engine undercover, using power tools. Drain engine coolant (VK45DE). Refer to CO-35, "Changing Engine Coolant" . Remove cooling fan shroud after removing radiator upper hose (VK45DE). Refer to CO-38, "RADIATOR" . Remove mounting bolt for high-pressure flexible hose bracket. RJIA2065E 7. a. b. c. Disconnect high-pressure flexible hose and high-pressure pipe 1 from condenser. Set a disconnector (Condenser outlet: 92530-89908, Condenser inlet: 92530-89912) on A/C piping. Slide a disconnector upward until it clicks. Slide A/C piping upward and disconnect it. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. RJIA2066E 8. Remove mounting bolts for condenser. RJIA2075E 9. Remove radiator upper mount, move radiator and condenser to the engine side. 10. Remove condenser. CAUTION: Be careful not to damage the core surface of the condenser and the radiator. INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. Revision; 2004 April ATC-166 2003 FX REFRIGERANT LINES ● ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. When recharging refrigerant, check for leaks. Bolt mounting the high-pressure flexible hose bracket Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) Removal and Installation of Refrigerant Pressure Sensor B AJS00160 C REMOVAL 1. 2. A Remove condenser. Refer to ATC-166, "Removal and Installation of Condenser" . Remove refrigerant pressure sensor from condenser. CAUTION: When working, be careful not to damage the condenser fins. D E F RJIA2076E INSTALLATION G Installation is basically the reverse order of removal. CAUTION: Apply compressor oil to the O-ring of the refrigerant pressure sensor when installing it. Removal and Installation of Evaporator H AJS001BJ REMOVAL 1. 2. 3. 4. 5. I Set the temperature at 18°C (60°F), and then disconnect the battery negative cable. Using a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove low-pressure pipe 2 and high-pressure pipe 3. Refer to ATC-163, "Removal and Installation of ATC Low-pressure Pipe 2 and High-pressure Pipe 3" . CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. K Slide evaporator, then remove it from heater & cooling unit. Remove intake sensor from evaporator, then remove evaporator. L M RJIA0928E INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, then apply compressor oil to it when installing it. ● Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. ● Insert one-touch joint connection point securely until it clicks. ● After piping has been connected, pull male-side piping by hand to make sure piping does not come off. ● The O-rings are different from low-pressure pipe 1 (high-pressure pipe 2) and low-pressure pipe 2 (high-pressure pipe 3). ● Mark the mounting position of the intake sensor bracket. Revision; 2004 April ATC-167 2003 FX REFRIGERANT LINES ● When recharging refrigerant, check for leaks. Bolt mounting low-pressure pipe 1 bracket Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) Revision; 2004 April ATC-168 2003 FX REFRIGERANT LINES Removal and Installation of Expansion Valve AJS001BK REMOVAL A 1. 2. 3. 4. B Set the temperature at 18°C (60°F), and then disconnect the battery negative cable. Using a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove evaporator. Refer to ATC-167, "Removal and Installation of Evaporator" . Remove mounting bolts for expansion valve, then remove expansion valve. C D E RJIA1864E INSTALLATION F Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings with new ones, then apply compressor oil to them when installing them. ● The O-rings are different from low-pressure pipe 1 (high-pressure pipe 2) and low-pressure pipe 2 (high-pressure pipe 3). ● When recharging refrigerant, check for leaks. Bolts mounting expansion valve Tightening torque : 3.9N·m (0.4 kg-m, 35 in-lb) G H I ATC K L M Revision; 2004 April ATC-169 2003 FX REFRIGERANT LINES Checking for Refrigerant Leaks AJS00163 Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. 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 or fluorescent dye leak detector. If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak 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 leak detector, move the probe along the suspected leak area at 1 to 2 inches per second and no further than 1/4 inch from the component. CAUTION: Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak. Checking System for Leaks Using the Fluorescent Leak Detector AJS00164 1. Check A/C system for leaks using the UV lamp 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 (tubes, core or expansion valve) leak. 2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or cloth, with the UV lamp for dye residue. 3. After the leak is repaired, remove any residual dye using dye cleaner (J-43872) to prevent future misdiagnosis. 4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector. 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 detector to contact with any substance. This can also cause false readings and may damage the detector. Dye Injection AJS00165 (This procedure is only necessary when recharging the system or when the compressor has seized and was replaced.) Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm2 , 50 psi). Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459). Connect the injector tool to the A/C Low-pressure side service fitting. Start engine and switch A/C ON. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture′s operating instructions). 6. With the engine still running, disconnect the injector tool from the service fitting. CAUTION: Be careful the A/C system or replacing a component, pour the dye directly into the open system connection and proceed with the service procedures. 7. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to penetrate a leak and become visible. 1. 2. 3. 4. 5. Revision; 2004 April ATC-170 2003 FX REFRIGERANT LINES Electronic Refrigerant Leak Detector AJS00166 PRECAUTIONS FOR HANDLING LEAK DETECTOR A When performing a refrigerant leak check, use a J-41995 A/C leak detector or equivalent. Ensure that the instrument is calibrated and set properly per the operating instructions. The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance. B C D SHA196FA 1. E Position probe approximately 5 mm (3/16 in) away from point to be checked. F G H SHA707EA 2. When testing, circle each fitting completely with probe. I ATC K SHA706E L 3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec. M SHA708EA Revision; 2004 April ATC-171 2003 FX REFRIGERANT LINES CHECKING PROCEDURE 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 calm area (low air/wind movement) so that the leaking refrigerant is not dispersed. 1. Turn engine OFF. 2. Connect a suitable A/C manifold gauge set to the A/C service ports. 3. 4. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm2 , 50 psi) above 16°C (61°F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. NOTE: At temperatures below 16°C (61°F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm2 , 50 psi). Perform the leak test from the high side (compressor discharge a to evaporator inlet h) to the low side [evaporator drain hose h to shaft seal o (VK45DE) or n (VQ35DE)]. Refer to ATC-151, "Components" . Perform a leak check for the following areas carefully. Clean the component to be checked and move the leak detected probe completely around the connection/component. Compressor Check the fitting of high- and low-pressure hoses, relief valve and shaft seal. Liquid tank Check the refrigerant connection. Service valves Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). NOTE: After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any false readings by leak detector. Cooling unit (Evaporator) With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer′s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. 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 detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above. 6. Do not stop when one leak is found. Continue to check for additional leaks at all system components. If no leaks are found, perform steps 7-10. 7. Start engine. 8. Set the heater A/C control as follows; a. A/C switch: ON b. Face mode c. Intake position: Recirculation d. Max cold temperature e. Fan speed: High 9. Run engine at 1,500 rpm for at least 2 minutes. 10. Turn engine off and perform leak check again following steps 4 through 6 above. Revision; 2004 April ATC-172 2003 FX REFRIGERANT LINES Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high pressure side will gradually drop after refrigerant circulation stops and pressure on the low pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high. A B C SHA839E D 11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines and then check refrigerant purity. 12. Confirm refrigerant purity in supply tank using ACR4 and refrigerant identifier. 13. Confirm refrigerant purity in vehicle A/C system using ACR4 and refrigerant identifier. 14. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component as necessary. 15. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks. 16. Perform A/C performance test to ensure system works properly. E F G H I ATC K L M Revision; 2004 April ATC-173 2003 FX SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Compressor PFP:00030 AJS00167 Model Calsonic Kansei make V-6 Type V-6 variable displacement Displacement Max. 184 (11.228) cm3 (cu in)/rev Min. 14.5 (0.885) Cylinder bore × stroke mm (in) 37 (1.46) × [2.3 - 28.6 (0.091 - 1.126)] Direction of rotation Clockwise (viewed from drive end) Drive belt Poly V Lubricant AJS00168 Model Calsonic Kansei make V-6 Name Nissan A/C System Oil Type S (DH-PS) Part number Capacity m (US fl oz, lmp fl oz) KLH00-PAGS0 Total in system 180 (6.0, 6.3) Compressor (Service part) charging amount 180 (6.0, 6.3) Refrigerant AJS00169 Type HFC-134a (R-134a) Capacity kg (lb) 0.55 (1.21) Engine Idling Speed AJS0016A Refer to EC-50, "Idle Speed and Ignition Timing Check" (VQ35DE) or EC-691, "Idle Speed and Ignition Timing Check" (VK45DE). Belt Tension AJS0016B Refer to EM-15, "DRIVE BELTS" (VQ35DE) or EM-167, "DRIVE BELTS" (VK45DE). Revision; 2004 April ATC-174 2003 FX
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