ATC-144
REFRIGERANT LINES
4. Disconnect the refrigerant pressure sensor connector (For QR
engine) or dual-pressure switch connector (For YD engine).
5. Remove the front grille and radiator mounting bracket.
6. Remove the mounting nuts from the condenser.
7. Remove the radiator from the lower mount, move it to the engine
side, then remove the condenser between the radiator and the
radiator core support.
CAUTION:
Be careful not to damage the core surface of the condenser
and the radiator.
INSTALLATION
CAUTION:
●Replace the O-rings of the high-pressure pipe and the high-pressure flexible hose with new ones,
then apply compressor oil to them after installing them.
●When pouring refrigerant, check for leaks.
RJIA0690E
RJIA0691E
RJIA0081E
High-pressure flexible hose mounting bolts
Tightening torque :8 - 18 N·m (0.8 - 1.9 kg·m, 70 - 164 in-lb)
High-pressure pipe mounting bolts
Tightening torque :3.4 - 5.9 N·m (0.35 - 0.60 kg·m, 30 - 52 in-lb)
Condenser mounting bolts
Tightening torque :3.82 - 4.51 N·m (0.39 - 0.46 kg·m 34 - 39 in-lb)
REFRIGERANT LINES
ATC-147
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Checking System for Leaks Using the Fluorescent Leak DetectorEJS000VK
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 indi-
cates 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 misdiag-
nosis.
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 InjectionEJS000VL
(This procedure is only necessary when recharging the system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (50 psi).
2. Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool (J-41459).
3. Connect the injector tool to the A/C LOW PRESSURE side service fitting.
4. Start engine and switch A/C ON.
5. 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 operat-
ing 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 con-
nection 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.
Electronic Refrigerant Leak DetectorEJS000VM
PRECAUTIONS FOR HANDLING LEAK DETECTOR
When performing a refrigerant leak check, use an A/C leak detector
or equivalent. Ensure that the instrument is calibrated and set prop-
erly per the operating instructions.
The leak detector is a delicate device. In order to use the leak detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance.
SHA705EB
ATC-148
REFRIGERANT LINES
1. Position probe approximately 5 mm (3/16 in) away from point to
be checked.
2. When testing, circle each fitting completely with probe.
3. Move probe along component approximately 25 to 50 mm (1 to
2 in)/sec.
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. Check if the A/C refrigerant pressure is at least 345 kPa (3.52 kg/cm
2 , 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 (3.54
kg/cm
2 , 50 psi).
4. Conduct the leak test from the high side (compressor discharge a to evaporator inlet g) to the low side
(evaporator drain hose h to shaft seal k). Refer to ATC-131, "
Components" \. Perform a leak check for the
following areas carefully. Clean the component to be checked and move the leak detected probe com-
pletely around the connection/component.
Compressor
Check the fitting of high and low pressure hoses, relief valve and shaft seal.
Liquid tank
Check the refrigerant pressure sensor or dual pressure switch.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to pre-
vent leaks).
SHA707EA
SHA706E
SHA708EA
REFRIGERANT LINES
ATC-149
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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.
Refrigerant leaks should be checked immediately after stopping the
engine. Begin with the leak detector at the compressor. The pres-
sure 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.
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. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or com-
ponent as necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Conduct A/C performance test to ensure system works properly.
SHA839E
TROUBLE DIAGNOSIS
MTC-7
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MTC
Operational CheckEJS001FE
The purpose of the operational check is to confirm that the system operates properly.
CHECKING BLOWER
1. Turn fan switch to 1-speed. Blower should operate on low
speed.
2. Then turn fan switch to 2-speed, and continue checking blower
speed until all speeds are checked.
3. Leave blower on 4-speed.
If NG, go to trouble diagnosis procedure for MTC-14, "
Blower Motor
Circuit" .
If OK, continue with next check.
CHECKING DISCHARGE AIR
1. Set the mode control dial to each position.
2. Confirm that discharge air comes out according to the air distri-
bution table.Refer to MTC-5, "
Discharge Air Flow" .
Intake door position is checked in the next step.
If NG, go to trouble diagnosis procedure for mode door motor.
If OK, continue with next check.
CHECKING RECIRCULATION
1. Press REC switch one time. Recirculation indicator should illu-
minate.
2. Listen for intake door position change (you should hear blower
sound change slightly).
If NG, go to trouble diagnosis procedure for MTC-11, "
Intake Door
Motor Circuit" .
If OK, continue with next check.Conditions :Engine running and at normal operating temperature
RJIA0587E
RJIA0588E
RJIA0492E
RJIA0589E
TROUBLE DIAGNOSIS
MTC-19
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MTC
*1 QR engine; CO-9, "Changing Engine
Coolant" .
YD engine; CO-29, "
Changing
Engine Coolant" .*2 QR engine; CO-12, "
Checking Radi-
ator Cap"
YD engine; CO-33, "Checking Radi-
ator Cap" .*3 QR25 engine; (WITH EURO-OBD)
EC-153, "
ENGINE COOLANT TEM-
PERATURE SENSOR" .
QR25 engine; (WITHOOUT EUR-
OBD)EC-527, "
ENGINE COOLANT
TEMPERATURE SENSOR" .
QR20 engine; (WITH EURO-OBD)
EC-885, "
ENGINE COOLANT TEM-
PERATURE SENSOR" .
QR20 engine; (WITHOUT EURO-
OBD)EC-1213, "
ENGINE COOLANT
TEMPERATURE SENSOR" .
YD engine; EC-1508, "
SYSTEM
DESCRIPTION" .
*4 QR engine; CO-9, "
Changing Engine
Coolant" .
YD engine; CO-29, "
Changing
Engine Coolant" .*5 MTC-7, "
Operational Check"*6MTC-3, "SYMPTOM TABLE"
SC-1
STARTING & CHARGING SYSTEM
K ELECTRICAL
CONTENTS
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STARTING & CHARGING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Wiring Diagrams and Trouble Diagnosis .................. 2
BATTERY .................................................................... 3
How to Handle Battery ............................................. 3
METHODS OF PREVENTING OVER-DIS-
CHARGE ............................................................... 3
CHECKING ELECTROLYTE LEVEL .................... 3
SPECIFIC GRAVITY CHECK ............................... 4
Battery Test and Charging Chart .............................. 5
CHART I ................................................................ 5
CHART II ............................................................... 6
A: SLOW CHARGE ............................................... 7
B: STANDARD CHARGE ...................................... 8
C: QUICK CHARGE ............................................ 10
Removal and Installation ......................................... 11
CHARGING SYSTEM ............................................... 12
System Description ................................................ 12
Wiring Diagram — CHARGE — ............................. 13
Trouble Diagnoses ................................................. 14
WITH IC REGULATOR ....................................... 14
MALFUNCTION INDICATOR .............................. 14
Removal and Installation ........................................ 15
REMOVAL (QR ENGINE MODELS) ................... 15
REMOVAL (YD ENGINE MODELS) ................... 15
INSTALLATION ................................................... 15
Disassembly and Assembly ................................... 16
Disassembly ........................................................... 17
REAR COVER .................................................... 17
REAR BEARING ................................................. 18Inspection ............................................................... 18
ROTOR CHECK .................................................. 18
BRUSH CHECK .................................................. 18
PULLEY CHECK(WITH CLUTCH TYPE) ............ 18
STATOR CHECK ................................................. 18
Assembly ................................................................ 19
RING FITTING IN REAR BEARING .................... 19
REAR COVER INSTALLATION ........................... 19
STARTING SYSTEM ................................................. 20
System Description ................................................. 20
M/T MODELS ...................................................... 20
A/T MODELS ....................................................... 20
Wiring Diagram — START —/M/T models ............. 21
Wiring Diagram — START —/A/T models .............. 22
Trouble Diagnoses ..............................................
... 23
Removal and Installation ........................................ 24
REMOVAL ........................................................... 24
INSTALLATION ................................................... 24
Disassembly and Assembly .................................... 25
Inspection ............................................................... 28
MAGNETIC SWITCH CHECK ............................. 28
PINION/CLUTCH CHECK ................................... 28
BRUSH CHECK .................................................. 28
YOKE CHECK ..................................................... 29
ARMATURE CHECK ........................................... 30
Assembly ................................................................ 31
PINION PROTRUSION LENGTH ADJUST-
MENT .................................................................. 31
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 33
Battery .................................................................... 33
Starter ..................................................................... 33
Alternator ................................................................ 33
BATTERY
SC-3
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BATTERY PFP:00011
How to Handle Battery EKS00313
CAUTION:
●If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt
booster battery.
●After connecting battery cables, ensure that they are tightly clamped to battery terminals for good
contact.
●Never add distilled water through the hole used to check specific gravity.
METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-discharging a battery.
●The battery surface (particularly its top) should always be kept
clean and dry.
●The terminal connections should be clean and tight.
●At every routine maintenance, check the electrolyte level.
This also applies to batteries designated as “low maintenance”
and “maintenance-free”.
●When the vehicle is not going to be used over a long period of
time, disconnect the negative battery terminal. (If the vehicle has
an extended storage switch, turn it off.)
●Check the charge condition of the battery.
Periodically check the specific gravity of the electrolyte. Keep a
close check on charge condition to prevent over-discharge.
CHECKING ELECTROLYTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touch-
ing a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid con-
tacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention.
MEL040F
MEL041F
MEL042F