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TROUBLE DIAGNOSIS
ATC-81
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4.CHECK A/C RELAY AFTER DISCONNECTING IT
Refer to ATC-84, "
A/C Relay" .
OK or NG
OK >> Reconnect A/C relay. And GO TO 5.
NG >> 1. replace A/C relay.
2. Go to self-diagnosis AT C - 4 7 , "
PROCEDURE" and perform self-diagnosis STEP-4.Confirm that
magnet clutch operation is normal.
5.CHECK COIL SIDE CIRCUIT OF A/C RELAY
OK or NG
OK >> GO TO 6.
NG >> Repair harness or connector.
6.CHECK AMBIENT SENSOR
Refer to ATC-100, "
Ambient Sensor Circuit" .
OK or NG
OK >>●With gasoline engine: GO TO 7.
●With diesel engine: GO TO 14.
NG >> Repair or replace the malfunctioning part(s).
7.CHECK REFRIGERANT PRESSURE SENSOR (QR ENGINE)
Refer to ATC-85, "
Refrigerant Pressure Sensor (With Gasoline Engine)" .
OK or NG
OK >> GO TO 8.
NG >> Repair or replace the malfunctioning part(s).
8.CHECK VOLTAGE FOR AUTO AMP. (COMPRESSOR ON SIGNAL)
OK or NG
OK >> GO TO 9.
NG >>
●If the voltage is approx. 4.8V when the A/C switch is
ON: Replace the auto amp.
●If the voltage is approx. 0V when the A/C switch is OFF: GO TO 12.
Engine modelsTerminals
Voltag e (+)
(-)
ConnectorTerminal
(Wire color)
With gasoline
engineF43 26 (L)
Ground Battery voltage
With diesel
engineF34 D11 (I)
RJIA1946E
Terminals
Condition Voltage
(+) (-)
ConnectorTe r m i n a l ( W i r e
color)
GroundA/C SW: ON Approx. 0V
M52 4 (L/R) A/C SW: OFF Approx. 4.8V
RJIA0539E
Page 3361 of 3833
TROUBLE DIAGNOSIS
ATC-85
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Refrigerant Pressure Sensor (With Gasoline Engine)
The refrigerant pressure sensor is attached to the liquid tank (con-
denser).
Dual-Pressure Switch (With Diesel Engine)
Thermal Protector (With diesel engine)
Check continuity between compressor harness terminal and field
coil.
RJIA0690E
SHA315F
Compressor: ON
kPa (bar, kg/cm2 , psi)Compressor: OFF
kPa (bar, kg/cm2 , psi)
Low-pressure side 186 (1.86, 1.9, 27) 177 (1.77, 1.8, 26)
High-pressure side 1,569 (15.7, 16, 228) 2,746 (27.5, 28, 398)
RJIA0691E
RHA671H
Page 3410 of 3833
ATC-134
REFRIGERANT LINES
6. Remove the mounting bolts from compressor.
7. Remove the compressor from the lower side of the vehicle.
INSTALLATION
CAUTION:
●Replace the O-ring of the low-pressure flexible hose and
high-pressure flexible hose with a new one, then apply
compressor oil to it when installing it.
●When pouring refrigerant, check for leaks.
RJIA0021E
RJIA0580E
RJIA0023E
RJIA0581E
Bolts mounting the compressor (With gasoline engine)
Tightening torque : 28.4 - 33.3 N-m (2.9 - 3.4 kg-m, 21 - 24 ft- lb)
Bolts mounting the compressor (With diesel engine)
Tightening torque : 60 - 69 N-m (6.1 - 7.1 kg-m, 45 - 51 ft- lb)
Nut (bolt) mounting the high-pressure flexible hose
Tightening torque : 8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164 in-lb)
Nut (bolt) mounting the low-pressure flexible hose
Tightening torque : 8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164 in-lb)
Page 3414 of 3833
ATC-138
REFRIGERANT LINES
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.
Coil
Check coil for loose connection or cracked insulation.
INSTALLATION
With Gasoline Engine (CWV-615M Compressor)
1. Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head.
2. Install the field coil harness clip using a screwdriver.
3. Install the pulley assembly using the installer and a hand press,
and then install the snap ring using snap ring pliers.
RJIA0582E
RJIA0583E
RHA142E
RHA143EA
Page 3415 of 3833
REFRIGERANT LINES
ATC-139
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4. Install the clutch disc on the drive shaft, together with the original
shim(s). Press the clutch disc down by hand.
5. Using the holder to prevent clutch disc rotation.
After tightening the bolt, check that the pulley rotates smoothly.
6. Check clearance around the entire periphery of clutch disc.
If the specified clearance is not obtained, replace adjusting
spacer and readjust.
With Diesel Engine (DKV-11G Compressor)
1. Install the field coil.
Be sure to align the coil's pin with the hole in the compressor's
front head.
2. Install the field coil harness clip using a screwdriver.
RHA127F
Tightening torque : 14 N-m (1.4 kg-m, 10 ft-lb)
RHA086E
Disc to pulley clear-
ance: 0.3 - 0.6 mm (0.012 - 0.024 in)
RHA087E
RHA076C
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REFRIGERANT LINES
ATC-141
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Break-In Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty times. Break-in operation raises the level of transmitted torque.
Removal and Installation for Low-pressure flexible hoseEJS000VB
REMOVAL
1. Using the recycling and recovery equipment (for HFC-134a),
discharge the refrigerant from A/C system.
2. Remove the clips from the low-pressure flexible hose.
3. Remove the mounting bolts from the low-pressure flexible hose
bracket.
4. Remove the clip from the vacuum hose.
5. Remove the mounting bolts from the 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.
6. Remove the low-pressure flexible hose.
INSTALLATION
CAUTION:
●Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●When pouring refrigerant, check for leaks.
RJIA0074E
RJIA0584E
RJIA0075E
Low-pressure flexible hose and bolts mounting the high-pressure pipe (evaporator side)
Tightening torque :3.4 - 5.9 N-m (0.35 - 0.60 kg-m, 30 - 52 in-lb)
Nut (Bolt) mounting the low-pressure flexible hose (compressor side)
Tightening torque :8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164in-lb)
Page 3418 of 3833

ATC-142
REFRIGERANT LINES
Removal and Installation for High-pressure flexible hose
EJS000VC
REMOVAL
1. Using the recycling and recovery equipment (for HFC-134a),
discharge the refrigerant from A/C system.
2. Remove the mounting bolt and nut from the high-pressure flexi-
ble hose, then remove it.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as
vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
●When pouring refrigerant, check for leaks.
Removal and Installation for High-pressure pipeEJS000VD
REMOVAL
1. Using the recycling and recovery equipment (for HFC-134a),
discharge the refrigerant from A/C system.
2. Remove the low-pressure flexible hose.
3. Remove the high-pressure pipe from the clip.
4. Remove the mounting bolt from the high-pressure pipe.
5. Remove the high-pressure pipe.
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as
vinyl tape to avoid the entry of air.
INSTALLATION
CAUTION:
●Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
●When pouring refrigerant, check for leaks.
RJIA0076E
Bolt and nut mounting the high-pressure flexible hose
Tightening torque :8 - 18 N-m (0.8 - 1.9 kg-m, 70 - 164in-lb)
RJIA0077E
RJIA0078E
Bolts mounting the high-pressure pipe (condenser side, evaporator side)
Tightening torque :3.4 - 5.9 N-m (0.35 - 0.60 kg-m, 30 - 52 in-lb)
Page 3420 of 3833

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)