ATC-146
HEATER & COOLING UNIT ASSEMBLY
Revision: August 20072004 QX56
4. Remove the exhaust system. Refer to EX-3, "Removal and Installation" .
5. Disconnect the front heater hoses from the front heater core.
6. Disconnect the high/low pressure pipes from the front expansion valve.
7. Move the two front seats to the rearmost position on the seat track.
8. Remove the instrument panel and console panel. Refer to IP-10, "
INSTRUMENT PANEL ASSEMBLY" .
9. Remove the steering column. Refer to PS-10, "
Removal and Installation" .
10. Disconnect the instrument panel wire harness at the RH and LH in-line connector brackets, and the fuse
block (J/B) electrical connectors. Refer to PG-40, "
Harness Layout" .
11. Disconnect the steering member from each side of the vehicle body.
12. Remove the front heater and cooling unit assembly with it attached to the steering member, from the vehi-
cle.
CAUTION:
Use care not to damage the seats and interior trim panels when removing the front heater and
cooling unit assembly with it attached to the steering member.
13. Remove the front heater and cooling unit assembly from the steering member.
Installation
Installation is in the reverse order of removal.
CAUTION:
Replace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply
compressor oil to it when installing it.
After charging the refrigerant, check for leaks.
NOTE:
Fill the engine cooling system with the specified coolant mixture. Refer to MA-13, "REFILLING ENGINE
COOLANT" .
Recharge the A/C system. Refer to ATC-162, "Evacuating System and Charging Refrigerant" .
REAR HEATER AND COOLING UNIT ASSEMBLY
Removal
1. Discharge the refrigerant from the A/C system. Refer to ATC-162, "Discharging Refrigerant" .
2. Drain the coolant from the engine cooling system. Refer to MA-12, "
DRAINING ENGINE COOLANT" .
3. Disconnect the rear heater core hoses from the rear heater core.
4. Disconnect the rear A/C pipes from the rear expansion valve.
5. Remove the rear RH interior trim panel. Refer to EI-34,
"Removal and Installation" .
6. Disconnect the following electrical connectors:
Rear blower motor
Rear blower motor resistor
Rear air mix door motor
7. Disconnect the ducts from the rear heater and cooling unit
assembly.
8. Remove the rear heater and cooling unit assembly.
Installation
Installation is in the reverse order of removal.
CAUTION:
Replace the O-ring of the low-pressure pipe and high-pressure pipe with a new one, and apply
compressor oil to it when installing it.
After charging the refrigerant, check for leaks.
NOTE:
Fill the engine cooling system with the specified coolant mixture. Refer to MA-13, "REFILLING ENGINE
COOLANT" .
Recharge the A/C system. Refer to ATC-162, "Evacuating System and Charging Refrigerant" .
LJIA0021E
REFRIGERANT LINES
ATC-169
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Revision: August 20072004 QX56
2. Install the magnet coil harness clip using a screwdriver.
3. Install the pulley assembly using Tool and a wrench, then install
the snap ring using snap ring pliers.
4. Install the clutch disc on the compressor shaft, together with the
original shim(s). Press the clutch disc down by hand.
5. Install the clutch pulley bolt using Tool, to prevent the clutch disc
from turning and tighten the bolt to specification. Refer to AT C -
164, "Components" .
CAUTION:
After tightening the clutch pulley bolt, check that the clutch
pulley rotates smoothly.
6. Check the pulley clearance all the way around the clutch disc as
shown.
7. If the specified clearance is not obtained, replace the adjusting
spacer to readjust.
8. Connect the compressor electrical connector.
9. Install the drive belt. Refer to EM-13, "
Installation" .
10. Install the engine under cover and the splash shield.Tool number : — (J-38873-A)
WJIA0368E
WHA184
Tool number : J-44614
WHA229
Clutch disc-to-pulley clearance : 0.3 - 0.6 mm
(0.012 - 0.024 in)
WHA194
ATC-170
REFRIGERANT LINES
Revision: August 20072004 QX56
BREAK-IN OPERATION
When replacing compressor clutch assembly, always conduct the break-in operation. This is done by engag-
ing and disengaging the clutch about 30 times. Break-in operation raises the level of transmitted torque.
Removal and Installation for Low-pressure Flexible HoseEJS002DL
REMOVAL
1. Remove the engine room cover using power tools.
2. Remove the engine air cleaner and air ducts. Refer to EM-14, "
REMOVAL" .
3. Remove the cowl top extension. Refer to EI-18, "
COWL TOP" .
4. Discharge the refrigerant. Refer to ATC-162, "
HFC-134a (R-134a) Service Procedure" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of con-
taminants.
5. Remove the low-pressure flexible hose. Refer to ATC-164, "
Components" .
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-164, "
Components" .
CAUTION:
Replace the O-ring of the low-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for High-pressure Flexible HoseEJS002DM
REMOVAL
1. Remove the engine under cover.
2. Remove the engine air cleaner and air ducts. Refer to EM-14, "
REMOVAL" .
3. Discharge the refrigerant. Refer to ATC-162, "
HFC-134a (R-134a) Service Procedure" .
4. Remove the high-pressure flexible hose. Refer to ATC-164, "
Components" .
CAUTION:
Cap or wrap the joint of the hose with suitable material such as vinyl tape to avoid the entry of
contaminants.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-164, "
Components" .
CAUTION:
Replace the O-ring of the high-pressure flexible hose with a new one, then apply compressor oil to
it when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for High-pressure PipeEJ S00 2DN
REMOVAL
1. Remove the cowl top extension. Refer to EI-18, "COWL TOP" .
2. Disconnect the battery negative cable.
3. Reposition the IPDM E/R aside.
4. Remove the front right wheel and tire assembly. Refer to WT-6, "
Rotation" .
5. Position aside the front floor insulator.
6. Discharge the refrigerant. Refer to ATC-162, "
HFC-134a (R-134a) Service Procedure" .
7. Remove the low pressure pipe. Refer to ATC-171, "
Removal and Installation for Low-pressure Pipe" .
8. Remove the high-pressure pipe. Refer to ATC-164, "
Components" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of con-
taminants.
REFRIGERANT LINES
ATC-171
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Revision: August 20072004 QX56
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-164, "
Components" .
CAUTION:
Replace the O-ring of the high-pressure pipe with a new one, then apply compressor oil to it when
installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Low-pressure PipeEJ S00 2DO
REMOVAL
1. Discharge the refrigerant. Refer to ATC-162, "HFC-134a (R-134a) Service Procedure" .
2. Remove the cowl top and the cowl top extension. Refer to EI-18, "
COWL TOP" .
3. Remove the low-pressure pipe. Refer to ATC-164, "
Components" .
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of
contaminants.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-164, "
Components" .
CAUTION:
Replace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Rear High- and Low-pressure A/C and Heater Core
Pipes
EJS0060M
REMOVAL
1. Discharge the refrigerant. Refer to ATC-162, "HFC-134a (R-134a) Service Procedure" .
2. Drain the coolant from the engine cooling system. Refer to CO-8, "
Changing Engine Coolant" .
3. Disconnect the underfloor rear heater hoses (1 and 2) from the
rear heater pipes underneath the vehicle.
⇐: Front
4. Remove the rear high- and low-pressure pipes bolt (A) to dis-
connect the rear high- and low-pressure pipes from the under-
floor rear high- and low-pressure pipes underneath the vehicle.
CAUTION:
Cap or wrap the joint of the pipes with suitable material
such as vinyl tape to avoid the entry of air.
5. Remove the rear high- and low-pressure pipes nuts (B) under-
neath the vehicle.
NOTE:
The remaining steps are performed inside the rear luggage area of the vehicle.
6. Remove the luggage side finisher lower RH. Refer to EI-39, "
LUGGAGE FLOOR TRIM" .
7. Disconnect the rear heater core hoses (1 and 2) from the rear
heater core (3).
⇐: Front
WJIA2310E
WJIA2311E
ATC-172
REFRIGERANT LINES
Revision: August 20072004 QX56
8. Remove the rear high- and low-pressure pipes bracket bolt (A)
to release the bracket.
Rear blower motor (1)
⇐: Front
9. Remove the rear high- and low-pressure pipes bolt (A) to dis-
connect the rear high- and low-pressure pipes from the rear
expansion valve (1).
⇐: Front
CAUTION:
Cap or wrap the joint of the pipes with suitable material
such as vinyl tape to avoid the entry of air.
10. Disconnect the following electrical connectors:
Rear air mix door motor (1)
Rear blower motor resistor (2)
Rear blower motor (3)
⇐: Front
11. Disconnect the ducts from the rear heater and cooling unit assembly. Refer to ATC-157, "
Components" .
12. Remove the rear heater and cooling unit assembly.
CAUTION:
Cap or wrap the joint of the pipes with suitable material such as vinyl tape to avoid the entry of air.
13. Remove the rear high- and low-pressure A/C pipes.
INSTALLATION
Installation is in the reverse order of removal.
Refer to ATC-164, "
Components" .
CAUTION:
Replace the O-ring of the high/low-pressure pipe with a new one, then apply compressor oil to it
when installing it.
After charging refrigerant, check for leaks.
Removal and Installation for Underfloor Rear High- and Low-pressure A/C and
Heater Core Pipes
EJS0060N
REMOVAL
1. Drain the coolant from the engine cooling system. Refer to CO-8, "Changing Engine Coolant" .
2. Disconnect the battery negative terminal.
3. Disconnect the generator harness.
4. Discharge the refrigerant. Refer to ATC-162, "
HFC-134a (R-134a) Service Procedure" .
WJIA2312E
WJIA2313E
WJIA2314E
REFRIGERANT LINES
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Revision: August 20072004 QX56
2. Pour one bottle 7.4 cc (1/4 ounce) of the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) into
the HFC-134a (R-134a) dye injector (J-41459).
CAUTION:
If repairing the A/C system or replacing a component, pour the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) directly into the open system connection and proceed with the service
procedures.
3. Connect the refrigerant dye injector (J-41459) to the low-pressure service valve.
4. Start the engine and switch the A/C system ON.
5. When the A/C system is operating (compressor running), inject one bottle 7.4 cc (1/4 ounce) of HFC-134a
(R-134a) fluorescent leak detection dye (J-41447) through the low-pressure service valve using HFC-
134a (R-134a) dye injector (J-41459). Refer to the manufacturer's operating instructions.
6. With the engine still running, disconnect the HFC-134a (R-134a) dye injector (J-41459) from the low-pres-
sure service valve.
7. Operate the A/C system for a minimum of 20 minutes to mix the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) with the A/C system oil. Depending on the leak size, operating conditions and
location of the leak, it may take from minutes to days for the HFC-134a (R-134a) fluorescent leak detec-
tion dye to penetrate an A/C system leak and become visible.
Electronic Refrigerant Leak DetectorEJS002DY
PRECAUTIONS FOR HANDLING LEAK DETECTOR
NOTE:
When performing a refrigerant leak check, use a electronic refrigerant leak detector (J-41995) or equivalent.
Ensure that the electronic refrigerant leak detector (J-41995) is calibrated and set properly according to the
manufacturer's operating instructions.
The electronic refrigerant leak detector (J-41995) is a delicate
device. To use the leak detector properly, read the manufacturer's
operating instructions and perform any specified maintenance.
1. Position the probe approximately 5 mm (3/16 in) away from the
point to be checked as shown.
AHA2 81 A
SHA707EA
AV-2Revision: August 20072004 QX56 “VIEW” MODE ..................................................... 70
“HEADING” MODE .............................................. 71
“NEARBY DISPLAY ICONS” MODE ................... 71
“SAVE CURRENT LOCATION” MODE ............... 71
“ADJUST CURRENT LOCATION” MODE ........... 71
“AUTO RE-ROUTE” MODE ................................. 72
“AVOID AREA SETTINGS” MODE ...................... 72
“CLEAR MEMORY” MODE ................................. 72
“EDIT ADDRESS BOOK” MODE ........................ 73
“GPS INFORMATION” MODE ............................. 73
“QUICK STOP CUSTOMER SETTING” MODE ... 73
“SET AVERAGE SPEED” MODE ........................ 73
“TRACKING” MODE ............................................ 74
GUIDANCE VOLUME ......................................... 74
DISPLAY WITH PUSHED “TRIP” BUTTON ........ 74
TRIP 1 OR TRIP 2 ............................................... 75
FUEL ECONOMY ................................................ 75
MAINTENANCE .................................................. 75
ENGINE OIL OR TIRE ROTATION ..................... 75
TIRE PRESSURE ................................................ 76
WARNING INDICATIONS ................................... 76
CAN Communication System Description .............. 76
Component Parts Location ..................................... 77
Schematic ............................................................... 78
Wiring Diagram —NAVI— ....................................... 79
Schematic ............................................................... 86
Wiring Diagram — COMM — ................................. 87
Terminals and Reference Value for NAVI Control
unit .......................................................................... 90
Terminals and Reference Value for Display Control
unit .......................................................................... 92
Terminals and Reference Value for Display unit ..... 96
Terminals and Reference Value for AV Switch ....... 98
Terminals and Reference Value for BCM ................ 99
On Board Self-Diagnosis Function .......................101
DESCRIPTION ..................................................101
DIAGNOSIS ITEM .............................................101
Self-Diagnosis Mode (DCU) .................................101
OPERATION PROCEDURE ..............................101
SELF–DIAGNOSIS RESULT .............................103
Self-Diagnosis Mode (NAVI) .................................104
OPERATION PROCEDURE ..............................104
SELF–DIAGNOSIS RESULT .............................105
Confirmation/Adjustment Mode ............................107
OPERATION PROCEDURE ..............................107
DISPLAY DIAGNOSIS .......................................108
VEHICLE SIGNALS ...........................................108
NAVIGATION .....................................................109
DISPLAY DIAGNOSIS .......................................109
VEHICLE SIGNALS ...........................................110
HISTORY OF ERRORS ....................................110
DIAGNOSIS BY HISTORY OF ERRORS ..........110
NAVIGATION .....................................................112
CAN DIAG SUPPORT MONITOR ........................114
OPERATION PROCEDURE ..............................114
AV Switch Self-Diagnosis Function .......................115
Power Supply and Ground Circuit Check for NAVI
Control Unit ...........................................................116
Power Supply and Ground Circuit Check for Display Control Unit ...........................................................117
Power Supply and Ground Circuit Check for Display
Unit ........................................................................118
Power Supply and Ground Circuit Check for AV
Switch ................................................................... 120
Vehicle Speed Signal Check for NAVI Control Unit . 121
Vehicle Speed Signal Check for Display Control Unit . 122
Illumination Signal Check for NAVI Control Unit ... 123
Illumination Signal Check for Display Control Unit . 123
Ignition Signal Check for NAVI Control Unit .......... 123
Ignition Signal Check for Display Control Unit ...... 124
Reverse Signal Check for NAVI Control Unit ........ 124
Reverse Signal Check for Display Control Unit .... 124
AV Communication Line Check (Between Display
Control Unit and NAVI Control Unit) ...................... 125
Audio Communication Line Check (Between Dis-
play Control Unit and Audio Unit) .......................... 126
Display Communication Line Check (Between Dis-
play Control Unit and Display Unit) ....................... 128
AV Communication Line Check (Between Display
Control Unit and AV Switch) .................................. 130
CAN Communication Line Check ......................... 131
If NAVI Control Unit Detects That DVD-ROM Map
is Not Inserted ....................................................... 131
If NAVI Control Unit Detects That Inserted DVD-
ROM Map Malfunctioning or If It is Impossible to
Load Data from DVD-ROM Map ........................... 131
If Connection Between NAVI Control Unit and GPS
Antenna is Malfunctioning ..................................... 132
Operating Screen for Audio and A/C is Not Dis-
played When Showing NAVI Screen ..................... 132
Color of RGB Image is Not Proper (Only NAVI
Screen Looks Bluish) ............................................ 134
Color of RGB Image is Not Proper (Only NAVI
Screen Looks Reddish) ......................................... 135
Color of RGB Image is Not Proper (Only NAVI
Screen Looks Yellowish) ....................................... 136
Color of RGB Image is Not Proper (All Screen Looks
Bluish) ................................................................... 137
Color of RGB Image is Not Proper (All Screen Looks
Reddish) ................................................................ 138
Color of RGB Image is Not Proper (All Screen Looks
Yellowish) .............................................................. 139
NAVI Screen is Rolling .......................................... 140
Guide Sound is Not Heard .................................... 142
Screen is Not Shown ............................................ 143
A/C Screen is Not Shown (NAVI Screen is Shown) . 143
FUEL ECONOMY Screen is Not Shown ............... 143
Average Fuel Economy Displayed is Not Shown (“
*** ” is Shown) ....................................................... 143
Distance to Empty Displayed is Not Shown (“ *** ”
is Shown) .............................................................. 144
Driving Distance or Average Speed Displayed is Not
Shown (“ *** ” is Shown) ....................................... 144
WARNING DOOR OPEN Screen is Not Shown ... 144
Unable to Operate All of AV Switches (Unable to
Start Self-Diagnosis) ............................................. 145
Audio Does Not Work ........................................... 145
Navigation System Does Not Activate .................. 145
AV-30
AUDIO
Revision: August 20072004 QX56
FOR CD ONLY
Noise InspectionEKS007KK
The vehicle itself can be a source of noise if noise prevention parts or electrical equipment is malfunctioning.
Check if noise is caused and/or changed by engine speed, ignition switch turned to each position, and opera-
tion of each piece of electrical equipment, and determine the cause.
NOTE:
The source of the noise can be found easily by listening to the noise while removing the fuses of electrical
components, one by one.
TYPE OF NOISE AND POSSIBLE CAUSE
Power Supply Circuit InspectionEKS007KL
1. CHECK FUSES
Check that the following fuses are not blown.
OK or NG
OK >> GO TO 2.
NG >> If fuse is blown, be sure to eliminate cause of problem before installing new fuse. Refer to PG-4,
"POWER SUPPLY ROUTING CIRCUIT" .
Symptom Possible cause
CD cannot be inserted.
CD
Audio unit CD cannot be ejected.
The CD cannot be played.
The sound skips, stops suddenly, or is distorted.
Occurrence condition Possible cause
Occurs only when engine is ON.A continuous growling noise occurs. The speed of
the noise varies with changes in the engine speed.
Ignition components
A whistling noise occurs while the engine speed is
high. A booming noise occurs while the engine is
running and the lighting switch is ON.
Generator
The occurrence of the noise is linked with the operation of the fuel pump.
Fuel pump condenser
Noise only occurs when various
electrical components are oper-
ating.A cracking or snapping sound occurs with the
operation of various switches.
Relay malfunction, audio unit malfunction
The noise occurs when various motors are operat-
ing.
Motor case ground
Motor
The noise occurs constantly, not just under certain conditions.
Rear defogger coil malfunction
Open circuit in printed heater
Poor ground of antenna amplifier or
antenna feeder line
A cracking or snapping sound occurs while the vehicle is being driven, especially
when it is vibrating excessively.
Ground wire of body parts
Ground due to improper part installation
Wiring connections or a short circuit
Unit Terminals Signal name Fuse No.
Audio unit6 Battery power 31
10 Ignition switch ACC or ON 4
AV s w i t c h1 Battery power 31
2 Ignition switch ACC or ON 4
BOSE speaker amp. 1 Battery power 31
Subwoofer 6 Battery power 17