MTC-56
TROUBLE DIAGNOSIS
Revision: June 20062007 Versa
High-pressure Side is Too Low and Low-pressure Side is Too High
Both High- and Low-pressure Sides are Too Low
Gauge indication Refrigerant cycle Probable cause Corrective action
High-pressure side is too low
and low-pressure side is too
high.High- and low-pressure sides
become equal soon after com-
pressor operation stops.Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.Replace compressor.
No temperature difference
between high- and low-pres-
sure sides.Compressor pressure operation
is improper.
↓
Damaged inside compressor
packings.Replace compressor.
AC356A
Gauge indication Refrigerant cycle Probable cause Corrective action
Both high- and low-pressure
sides are too low.
There is a big temperature
difference between liquid tank
outlet and inlet. Outlet tem-
perature is extremely low.
Liquid tank inlet and expan-
sion valve are frosted.Liquid tank inside is slightly
clogged.
Replace liquid tank.
Check oil for contamination.
Temperature of expansion
valve inlet is extremely low as
compared with areas near liq-
uid tank.
Expansion valve inlet may be
frosted.
Temperature difference
occurs somewhere in high-
pressure side.High-pressure pipe located
between liquid tank and expan-
sion valve is clogged.
Check and repair malfunc-
tioning parts.
Check oil for contamination.
Expansion valve and liquid tank
are warm or only cool when
touched.Low refrigerant charge.
↓
Leaking fittings or componentsCheck refrigerant for leaks.
Refer to MTC-92, "
Checking
for Refrigerant Leaks" .
There is a big temperature dif-
ference between expansion
valve inlet and outlet while the
valve itself is frosted.Expansion valve closes a little
compared with the specifica-
tion.
↓
1. Improper expansion valve
adjustment.
2. Malfunctioning expansion
valve.
3. Outlet and inlet may be
clogged.
Remove foreign particles by
using compressed air.
Replace expansion valve.
Check oil for contamination.
An area of the low-pressure
pipe is colder than areas near
the evaporator outlet.Low-pressure pipe is clogged or
crushed.
Check and repair malfunc-
tioning parts.
Check oil for contamination.
Air flow volume is not enough or
is too low.Evaporator is frozen.
Check thermo control amp.
Refer to MTC-41, "
Magnet
Clutch Circuit (If Equipped)"
.
Replace compressor.
Repair evaporator fins.
Replace evaporator.
Refer to MTC-37, "Blower
Motor Circuit" .
AC353A
TROUBLE DIAGNOSIS
MTC-57
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MTC
Revision: June 20062007 Versa
Low-pressure Side Sometimes Becomes Negative
Low-pressure Side Becomes Negative
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side sometimes
becomes negative.
Air conditioning system
does not function and does
not cyclically cool the com-
partment air.
The system constantly func-
tions for a certain period of
time after compressor is
stopped and restarted.Refrigerant does not dis-
charge cyclically.
↓
Moisture is frozen at expan-
sion valve outlet and inlet.
↓
Water is mixed with refriger-
ant.
Drain water from refrigerant
or replace refrigerant.
Replace liquid tank.
AC354A
Gauge indication Refrigerant cycle Probable cause Corrective action
Low-pressure side becomes nega-
tive.
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.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 refrig-
erant.
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 meth-
ods cannot correct the mal-
function, replace expansion
valve.
Replace liquid tank.
Check oil for contamination.
AC362A
REFRIGERANT LINES
MTC-85
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MTC
Revision: June 20062007 Versa
6. Remove bolts (A) from compressor (1), using power tools.
7. Remove compressor (1) downward from the engine compart-
ment.
INSPECTION FOR CLUTCH DISC TO PULLEY CLEARANCE
1. Check the clearance around the entire periphery of the clutch disc.
Measure the clearance for the type 1 compressor as shown.
Measure the clearance for the type 2 compressor as shown.
2. If specified clearance is not obtained, replace compressor.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones,
and apply compressor oil when installing.
When recharging refrigerant, check for leaks.
Removal and Installation of Low-pressure Flexible HoseEJS0058G
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove engine cover. Refer to EM-18, "
INTAKE MANIFOLD" .
3. Remove cowl top cover. Refer to EI-20, "
COWL TOP" .
4. Remove lower dash insulator.
SJIA0672E
Clutch disc to pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in)
RHA087E
RJIA1886E
Compressor bolts : 25 N·m (2.6 kg-m, 18 ft-lb)
MTC-86
REFRIGERANT LINES
Revision: June 20062007 Versa
5. Remove ground wire harness (1).
6. Remove bolt (A) and nut (B) from low-pressure flexible hose (2)
bracket.
7. Remove bolt (A), and then disconnect low-pressure flexible
hose (1) and 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.
8. Remove nut (A), and then remove low-pressure flexible hose (1)
from compressor (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure Flexible HoseEJS0058H
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove high-pressure flexible hose (1) bolt (A) from condenser
(2).
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SJIA0677E
REFRIGERANT LINES
MTC-87
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MTC
Revision: June 20062007 Versa
3. Remove bolt (A), and then remove high-pressure flexible hose
(1) from compressor (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of high-pressure flexible hose with a new ones, and apply compressor oil when
installing.
When recharging refrigerant, check for leaks.
Removal and Installation of High-pressure PipeEJS0058I
REMOVAL
1. Remove low-pressure flexible hose. Refer to MTC-85, "Removal and Installation of Low-pressure Flexible
Hose" .
2. Remove high-pressure pipe from the clips.
3. Remove high-pressure pipe bolt (A), and then remove high-
pressure pipe (1) from condenser (2).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of high-pressure pipe with a new ones, and apply compressor oil when installing.
When recharging refrigerant, check for leaks.
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1. High-pressure pipe A. High-pressure pipe clips
SJIA0679E
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MTC-88
REFRIGERANT LINES
Revision: June 20062007 Versa
Removal and Installation of Refrigerant Pressure SensorEJS0058J
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Disconnect connector, and then remove refrigerant pressure
sensor (1) from condenser (2).
CAUTION:
When working, be careful not to damage the condenser
fins.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of refrigerant pressure sensor with a new one, and apply compressor oil when
installing.
When recharging refrigerant, check for leaks.
Removal and Installation of CondenserEJS0058K
REMOVAL
1. Remove the three upper headlamp bolts to reposition the headlamps out of the way
2. Remove the radiator core support upper. Refer to BL-20, "
RADIATOR CORE SUPPORT" .
3. Remove high-pressure flexible hose and high-pressure pipe from condenser. Refer to MTC-86, "
Removal
and Installation of High-pressure Flexible Hose" and MTC-87, "Removal and Installation of High-pres-
sure Pipe" .
CAUTION:
Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.
4. Disconnect refrigerant pressure sensor connector.
5. Tilt radiator toward rear of vehicle, and then remove condenser
(1) from between radiator and radiator core support upper.
CAUTION:
Be careful not to damage the core surface of condenser and
radiator.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings for A/C piping with new ones, and apply compressor oil when installing.
When recharging refrigerant, check for leaks.
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REFRIGERANT LINES
MTC-91
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MTC
Revision: June 20062007 Versa
Removal and Installation of Expansion ValveEJS0058N
REMOVAL
1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove cowl top cover. Refer to EI-20, "
COWL TOP" .
3. Remove lower dash insulator.
4. Disconnect low-pressure flexible hose and high-pressure pipe from evaporator. Refer to MTC-64, "
A/C
UNIT ASSEMBLY" .
5. Remove expansion valve bolts (A), and then remove expansion
valve (1).
CAUTION:
Cap or wrap the joint of the pipe with suitable material such
as vinyl tape to avoid the entry of air.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace O-rings of evaporator with new ones, and apply compressor oil when installing.
When recharging refrigerant, check for leaks.
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MTC-92
REFRIGERANT LINES
Revision: June 20062007 Versa
Checking for Refrigerant LeaksEJS0058O
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C oil leak-
age, damage and corrosion. A/C oil leakage may indicate an area of refrigerant leakage. Allow extra inspec-
tion 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 25 to 50 mm (1 to 2 in) 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 DetectorEJS0058P
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 oils, 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 InjectionEJS0058Q
(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 (3.45 bar, 3.52 kg/cm
2 , 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
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.