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INSPECTION FOR CLUTCH DISC TO PULLEY CLEARANCE
1. Check the clearance (B) around the entire periphery of the clutch disc (1) and pulley (2) usi ng a suitable tool (A) as shown.
2. If specified clearance (B) 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 refrigeran t, check for leaks. Refer to MTC-86, " Checking of Refrigerant Leaks " .
Removal and Installation of Low-Pressure Flexible Hose INFOID:0000000004307092
REMOVAL 1. Use the recovery/recycling equipment to evacuate the refrigerant.
2. Remove engine cover (MR18DE only).
3. Remove cowl top cover. Refer to EI-22, " Removal and Installation " .
4. Remove lower dash insulator.
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 pi pe with suitable material such
as vinyl tape to avoid the entry of air. Clutch disc to pulley clearance (B) : 0.3 - 0.6 mm
(0.012 - 0.024 in)
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Removal and Installation of High-Pressure Pipe
INFOID:0000000004307094
REMOVAL 1. Remove low-pressure flexible hose. Refer to MTC-81, " 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 pi pe 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 ne w ones, and apply compressor oil when installing.
• When recharging refrigerant, check for leaks.
Removal and Installation of Refrigerant Pressure Sensor INFOID:0000000004307095
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 senso r with a new one, and apply compressor oil when
installing. 1. High-pressure pipe A. High-pressure pipe clips
Removal and Installation " .
3. Remove lower dash insulator.
4. Disconnect low-pressure flexible hose and high-pressure pipe from evaporator. Refer to MTC-58," Removal and Installation " .
5. Remove expansion valve bolts (A), and then remove expansion valve (1).
CAUTION:
Cap or wrap the joint of the pi pe 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.
Checking of Refrigerant Leaks INFOID:0000000004307100
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 electroni c 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 electroni c leak detector, move the probe along the suspected
leak area at 25 to 50 mm (1 to 2 in) per sec ond and no further than 1/4 inch from the component.
CAUTION:
REFRIGERANT LINES
MTC-87
< SERVICE INFORMATION >
C
D E
F
G H
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K L
M A
B MTC
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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 INFOID:0000000004307101
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. Fluoresc ent 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 l eak 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 INFOID:0000000004307102
(This procedure is only necessary when recharging t he system or when the compressor has seized and was
replaced.)
1. Check A/C system static (at rest) pressure. Pres sure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2
, 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 inje ctor 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 componen t, pour the dye directly into the open system
connection and proceed wi th 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 Detector INFOID:0000000004307103
PRECAUTIONS FOR HANDLING LEAK DETECTOR When performing a refrigerant leak c heck, use an A/C electrical leak
detector (SST) 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 detec-
tor properly, read the operating instructions and perform any speci-
fied maintenance. AHA281A
Item name
CONSULT-III
screen display Display or unit Monitor item selection
Description
ALL
SIGNALS MAIN
SIGNALS SELECTION
FROM MENU
Motor fan request MOTOR FAN
REQ 1/2/3/4 X X X Signal status input from ECM
Compressor re-
quest AC COMP REQ ON/OFF X X X Signal status input from ECM
Parking, license,
and tail lamp re-
quest TAIL & CLR REQ ON/OFF X X X Signal status input from BCM
Headlamp low
beam request HL LO REQ ON/OFF X X X Signal status input from BCM
Headlamp high
beam request HL HI REQ ON/OFF X X X Signal
status input from BCM
Front fog request FR FOG REQ ON/OFF X X X Signal status input from BCM
FR wiper request FR WIP REQ STOP/1LO/LO/HI X X X Signal status input from BCM
Wiper auto stop WIP AUTO
STOP ACT P/STOP P X X X Output status of IPDM E/R
Wiper protection WIP PROT OFF/LS/HS/Block X X X Control status of IPDM E/R
Starter request ST RLY REQ ON/OFF X X Status of input signal (*1)
Ignition relay
status IGN RLY ON/OFF X X X Ignition relay status monitored
with IPDM E/R
Rear defogger re-
quest RR DEF REQ ON/OFF X X X Signal status input from BCM
Oil pressure
switch OIL P SW OPEN/CLOSE X X
Signal status input from IPDM
E/R
Hood switch HOOD SW (*2) OFF X X Signal status input from IPDM
E/R
Door Switch Check (Hatchback) " when the auto active test cannot be
performed.
INSPECTION IN AUTO ACTIVE TEST MODE
When auto active test mode is actuated, t he following six steps are repeated three times.
(A): Oil pressure warning lamp is blin king when the auto active test is operating.
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24 Y Cooling fan relay-3 Output —
Conditions correct for cooling
fan high operation Battery voltage
Conditions not correct for
cooling fan high operation 0V
26 O Tail lamp relay (park-
ing lamps) Output — Lighting switch in 2nd position Battery voltage
27 BR Tail lamp relay (park-
ing lamps) Output — Lighting switch in 2nd position Battery voltage
28 GR Tail lamp relay (park-
ing lamps) Output — Lighting switch in 2nd position Battery voltage
29 P Tail lamp relay (park-
ing lamps) Output — Lighting switch in 2nd position Battery voltage
30
(A/T
only) R Fuse 54 Output — Ignition switch ON or START Battery voltage
Ignition switch OFF or ACC 0V
31 O Fuse 55 Output — Ignition switch ON or START Battery voltage
Ignition switch OFF or ACC 0V
32 L Wiper high speed sig-
nal OutputON or
START Wiper switch OFF, LO, INT 0V
HI Battery voltage
33 Y Wiper low speed sig-
nal OutputON or
START Wiper switch OFF 0V
LO or INT Battery voltage
35 BR Starter relay (inhibit
switch) InputON or
START Selector lever in "P" or "N"
(CVT or A/T) or clutch pedal
depressed (M/T) Battery voltage
Selector lever any other posi-
tion (CVT or A/T) or clutch
pedal released (M/T) 0V
36 BR Fuel pump relay Output — Ignition switch ON or START Battery voltage
Ignition switch OFF or ACC 0V
37 G Oil pressure switch Input ON or
START Engine running and oil pres-
sure within specification Battery voltage
Engine not running or oil pres-
sure below specification 0V
38 R Wiper auto stop signal Input ON or
START Wipers not in park position Battery voltage
Wipers in park position 0V
39 B Ground Input — — 0V
40 P CAN-L — ON — —
41 L CAN-H — ON — —
45 R Horn relay control Input — Horn switch PUSHED, alarm
switch activated or door lock/
unlock is confirmed when op-
erating lock system via the
keyfob 0V
Horn switch released, alarm
not active, keyfob not active Battery voltage
46 Y Throttle control motor
relay control Input —Ignition switch ON or START 0V
Ignition switch OFF or ACC Battery voltage
47 GR Fuel pump relay con-
trol Input —Ignition switch ON or START 0V
Ignition switch OFF or ACC Battery voltage
Terminal
Wire
color Signal name Signal
input/
output Measuring condition
Reference value
(Approx.)
Ignition
switch Operation or condition
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BODY HARNESS (HATCHBACK) B5 F3 B/1 : A/C compressor F5 F25 B/10 : Park/n
eutral position (PNP) switch (with A/T)
B4 F4 — : Generator C3 F26 W/2 : Condenser-2
A4 F5 — : Generator ground C5 F27 — : Starter motor
E3 F6 GR/2 : Engine coolant temperature sensor C5 F28 — : Starter motor
D2 F7 B/6 : Electric throttle control actuator F5 F30 B/8 : Terminal cord assembly
G4 F8 SMJ : To E8 F2 F31 B/6 : Mass air flow sensor
B4 F9 — : Engine ground C5 F32 GR/1 : Oil pressure switch
G2 F10 GR/32 : ECM F5 F33 GR/6 : To E19
G2 F11 BR/48 : ECM C3 F34 GR/3 : Ignition coil No. 1 (with power transistor)
D3 F12 GR/4 : Air fuel ratio (A/F) sensor 1 C3 F35 GR/3 : Ignition coil No. 2 (with power transistor)
E2 F13 B/4 : Heated oxygen sensor 2 C3 F36 GR/3 : Ignition coil No. 3 (with power transistor)
C4 F14 B/2 : Knock sensor C3 F37 GR/3 : Ignition coil No. 4 (with power transistor)
D3 F15 B/3 : Crankshaft position sensor (POS) E5 F38 BR/3 : Revolution sensor
C4 F16 — : Engine ground E4 F39 — : Fusible link box (battery)
B4 F17 GR/2 : Fuel injector No. 1 E4 F40 — : Fusible link box (battery)
C4 F18 GR/2 : Fuel injector No. 2 E2 F41 GR/2 : Vehicle speed sensor
C4 F19 GR/2 : Fuel injector No. 3 F5 F45 GR/3 : Turbine revolution sensor
D4 F20 GR/2 : Fuel injector No. 4 E5 F46 GR/22 : CVT unit
D4 F21 B/3 : Camshaft position sensor (PHASE) E5 F4 7 B/3 : Powertrain revolution sensor (with A/T)
C3 F22 GR/2 : EVAP canister purge volume control
solenoid valve E3 F48 B/3 : Secondary speed sensor (with M/T)