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HA-16
< SYMPTOM DIAGNOSIS >
REFRIGERATION SYSTEM SYMPTOMS
Both high and low-pressure sides
are too low.• The area around evapora-
tor outlet does not become
cold.
• The area around evapora- tor inlet becomes frosted. Clogged expansion valve.
• Breakage of temperature
sensor.
• Clogging by foreign material. Eliminate foreign material from
expansion valve, or replace it.
• There is a temperature dif- ference between the areas
around outlet and inlet
pipes of liquid tank.
• Liquid tank becomes frost- ed. Malfunction inside liquid tank
(clogged strainer).
Replace condenser (includes
liquid tank). Refer to HA-31, "CONDENSER : Removal and
Installation".
Evaporator becomes frosted. Clogged or crushed low-pres-
sure pipe.
Repair or replace malfunction-
ing parts.
Malfunctioning thermo amp. Check thermo amp. system.
Refer to HAC-32, "
Diagnosis
Procedure".
There is a small temperature
difference between the high
and low pressure pipes. • Low refrigerant charge.
• Leak or leaks in A/C system. • Check for leaks. Refer to
HA-
18, "Leak Test".
• Recover refrigerant, evacu- ate system, and recharge
with the specified amount of
refrigerant. Refer to HA-20,
"Recycle Refrigerant".
Low-pressure side sometimes be-
comes negative. • Sometimes the area
around evaporator outlet
does not become cold.
• Sometimes the area around evaporator inlet is
frosted. • Icing caused by moisture
mixed with refrigerant.
• Deteriorated dryer material in liquid tank. Recover refrigerant then re-
place condenser (includes liq-
uid tank). Refer to HA-31,
"CONDENSER : Removal and
Installation". Evacuate system
and recharge with the specified
amount of refrigerant. Refer to
HA-20, "
Charge Refrigerant".
Gauge indication
Refrigerant cycleProbable causeCorrective action
AC353A
AC354A
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NOISEHA-17
< SYMPTOM DIAGNOSIS >
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NOISE
Symptom TableINFOID:0000000012431996
Symptom Noise source Probable cause Corrective action
Unusual noise from compressor
when A/C is ON. Inside of compressor
Worn, broken, or clogged internal com-
ponents. Check compressor oil. Re-
fer to HA-22, "
Inspection".
Magnet clutch Contact of clutch disc with pulley. Check clearance between
clutch disc and pulley. Refer
to HA-27, "
Inspection".
Compressor body Loose compressor mounting bolts. Check torque of mounting
bolts. Refer to
HA-26, "
Ex-
ploded View".
Unusual noise from cooler piping. Cooler piping (pipe and
flexible hose)Loose or improper installation of clip
and bracket. Check installation of cooler
piping. Refer to
HA-28, "
Ex-
ploded View".
Unusual noise from expansion
valve when A/C is ON. Expansion valveLow refrigerant charge. • Check for leaks. Refer to
HA-18, "
Leak Test".
• Recover refrigerant,
evacuate system, and re-
charge with the specified
amount of refrigerant.
Worn, broken, or clogged internal com-
ponents. Eliminate foreign material
from expansion valve, or re-
place it.
Unusual noise from belt. —Loose belt
Check belt tension. Refer to
EM-17, "
Adjustment".
Damaged or broken components in-
side compressor. Replace compressor. Refer
to HA-26, "
Removal and In-
stallation".
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HA-18
< PERIODIC MAINTENANCE >
REFRIGERANT
PERIODIC MAINTENANCE
REFRIGERANT
DescriptionINFOID:0000000012431997
CONNECTION OF SERVICE TOOLS AND EQUIPMENT
Leak TestINFOID:0000000012431998
CHECK REFRIGERANT LEAKS USING FLUORESCENT LEAK DETECTION DYE
1. Install a fender cover (1).
2. Wear UV safety goggles (2) provided with refrigerant dye leak detection kit.
3. Connect power cable (4) of UV lamp (6) to positive and negative terminals of the battery (3).
1. Shut-off valve2. A/C service valve 3. Recovery/recycling/recharging
equipment
4. Refrigerant container (HFC-134a) 5. Weight scale 6. Vacuum pump
7. Manifold gauge set
A. Preferred (best) method B. Alternative methodC. For charging
JSIIA0239ZZ
RJIA3815J
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REFRIGERANTHA-19
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4. Press UV lamp switch (5) and check A/C system for re frigerant leaks. (Where refrigerant leaks occur, flu-
orescent leak detection dye appears green in color.)
WARNING:
Do not look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, fo llow the manufacturer’s operating instructions.
• Illuminate pipe joints from different angles using UV lamp to check for leaks.
• Use a mirror in areas that are di fficult to see to check for leaks.
• Refrigerant leaks from the evaporator can be detected by soaking a cotton swab or similar material with
drain hose water and illuminating it using the UV lamp.
• Dust, dirt, and packing material adhesives used for condenser, evaporator, and other components may fluoresce. Be careful not to misidentify leaks.
5. Repair or replace parts where refrigerant lea ks occur and wipe off fluorescent leak detection dye.
NOTE:
Completely wipe off fluorescent leak detection dye from gaps between parts, screw threads, and other
components using a cotton swab or similar material.
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work. WARNING:
Do not look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, fo llow the manufacturer’s operating instructions.
• Dust, dirt, and packing material adhesives used for condenser, evaporator, and other components may
fluoresce. Be careful not to misidentify leaks.
CHECK REFRIGERANT LEAKS USING ELECTRONIC LEAK DETECTOR
WARNING:
Do not check for refrigerant leaks while the engine is running.
CAUTION:
Be careful of the following items so that in accurate checks or misidentifications are avoided.
• Do not allow refrigerant vapor, shop chemical vapors, cigarette smoke or other contaminates around the vehicle.
• Always check refrigerant leaks in a low air flow en vironment so that refrigerant may not disperse.
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set to the A/C service valves.
3. Check that A/C refrigerant pressure is 345 kPa (3.52 kg/cm
2, 50 psi) or more when temperature is 16 °C
(61 °F) or more. When pressure is lower than the specified value, recycle refrigerant completely and
recharge refrigerant to the specified level.
NOTE:
Leaks may not be detected if A/C refriger ant pressure is 345 kPa (3.52 kg/cm
2, 50 psi) or less when tem-
perature is less than 16° C (61°F).
4. Clean the area where the refrigerant leak check is performed and check for refrigerant leaks along all sur- faces of pipe connections and A/C system co mponents using electronic leak detector probe.
CAUTION:
• Continue checking once leaks are found. Always co ntinue and complete checking along all pipe
connections and A/C system comp onents for additional leaks.
• When leaks are detected, clean leak ar ea using compressed air and re-check.
• When checking the evaporator for leaks, always clean inside of drain hose so that the probe sur-
face may not be exposed to water or dirt.
NOTE:
• Always check for leaks starting from the high-pressure side and continue to the low-pressure side.
• When checking the evaporator for leaks, operate blower motor for 15 minut\
es or more at the maximum speed while the engine is stopped. Insert electronic leak detector probe into drain hose and hold for 10
minutes or more.
• When disconnecting shut-off valve that is connected to A/C service valve, always evacuate remaining
refrigerant so that misidentification can be avoided.
5. Repair or replace parts where refrigerant leaks occur.
6. Start the engine and set A/C control in the following conditions. • A/C switch: ON
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HA-20
< PERIODIC MAINTENANCE >
REFRIGERANT
• Air flow: VENT (ventilation)
• Intake door position: Recirculation
• Temperature setting: Full cold
• Blower speed: Maximum
7. Run the engine at approximately 1,500 rpm for two minutes or more.
8. Stop the engine. Check for refrigerant leaks. Go to step 4. WARNING:
Be careful not to get burned when the engine is hot.
NOTE:
• Start refrigerant leak check immediately after the engine is stopped.
• When refrigerant circulation is stopped, pressure on the low- pressure side rises gradually and pressure on the high-pres-
sure side falls gradually.
• The higher the pressure is, the easier it is to find refrigerant leaks.
Recycle RefrigerantINFOID:0000000012431999
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC- 12 is accidentally charged, compressor damage
may result due to in sufficient lubrication.
• Always observe and follow precaution s described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite or the loss of eyesight.
• Do not breathe A/C refrigerant and oil vapor or mi st. Exposure may irritate eyes, nose, or throat.
• Do not allow HFC-134a to be exposed to an open flame. Poisonous gas is produced if refrigerant
burns. Keep workshop well ventilated.
1. Perform oil return operation. Refer to HA-22, "
Perform Oil Return Operation". (If refrigerant or oil leaks are
detected in a large amount, omit this step, and go to step 2.)
CAUTION:
Do not perform oil return operation if a la rge amount of refrigerant or oil has leaked.
2. Check pressure gauge readings of recovery/recyc ling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose.
NOTE:
Follow manufacturer instructions for the handling or maintenance of the equipment. Do not fill the equip-
ment with non-specified refrigerant.
3. Remove A/C service valve caps from the vehicle.
4. Connect recovery/recycling/recharging equipment to A/C service valves.
5. Operate recovery/recycling/recharging equipm ent, and recycle refrigerant from the vehicle.
6. Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated in the compressor oil,
etc.
7. Refrigerant recycle operation is complete.
Charge RefrigerantINFOID:0000000012432000
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC- 12 is accidentally charged, compressor damage
may result due to in sufficient lubrication.
• Always observe and follow precaution s described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant co ntainer, frostbite, or the loss of eyesight.
• Do not breathe A/C refrigerant and oil vapor or mi st. Exposure my irritate eyes, nose, or throat.
• Do not allow HFC-134a to be exposed to an open flame. Poisonous gas is produce if refrigerant burns. Keep workshop well ventilated.
1. Connect recovery/recycling/recharging equipment to the A/C service valves.
SHA839E
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2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or more.
CAUTION:
Evacuate air for 15 minutes or more if parts are replaced.
3. Check the airtightness of A/C system for 25 minutes or more. If pressure raises more than the specified
level, charge A/C system with approximately 200g of refrigerant and check that there are no refrigerant
leaks. Refer to HA-18, "
Leak Test".
CAUTION:
Check the airtightness for 15 minutes or more if parts are replaced.
4. If parts other than the compressor are replaced, fill compressor oil according to parts that are replaced.
Refer to HA-22, "
Oil Adjusting Procedure for Components Replacement Except Compressor".
5. Charge the specified amount of refrigerant into A/C system.
6. Check that the A/C system operates normally.
7. Collect the refrigerant from the high-pressure hos e and low-pressure hose of recovery/recycling/recharg-
ing equipment. Disconnect recovery/recycling/recharging equipment.
8. Install A/C service valve caps.
9. Refrigerant charge is complete.
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HA-22
< PERIODIC MAINTENANCE >
OIL
OIL
DescriptionINFOID:0000000012432001
MAINTENANCE OF OIL LEVEL
The compressor oil circulates in the system together with the refrigerant. It is necessary to add oil to the com-
pressor when replacing A/C system components or when a large amount of refrigerant leaks from the system.
It is important to always maintain oil level within t he specified level. Otherwise, the following conditions may
occur.
• Insufficient oil amount: Stuck compressor
• Excessive oil amount: Insufficient cooling (caused by insufficient heat exchange)
InspectionINFOID:0000000012432002
If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.COMPRESSOR OIL JUDGMENT
1. Remove the compressor. Refer to HA-26, "
Removal and Installation".
2. Sample the compressor oil and judge on the figure.
Judgement result 1>>Replace compressor only.
Judgement result 2>>Replace compressor and condenser (includes liquid tank).
Perform Oil Retu rn OperationINFOID:0000000012432003
CAUTION:
If a large amount of refrigerant or oil leaks from the system, do not perform oil return operation.
1. Start the engine and set the front air control to the following conditions. • Engine speed: Idling to 1,200 rpm
• A/C switch: ON
• Blower speed: Maximum
• Intake door position: Recirculation
• Temperature setting: Full cold
2. Perform oil return operation for approximately 10 minutes.
3. Stop the engine.
4. Oil return operation is complete.
Oil Adjusting Procedure for Compon ents Replacement Except Compressor
INFOID:0000000012432004
Add the amount of oil that is calculated according to the following conditions.
Example: Oil amount to be added when replacing evaporator [m (Imp fl oz.)] = 35 (1.2) + α
Name A/C System Oil Type: DH-PR
JSIIA0927GB
Conditions
Oil amount to be added to A/C system
m (Imp fl oz.)
Replace evaporator 35 (1.2)
Replace condenser (includes liquid tank) 20 (0.7)
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OIL
HA-23
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Oil Adjusting Procedure for Compressor ReplacementINFOID:0000000012432005
1. Drain oil from removed compressor and measure amount drained. • Drain oil from high-pressure port (A) and low-pressure port (B)
while rotating magnet clutch.
• Measure total amount of oil that is drained from removed com-
pressor.
2. Drain oil from a new compressor that is calculated according to the following conditions.
CAUTION:
If oil amount that is drained from removed compr essor is less than 60 m (2.1 Imp fl oz.), perform
calculation by setting “D” as 40 m (1.4 Imp fl oz.).
Example: Oil amount to be drained from a new compressor when replacing compressor [m (Imp fl oz.)]
[D = 60 (2.1), α = 5 (0.2)]
120 (4.2) − [60 (2.1) + 20 (0.7) + 5 (0.2)] = 35 (1.1)
3. Install compressor and check the operation.
Refrigerant leak is detected Large amount leakage
30 (1.1)
Small amount leakage —
Oil amount that is recycled together with refrigerant during recycle operation α
Conditions
Oil amount to be added to A/C system
m (Imp fl oz.)
JMIIA0940ZZ
Amount to be drained (A) [m (Imp fl oz.)] = F − (D
+ S + R + α)
F: Oil amount that a new compressor contains [120 (4.2)]
D: Oil amount that is drained from removed com- pressor
S: Oil amount that rema ins inside of removed
compressor [20 (0.7)]
R: Oil amount to be added according to compo- nents that are removed except compressor
α : Oil amount that is recycled together with re-
frigerant during recycle operation
Conditions Oil amount to be added to A/C system
m (Imp fl oz.)
Replace evaporator 35 (1.2)
Replace condenser (in-
cludes liquid tank) 20 (0.7)
JPIIA1455GB
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