Nissan Maxima 2002 User Manual

HEATER &

CONTENTS

AUTO

PRECAUTIONS ...............................................................3

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...............3

Precautions for Working with HFC-134a (R-134a) .....3

General Refrigerant Precautions.................................4

Precautions for Leak Detection Dye............................4

Precaution for Identification Label on Vehicle.............5

Precautions for Refrigerant Connection......................5

Precautions for Servicing Compressor........................8

Precautions for Service Equipment.............................8

Wiring Diagrams and Trouble Diagnosis...................10

PREPARATION .............................................................11

Special Service Tools ................................................11

HFC-134a (R-134a) Service Tools and

Equipment..................................................................12

DESCRIPTION...............................................................15

Refrigeration System.................................................15

V-6 Variable Displacement Compressor....................16

Component Layout ....................................................20

Introduction................................................................21

Features.....................................................................21

Overview of Control System......................................24

Control Operation ......................................................24

Discharge Air Flow.....................................................26

System Description....................................................27

TROUBLE DIAGNOSES................................................28

Component Location..................................................28

Circuit Diagram (Without Navigation System)...........30

Wiring Diagram - A/C, A -/Without Navigation

System.......................................................................31

Circuit Diagram (With Navigation System)................34

Wiring Diagram - A/C, A -/With Navigation

System.......................................................................35

Auto Amp. Terminals and Reference Value...............39

Self-diagnosis ............................................................43

How to Perform Trouble Diagnoses for Quick

and Accurate Repair..................................................64

AIR CONDITIONER

SECTION

Operational Check.....................................................65

A/C System................................................................70

Mode Door Motor.......................................................75

Air Mix Door Motor ....................................................83

Intake Door Motor......................................................87

Blower Motor..............................................................91

Magnet Clutch..........................................................101

Insufficient Cooling ..................................................108

Insufficient Heating..................................................117

Noise........................................................................119

Self-diagnosis ..........................................................120

Memory Function.....................................................121

ECON (ECONOMY) Mode......................................122

Ambient Sensor Circuit............................................123

In-vehicle Sensor Circuit..........................................126

Sunload Sensor Circuit............................................129

Intake Sensor Circuit...............................................133

Air Mix Door Motor PBR Circuit ..............................135

Multiplex Communication Circuit.............................136

SERVICE PROCEDURE..............................................138

HFC-134a (R-134a) Service Procedure..................138

Maintenance of Lubricant Quantity in

Compressor .............................................................140

Compressor .............................................................143

Compressor Clutch..................................................143

Heater Unit (Heater Core).......................................147

Blower and Cooling Unit (A/C Evaporator) .............148

Refrigerant Lines .....................................................149

Fluorescent Dye Leak Detector...............................153

Belt...........................................................................154

Ventilation Air Filter..................................................154

SERVICE DATA AND SPECIFICATIONS (SDS).......155

Auto..........................................................................155

PRECAUTIONS ...........................................................156

Supplemental Restraint System (SRS) ″AIR

BAG″ and ″SEAT BELT PRE-TENSIONER″...........156

MANUAL

IDX

CONTENTS (Cont’d)

Precautions for Working with HFC-134a

(R-134a)...................................................................156

General Refrigerant Precautions.............................157

Precautions for Leak Detection Dye........................157

Precaution for Identification Label on Vehicle.........158

Precautions for Refrigerant Connection..................158

Precautions for Servicing Compressor....................161

Precautions for Service Equipment.........................161

Wiring Diagrams and Trouble Diagnosis.................163

PREPARATION ...........................................................164

Special Service Tools ..............................................164

HFC-134a (R-134a) Service Tools and

Equipment................................................................165

DESCRIPTION.............................................................168

Refrigeration System...............................................168

V-6 Variable Displacement Compressor..................169

Component Layout ..................................................173

Control Operation ....................................................174

Discharge Air Flow...................................................175

System Description..................................................176

TROUBLE DIAGNOSES..............................................177

Component Location................................................177

Circuit Diagram - Air Conditioner.............................179

Wiring Diagram - A/C, M -.......................................180

How to Perform Trouble Diagnoses for Quick

and Accurate Repair................................................184

Operational Check...................................................185

A/C System..............................................................187

Intake Door..............................................................190

Blower Motor............................................................194

Insufficient Cooling ..................................................200

Insufficient Heating..................................................208

Air Mix Door.............................................................209

Mode Door...............................................................213

Magnet Clutch..........................................................216

Noise........................................................................223

SERVICE PROCEDURE..............................................224

HFC-134a (R-134a) Service Procedure..................224

Maintenance of Lubricant Quantity in

Compressor .............................................................226

Compressor .............................................................230

Compressor Clutch..................................................230

Heater Unit (Heater Core).......................................234

Blower and Cooling Unit (A/C Evaporator) .............235

Refrigerant Lines .....................................................236

Fluorescent Dye Leak Detector...............................240

Belt...........................................................................241

Ventilation Air Filter..................................................241

SERVICE DATA AND SPECIFICATIONS (SDS).......242

Manual.....................................................................242

HA-2

PRECAUTIONS

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

AUTO

Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER”

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELTPRE-TENSIONER” used along with a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. The SRS system composition which is available to NISSAN MODEL A33 is as follows:

I For a frontal collision

The Supplemental Restraint System consists of driver air bag module (located in the center of the steering wheel), front passenger air bag module (located on the instrument panel on passenger side), seat belt pre-tensioners, a diagnosis sensor unit, warning lamp, wiring harness and spiral cable.

I For a side collision

The Supplemental Restraint System consists of front side air bag module (located in the outer side of front seat), satellite sensor, diagnosis sensor unit (one of components of air bags for a frontal collision), wiring harness, warning lamp (one of components of air bags for a frontal collision).

Information necessary to service the system safely is included in the RS section of this Service Manual.

WARNING:

I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance should be performed by an authorized NISSAN dealer.

I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-

sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the RS section.

I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this

Service Manual. SRS wiring harnesses can be identified by yellow harness connector.

NFHA0153

Precautions for Working with HFC-134a (R-134a)

WARNING:

I CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants

are mixed and compressor failure is likely to occur, refer to “CONTAMINATED REFRIGERANT” below. To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment (ACR4) (J-39500-NI) and Refrigerant Identifier.

I Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-

nents. If lubricant other than that specified is used, compressor failure is likely to occur.

I The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-

lowing handling precautions must be observed:

a) When removing refrigerant components from a vehicle, immediately cap (seal) the component to

minimize the entry of moisture from the atmosphere.

b) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just

before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system.

c) Only use the specified lubricant from a sealed container. Immediately reseal containers of lubri-

cant. Without proper sealing, lubricant will become moisture saturated and should not be used.

d) Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and

throat. Remove R-134a from the A/C system, using certified service equipment meeting requirements of SAE J2210 (R-134a recycling equipment), or J2209 (R-134a recovery equipment). If accidental system discharge occurs, ventilate work area before resuming service.Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

e) Do not allow lubricant (Nissan A/C System Oil Type S) to come in contact with styrofoam parts.

Damage may result.

CONTAMINATED REFRIGERANT

If a refrigerant other than pure R-134a is identified in a vehicle, your options are:

I Explain to the customer that environmental regulations prohibit the release of contaminated refrigerant into

the atmosphere.

I Explain that recovery of the contaminated refrigerant could damage your service equipment and refriger-

ant supply.

NFHA0154

NFHA0154S01

IDX

HA-3

PRECAUTIONS

Precautions for Working with HFC-134a (R-134a) (Cont’d)

I Suggest the customer return the vehicle to the location of previous service where the contamination may

have occurred.

I If you choose to perform the repair, recover the refrigerant using only dedicated equipment and con-

tainers. Do not recover contaminated refrigerant into your existing service equipment. If your facil-

ity does not have dedicated recovery equipment, you may contact a local refrigerant product retailer for available service. This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended.

I If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan

Customer Affairs for further assistance.

AUTO

General Refrigerant Precautions

WARNING:

I Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the

refrigerant every time an air conditioning system is discharged.

I Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or

air conditioning system.

I Do not store or heat refrigerant containers above 52°C (125°F). I Do not heat a refrigerant container with an open flame; if container warming is required, place the

bottom of the container in a warm pail of water.

I Do not intentionally drop, puncture, or incinerate refrigerant containers. I Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. I Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent

suffocation.

I Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air condi-

tioning systems with compressed air during repair. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers.

Precautions for Leak Detection Dye

I The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultravio-

let (UV) lamp is required to illuminate the dye when inspecting for leaks.

I Always wear fluorescence enhancing UV safety glasses to protect your eyes and enhance the visibility of

the fluorescent dye.

I A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal

should only be repaired after confirming the leak with an electronic refrigerant leak detector (J-41995).

I Always remove any dye from the leak area after repairs are complete to avoid a misdiagnosis during a

future service.

I Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled,

clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed.

I Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). I Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system. I Leak detection dyes for R-134a and R12 A/C systems are different. Do not use R-134a leak detection dye

in R-12 A/C system or R-12 leak detection dye in R-134a A/C systems orA/C system damage may result.

I The fluorescent properties of the dye will remain for over three (3) years unless a compressor failure

occurs.

NFHA0155

NFHA0265

HA-4

PRECAUTIONS

AUTO

Precaution for Identification Label on Vehicle

I Vehicles with factory installed fluorescent dye have this iden-

tification label on the under side of hood.

I Vehicles with factory installed fluorescent dye have a green

label.

I Vehicles without factory installed fluorescent dye have a blue

label.

SHA436FA

Precautions for Refrigerant Connection

A new type refrigerant connection has been introduced to all refrigerant lines except the following location. I Expansion valve to cooling unit

FEATURES OF NEW TYPE REFRIGERANT CONNECTION

I The O-ring has been relocated. It has also been provided with a groove for proper installation. This elimi-

nates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics.

I The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby

facilitating piping connections.

NFHA0266

NFHA0156

NFHA0156S01

SHA815E

HA-5

IDX

Precautions for Refrigerant Connection (Cont’d)

PRECAUTIONS

AUTO

O-RING AND REFRIGERANT CONNECTION

NFHA0156S02

RHA030I

CAUTION:

The new and former refrigerant connections use different O-ring configurations. Do not confuse O-rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection.

HA-6

PRECAUTIONS

AUTO

Precautions for Refrigerant Connection (Cont’d)

O-Ring Part Numbers and Specifications

Connection

type New

Former 92470 N8200 6.07 (0.2390) 1.78 (0.0701)

New

Former 92475 71L00 11.0 (0.433) 2.4 (0.094)

New

Former 92475 72L00 14.3 (0.563) 2.3 (0.091)

SHA814E

WARNING:

Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it.

CAUTION:

When replacing or cleaning refrigerant cycle components, observe the following. I When the compressor is removed, store it in the same position as it is when mounted on the car.

Failure to do so will cause lubricant to enter the low pressure chamber.

I When connecting tubes, always use a torque wrench and a back-up wrench. I After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. I When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera-

tion. Do not remove the seal caps of pipes and other components until just before required for connection.

I Allow components stored in cool areas to warm to working area temperature before removing seal

caps. This prevents condensation from forming inside A/C components.

I Thoroughly remove moisture from the refrigeration system before charging the refrigerant. I Always replace used O-rings. I When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not

to apply lubricant to threaded portion. Lubricant name: Nissan A/C System Oil Type S Part number: KLH00-PAGS0

I O-ring must be closely attached to dented portion of tube. I When replacing the O-ring, be careful not to damage O-ring and tube. I Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that

the O-ring is installed to tube correctly.

I After connecting line, conduct leak test and make sure that there is no leakage from connections.

When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque.

New

Former 92477 N8200 17.12 (0.6740) 1.78 (0.0701)

O-ring

size

Part number D mm (in) W mm (in)

92471 N8210 6.8 (0.268) 1.85 (0.0728)

92472 N8210 10.9 (0.429) 2.43 (0.0957)

92473 N8210 13.6 (0.535) 2.43 (0.0957)

92474 N8210 16.5 (0.650) 2.43 (0.0957)

NFHA0156S0201

HA-7

IDX

Precautions for Refrigerant Connection (Cont’d)

PRECAUTIONS

AUTO

RHA861F

Precautions for Servicing Compressor

NFHA0157

I Plug all openings to prevent moisture and foreign matter from entering. I When the compressor is removed, store it in the same position as it is when mounted on the car. I When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres-

sor” exactly. Refer to HA-140.

I Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with

lubricant, wipe it off by using a clean waste cloth moistened with thinner.

I After compressor service operation, turn the compressor shaft by hand more than five turns in

both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour.

I After replacing the compressor magnet clutch, apply voltage to the new one and check for normal

operation.

Precautions for Service Equipment

RECOVERY/RECYCLING EQUIPMENT

NFHA0158

NFHA0158S01

Be certain to follow the manufacturers instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine.

ELECTRONIC LEAK DETECTOR

NFHA0158S02

Be certain to follow themanufacturer’s instructionsfor tester operation and tester maintenance.

HA-8

PRECAUTIONS

AUTO

Precautions for Service Equipment (Cont’d)

RHA270DA

VACUUM PUMP

The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hose-to-pump connection, as follows.

I Usually vacuum pumps have a manual isolator valve as part

of the pump. Close this valve to isolate the service hose from the pump.

I For pumps without an isolator, use a hose equipped with a

manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump.

I If the hose has an automatic shut off valve, disconnect the

hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate.

Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump’s ability to pull a deep vacuum and are not recommended.

MANIFOLD GAUGE SET

Be certain that the gauge face indicates R-134a or 134a. Be sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC134a (R-134a) and specified lubricants.

NFHA0158S03

NFHA0158S04

SHA533D

RHA272D

SERVICE HOSES

Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge.

SERVICE COUPLERS

Never attempt to connect HFC-134a (R-134a) service couplers to an CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur.

Shut-off valve rotation A/C service valve

NFHA0158S05

NFHA0158S06

IDX

RHA273D

Clockwise Open Counterclockwise Close

HA-9

Precautions for Service Equipment (Cont’d)

PRECAUTIONS

AUTO

RHA274D

REFRIGERANT WEIGHT SCALE

NFHA0158S07

Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″-16 ACME.

CALIBRATING ACR4 WEIGHT SCALE

NFHA0158S08

Calibrate the scale every three months. To calibrate the weight scale on the ACR4 (J-39500-NI):

1. Press Shift/Reset and Enter at the same time.

2. Press 8787.“A1” will be displayed.

3. Remove all weight from the scale.

4. Press 0, then press Enter.“0.00” will be displayed and change to “A2”.

5. Place a known weight (dumbbell or similar weight), between

4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale.

6. Enter the known weight using four digits. (Example 10 lb =

10.00, 10.5 lb = 10.50)

7. Press Enter — the display returns to the vacuum mode.

8. Press Shift/Reset and Enter at the same time.

9. Press 6 — the known weight on the scale is displayed.

10. Remove the known weight from the scale. “0.00” will be displayed.

11. Press Shift/Reset to return the ACR4 to the program mode.

CHARGING CYLINDER

NFHA0158S09

Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment.

Wiring Diagrams and Trouble Diagnosis

NFHA0159

When you read wiring diagrams, refer to the following:

I GI-11, “HOW TO READ WIRING DIAGRAMS” in GI section I EL-11, “Wiring Diagram — POWER —” for power distribution

circuit in EL section

When you perform trouble diagnosis, refer to the following: I GI-35, “HOW TO FOLLOW TEST GROUPS IN TROUBLE

DIAGNOSES” in GI section

I GI-24,“HOWTOPERFORMEFFICIENTDIAGNOSISFORAN

ELECTRICAL INCIDENT” in GI section

HA-10

PREPARATION

AUTO

Special Service Tools

The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.

Tool number (Kent-Moore No.) Tool name

KV99106100 (J-41260) Clutch disc wrench

Description

Removing center bolt

NT232

NFHA0160

KV99232340 (J-38874) or KV992T0001 (—) Clutch disc puller

KV99106200 (J-41261) Pulley installer

NT378

NT376

NT235

Removing clutch disc

Installing pulley

HA-11

IDX

PREPARATION

AUTO

HFC-134a (R-134a) Service Tools and Equipment

Never mix HFC-134a refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/ lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor failure will result.

Tool number (Kent-Moore No.) Tool name

Description

=NFHA0161

HFC-134a (R-134a) refrigerant

KLH00-PAGS0 (—) Nissan A/C System Oil Type S

(J-39500-NI) Recovery/Recycling Recharging equipment (ACR4)

(J-41995) Electrical leak detector

Container color: Light blue Container marking: HFC-134a (R-134a) Fitting size: Thread size I Large container 1/2″-16 ACME

NT196

Type: Poly alkylene glycol oil (PAG), type S Application: HFC-134a (R-134a) swash plate (piston) compressors (Nissan only) Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz)

NT197

Function: Refrigerant Recovery and Recycling and Recharging

NT195

Power supply: I DC 12V (Cigarette lighter)

AHA281A

HA-12

Tool number (Kent-Moore No.) Tool name

Description

PREPARATION

HFC-134a (R-134a) Service Tools and Equipment (Cont’d)

AUTO

(J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety glasses (J-41459) Refrigerant dye injector (J-41447) qty. 24 R-134a refrigerant dye (J-43872) Refrigerant dye cleaner

(J-42220) Fluorescent dye leak detector

(J-41447) R134a Fluorescent Leak Detection Dye (Box of 24, 1/4 ounce bottles)

ZHA200H

SHA438F

UV lamp UV safety glasses

Dye

Power supply: DC 12V (Battery terminal)

Power supply: DC12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system. Includes: UV lamp and UV safety glasses

Application: For R-134a PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.)

(J-41459) R134a Dye Injector Use with J-41447, 1/4 ounce bottle

(J-43872) Dye cleaner

(J-39183) Manifold gauge set (with hoses and couplers)

SHA439F

SHA440F

SHA441F

Dye injector

For injecting 1/4 ounce of Fluorescent Leak Detection Dye into A/C system.

For cleaning dye spills.

Identification: I The gauge face indicates R-134a. Fitting size: Thread size I 1/2″-16 ACME

IDX

NT199

HA-13

PREPARATION

HFC-134a (R-134a) Service Tools and Equipment (Cont’d)

Tool number (Kent-Moore No.) Tool name

Description

AUTO

Service hoses I High side hose

(J-39501-72)

I Low side hose

(J-39502-72)

I Utility hose

(J-39476-72)

Service couplers I High side coupler

(J-39500-20)

I Low side coupler

(J-39500-24)

(J-39650) Refrigerant weight scale

(J-39649) Vacuum pump (Including the isolator valve)

Hose color:

I Low hose: Blue with black stripe I High hose: Red with black stripe I Utility hose: Yellow with black stripe or green

with black stripe Hose fitting to gauge: I 1/2″-16 ACME

NT201

Hose fitting to service hose: I M14 x 1.5 fitting is optional or permanently

attached.

NT202

For measuring of refrigerant Fitting size: Thread size I 1/2″-16 ACME

NT200

Capacity:

I Air displacement: 4 CFM I Micron rating: 20 microns I Oil capacity: 482 g (17 oz)

Fitting size: Thread size I 1/2″-16 ACME

NT203

COMMERCIAL SERVICE TOOL

Tool name Description Refrigerant identifier

equipment

NT765

NFHA0161S01

For checking refrigerant purity and for system contamination

HA-14

DESCRIPTION

Refrigeration System

AUTO

Refrigeration System

REFRIGERATION CYCLE Refrigerant Flow

The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expansion valve, located inside the evaporator case.

NFHA0162

NFHA0162S01

Freeze Protection

Under normal operating conditions, when the A/C is switched on, the compressor runs continuously, and the evaporator pressure, and therefore, temperature is controlled by the V-6 variable displacement compressor to prevent freeze up.

Refrigerant System Protection

Refrigerant Pressure Sensor

The refrigerant system is protected against excessively high or low pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm kPa (1.8 kg/cm

Pressure Relief Valve

The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an abnormal level [more than 3,727 kPa (38

kg/cm into the atmosphere.

, 540 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant

, 26 psi).

, 398 psi), psi or below about 177

NFHA0162S02

NFHA0162S03

NFHA0162S0301

NFHA0162S0302

RHA031I

IDX

HA-15

DESCRIPTION

V-6 Variable Displacement Compressor

AUTO

V-6 Variable Displacement Compressor

GENERAL INFORMATION

1. The V-6 variable compressor differs from previous units. The vent temperatures of the V-6 variable compress do not drop too far below 5°C (41°F) when:

I evaporator intake air temperature is less than 20°C (68°F) I engine is running at speeds less than 1,500 rpm.

This is because the V-6 compressor provides a means of “capacity” control.

2. The V-6 variable compressor provides refrigerant control under varying conditions. During cold winters, it may not produce high refrigerant pressure discharge (compared to previous units) when used with air conditioning systems.

3. A “clanking” sound may occasionally be heard during refrigerant charge. The sound indicates that the tilt angle of the swash plate has changed and is not a problem.

4. For air conditioning systems with the V-6 compressor, the clutch remains engaged unless: the system main switch, fan switch or ignition switch is turned OFF. When ambient (outside) temperatures are low or when the amount of refrigerant is insufficient, the clutch is disengaged to protect the compressor.

5. A constant range of suction pressure is maintained when engine speed is greater than a certain value. It normally ranges from 147 to 177 kPa (1.5 to 1.8 kg/cm In previous compressors, however, suction pressure was reduced with increases in engine speed.

, 21 to 26 psi) under varying conditions.

=NFHA0163

HA-16

DESCRIPTION

AUTO

V-6 Variable Displacement Compressor (Cont’d)

DESCRIPTION General

The variable compressor is basically a swash plate type that changes piston stroke in response to the required cooling capacity. The tilt of the swash plate allows the piston’s stroke to change so that refrigerant discharge can be continuously changed from 14.5 to 184 cm

(0.885 to 11.228 cu in).

=NFHA0164

NFHA0164S01

HA-17

RHA037DD

IDX

V-6 Variable Displacement Compressor (Cont’d)

DESCRIPTION

AUTO

Operation

1. Operation Control Valve

=NFHA0164S02

NFHA0164S0201

Operation control valve is located in the suction port (low-pressure) side, and opens or closes in response to changes in refrigerant suction pressure. Operation of the valve controls the internal pressure of the crankcase. The angle of the swash plate is controlled between the crankcase’s internal pressure and the piston cylinder pressure.

2. Maximum Cooling

NFHA0164S0202

Refrigerant pressure on the low-pressure side increases with an increase in heat loads. When this occurs, the control valve’s bellows compress to open the low-pressure side valve and close the high-pressure side valve. This causes the following pressure changes:

I the crankcase’s internal pressure to equal the pressure on the low-pressure side; I the cylinder’s internal pressure to be greater than the crankcase’s internal pressure.

Under this condition, the swash plate is set to the maximum stroke position.

RHA473C

HA-18

DESCRIPTION

AUTO

V-6 Variable Displacement Compressor (Cont’d)

3. Capacity Control

I Refrigerant pressure on suction side is low during high speed driving or when ambient or interior tempera-

ture is low.

I The bellows expands when refrigerant pressure on the suction pressure side drops below approximately

177 kPa (1.8 kg/cm Since suction pressure is low, it makes the suction port close and the discharge port open. Thus, crankcase pressure becomes high as high pressure enters the crankcase.

I The force acts around the journal pin near the swash plate, and is generated by the pressure difference

before and behind the piston. The drive lug and journal pin are located where the piston generates the highest pressure. Piston pressure is between suction pressure Ps and discharge pressure Pd, which is near suction pressure Ps. If crankcase pressure Pc rises due to capacity control, the force around the journal pin makes the swash plate angle decrease and also the piston stroke decrease. In other words, crankcase pressure increase triggers pressure difference between the piston and the crankcase. The pressure difference changes the angle of the swash plate.

, 26 psi).

=NFHA0164S0203

RHA474C

HA-19

IDX

Component Layout

DESCRIPTION

AUTO

Component Layout

NFHA0166

HA-20

RHA349H

DESCRIPTION

AUTO

Introduction

AIR CONDITIONER LAN SYSTEM OVERVIEW CONTROL SYSTEM

The LAN system consists of auto amp., air mix door motor, intake door motor and mode door motor. A configuration of these components is shown in the diagram below.

Features

SYSTEM CONSTRUCTION (LAN)

A small network is constructed between the auto amplifier, air mix door motor, mode door motor and intake door motor. The auto amplifier and motors are connected by data transmission lines and motor power supply lines. The LAN network is built through the ground circuits of the three motors. Addresses, motor opening angle signals, motor stop signals and error checking messages are all transmitted through the data transmission lines connecting the auto amplifier and three motors. The following functions are contained in LCUs built into the air mix door motor, intake door motor and the mode door motor.

I Address I Motor opening angle signals I Data transmission I Motor stop and drive decision I Opening angle sensor (PBR function) I Comparison I Decision (Auto amplifier indicated value and motor opening angle comparison)

NFHA0167

NFHA0167S01

RHA439GB

NFHA0168

NFHA0168S01

RHA350H

Operation

The auto amplifier receives data from each of the sensors. The amplifier sends air mix door, intake door and mode door opening angle data to the air mix door motor LCU, mode door LCU and intake door motor LCU. The air mix door motor, intake door motor and mode door motor read their respective signals according to the address signal. Opening angle indication signals received from the auto amplifier and each of the motor position sensors are compared by the LCUs in each motor with the existing decision and opening angles. Subsequently, HOT/COLD, FRESH/RECIRCULATION or DEFROST/VENT operation is selected. The new selection data is returned to the auto amplifier.

NFHA0168S0101

HA-21

IDX

Features (Cont’d)

DESCRIPTION

AUTO

RHA351H

Transmission Data and Transmission Order

NFHA0168S0102

Amplifier data is transmitted consecutively to each of the door motors following the form shown in figure below. Start: Initial compulsory signal sent to each of the door motors. Address: Data sent from the auto amplifier is selected according to data-based decisions made by the air mix door motor, intake door motor and mode door motor. If the addresses are identical, the opening angle data and error check signals are received by the door motor LCUs. The LCUs then make the appropriate error decision. If the opening angle data is normal, door control begins. If an error exists, the received data is rejected and corrected data received. Finally, door control is based upon the corrected opening angle data. Opening angle: Data that shows the indicated door opening angle of each door motor. Error check: Procedure by which sent and received data is checked for errors. Error data is then compiled. The error check prevents corrupted data from being used by the air mix door motor, intake door motor and mode door motor. Error data can be related to the following problems.

I Abnormal electrical frequency I Poor electrical connections I Signal leakage from transmission lines I Signal level fluctuation

Stop signal: At the end of each transmission, a stop operation, in-operation, or internal problem message is delivered to the auto amplifier. This completes one data transmission and control cycle.

RHA352H

Air Mix Door Control (Automatic Temperature Control)

NFHA0168S0103

The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined value by: The temperature setting, ambient temperature, in-vehicle temperature and amount of sunload.

HA-22

DESCRIPTION

AUTO

Features (Cont’d)

Fan Speed Control

Blower speed is automatically controlled based on temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position. With FAN switch set to “AUTO”, the blower motor starts to gradually increase air flow volume. When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing.

Intake Door Control

The intake doors are automatically controlled based on temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload, air mix door position and ON-OFF operation of the compressor.

Outlet Door Control

The outlet door is automatically controlled by: The temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload.

Magnet Clutch Control

The ECM controls compressor operation using input signals from the throttle position sensor, refrigerant pressure sensor and auto amplifier.

Self-diagnostic System

The self-diagnostic system is built into the auto amplifier (LCU) to quickly locate the cause of problems.

NFHA0168S0104

NFHA0168S0105

NFHA0168S0106

NFHA0168S0107

NFHA0168S0108

HA-23

IDX

Overview of Control System

DESCRIPTION

AUTO

Overview of Control System

=NFHA0169

The control system consists of input sensors, switches, the automatic amplifier (microcomputer) and outputs. The relationship of these components is shown in the diagram below:

Control Operation

RHA032I

NFHA0170

RHA033I

HA-24

DESCRIPTION

AUTO

Control Operation (Cont’d)

RHA085I

DISPLAY SCREEN

Displays the operational status of the system.

AUTO SWITCH

The compressor, intake doors, air mix door, outlet doors, and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator.

ECON SWITCH

By pressing the ECON switch, the display should indicate ECON and the compressor always turns OFF. With the compressor OFF, the system will not remove heat (cool) or de-humidify. The system will maintain the invehicle temperature at the set temperature when the set temperature is above the ambient (outside) temperature. The system will set the intake doors to the outside air position.

TEMPERATURE DIAL (POTENTIO TEMPERATURE CONTROL)

Increases or decreases the set temperature.

OFF SWITCH

The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot (80% foot and 20% defrost) position.

FAN SWITCH

Manual control of the blower speed. Four speeds are available for manual control (as shown on the display screen): low

, medium low , medium high , high

NFHA0170S01

NFHA0170S02

NFHA0170S03

NFHA0170S04

NFHA0170S05

NFHA0170S06

RECIRCULATION (REC) SWITCH

OFF position: Outside air is drawn into the passenger compartment. ON position: Interior air is recirculated inside the vehicle.

DEFROSTER (DEF) SWITCH

Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position.

MODE SWITCH

Control the air discharge outlets.

REAR WINDOW DEFOGGER SWITCH (WITHOUT NAVIGATION SYSTEM)

When illumination is ON, rear window is defogged.

NFHA0170S07

NFHA0170S08

NFHA0170S09

NFHA0170S10

HA-25

IDX

Discharge Air Flow

DESCRIPTION

AUTO

Discharge Air Flow

NFHA0171

HA-26

RHA355H

DESCRIPTION

AUTO

System Description

SWITCHES AND THEIR CONTROL FUNCTIONS

Position or switch

VENT B/L FOOT D/F ON OFF ON OFF

MODE SW Front DEF SW

AUTOSWECON

NFHA0246S01

RHA044GA

REC SW Temperature DIAL

NFHA0246

Door 18.0°C

(60°F)

Ventilator door

Foot door A B C C A — — Defroster

door Air mix

door Intake

door

*1: Automatically controlled when REC switch is OFF.

ABCCC

AABCC — —

— — — A AUTO B

— C A AUTO*1 —

— AUTO AUTO

——

—

32.0°C (90°F)

HA-27

IDX

Component Location

TROUBLE DIAGNOSES

AUTO

Component Location

ENGINE COMPARTMENT

NFHA0172

NFHA0172S01

HA-28

RHA034I

TROUBLE DIAGNOSES

AUTO

Component Location (Cont’d)

PASSENGER COMPARTMENT

NFHA0172S02

HA-29

IDX

SHA628F

Circuit Diagram (Without Navigation System)

TROUBLE DIAGNOSES

AUTO

Circuit Diagram (Without Navigation System)

NFHA0173

HA-30

MHA170B

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