VENTILATION, HEATER & AIR CONDITIONER

HEATER & AIR CONDITIONING SYSTEM

SECTION HA B

E
CONTENTS
YD25DDTi Description ...............................................................25 F
Inspection ................................................................25
PRECAUTION ............................................... 4 Perform Lubricant Return Operation .......................25
Lubricant Adjusting Procedure for Components G
PRECAUTIONS ................................................... 4 Replacement Except Compressor ...........................25
Precaution for Supplemental Restraint System Lubricant Adjusting Procedure for Compressor
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Replacement ...........................................................26
SIONER" ................................................................... 4 H
Precautions Necessary for Steering Wheel Rota- PERFORMANCE TEST .................................... 27
tion After Battery Disconnection ................................ 4 Inspection ................................................................27
Precautions for Removing Battery Terminal ............. 5 HA
Precaution for Procedure without Cowl Top Cover...... 5 SYMPTOM DIAGNOSIS .............................. 29
Precautions For Refrigerant System Service ............ 5
Service Equipment .................................................... 8
REFRIGERATION SYSTEM SYMPTOMS ........ 29
Trouble Diagnosis For Unusual Pressure ................29 J
PREPARATION ........................................... 10 Symptom Table .......................................................29

PREPARATION ..................................................10 NOISE ................................................................ 31 K

Special Service Tool ............................................... 10 Symptom Table .......................................................31
Commercial Service Tools ..................................... 11
Sealant or/and Lubricant ......................................... 12
REMOVAL AND INSTALLATION ............... 32
L
COMPRESSOR ................................................. 32
SYSTEM DESCRIPTION ............................. 14
Exploded View .........................................................32
COMPONENT PARTS .......................................14 COMPRESSOR ..........................................................33 M
Component Parts Location ...................................... 14 COMPRESSOR : Removal and Installation ............33
SYSTEM .............................................................17 MAGNET CLUTCH ....................................................34
System Diagram ...................................................... 17 N
MAGNET CLUTCH : Removal and Installation .......34
System Description ................................................. 17 Inspection ................................................................35
BASIC INSPECTION ................................... 19 COOLER PIPE AND HOSE .............................. 36 O
Exploded View .........................................................36
DIAGNOSIS AND REPAIR WORKFLOW .........19
Work Flow ............................................................... 19 HIGH-PRESSURE FLEXIBLE HOSE ........................37
HIGH-PRESSURE FLEXIBLE HOSE : Removal P
REFRIGERANT ..................................................21 and Installation ........................................................37
Description .............................................................. 21
Leak Test ................................................................ 21 LOW-PRESSURE FLEXIBLE HOSE .........................38
Recycle Refrigerant ................................................. 23 LOW-PRESSURE FLEXIBLE HOSE : Removal
Charge Refrigerant .................................................. 23 and Installation ........................................................38
LUBRICANT .......................................................25 HIGH-PRESSURE PIPE ............................................39

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 HIGH-PRESSURE PIPE : Removal and Installa- Service Equipment .................................................. 67
tion .......................................................................... 39
PREPARATION .......................................... 69
LOW-PRESSURE PIPE ............................................ 40
LOW-PRESSURE PIPE : Removal and Installa- PREPARATION ................................................. 69
tion .......................................................................... 40 Special Service Tool ............................................... 69
Commercial Service Tools .................................... 70
CONDENSER .................................................... 42 Sealant or/and Lubricant ......................................... 71
Exploded View ........................................................ 42
SYSTEM DESCRIPTION ........................... 73
CONDENSER ............................................................ 42
CONDENSER : Removal and Installation .............. 42 COMPONENT PARTS ....................................... 73
Component Parts Location ..................................... 73
LIQUID TANK ............................................................ 44
LIQUID TANK : Removal and Installation ............... 44 SYSTEM ............................................................ 74
System Diagram ..................................................... 74
REFRIGERANT PRESSURE SENSOR .................... 44
System Description ................................................. 74
REFRIGERANT PRESSURE SENSOR : Remov-
al and Installation .................................................... 44 BASIC INSPECTION .................................. 76
CONDENSER PIPE ASSEMBLY .............................. 45 DIAGNOSIS AND REPAIR WORKFLOW ......... 76
CONDENSER PIPE ASSEMBLY : Removal and
Work Flow ............................................................... 76
Installation .............................................................. 45
REFRIGERANT ................................................. 78
HEATER & COOLING UNIT ASSEMBLY ......... 47 Description .............................................................. 78
Exploded View ........................................................ 47
Leak Test ................................................................ 78
HEATER & COOLING UNIT ASSEMBLY ................ 56 Recycle Refrigerant ................................................ 80
HEATER & COOLING UNIT ASSEMBLY : Re- Charge Refrigerant ................................................. 80
moval and Installation ............................................. 56
LUBRICANT ...................................................... 82
EXPANSION VALVE ................................................. 58 Description .............................................................. 82
EXPANSION VALVE : Removal and Installation ... 59 Inspection ................................................................ 82
Perform Lubricant Return Operation ....................... 82
EVAPORATOR ......................................................... 59 Lubricant Adjusting Procedure for Components
EVAPORATOR : Removal and Installation ............ 59 Replacement Except Compressor .......................... 82
Lubricant Adjusting Procedure for Compressor
HEATER CORE ......................................................... 60
Replacement ........................................................... 83
HEATER CORE : Removal and Installation ........... 60
PERFORMANCE TEST ..................................... 84
SERVICE DATA AND SPECIFICATIONS Inspection ................................................................ 84
(SDS) ........................................................... 62
SYMPTOM DIAGNOSIS ............................ 86
SERVICE DATA AND SPECIFICATIONS
(SDS) .................................................................. 62 REFRIGERATION SYSTEM SYMPTOMS ........ 86
Compressor ............................................................ 62 Trouble Diagnosis For Unusual Pressure ............... 86
Lubricant ................................................................. 62 Symptom Table ....................................................... 86
Refrigerant .............................................................. 62
Engine Idling Speed ............................................... 62 NOISE ................................................................ 88
Belt Tension ............................................................ 62 Symptom Table ....................................................... 88
QR25DE REMOVAL AND INSTALLATION .............. 89
PRECAUTION ............................................. 63 COMPRESSOR ................................................. 89
PRECAUTIONS ................................................. 63 Exploded View ........................................................ 89
Precaution for Supplemental Restraint System COMPRESSOR ......................................................... 89
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- COMPRESSOR : Removal and Installation ............ 90
SIONER" ................................................................. 63
Precautions Necessary for Steering Wheel Rota- MAGNET CLUTCH .................................................... 91
tion After Battery Disconnection ............................. 63 MAGNET CLUTCH : Removal and Installation ....... 91
Precautions for Removing Battery Terminal ........... 64 Inspection ................................................................ 92
Precaution for Procedure without Cowl Top Cover... 64
Precautions For Refrigerant System Service .......... 64 COOLER PIPE AND HOSE ............................... 93

Revision: 2014 December HA-2 D23

 Exploded View ........................................................ 93 CONDENSER PIPE ASSEMBLY ............................ 101
CONDENSER PIPE ASSEMBLY : Removal and A
HIGH-PRESSURE FLEXIBLE HOSE ........................ 93 Installation ............................................................. 101
HIGH-PRESSURE FLEXIBLE HOSE : Removal
and Installation ........................................................ 93 HEATER & COOLING UNIT ASSEMBLY ...... 103
Exploded View ....................................................... 103 B
LOW-PRESSURE FLEXIBLE HOSE ........................ 94
LOW-PRESSURE FLEXIBLE HOSE : Removal HEATER & COOLING UNIT ASSEMBLY ............... 107
and Installation ........................................................ 94 HEATER & COOLING UNIT ASSEMBLY : Re- C
moval and Installation ............................................ 107
HIGH-PRESSURE PIPE ............................................ 95
HIGH-PRESSURE PIPE : Removal and Installa- EXPANSION VALVE ............................................... 109
tion .......................................................................... 95 EXPANSION VALVE : Removal and Installation .. 110 D

LOW-PRESSURE PIPE ............................................. 96 EVAPORATOR ........................................................ 110

LOW-PRESSURE PIPE : Removal and Installa- EVAPORATOR : Removal and Installation ........... 110
tion .......................................................................... 96 E
HEATER CORE ....................................................... 111
CONDENSER .....................................................98 HEATER CORE : Removal and Installation .......... 111
Exploded View ........................................................ 98 F
SERVICE DATA AND SPECIFICATIONS
CONDENSER ............................................................ 98 (SDS) .......................................................... 113
CONDENSER : Removal and Installation ............... 98
SERVICE DATA AND SPECIFICATIONS G
LIQUID TANK .......................................................... 100
(SDS) ............................................................... 113
LIQUID TANK : Removal and Installation ............. 100
Compressor ........................................................... 113
REFRIGERANT PRESSURE SENSOR .................. 100 Lubricant ................................................................ 113 H
REFRIGERANT PRESSURE SENSOR : Remov- Refrigerant ............................................................. 113
al and Installation .................................................. 100 Engine Idling Speed .............................................. 113
Belt Tension ........................................................... 113 HA

Revision: 2014 December HA-3 D23

 PRECAUTIONS
< PRECAUTION > [YD25DDTi]

PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000011671987

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000011671988

CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro-
cedure below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

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 PRECAUTIONS
< PRECAUTION > [YD25DDTi]
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock A
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precautions for Removing Battery Terminal INFOID:0000000011671989
B

When disconnecting the battery terminal, pay attention to the following.

• Always use a 12V battery as power source. C
• Never disconnect battery terminal while engine is running.
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
D
• For vehicles with the engine listed below, remove the battery termi-
nal after a lapse of the specified time:

D4D engine : 20 minutes ZD30DDTi : 60 seconds E

HRA2DDT : 12 minutes ZD30DDTT : 60 seconds
K9K engine : 4 minutes
M9R engine : 4 minutes F
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes G
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur. H
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE: HA
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope. J
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE: K
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE: L
The removal of 12V battery may cause a DTC detection error.
Precaution for Procedure without Cowl Top Cover INFOID:0000000011671991
M
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. N

P
PIIB3706J

Precautions For Refrigerant System Service INFOID:0000000011671992

GENERAL REFRIGERANT PRECAUTION

WARNING:

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 PRECAUTIONS
< PRECAUTION > [YD25DDTi]
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant.
Ventilate work area before resuming service if accidental system discharge occurs. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
• Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to cap-
ture the refrigerant each time an air conditioning system is discharged.
• Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or air
conditioning system.
• Never store or heat refrigerant containers above 52°C (126°F).
• Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm
pail of water if container warming is required.
• Never intentionally drop, puncture, or incinerate refrigerant containers.
• Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns.
• Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo-
cation.
• Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air condi-
tioning systems with compressed air during repair. Some mixtures of air and HFC-134a (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 refriger-
ant manufacturers.
WORKING WITH HFC-134a (R-134a)
CAUTION:
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These regrigerants
must never be mixed, even in the smallest amounts. Compressor malfunction is likely occur if the
refrigerants are mixed.
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. Compressor malfunction is likely to occur if lubricant other than that specified is used.
• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed:
- Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere when
removing refrigerant components from a vehicle.
- Never remove the caps (unseal) until just before connecting the components when installing refrig-
erant components to a vehicle. Connect all refrigerant loop components as quickly as possible to
minimize the entry of moisture into system.
- Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant.
Lubricant becomes moisture saturated and should not be used without proper sealing.
- Never allow lubricant (A/C system Oil Type S) to come in contact with styrene foam parts. Damage
may result.
REFRIGERANT CONNECTION
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
• Expansion valve to evaporator
• Refrigerant pressure sensor to condenser & liquid tank assembly
WARNING:
Check that 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:
Observe the following when replacing or cleaning refrigerant cycle components.
• Store it in the same way at it is when mounted on the car when the compressor is removed. Failure
to do so will cause lubricant to enter the low-pressure chamber.
• Use always a torque wrench and a back-up wrench when connecting tubes.
• Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes.
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle.
Never remove the seal caps of pipes and other components until just before required for connection.
• 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.
• Remove thoroughly moisture from the refrigeration system before charging the refrigerant.
• Replace always used O-rings.
• Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to
apply lubricant to threaded portion.

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 PRECAUTIONS
< PRECAUTION > [YD25DDTi]

Name : A/C system Oil Type S A

• O-ring must be closely attached to the groove portion of tube.
• Be careful not to damage O-ring and tube when replacing the O-ring.
• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is B
installed to tube correctly.
• Perform leakage test and make sure that there is no leakage from connections after connecting line.
Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tighten
C
connections of seal seat to the specified torque.

H
RHA861F

COMPRESSOR HA
CAUTION:
• Plug all openings to prevent moisture and foreign matter from entering.
• Store it in the same way at it is when mounted on the car when the compressor is removed.
• Follow “MAINTENANCE OF LUBRICANT LEVEL IN COMPRESSOR” exactly when replacing or repair- J
ing compressor. Refer to HA-25, "Description".
• Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth
moistened with thinner if the surface is contaminated with lubricant. K
• Turn the compressor shaft by hand more than five turns in both directions after compressor service
operation. This distributes equally lubricant inside the compressor. Let the engine idle and operate
the compressor for one hour after the compressor is installed.
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet L
clutch.
LEAK DETECTION DYE M
CAUTION:
• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An
ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages.
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of N
the fluorescent dye.
• The fluorescent dye leak detector is not a replacement for an electrical leak detector. The fluorescent
dye leak detector should be used in conjunction with an electrical leak detector to pin-point refriger- O
ant leakages.
• Read and follow all manufacture’s operating instructions and precautions prior to performing the
work for the purpose of safety and customer’s satisfaction.
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres- P
sor shaft seal should only be repaired after confirming the leakage with an electrical leak detector.
• Remove always any remaining dye from the leakage area after repairs are completed to avoid a mis-
diagnosis during a future service.
• Never allow dye to come into contact with painted body panels or interior components. Clean imme-
diately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for an
extended period of time cannot be removed.
• Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).

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 PRECAUTIONS
< PRECAUTION > [YD25DDTi]
• Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system.
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C system, or A/C system damage may result.
• The fluorescent properties of the dye remains for three or more years unless a compressor malfunc-
tion occurs.
NOTE:
Identification
• Vehicles with factory installed fluorescent dye have a green label.
• Vehicles without factory installed fluorescent dye have a blue label.
Service Equipment INFOID:0000000011671993

RECOVERY/RECYCLING RECHARGING EQUIPMENT

Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine.
ELECTRICAL LEAK DETECTOR
Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
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 pres-
sure. 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 per the following.
• Vacuum pumps usually have a manual isolator valve as part of the
pump. Close this valve to isolate the service hose from the pump.
• Use a hose equipped with a manual shut-off valve near the pump
end for pumps without an isolator. Close the valve to isolate the
hose from the pump.
• Disconnect the hose from the pump if the hose has an automatic
shut-off valve. 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 no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.

RHA270DA

MANIFOLD GAUGE SET

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

SHA533D

SERVICE HOSES

Revision: 2014 December HA-8 D23

 PRECAUTIONS
< PRECAUTION > [YD25DDTi]
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must equip positive shut- A
off devices (either manual or automatic) near the end of the hoses
opposite to the manifold gauge.
B

RHA272D

D
SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
the CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
do not properly connect to the CFC-12 (R-12) system. However, if an E
improper connection is attempted, discharging and contamination
may occur.
F
Shut-off valve rotation A/C service valve
Clockwise Open
Counterclockwise Close
G

RHA273D

REFRIGERANT WEIGHT SCALE H

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

K
RHA274D

CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale each three month. L
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset” and “Enter” at the same time.
M
2. Press “8787”. “A1” is displayed.
3. Remove all weight from the scale.
4. Press “0”, then press “Enter”. “0.00” is displayed and change to “A2”.
N
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) O
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. P
10. Remove the known weight from the scale. “0.00” is displayed.
11. Press “Shift/Reset” to return the ACR4 to the program mode.
CHARGING CYLINDER
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.

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 PREPARATION
< PREPARATION > [YD25DDTi]

PREPARATION
PREPARATION
Special Service Tool INFOID:0000000011671994

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

• Never mix HFC-134a (R-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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.

Tool number
(SPX-North America No.) Description
Tool name

KV99106200
Installing pulley
Pulley installer

S-NT235

Refrigerant dye leak detection

kit
Kit includes:
UV lamp and UV safety goggles
HFC-134a (R-134a) dye injector
Power supply:
Use with J-41447, 1/4 ounce
DC 12 V (Battery terminal)
bottle
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
Refrigerant dye cleaner
ZHA200H

Power supply:
DC 12 V (Battery terminal)
For checking refrigerant leak when fluores-
UV lamp and UV safety goggles
cent dye is installed in A/C system
Includes:
UV lamp and UV safety goggles
SHA438F

Application:
For HFC-134a (R-134a) PAG oil
HFC-134a (R-134a) fluorescent Container:
leak detection dye 1/4 ounce (7.4 cc) bottle
(Box of 24, 1/4 ounce bottles) (Includes self-adhesive dye identification
labels for affixing to vehicle after charging
system with dye.)
SHA439F

Revision: 2014 December HA-10 D23

 PREPARATION
< PREPARATION > [YD25DDTi]
Tool number
(SPX-North America No.) Description A
Tool name

B
HFC-134a (R-134a) dye injector
For injecting 1/4 ounce of fluorescent leak
Use with J-41447, 1/4 ounce
detection dye into A/C system
bottle C

SHA440F

Refrigerant dye cleaner For cleaning dye spills E

SHA441F F

Commercial Service Tools INFOID:0000000011671995

G
HFC-134a (R-134a) Service Tool and Equipment
• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/
or its lubricant. H
• 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 HA
mixed use of the refrigerants/lubricant.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result. J

Tool name Description

L
Recovery/recycling/recharg- Function: Refrigerant recovery, recycling
ing equipment (ACR4) and recharging
M

RJIA0195E N

Power supply:
Electrical leak detector P
DC 12 V (Cigarette lighter)

SHA705EB

Revision: 2014 December HA-11 D23

 PREPARATION
< PREPARATION > [YD25DDTi]
Tool name Description

Identification:
• The gauge face indicates HFC-134a (R-
Manifold gauge set (with hos- 134a).
es and couplers) Fitting size: Thread size
• 1/2″-16 ACME

RJIA0196E

Hose color:
• Low-pressure side hose: Blue with black
stripe
Service hoses • High-pressure side hose: Red with black
• High-pressure side hose stripe
• Low-pressure side hose • Utility hose: Yellow with black stripe or
• Utility hose green with black stripe
Hose fitting to gauge:
S-NT201
• 1/2″-16 ACME

Service couplers Hose fitting to service hose:

• High-pressure side coupler M14 x 1.5 fitting is optional or permanently
• Low-pressure side coupler attached.

S-NT202

For measuring of refrigerant

Refrigerant weight scale Fitting size: Thread size
1/2″-16 ACME

S-NT200

Capacity:
• Air displacement: 4 CFM
Vacuum pump • Micron rating: 20 microns
(Including the isolator valve) • Oil capacity: 482 g (17 oz.)
Fitting size: Thread size
• 1/2″-16 ACME
S-NT203

Sealant or/and Lubricant INFOID:0000000011671996

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

• Never mix HFC-134a (R-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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.

Revision: 2014 December HA-12 D23

 PREPARATION
< PREPARATION > [YD25DDTi]

Tool name Description A

Container color: Light blue

Container marking: HFC-134a (R- B
HFC-134a (R-134a) refrigerant 134a)
Fitting size: Thread size
• Large container 1/2″-16 ACME
C
S-NT196

Type: Polyalkylene glycol oil (PAG), D

type S (DH-PS)
Application:
A/C system Oil Type S (DH-PS)
HFC-134a (R-134a) swash plate com-
pressors
E
Capacity: 40 m (1.4 Imp fl oz.)
JMIIA1759ZZ

HA

Revision: 2014 December HA-13 D23

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [YD25DDTi]

SYSTEM DESCRIPTION
COMPONENT PARTS
Component Parts Location INFOID:0000000011671997

LHD MODELS

JMIIA4007ZZ

Built-in heater & cooling unit assembly

Component Description
• Refer to HAC-19, "Refrigerant Pressure Sensor". (Automatic air conditioning)
• Refer to HAC-134, "Refrigerant Pressure Sensor". [Manual air conditioning (Full-elc)]
Refrigerant pressure sensor
• Refer to HAC-221, "Refrigerant Pressure Sensor". [Manual air conditioning & cool (Semi-
elc)]
Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant.

Liquid tank Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.
Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant
Compressor
cycle.

Revision: 2014 December HA-14 D23

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [YD25DDTi]
Component Description
A
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.
The mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from
Evaporator B
blower motor. The air is cooled by the heat by evaporation.

RHD MODELS
C

HA

M
JSIIA1997ZZ

Built-in heater & cooling unit assembly N

Component Description
• Refer to HAC-19, "Refrigerant Pressure Sensor". (Automatic air conditioning) O
• Refer to HAC-134, "Refrigerant Pressure Sensor". [Manual air conditioning (Full-elc)]
Refrigerant pressure sensor
• Refer to HAC-221, "Refrigerant Pressure Sensor". [Manual air conditioning & cool (Semi-
elc)]
Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant. P

Liquid tank Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.
Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant
Compressor
cycle.

Revision: 2014 December HA-15 D23

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [YD25DDTi]
Component Description
The mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from
Evaporator
blower motor. The air is cooled by the heat by evaporation.
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.

Revision: 2014 December HA-16 D23

 SYSTEM
< SYSTEM DESCRIPTION > [YD25DDTi]
SYSTEM
A
System Diagram INFOID:0000000011671998

HA
JPIIA1671GB

System Description INFOID:0000000011671999

J

REFRIGERANT CYCLE
Refrigerant Flow K
The refrigerant from the compressor, flows the condenser with liquid tank assembly, the evaporator, and
returns to the compressor. The refrigerant evaporation in the evaporator is controlled by an expansion valve.
Freeze Protection L
When evaporator fin temperature is low, compressor stops so that freeze of evaporator can be prevented.
Refer to the following.
• Auto air conditioning: HAC-24, "AUTOMATIC AIR CONDITIONING SYSTEM : Compressor Control". M
• Manual air conditioning (Full-elc): HAC-137, "Compressor Control".
• Manual air conditioning & cool (Semi-elc): HAC-223, "Compressor Control".
REFRIGERANT SYSTEM PROTECTION N
Refrigerant Pressure Sensor
• The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure
sensor, installed at the condenser with liquid tank assembly exit. The refrigerant pressure sensor detects the O
pressure inside the refrigerant line and sends the voltage signal to the ECM if the system pressure rises
above, or falls below the specifications.
• ECM turns the A/C relay to OFF and stops the compressor when the high-pressure side detected by refriger- P
ant pressure sensor is following conditions;
- Approximately 3,120 kPa (31.2 bar, 31.8 kg/cm2, 452 psi) or more (Engine speed is less than 1,500 rpm.)
- Approximately 2,740 kPa (27.4 bar, 27.9 kg/cm2, 397 psi) or more (Engine speed is 1,500 rpm or more.)
- Approximately 140 kPa (1.4 bar, 1.4 kg/cm2, 17 psi) or less
Pressure Relief Valve

Revision: 2014 December HA-17 D23

 SYSTEM
< SYSTEM DESCRIPTION > [YD25DDTi]
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere
when the pressure of refrigerant in the system increases to an unusual level [more than 3,800 kPa (38 bar,
38.8 kg/cm2, 551 psi)].

Revision: 2014 December HA-18 D23

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [YD25DDTi]

BASIC INSPECTION A
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000011672000
B

OVERALL SEQUENCE
C

HA

P
NNIIA0143GB

DETAILED FLOW
[Link] FOR MALFUNCTION
Interview the symptom to the customer.

Revision: 2014 December HA-19 D23

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [YD25DDTi]
>> GO TO 2.
[Link] CHECK
Check the symptom from the customer's information. Check that any symptom occurs other than the inter-
viewed symptom.

Insufficient cooling/heating>>GO TO 3.
Refrigerant leakage>>GO TO 6.
Noise >> GO TO 7.
[Link] SYSTEM DIAGNOSIS
Perform the system diagnosis for the A/C control system. Refer to the following.
• Auto air conditioning: HAC-55, "Work Flow".
• Manual air conditioning (Full-elc): HAC-164, "Work Flow".
• Manual air conditioning & cool (Semi-elc): HAC-252, "Work Flow".
Is A/C control system normal?
YES >> GO TO 4.
NO >> GO TO 8.
[Link] TEST
Perform the performance test. Check the operation of each part. Refer to HA-27, "Inspection".

>> GO TO 5.
[Link] DIAGNOSIS FOR UNUSUAL PRESSURE
Diagnose using a manifold gauge whenever system's high and/or low side pressure(s) is/are unusual. Specify
the malfunctioning part. Refer to HA-29, "Symptom Table".

Low refrigerant charge>>GO TO 6.

Except above>>GO TO 8.
[Link] REFRIGERANT FOR LEAKAGES
Check refrigerant for leakages. Specify the malfunctioning part. Refer to HA-21, "Leak Test".

>> GO TO 8.
[Link] DIAGNOSIS FOR NOISE
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-31, "Symptom Table".

>> GO TO 8.
[Link] PART REPAIR
Repair or replace the malfunctioning part.

>> GO TO 9.
[Link] CHECK (OPERATION CHECK)
Check the operation of each part.
Does it operate normally?
YES >> INSPECTION END
NO >> GO TO 2.

Revision: 2014 December HA-20 D23

 REFRIGERANT
< BASIC INSPECTION > [YD25DDTi]
REFRIGERANT
A
Description INFOID:0000000011672001

CONNECTION OF SERVICE TOOLS AND EQUIPMENT B

JSIIA0258ZZ

H
Shut-off valve A/C service valve Recovery/recycling recharging
equipment
Vacuum pump Manifold gauge set Refrigerant container (HFC-134a)
HA
Weight scale
Preferred (best) method Alternative method For charging
J
Leak Test INFOID:0000000011672002

CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE K

P
RJIA3815J

1. Install a fender cover .

2. Wear UV safety goggles provided with refrigerant dye leak detection kit.
3. Connect power cable of UV lamp to positive and negative terminals of the battery .
4. Press UV lamp switch and check A/C system for refrigerant leakage. (Where refrigerant leakage
occurs, fluorescent leak detection dye appears in green color.)

Revision: 2014 December HA-21 D23

 REFRIGERANT
< BASIC INSPECTION > [YD25DDTi]
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Illuminate piping joints from different angles using UV lamp and check that there is no leakage.
• Use a mirror in area that is difficult to see to check refrigerant leakage.
• Refrigerant leakage from evaporator can be detected by soaking cotton swab or a similar material with
drain hose water and illuminating it using UV lamp.
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and
other locations may fluoresce. Be careful not to misidentify leakage.
5. Repair or replace parts where refrigerant leakage occurs and wipe off fluorescent leak detection dye.
NOTE:
Completely wipe off fluorescent leak detection dye from gaps between parts, screw threads, and others
using a cotton swab or similar materials.
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work.
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and
other locations may fluoresce. Be careful not to misidentify leakage.
CHECK REFRIGERANT LEAKAGE USING ELECTRICAL LEAK DETECTOR
WARNING:
Never check refrigerant leakage while the engine is running.
CAUTION:
Be careful of the following items so that inaccurate checks or misidentifications are avoided.
• Never allow refrigerant vapor, shop chemical vapors, cigarette smoke, or others around the vehicle.
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse
when leakage occurs.
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set to A/C service valve.
3. Check that A/C refrigerant pressure is 345 kPa (3.45 bar, 3.52 kg/cm2, 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 fill refrigerant to the specified level.
NOTE:
Leakages may not be detected if A/C refrigerant pressure is 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) or
less when temperature is less than 16°C (61°F).
4. Clean area where refrigerant leakage check is performed, and check refrigerant leakage along all sur-
faces of pipe connections and A/C system components using electrical leak detector probe.
CAUTION:
• Continue checking when a leakage is found. Always continue and complete checking along all
pipe connections and A/C system components for additional leakage.
• When a leakage is detected, clean leakage area using compressed air and check again.
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the
probe surface may not be exposed to water or dirt.
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side.
• When checking leakage of cooling unit inside, operate blower fan motor for 15 minutes or more at the
maximum fan speed while the engine is stopped, and then insert electrical 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 leakage is detected. (Leakage is detected but leakage area is
unknown. GO TO 6.)
6. Start the engine and set A/C control in the following conditions.
• A/C switch ON
• Air flow: VENT (Ventilation)

Revision: 2014 December HA-22 D23

 REFRIGERANT
< BASIC INSPECTION > [YD25DDTi]
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold A
• Fan speed: Maximum speed set
7. Run the engine at approximately 1,500 rpm for 2 minutes or more.
8. Stop the engine. Check again for refrigerant leakage. GO TO 4. B
WARNING:
Never to get burned when the engine is hot.
NOTE: C
• Start refrigerant leakage check immediately after the engine is
stopped.
• When refrigerant circulation is stopped, pressure on the low-
pressure side rises gradually, and after this, pressure on the D
high-pressure side falls gradually.
• The higher the pressure is, the easier it is to find the refriger-
ant leakage. E

F
SHA839E

Recycle Refrigerant INFOID:0000000011672003

G
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication. H
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, or
throat. HA
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1. Perform lubricant return operation. Refer to HA-25, "Perform Lubricant Return Operation". (If refrigerant or J
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is K
detected.
2. Check gauge pressure readings of recovery/recycling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose. L
NOTE:
Follow manufacturer instructions for the handling or maintenance of the equipment. Never fill the equip-
ment with non-specified refrigerant.
3. Remove A/C service valve cap from the vehicle. M
4. Connect recovery/recycling/recharging equipment to A/C service valve.
5. Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
N
6. Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated to compressor lubri-
cant, etc.
7. Refrigerant recycle operation is complete.
O
Charge Refrigerant INFOID:0000000011672004

WARNING: P
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure my irritate eyes, nose, or throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.

Revision: 2014 December HA-23 D23

 REFRIGERANT
< BASIC INSPECTION > [YD25DDTi]
1. Connect recovery/recycling/recharging equipment to the A/C service valve.
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 the parts are replaced.
3. Check the airtightness of A/C system for 25 minutes or more. If pressure rises more than the specified
level, charge A/C system with approximately 200 g (0.4 lb) refrigerant and check that there is no refriger-
ant leakage. Refer to HA-21, "Leak Test".
CAUTION:
Check the airtightness for 15 minutes or more if the parts are replaced.
4. If parts other than compressor are replaced, fill compressor lubricant according to parts that are replaced.
5. Charge the specified amount of refrigerant to A/C system.
6. Check that A/C system operates normally.
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose
and low-pressure hose of recovery/recycling/recharging equipment.)
8. Install A/C service valve cap.
9. Refrigerant charge is complete.

Revision: 2014 December HA-24 D23

 LUBRICANT
< BASIC INSPECTION > [YD25DDTi]
LUBRICANT
A
Description INFOID:0000000011672005

MAINTENANCE OF LUBRICANT LEVEL B

The compressor lubricant is circulating in the system together with the refrigerant. It is necessary to fill com-
pressor with lubricant when replacing A/C system parts or when a large amount of refrigerant leakage is
detected. It is important to always maintain lubricant level within the specified level. Otherwise, the following C
conditions may occur.
• Insufficient lubricant amount: Stuck compressor
• Excessive lubricant amount: Insufficient cooling (caused by insufficient heat exchange)
D
Name : A/C system Oil Type S

Inspection INFOID:0000000011672006 E

If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
[Link] OIL JUDGMENT F
1. Remove compressor. Refer to HA-33, "COMPRESSOR : Removal and Installation".
2. Sample a compressor oil and judge on the figure.
G

HA

JSIIA0927GB

J
Judgement result 1>>Replace compressor only.
Judgement result 2>>Replace compressor and condenser & liquid tank assembly.
K
Perform Lubricant Return Operation INFOID:0000000011672007

CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera- L
tion.
1. Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm M
• A/C switch: ON
• Fan speed: Maximum speed set
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold N
2. Perform lubricant return operation for approximately 10 minutes.
3. Stop the engine.
O
4. Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000011672008 P
Fill with lubricant for the amount that is calculated according to the following conditions.
Example: Lubricant amount to be added when replacing evaporator, condenser and liquid tank [m (Imp fl
oz.)] = 45 (1.6) + 30 (1.1) + 15 (0.5) + α

Revision: 2014 December HA-25 D23

 LUBRICANT
< BASIC INSPECTION > [YD25DDTi]

Lubricant amount to be added to A/C system

Conditions
m (Imp fl oz.)
Replace evaporator 45 (1.6)
Replace condenser 30 (1.1)
Replace liquid tank 15 (0.5)
Large amount leakage 30 (1.1)
Refrigerant leakage is detected
Small amount leakage —
Lubricant amount that is recycled together with refrigerant during recycle operation α

Lubricant Adjusting Procedure for Compressor Replacement INFOID:0000000011672009

1. Drain lubricant from removed compressor and measure lubricant amount.

1. Drain lubricant from high-pressure port and low-pressure
port while rotating magnet clutch.
2. Measure total amount of lubricant that is drained from
removed compressor.

JSIIA1933ZZ

2. Drain lubricant from a new compressor that is calculated accord-

ing to the following conditions.

Amount to be drained (A)

[m (Imp fl oz.)] = F − (D + S + R + α)
F : Lubricant amount that a new compressor con-
tains [150 (5.3)]
D : Lubricant amount that is drained from removed
compressor
S : Lubricant amount that remains inside of re- JPIIA1455GB

moved compressor [20 (0.7)]

R : Lubricant amount to be added according to com-
ponents that are removed except compressor
α : Lubricant amount that is recycled together with
refrigerant during recycle operation
CAUTION:
If lubricant amount that is drained from removed compressor is less than 60 m (2.1 Imp fl oz.),
perform calculation by setting “D” as 40 m (1.4 Imp fl oz.).

Lubricant amount to be added to A/C system

Conditions
m (Imp fl oz.)
Replace evaporator 45 (1.6)
Replace condenser 30 (1.1)
Replace liquid tank 15 (0.5)
Example: Lubricant amount to be drained from a new compressor when replacing compressor, condenser
and liquid tank [m (Imp fl oz.)] [D = 60 (2.1), α = 5 (0.2)]
150 (5.3) − [60 (2.1) + 20 (0.7) + 30 (1.1) + 15 (0.5) + 5 (0.2)] = 20 (0.7)
3. Install compressor and check the operation.

Revision: 2014 December HA-26 D23

 PERFORMANCE TEST
< BASIC INSPECTION > [YD25DDTi]
PERFORMANCE TEST
A
Inspection INFOID:0000000011672010

INSPECTION PROCEDURE B
1. Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge.
2. Start the engine, and set to the following condition.
C
Test condition
Surrounding condition Indoors or in the shade (in a well-ventilated place)
Door Closed
D
Door glass Full open
Vehicle condition
Hood Open
Engine speed Idle speed E
Temperature control switch or dial Full cold
A/C switch ON
F
A/C condition Air outlet VENT (Ventilation)
Intake door position REC (Recirculation)
Fan speed Maximum speed set G
3. Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4. Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to-
operating pressure” are within the specified value. H
5. When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to HA-29,
"Symptom Table". HA
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE

Inside air (Recirculating air) at blower assembly inlet

J
Discharge air temperature from center ventilator
Relative humidity Air temperature °C (°F)
% °C (°F)
K
20 (68) 4.7 – 6.7 (40 – 44)
25 (77) 8.6 – 11.1 (47 – 52)
50 – 60
30 (86) 12.6 – 15.6 (55 – 60) L
35 (95) 19.0 – 22.5 (66 – 73)
20 (68) 6.7 – 8.7 (44 – 48)
25 (77) 11.1 – 13.6 (52 – 56) M
60 – 70
30 (86) 15.6 – 18.6 (60 – 65)
35 (95) 22.5 – 26.0 (73 – 79)
N

AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE

O

Revision: 2014 December HA-27 D23

 PERFORMANCE TEST
< BASIC INSPECTION > [YD25DDTi]

Fresh air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
% °C (°F)
909 – 1,112 159 – 194
25 (77)
(9.1 – 11.1, 9.2 – 11.3, 131.8 – 161.2) (1.6 – 1.9, 1.6 – 2.0, 23.1 – 28.1)
1,073 – 1,312 211 – 259
30 (86)
(10.7 – 13.1, 10.9 – 13.4, 155.6 – 190.2) (2.1 – 2.6, 2.2 – 2.6, 30.6 – 37.6)
50 – 70
1,445 – 1,766 247 – 300
35 (95)
(14.5 – 17.7, 14.7 – 18.0, 209.5 – 256.1) (2.5 – 3.0, 2.5 – 3.1, 35.8 – 43.5)
1,650 – 2,017 290 – 355
40 (104)
(16.5 – 20.2, 16.8 – 20.6, 239.3 – 292.5) (2.9 – 3.6, 3.0 – 3.6, 42.1 – 51.5)

Revision: 2014 December HA-28 D23

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [YD25DDTi]

SYMPTOM DIAGNOSIS A
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000011672011
B
Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer to
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how- C
ever, differs from vehicle to vehicle.
Symptom Table INFOID:0000000011672012
D

Gauge indication Refrigerant cycle Probable cause Corrective action

E
Collect all refrigerant, evacuate
The pressure returns to nor-
refrigerant cycle again, and
mal soon after sprinkling wa- Overfilled refrigerant.
then refill it with the specified
ter on condenser.
amount of refrigerant. F
Insufficient condenser cooling
performance.
Both high- and low-pressure sides • Poor fan rotation of radiator • Repair or replace malfunc-
Air flow to condenser is insuf- and condenser. tioning parts. G
are too high.
ficient. • Improper installation of air • Clean and repair condenser
guide. fins.
• Clogged or dirty condenser H
fins.
When compressor is stopped,
a high-pressure reading Collect all refrigerant, evacuate
quickly drops by approximate- refrigerant cycle again, and HA
AC359A
ly 196 kPa (1.96 bar, 2 kg/ Air mixed in refrigerant cycle.
then refill it with the specified
cm2, 28 psi). It then gradually amount of refrigerant.
decreases. J
• Low-pressure pipe is cooler
than the outlet of evapora- Expansion valve opened too
tor. much (excessive flow of refrig- Replace expansion valve.
• Low-pressure pipe is frost- erant). K
ed.
High-pressure side is excessively
high and low-pressure side is too L
low.
High-pressure pipe and upper
Clogged or crushed high-pres-
side of condenser become Repair or replace the malfunc- M
sure pipe located between
hot, however, liquid tank does tioning parts.
compressor and condenser.
not become so hot.

N
AC360A

High-pressure side is too low and

low-pressure side is too high. • The readings of both sides O
Malfunction in compressor sys-
become equal soon after
tem (insufficient compressor
compressor operation
pressure operation).
stops. Replace compressor.
• Damage or breakage of P
• There is no temperature dif-
valve.
ference between high- and
• Malfunctioning gaskets.
low-pressure sides.
AC356A

Revision: 2014 December HA-29 D23

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [YD25DDTi]
Gauge indication Refrigerant cycle Probable cause Corrective action
• The area around evapora-
Clogged expansion valve.
tor outlet does not become
• Breakage of temperature Eliminate foreign material from
cold.
sensor. expansion valve, or replace it.
• The area around evapora-
• Clogging by foreign material.
tor inlet becomes frosted.
• There is a temperature dif-
Both high- and low-pressure sides ference between the areas
are too low. around outlet and inlet Malfunction in inner liquid tank Replace condenser & liquid
pipes of liquid tank. (clogged strainer). tank assembly.
• Liquid tank becomes frost-
ed.
Clogged or crushed low-pres- Repair or replace malfunction-
sure pipe. ing parts.
Evaporator becomes frosted. • Intake sensor. Refer to HAC-
Malfunction in intake sensor or
AC353A 70, "Diagnosis Procedure".
thermo control amp..
• Check thermo control amp..
• Check for leakage.
There is a small temperature
• Collect all refrigerant, evacu-
difference between the high • Shortage of refrigerant.
ate refrigerant cycle again,
and low pressure pipes for re- • Leakage of refrigerant.
and then refill it with the spec-
frigerant cycle.
ified amount of refrigerant.
Low-pressure side sometimes be-
comes negative. • Collect all refrigerant.
• Sometimes the area
• Evacuate refrigerant cycle
around evaporator outlet • Icing caused by the mixing of
completely, and then refill it
does not become cold. water in cooler cycle.
with the specified amount of
• Sometimes the area • Deteriorated dryer in liquid
refrigerant. At this time, al-
around evaporator inlet is tank.
ways replace condenser &
frosted.
liquid tank assembly.
AC354A

Revision: 2014 December HA-30 D23

 NOISE
< SYMPTOM DIAGNOSIS > [YD25DDTi]
NOISE
A
Symptom Table INFOID:0000000011672013

B
Symptom Noise source Probable cause Corrective action
Wear, breakage, or clogging of foreign Check compressor oil. Re-
Inside of compressor
material in inner parts. fer to HA-25, "Inspection".
C
Check clearance between
Unusual noise from compressor Magnet clutch Contact of clutch disc with pulley. clutch disc and pulley. Refer
when A/C is ON. to HA-35, "Inspection".
D
Check bolts for tightness.
Compressor body Loosened compressor mounting bolts. Refer to HA-32, "Exploded
View".
Check the installation condi-
E
Cooler piping (pipe and Improper installation of clip and brack- tion of the cooler piping. Re-
Unusual noise from cooler piping.
flexible hose) et. fer to HA-36, "Exploded
View".
F
• Check for leakage.
• Collect all refrigerant,
evacuate refrigerant cycle
Shortage of refrigerant. G
again, and then refill it
Unusual noise from expansion with the specified amount
Expansion valve
valve when A/C is ON. of refrigerant.
Eliminate foreign material H
Wear, breakage, or clogging of foreign
from expansion valve, or re-
material in inner parts.
place it.
Check belt tension. Refer to HA
Loosened belt
Unusual noise from belt. — EM-152, "Inspection".
Internal compressor parts get locked Replace compressor.
J

Revision: 2014 December HA-31 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [YD25DDTi]

REMOVAL AND INSTALLATION

COMPRESSOR
Exploded View INFOID:0000000011672015

REMOVAL

JSIIA1872GB

Alternator & compressor bracket Compressor

: N·m (kg-m, ft-lb)

DISASSEMBLY

JMIIA0746GB

Revision: 2014 December HA-32 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [YD25DDTi]

Compressor unit Field coil Snap ring A

Pulley assembly Snap ring Shim
Clutch disc
B
: N·m (kg-m, ft-lb)

COMPRESSOR
C
COMPRESSOR : Removal and Installation INFOID:0000000011672017

CAUTION: D
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation".
E
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant". F
2. Remove front fender protector LH. Refer to EXT-23, "Removal and Installation".
3. Disconnect magnet clutch connector .
G

HA

JSIIA1902ZZ

J
4. Remove drive belt. Refer to EM-151, "Removal and Installation".
5. Remove mounting bolt , and then disconnect low-pressure
flexible hose from compressor. K
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
L

JSIIA1903ZZ

N
6. Remove mounting bolt , and then disconnect high-pressure
flexible hose from compressor.
CAUTION: O
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.
P

JSIIA1904ZZ

Revision: 2014 December HA-33 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [YD25DDTi]
7. Remove mounting bolts , and then remove compressor
from the vehicle.

JSIIA1920ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-26, "Lubricant
Adjusting Procedure for Compressor Replacement".
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".
• Check tension of the drive belt after installing compressor. Refer to EM-152, "Inspection".
• For installing alternator & compressor bracket, temporarily
tighten bolts in the order 1→2 (parts shall not be in contact) as
shown in the figure, so that position of bracket may be
adjusted. Tighten bolts to the specified torque in the order of
3→5, and then tighten bolts to the specified torque in the
order of 1→2.

JSIIA1906ZZ

• For installing compressor, temporarity tighten bolts in the

order of 1→4 as shown in the figure, and then tighten bolts to
the specified torque in the order of 1→4.

JSIIA1907ZZ

MAGNET CLUTCH
MAGNET CLUTCH : Removal and Installation INFOID:0000000011672018

REMOVAL
1. Fix clutch disc.
2. Remove center bolt, and then remove clutch disc.
3. Remove snap ring using external snap ring pliers.
4. Position center pulley puller on the end of the drive shaft, and remove pulley assembly using any commer-
cially available pulley puller.
To prevent pulley groove from being deformed, puller claws should be positioned into the edge of the pul-
ley assembly.
5. Disconnect field coil harness from compressor unit.
6. Remove snap ring using external snap ring pliers, and then remove field coil.

Revision: 2014 December HA-34 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [YD25DDTi]
INSTALLATION
1. Install field coil . A
Be sure to align the coil’s pin with the hole in the compres-
sor’s front head.
2. Connect field coil harness to compressor unit. B

D
JMIIA0575ZZ

3. Install pulley assembly using installer (SST: J-41260) (A) and

E
a hand press, and then install snap ring using snap ring pli-
ers.

JMIIA0576ZZ
H

4. Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand.
5. Using holder to prevent clutch disc rotation. HA
After tightening the bolt, check that the pulley rotates smoothly.
Break-in Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag- J
ing and disengaging the clutch about thirty-times. Break-in operation raises the level of transmitted torque.
Inspection INFOID:0000000011672019

K
CHECK DISC TO PULLEY CLEARANCE
Check the clearance (B) between pulley assembly and clutch disc
along the entire periphery with a feeler gauge (A). L

Clearance : Refer to HA-62, "Compressor".

CAUTION: M
Replace compressor if specified clearance is not obtained,
replace adjusting spacer and readjust.
N

SJIA1918E

Revision: 2014 December HA-35 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [YD25DDTi]
COOLER PIPE AND HOSE
Exploded View INFOID:0000000011672020

LHD models

JMIIA3999GB

High-pressure pipe O-ring Condenser & liquid tank assembly

High-pressure flexible hose Compressor Low-pressure pipe bracket
Low-pressure pipe Heater & cooling unit assembly Low-pressure flexible hose
: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

Revision: 2014 December HA-36 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [YD25DDTi]
RHD models
A

HA

JSIIA1890GB
K

High-pressure pipe O-ring Condenser & liquid tank assembly

L
High-pressure flexible hose Compressor Low-pressure pipe
Heater & cooling unit assembly Low-pressure flexible hose
: Always replace after every disassembly. M
: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb) N

HIGH-PRESSURE FLEXIBLE HOSE
HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000011672021 O

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large P
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Remove front wheel and tire (LH side only). Refer to WT-7, "Removal and Installation".

Revision: 2014 December HA-37 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [YD25DDTi]
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation".
4. Remove mounting bolt , and then disconnect high-pressure
flexible hose from condenser inlet pipe assembly.
CAUTION:
Cap or wrap the joint of the A/C piping and condenser & liq-
uid tank assembly with suitable material such as vinyl tape
to avoid the entry of air.

JSIIA1908ZZ

5. Remove mounting bolt , and then disconnect high-pressure

flexible hose from compressor side.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

JSIIA1904ZZ

6. Remove high-pressure flexible hose from the vehicle.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

LOW-PRESSURE FLEXIBLE HOSE

LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000011672022

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Remove front wheel and tire (LH side only). Refer to WT-7, "Removal and Installation".
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation".
4. Remove mounting bolt , and then disconnect low-pressure
flexible hose from low-pressure pipe.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JSIIA1909ZZ

Revision: 2014 December HA-38 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [YD25DDTi]

5. Remove mounting bolt , and then disconnect low-pressure

flexible hose from compressor. A
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air. B

JSIIA1903ZZ
D
6. Remove low-pressure flexible hose from the vehicle.

INSTALLATION E
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. F
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

HIGH-PRESSURE PIPE G

HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000011672023

H
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation". HA
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy- J
cle Refrigerant".
2. Remove low-pressure flexible hose. Refer to HA-38, "LOW-PRESSURE FLEXIBLE HOSE : Removal and
Installation".
K
3. Remove air filter assembly. Refer to EM-159, "Removal and Installation".
4. Remove fuel filter assembly (RHD models). Refer to FL-30, "Removal and Installation".
5. Remove mounting bolt , and then disconnect high-pressure L
pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air. M

JSIIA1910ZZ
O

Revision: 2014 December HA-39 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [YD25DDTi]
6. Remove mounting bolt and then disconnect high-pressure
pipe from condenser outlet pipe assembly.

JSIIA1912ZZ

7. Remove fixing clips, and then remove high pressure pipe from vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

LOW-PRESSURE PIPE
LOW-PRESSURE PIPE : Removal and Installation INFOID:0000000011672024

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Remove fuel filter bracket mounting bolt and nut to make work space.(LHD models)
3. Remove mounting bolt , and then disconnect low-pressure
pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air.

JSIIA1914ZZ

4. Remove mounting bolt , and then disconnect low-pressure

pipe from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JSIIA1913ZZ

Revision: 2014 December HA-40 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [YD25DDTi]
5. Remove low-pressure pipe mounting bracket bolts , and then
remove low-pressure pipe . A

: Bracket
B

JSIIA1924ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. E
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

HA

Revision: 2014 December HA-41 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [YD25DDTi]
CONDENSER
Exploded View INFOID:0000000011672025

JSIIA1891GB

Condenser upper bracket RH O-ring Refrigerant pressure sensor

Outlet pipe assembly Condenser Inlet pipe assembly
Condenser lower bracket Bracket Liquid tank
Liquid tank bracket Condenser upper bracket LH
: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

CONDENSER
CONDENSER : Removal and Installation INFOID:0000000011672026

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Remove front grille. Refer to EXT-19, "Removal and Installation".
3. Remove radiator upper seal. Refer to DLK-169, "Removal and Installation" (With Intelligent Key system)
or DLK-375, "Removal and Installation" (Without Intelligent Key system).
4. Remove front bumper fascia assembly. Refer to EXT-11, "Removal and Installation".
5. Remove condenser inlet pipe assembly and outlet pipe assembly from the condenser. Refer to HA-45,
"CONDENSER PIPE ASSEMBLY : Removal and Installation".
6. Remove AT fluid cooler mounting bolt, and then disengage AT fluid cooler fixing pawls from radiator. Refer
to TM-321, "Exploded View".
CAUTION:
Never damage the core surface of AT fluid cooler.

Revision: 2014 December HA-42 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [YD25DDTi]
7. Remove condensor upper bracket mounting bolt .
A

JSIIA1915ZZ

D
8. Remove condenser upper bracket RH by pressing the lock as
shown in the figure.
E

G
JSIIA1916ZZ

9. Remove radiator mounting bolts (LH and RH). H

HA

JSIIA1917ZZ
K
10. Lift up radiator, and then remove radiator from radiator mounting rubber.
CAUTION:
Never damage the cooling fan and radiator shroud. L
11. Move the radiator to the rear direction to make enough space and take out the condenser assembly
upwards.
CAUTION: M
• Never give heavy load to the radiator.
• Never damage the core surface of condenser.
N

JSIIA1942ZZ

Revision: 2014 December HA-43 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [YD25DDTi]
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant.

LIQUID TANK
LIQUID TANK : Removal and Installation INFOID:0000000011672027

REMOVAL
1. Remove condenser assembly. Refer to HA-42, "CONDENSER : Removal and Installation".
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank.
CAUTION:
Be sure to clean carefully.
3. Remove mounting bolts , and then remove liquid tank .
CAUTION:
Cap or wrap the joint of the A/C piping and liquid tank with
suitable material such as vinyl tape to avoid the entry of air.

JSIIA1919ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Install liquid tank, and then install liquid tank bracket on condenser.
• Check that liquid tank bracket is securely installed at protrusion of condenser. (Check that liquid
tank bracket does not move to a position below center of liquid tank.)
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to HA-26, "Lubricant
Adjusting Procedure for Compressor Replacement".
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

REFRIGERANT PRESSURE SENSOR

REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000011672028

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Remove condenser outlet pipe assembly. Refer to HA-45, "CONDENSER PIPE ASSEMBLY : Removal
and Installation".
3. Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then
remove the refrigerant pressure sensor from the condenser.
CAUTION:
• Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry
of air.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

Revision: 2014 December HA-44 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [YD25DDTi]
CONDENSER PIPE ASSEMBLY
A
CONDENSER PIPE ASSEMBLY : Removal and Installation INFOID:0000000011672029

REMOVAL B
1. Use refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Remove bumper fascia assembly. Refer to EXT-11, "Removal and Installation". C
3. Remove mounting bolt , and then disconnect condenser inlet
pipe assembly from high-pressure flexible hose assembly .
CAUTION: D
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
E

F
JSIIA1896ZZ

4. Remove mounting bolt , and then disconnect condenser inlet G

pipe assembly from condenser assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- H
rial such as vinyl tape to avoid the entry of air.

HA

JSIIA1897ZZ J

5. Remove condenser inlet pipe assembly from vehicle.

6. Disconnect the refrigerant pressure sensor connector . K

JSIIA1911ZZ N

7. Remove mounting bolt , and then disconnect condenser outlet

pipe assembly from high-pressure pipe assembly .
O
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
P

JSIIA1898ZZ

Revision: 2014 December HA-45 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [YD25DDTi]
8. Remove mounting bolt , and then disconnect condenser outlet
pipe assembly from condenser assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JSIIA1899ZZ

9. Remove condenser outlet pipe assembly from vehicle.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

Revision: 2014 December HA-46 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
HEATER & COOLING UNIT ASSEMBLY
A
Exploded View INFOID:0000000011672030

REMOVAL B
LHD models
C

HA

JMIIA4038GB K

Steering member Instrument stay LH Instrument stay RH

Drain hose Blower unit assembly Heater & cooling unit assembly L
: N·m (kg-m, ft-lb)

Revision: 2014 December HA-47 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
RHD models

JSIIA1938GB

Heater & cooling unit assembly Blower unit assembly Drain hose
Instrument stay LH Instrument stay RH Steering member

: N·m (kg-m, ft-lb)

DISASSEMBLY
LHD Models

Revision: 2014 December HA-48 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
Manual air conditioning (switch type)
A

HA

L
JMIIA4035GB

Adapter case Foot door assembly Power module assembly M

Heater & cooling unit case RH Heater pipe cover Evaporator pipe cover
AC cover Foot duct Heater pipe grommet
N
Heater core O-ring Expansion valve packing
Expansion valve Evaporator insulator Evaporator assembly
Defroster lever Mix adapter Air mix door motor assembly O
Mode door motor assembly Mode lever Main link
Ventilator lever Foot link Defroster link
P
Foot lever Heater & cooling unit case LH Defroster door
Ventilator door Center plate case Defroster seal
Ventilator seal Inner duct case Slide door unit
Sub harness Intake outlet packing Intake sensor assembly
AC drain case Air guide case

Revision: 2014 December HA-49 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
: Always replace after every disassembly.

: N·m (kg-m, in-lb)

Manual air conditioning (dial type)

JMIIA4036GB

Adapter case Foot door assembly Inner duct case

Resistance assembly Sub harness Heater & cooling unit case RH
Heater pipe cover Evaporator pipe cover AC cover
Foot duct Thermo control amp. Heater pipe grommet
Heater core O-ring Expansion valve packing
Expansion valve Evaporator insulator Evaporator assembly
Air mix gear lever Mix link Mix lever
Main link Ventilator lever Foot link
Defroster lever Defroster link Foot lever
Defroster door Ventilator door Center plate case

Revision: 2014 December HA-50 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
Defroster seal Ventilator seal Slide door unit
A
Sub harness Intake outlet packing AC drain case
Heater & cooling unit case LH
: Always replace after every disassembly. B
: N·m (kg-m, in-lb)

C
Auto air conditioning (dual type)

HA

JMIIA4037GB
L
Adapter case Foot door assembly Power module assembly
Sub harness Heater & cooling unit case RH Mix adapter
Air mix door motor assembly Heater pipe cover Evaporator pipe cover
M

AC cover Foot duct Heater pipe grommet

Heater core O-ring Expansion valve packing N
Expansion valve Evaporator insulator Evaporator assembly
Aspirator Mode lever Defroster link
Defroster lever Main link Defroster link O
Mode door motor assembly Ventilator lever Foot link
Foot lever Defroster door Ventilator door
P
Center plate case Defroster seal Ventilator seal
Inner duct case Slide door assembly Intake outlet packing
Intake sensor assembly AC drain case Air guide case
Heater & cooling unit case LH

Revision: 2014 December HA-51 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
: Always replace after every disassembly.

: N·m (kg-m, in-lb)

RHD Models
Manual air conditioning (switch type)

JSIIA1900GB

Ventilator seal Defroster seal Ventilator door

Defroster door Center plate case Heater & cooling unit case RH
Foot lever Defroster link Foot link
Ventilator lever Main link Mode lever
Mode door motor assembly Air mix door motor assembly Mix adapter
Defroster lever Evaporator assembly Evaporator insulator
Expansion valve Expansion valve packing O-ring
Heater core Heater pipe grommet Foot duct
AC cover Evaporator pipe cover Heater pipe cover
Heater & cooling unit case LH Intake outlet packing Sub harness

Revision: 2014 December HA-52 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
Power module assembly Adapter case Foot door assembly
A
Inner duct case Slide door unit Air guide case
AC drain case Intake sensor assembly
: Always replace after every disassembly. B
: N·m (kg-m, in-lb)

C
Manual air conditioning (dial type)

HA

JSIIA1943GB O

Ventilator seal Defroster seal Ventilator door

Defroster door Center plate case Foot lever P
Defroster link Defroster lever Foot link
Ventilator lever Main link Mix lever
Mix link Air mix gear lever Evaporator assembly
Evaporator insulator Expansion valve Expansion valve packing
O-ring Heater core Heater pipe grommet

Revision: 2014 December HA-53 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
Thermo control amp. Foot duct AC cover
Evaporator pipe cover Heater pipe cover Heater & cooling unit case LH
Sub harness Resistance assembly Inner duct case
Foot duct assembly Adapter case Slide door unit
Air guide duct Heater & cooling unit case RH AC drain case
Intake outlet packing
: Always replace after every disassembly.

: N·m (kg-m, in-lb)

Manual cooler

JMIIA4048GB

Ventilator seal Defroster seal Ventilator door

Defroster door Center plate case Foot lever
Defroster link Defroster lever Foot link
Ventilator lever Main link Evaporator assembly

Revision: 2014 December HA-54 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
Evaporator insulator Expansion valve Expansion valve packing
A
O-ring grommet Thermo control amp.
Foot duct AC cover Evaporator pipe cover
Heater pipe grommet Heater & cooling unit case LH Sub harness B
Resistance assembly Inner duct case Foot duct assembly
Adapter case Air guide duct Heater & cooling unit case RH
C
AC drain case Intake outlet packing
: Always replace after every disassembly.

: N·m (kg-m, in-lb) D

Auto air conditioning (dual type)

E

HA

M
JSIIA1944GB

Ventilator seal Defroster seal Ventilator door N

Defroster door Center plate case Foot lever
Foot link Vent lever Mode door motor assembly
Mode lever Main link Defroster lever O
Defroster link Mix adapter Air mix door motor assembly
Aspirator Evaporator assembly Evaporator insulator
P
Expansion valve Expansion valve packing O-ring
Heater core Heater pipe grommet Foot duct
AC cover Evaporator pipe cover Heater pipe cover
Air mix door motor assembly Heater & cooling unit case LH Intake outlet packing
Sub harness Power module assembly Adapter case

Revision: 2014 December HA-55 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
Foot door assembly Inner duct case Slide door assembly
Heater & cooling unit case RH Air guide case AC drain case
Intake sensor assembly
: Always replace after every disassembly.

: N·m (kg-m, in-lb)

HEATER & COOLING UNIT ASSEMBLY

HEATER & COOLING UNIT ASSEMBLY : Removal and Installation INFOID:0000000011672031

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
2. Drain engine coolant from cooling system. Refer to CO-38, "Inspection".
3. Remove wiper drive assembly. Refer to WW-49, "WIPER DRIVE ASSEMBLY : Removal and Installation"
(With Intelligent Key system) or WW-105, "WIPER DRIVE ASSEMBLY : Removal and Installation" (With-
out Intelligent Key system).
4. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air.

JSIIA1925ZZ

5. Remove fixing clamps , and then disconnect heater hoses

.(with air conditioning)
CAUTION:
• Some coolant may spill when heater hoses are discon-
nected.
• Close off the coolant inlet and outlet on the heater pipes
(2 locations) with shop cloths.

JSIIA1927ZZ

6. Remove instrument panel assembly. Refer to IP-14, "Removal and Installation" (LHD models) or IP-40,
"Removal and Installation" (RHD models).

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 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
7. Remove blower mounting bolts .
A

JSIIA1892ZZ

D
8. Remove mounting nuts , mounting bolts and then remove
instrument stay .
E

G
JSIIA1928ZZ

9. Disconnect drain hose from heater & cooling unit assembly. H

HA

JSIIA1929ZZ
K
10. Remove mounting bolts of ground wires.
L

N
JSIIA1931ZZ

11. Remove all of harness connectors and mounting nuts necessary to allow steering column assembly to be O
moved. Refer to ST-15, "Removal and Installation".
12. Move steering column assembly to secure work space.
13. Remove all of harness connectors and clips necessary to allow steering member to be removed. Move P
main harness aside and secure work space so that steering member can be easily removed.

Revision: 2014 December HA-57 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
14. Remove mounting bolts , and then remove steering member from the vehicle.

JSIIA1930ZZ

CAUTION:
When removing steering member, 2 workers are required to prevent it from dropping.
15. Disconnect the intake door motor and blower motor connectors.
16. Remove mounting screws , and then remove blower unit
assembly .

JSIIA1939ZZ

17. Remove heater & cooling unit assembly from the vehicle.
CAUTION:
When removing heater & cooling unit assembly, 2 workers are required to prevent it from drop-
ping.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".
NOTE:
When filling radiator with engine coolant. Refer to CO-39, "Refilling".

EXPANSION VALVE

Revision: 2014 December HA-58 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
EXPANSION VALVE : Removal and Installation INFOID:0000000011672032

A
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA- B
25, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy- C
cle Refrigerant".
2. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve. D
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry E
of air.

JSIIA1925ZZ

G
3. Remove mounting bolts , and then remove expansion valve.
CAUTION:
Cap or wrap the joint of the expansion valve and evaporator H
with suitable material such as vinyl tape to avoid the entry
of air.

HA

J
JSIIA1926ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal. K
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test". L

EVAPORATOR
M
EVAPORATOR : Removal and Installation INFOID:0000000011672033

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large N
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
25, "Perform Lubricant Return Operation".
REMOVAL O

1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-23, "Recy-
cle Refrigerant".
P
2. Remove heater & cooling unit assembly. Refer to HA-56, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
3. Disassemble heater & cooling unit assembly, and then remove evaporator assembly.
4. Disconnect intake sensor or thermo control amp.. Refer to HA-47, "Exploded View".
5. Remove expansion valve from evaporator. Refer to HA-47, "Exploded View".

INSTALLATION

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< REMOVAL AND INSTALLATION > [YD25DDTi]
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• When install the intake sensor or thermo control amp., set the same position before replacement.
• Never rotate the bracket insertion part when removing and installing the intake sensor.
• Perform lubricant adjusting procedure after installing new evaporator. Refer to HA-25, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000011672034

REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-56, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
2. Remove heater pipe grommet .

JSIIA1941ZZ

3. Remove mounting screws , and then remove heater pipe

cover .

JSIIA1893ZZ

4. Slide heater core to leftward (as shown in the figure).

JSIIA1894ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-21, "Leak Test".

Revision: 2014 December HA-60 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [YD25DDTi]
NOTE:
When filling radiator with engine coolant. Refer to CO-39, "Refilling". A

HA

Revision: 2014 December HA-61 D23

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi]

SERVICE DATA AND SPECIFICATIONS (SDS)

SERVICE DATA AND SPECIFICATIONS (SDS)
Compressor INFOID:0000000011672035

VALEO THERMAL SYSTEMS THI make

Model
DKS-17DT
Type Swash plate
Displacement
Maximum 175 (10.7)
cm3 (cu in)/rev
Cylinder bore × stroke (Max.)mm (in.) 30.5 (1.20) × 24 (0.94)
Direction of rotation Clockwise (viewed from clutch)
Drive belt Poly V
Disc to pulley clearance 0.3 – 0.6
Standard
mm (in) (0.012 – 0.028)

Lubricant INFOID:0000000011672036

Name A/C System Oil Type S (DH-PS)

Capacity Total in system 150 (5.3)

m (Imp fl oz.) Compressor (service part) charging amount 150 (5.3)

Refrigerant INFOID:0000000011672037

Type HFC-134a (R-134a)

Capacity
0.50 (1.1)
kg (lb)

Engine Idling Speed INFOID:0000000011672038

Refer to EC-744, "General Specification".

Belt Tension INFOID:0000000011672039

Refer to EM-152, "Inspection".

Revision: 2014 December HA-62 D23

 PRECAUTIONS
< PRECAUTION > [QR25DE]

PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT B
PRE-TENSIONER" INFOID:0000000011014042

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING: D
Always observe the following items for preventing accidental activation.
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision that would result in air bag inflation, all maintenance must be performed by E
an authorized NISSAN/INFINITI dealer.
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
F
Module, see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors. G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: H
Always observe the following items for preventing accidental activation.
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing HA
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service. J
Precautions Necessary for Steering Wheel Rotation After Battery Disconnection
INFOID:0000000011013040

K
CAUTION:
Comply with the following cautions to prevent any error and malfunction.
• Before removing and installing any control units, first turn the ignition switch to the LOCK position,
then disconnect both battery cables. L
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect
both battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing M
work. If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
For vehicle with steering lock unit, if the battery is disconnected or discharged, the steering wheel will lock and
cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the operation pro- N
cedure below before starting the repair operation.
OPERATION PROCEDURE
O
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Turn the ignition switch to ACC position. P
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.

Revision: 2014 December HA-63 D23

 PRECAUTIONS
< PRECAUTION > [QR25DE]
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the ignition switch from ACC position to ON position, then to LOCK position. (The steering wheel will lock
when the ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.
Precautions for Removing Battery Terminal INFOID:0000000010590076

When disconnecting the battery terminal, pay attention to the following.

• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running.
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi-
nal after a lapse of the specified time:

D4D engine : 20 minutes ZD30DDTi : 60 seconds

HRA2DDT : 12 minutes ZD30DDTT : 60 seconds
K9K engine : 4 minutes
M9R engine : 4 minutes
R9M engine : 4 minutes
SEF289H
V9X engine : 4 minutes
YD25DDTi : 2 minutes
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope.
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Precaution for Procedure without Cowl Top Cover INFOID:0000000010585715

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield.

PIIB3706J

Precautions For Refrigerant System Service INFOID:0000000010585717

GENERAL REFRIGERANT PRECAUTION

WARNING:

Revision: 2014 December HA-64 D23

 PRECAUTIONS
< PRECAUTION > [QR25DE]
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and
throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. A
Ventilate work area before resuming service if accidental system discharge occurs. Additional health
and safety information may be obtained from refrigerant and lubricant manufacturers.
• Never release refrigerant into the air. Use approved recovery/recycling recharging equipment to cap-
B
ture the refrigerant each time an air conditioning system is discharged.
• Wear always eye and hand protection (goggles and gloves) when working with any refrigerant or air
conditioning system.
• Never store or heat refrigerant containers above 52°C (126°F). C
• Never heat a refrigerant container with an open flame; Place the bottom of the container in a warm
pail of water if container warming is required.
• Never intentionally drop, puncture, or incinerate refrigerant containers. D
• Keep refrigerant away from open flames: poisonous gas is produced if refrigerant burns.
• Refrigerant displaces oxygen, therefore be certain to work in well ventilated areas to prevent suffo-
cation.
• Never pressure test or leakage test HFC-134a (R-134a) service equipment and/or vehicle air condi- E
tioning systems with compressed air during repair. Some mixtures of air and HFC-134a (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 refriger- F
ant manufacturers.
WORKING WITH HFC-134a (R-134a)
CAUTION: G
• CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. These regrigerants
must never be mixed, even in the smallest amounts. Compressor malfunction is likely occur if the
refrigerants are mixed.
H
• Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) compo-
nents. Compressor malfunction is likely to occur if lubricant other than that specified is used.
• The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The fol-
lowing handling precautions must be observed: HA
- Cap (seal) immediately the component to minimize the entry of moisture from the atmosphere when
removing refrigerant components from a vehicle.
- Never remove the caps (unseal) until just before connecting the components when installing refrig- J
erant components to a vehicle. Connect all refrigerant loop components as quickly as possible to
minimize the entry of moisture into system.
- Use only the specified lubricant from a sealed container. Reseal immediately containers of lubricant.
Lubricant becomes moisture saturated and should not be used without proper sealing. K
- Never allow lubricant (A/C system Oil Type S) to come in contact with styrene foam parts. Damage
may result.
REFRIGERANT CONNECTION L
A new type refrigerant connection has been introduced to all refrigerant lines except the following location.
• Expansion valve to evaporator
• Refrigerant pressure sensor to condenser & liquid tank assembly M
WARNING:
Check that 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. N
CAUTION:
Observe the following when replacing or cleaning refrigerant cycle components.
• Store it in the same way at it is when mounted on the car when the compressor is removed. Failure
to do so will cause lubricant to enter the low-pressure chamber. O
• Use always a torque wrench and a back-up wrench when connecting tubes.
• Plug immediately all openings to prevent entry of dust and moisture after disconnecting tubes.
• Connect the pipes at the final stage of the operation when installing an air conditioner in the vehicle. P
Never remove the seal caps of pipes and other components until just before required for connection.
• 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.
• Remove thoroughly moisture from the refrigeration system before charging the refrigerant.
• Replace always used O-rings.
• Apply lubricant to circle of the O-rings shown in illustration when connecting tube. Be careful not to
apply lubricant to threaded portion.

Revision: 2014 December HA-65 D23

 PRECAUTIONS
< PRECAUTION > [QR25DE]

Name : A/C system Oil Type S

• O-ring must be closely attached to the groove portion of tube.
• Be careful not to damage O-ring and tube when replacing the O-ring.
• Connect tube until a click can be heard. Then tighten the nut or bolt by hand. Check that the O-ring is
installed to tube correctly.
• Perform leakage test and make sure that there is no leakage from connections after connecting line.
Disconnect that line and replace the O-ring when the refrigerant leaking point is found. Then tighten
connections of seal seat to the specified torque.

RHA861F

COMPRESSOR
CAUTION:
• Plug all openings to prevent moisture and foreign matter from entering.
• Store it in the same way at it is when mounted on the car when the compressor is removed.
• Follow “MAINTENANCE OF LUBRICANT LEVEL IN COMPRESSOR” exactly when replacing or repair-
ing compressor. Refer to HA-82, "Description".
• Keep friction surfaces between clutch and pulley clean. Wipe it off by using a clean waste cloth
moistened with thinner if the surface is contaminated with lubricant.
• Turn the compressor shaft by hand more than five turns in both directions after compressor service
operation. This distributes equally lubricant inside the compressor. Let the engine idle and operate
the compressor for one hour after the compressor is installed.
• Apply voltage to the new one and check for normal operation after replacing the compressor magnet
clutch.
LEAK DETECTION DYE
CAUTION:
• The A/C system contains a fluorescent leak detection dye used for locating refrigerant leakages. An
ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leakages.
• Wear always fluorescence enhancing UV safety goggles to protect eyes and enhance the visibility of
the fluorescent dye.
• The fluorescent dye leak detector is not a replacement for an electrical leak detector. The fluorescent
dye leak detector should be used in conjunction with an electrical leak detector to pin-point refriger-
ant leakages.
• Read and follow all manufacture’s operating instructions and precautions prior to performing the
work for the purpose of safety and customer’s satisfaction.
• A compressor shaft seal should not necessarily be repaired because of dye seepage. The compres-
sor shaft seal should only be repaired after confirming the leakage with an electrical leak detector.
• Remove always any remaining dye from the leakage area after repairs are completed to avoid a mis-
diagnosis during a future service.
• Never allow dye to come into contact with painted body panels or interior components. Clean imme-
diately with the approved dye cleaner if dye is spilled. Fluorescent dye left on a surface for an
extended period of time cannot be removed.
• Never spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.).

Revision: 2014 December HA-66 D23

 PRECAUTIONS
< PRECAUTION > [QR25DE]
• Never use more than one refrigerant dye bottle [1/4 ounce (7.4 cc)] per A/C system.
• Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Never use A
HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system, or CFC-12 (R-12) leak detection
dye in HFC-134a (R-134a) A/C system, or A/C system damage may result.
• The fluorescent properties of the dye remains for three or more years unless a compressor malfunc-
B
tion occurs.
NOTE:
Identification
• Vehicles with factory installed fluorescent dye have a green label. C
• Vehicles without factory installed fluorescent dye have a blue label.
Service Equipment INFOID:0000000010585718
D
RECOVERY/RECYCLING RECHARGING EQUIPMENT
Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never
introduce any refrigerant other than that specified into the machine. E

ELECTRICAL LEAK DETECTOR

Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance.
F
VACUUM PUMP
The lubricant contained inside the vacuum pump is not compatible
with the specified lubricant for HFC-134a (R-134a) A/C systems. G
The vent side of the vacuum pump is exposed to atmospheric pres-
sure. 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. H
To prevent this migration, use a manual valve placed near the hose-
to-pump connection, as per the following.
• Vacuum pumps usually have a manual isolator valve as part of the HA
pump. Close this valve to isolate the service hose from the pump.
• Use a hose equipped with a manual shut-off valve near the pump
end for pumps without an isolator. Close the valve to isolate the
hose from the pump. J
• Disconnect the hose from the pump if the hose has an automatic
shut-off valve. As long as the hose is connected, the valve is open
and lubricating oil may migrate. K
Some one-way valves open when vacuum is applied and close
under no vacuum condition. Such valves may restrict the pump’s
ability to pull a deep vacuum and are not recommended.
L

M
RHA270DA

MANIFOLD GAUGE SET

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

SHA533D

SERVICE HOSES

Revision: 2014 December HA-67 D23

 PRECAUTIONS
< PRECAUTION > [QR25DE]
Be certain that the service hoses display the markings described
(colored hose with black stripe). All hoses must equip positive shut-
off devices (either manual or automatic) near the end of the hoses
opposite to the manifold gauge.

RHA272D

SERVICE COUPLERS
Never attempt to connect HFC-134a (R-134a) service couplers to
the CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers
do 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

Clockwise Open
Counterclockwise Close
RHA273D

REFRIGERANT WEIGHT SCALE

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

RHA274D

CALIBRATING ACR4 WEIGHT SCALE

Calibrate the scale each three month.
To calibrate the weight scale on the ACR4:
1. Press “Shift/Reset” and “Enter” at the same time.
2. Press “8787”. “A1” is displayed.
3. Remove all weight from the scale.
4. Press “0”, then press “Enter”. “0.00” is 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” is displayed.
11. Press “Shift/Reset” to return the ACR4 to the program mode.
CHARGING CYLINDER
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.

Revision: 2014 December HA-68 D23

 PREPARATION
< PREPARATION > [QR25DE]

PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000010585663
B

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

• Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/ C
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 D
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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and E
compressor malfunction may result.

Tool number
F
(SPX-North America No.) Description
Tool name

KV99106200
Installing pulley
Pulley installer H

S-NT235
HA
Refrigerant dye leak detection
kit
Kit includes: J
UV lamp and UV safety goggles
HFC-134a (R-134a) dye injector
Power supply:
Use with J-41447, 1/4 ounce
DC 12 V (Battery terminal)
bottle K
HFC-134a (R-134a) fluorescent
leak detection dye
(Box of 24, 1/4 ounce bottles)
Refrigerant dye cleaner L
ZHA200H

Power supply: M
DC 12 V (Battery terminal)
For checking refrigerant leak when fluores-
UV lamp and UV safety goggles
cent dye is installed in A/C system
Includes: N
UV lamp and UV safety goggles
SHA438F

O
Application:
For HFC-134a (R-134a) PAG oil
HFC-134a (R-134a) fluorescent Container:
leak detection dye 1/4 ounce (7.4 cc) bottle P
(Box of 24, 1/4 ounce bottles) (Includes self-adhesive dye identification
labels for affixing to vehicle after charging
system with dye.)
SHA439F

Revision: 2014 December HA-69 D23

 PREPARATION
< PREPARATION > [QR25DE]
Tool number
(SPX-North America No.) Description
Tool name

HFC-134a (R-134a) dye injector

For injecting 1/4 ounce of fluorescent leak
Use with J-41447, 1/4 ounce
detection dye into A/C system
bottle

SHA440F

Refrigerant dye cleaner For cleaning dye spills

SHA441F

Commercial Service Tools INFOID:0000000010585664

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

• Never mix HFC-134a (R-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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.

Tool name Description

Recovery/recycling/recharg- Function: Refrigerant recovery, recycling

ing equipment (ACR4) and recharging

RJIA0195E

Power supply:
Electrical leak detector
DC 12 V (Cigarette lighter)

SHA705EB

Revision: 2014 December HA-70 D23

 PREPARATION
< PREPARATION > [QR25DE]
Tool name Description
A

Identification:
B
• The gauge face indicates HFC-134a (R-
Manifold gauge set (with hos- 134a).
es and couplers) Fitting size: Thread size C
• 1/2″-16 ACME

D
RJIA0196E

Hose color:
• Low-pressure side hose: Blue with black
E
stripe
Service hoses • High-pressure side hose: Red with black
• High-pressure side hose stripe
• Low-pressure side hose • Utility hose: Yellow with black stripe or
• Utility hose F
green with black stripe
Hose fitting to gauge:
S-NT201
• 1/2″-16 ACME
G

Service couplers Hose fitting to service hose: H

• High-pressure side coupler M14 x 1.5 fitting is optional or permanently
• Low-pressure side coupler attached.

HA
S-NT202

J
For measuring of refrigerant
Refrigerant weight scale Fitting size: Thread size
1/2″-16 ACME
K

S-NT200

L
Capacity:
• Air displacement: 4 CFM
Vacuum pump • Micron rating: 20 microns
(Including the isolator valve) • Oil capacity: 482 g (17 oz.) M
Fitting size: Thread size
• 1/2″-16 ACME
S-NT203
N
Sealant or/and Lubricant INFOID:0000000010585665

O
HFC-134a (R-134a) Service Tool and Equipment
• Never mix HFC-134a (R-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/ P
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.
• Never use adapters that convert one size fitting to another: refrigerant/lubricant contamination occurs and
compressor malfunction may result.

Revision: 2014 December HA-71 D23

 PREPARATION
< PREPARATION > [QR25DE]

Tool name Description

Container color: Light blue

Container marking: HFC-134a (R-
HFC-134a (R-134a) refrigerant 134a)
Fitting size: Thread size
• Large container 1/2″-16 ACME

S-NT196

Type: Polyalkylene glycol oil (PAG),

type S (DH-PS)
Application:
A/C system Oil Type S (DH-PS)
HFC-134a (R-134a) swash plate com-
pressors
Capacity: 40 m (1.4 Imp fl oz.)
JMIIA1759ZZ

Revision: 2014 December HA-72 D23

 COMPONENT PARTS
< SYSTEM DESCRIPTION > [QR25DE]

SYSTEM DESCRIPTION A
COMPONENT PARTS
Component Parts Location INFOID:0000000010585666
B

HA

JMIIA4008ZZ
M

Built-in heater & cooling unit assembly

Component Description N
• Refer to HAC-134, "Refrigerant Pressure Sensor". [Manual air conditioning (Full-elc)]
Refrigerant pressure sensor • Refer to HAC-221, "Refrigerant Pressure Sensor". [Manual air conditioning & cool (Semi-
elc)] O
Condenser Cools refrigerant discharged from compressor, and transforms it to liquid refrigerant.

Liquid tank Eliminates foreign matter in refrigerant, and stores temporarily liquid refrigerant.
P
Intakes, compresses, and discharges refrigerant, to circulate refrigerant inside the refrigerant
Compressor
cycle.
The mist form liquid refrigerant transforms to gas by evaporation by the air conveyed from
Evaporator
blower motor. The air is cooled by the heat by evaporation.
Transforms high-pressure liquid refrigerant to mist form low-pressure liquid refrigerant by draw-
Expansion valve
ing function.

Revision: 2014 December HA-73 D23

 SYSTEM
< SYSTEM DESCRIPTION > [QR25DE]
SYSTEM
System Diagram INFOID:0000000010585667

JPIIA1671GB

System Description INFOID:0000000010585668

REFRIGERANT CYCLE
Refrigerant Flow
The refrigerant from the compressor, flows the condenser with liquid tank assembly, the evaporator, and
returns to the compressor. The refrigerant evaporation in the evaporator is controlled by an expansion valve.
Freeze Protection
When evaporator fin temperature is low, compressor stops so that freeze of evaporator can be prevented.
Refer to the following.
• Manual air conditioning (Full-elc): HAC-137, "Compressor Control".
• Manual air conditioning & cool (Semi-elc): HAC-223, "Compressor Control".
REFRIGERANT SYSTEM PROTECTION
Refrigerant Pressure Sensor
• The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure
sensor, installed at the condenser with liquid tank assembly exit. The refrigerant pressure sensor detects the
pressure inside the refrigerant line and sends the voltage signal to the ECM if the system pressure rises
above, or falls below the specifications.
• ECM turns the A/C relay to OFF and stops the compressor when the high-pressure side detected by refriger-
ant pressure sensor is following conditions;
- Approximately 3,120 kPa (31.2 bar, 31.8 kg/cm2, 452 psi) or more (Engine speed is less than 1,500 rpm.)
- Approximately 2,740 kPa (27.4 bar, 27.9 kg/cm2, 397 psi) or more (Engine speed is 1,500 rpm or more.)
- Approximately 140 kPa (1.4 bar, 1.4 kg/cm2, 17 psi) or less
Pressure Relief Valve
The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor.
The release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere

Revision: 2014 December HA-74 D23

 SYSTEM
< SYSTEM DESCRIPTION > [QR25DE]
when the pressure of refrigerant in the system increases to an unusual level [more than 3,800 kPa (38 bar,
38.8 kg/cm2, 551 psi)]. A

HA

Revision: 2014 December HA-75 D23

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [QR25DE]

BASIC INSPECTION
DIAGNOSIS AND REPAIR WORKFLOW
Work Flow INFOID:0000000010585676

OVERALL SEQUENCE

NNIIA0143GB

DETAILED FLOW
[Link] FOR MALFUNCTION
Interview the symptom to the customer.

Revision: 2014 December HA-76 D23

 DIAGNOSIS AND REPAIR WORKFLOW
< BASIC INSPECTION > [QR25DE]
>> GO TO 2.
[Link] CHECK A

Check the symptom from the customer's information. Check that any symptom occurs other than the inter-
viewed symptom.
B

Insufficient cooling/heating>>GO TO 3.
Refrigerant leakage>>GO TO 6.
C
Noise >> GO TO 7.
[Link] SYSTEM DIAGNOSIS
Perform the system diagnosis for the A/C control system. Refer to the following. D
• Manual air conditioning (Full-elc): HAC-164, "Work Flow".
• Manual air conditioning & cool (Semi-elc): HAC-252, "Work Flow".
Is A/C control system normal? E
YES >> GO TO 4.
NO >> GO TO 8.
[Link] TEST F
Perform the performance test. Check the operation of each part. Refer to HA-84, "Inspection".

G
>> GO TO 5.
[Link] DIAGNOSIS FOR UNUSUAL PRESSURE
Diagnose using a manifold gauge whenever system's high and/or low side pressure(s) is/are unusual. Specify H
the malfunctioning part. Refer to HA-86, "Symptom Table".

Low refrigerant charge>>GO TO 6. HA

Except above>>GO TO 8.
[Link] REFRIGERANT FOR LEAKAGES J
Check refrigerant for leakages. Specify the malfunctioning part. Refer to HA-78, "Leak Test".

>> GO TO 8. K
[Link] DIAGNOSIS FOR NOISE
Perform trouble diagnosis for noise. Specify the malfunctioning part. Refer to HA-88, "Symptom Table".
L

>> GO TO 8.
[Link] PART REPAIR M
Repair or replace the malfunctioning part.

N
>> GO TO 9.
[Link] CHECK (OPERATION CHECK)
Check the operation of each part. O
Does it operate normally?
YES >> INSPECTION END
NO >> GO TO 2. P

Revision: 2014 December HA-77 D23

 REFRIGERANT
< BASIC INSPECTION > [QR25DE]
REFRIGERANT
Description INFOID:0000000010585677

CONNECTION OF SERVICE TOOLS AND EQUIPMENT

JSIIA0258ZZ

Shut-off valve A/C service valve Recovery/recycling recharging

equipment
Vacuum pump Manifold gauge set Refrigerant container (HFC-134a)
Weight scale
Preferred (best) method Alternative method For charging

Leak Test INFOID:0000000010585678

CHECK REFRIGERANT LEAKAGE USING FLUORESCENT LEAK DETECTION DYE

RJIA3815J

1. Install a fender cover .

2. Wear UV safety goggles provided with refrigerant dye leak detection kit.
3. Connect power cable of UV lamp to positive and negative terminals of the battery .
4. Press UV lamp switch and check A/C system for refrigerant leakage. (Where refrigerant leakage
occurs, fluorescent leak detection dye appears in green color.)

Revision: 2014 December HA-78 D23

 REFRIGERANT
< BASIC INSPECTION > [QR25DE]
WARNING:
Never look directly into UV lamp light source. A
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions.
• Illuminate piping joints from different angles using UV lamp and check that there is no leakage.
B
• Use a mirror in area that is difficult to see to check refrigerant leakage.
• Refrigerant leakage from evaporator can be detected by soaking cotton swab or a similar material with
drain hose water and illuminating it using UV lamp.
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and C
other locations may fluoresce. Be careful not to misidentify leakage.
5. Repair or replace parts where refrigerant leakage occurs and wipe off fluorescent leak detection dye.
NOTE: D
Completely wipe off fluorescent leak detection dye from gaps between parts, screw threads, and others
using a cotton swab or similar materials.
6. Use a UV lamp to check that no fluorescent leak detection dye remains after finishing work. E
WARNING:
Never look directly into UV lamp light source.
NOTE:
• For continuous operating time of UV lamp, follow the manufacturer operating instructions. F
• Dust, dirt, and packing materials adhesive used for condenser & liquid tank assembly, evaporator, and
other locations may fluoresce. Be careful not to misidentify leakage.
G
CHECK REFRIGERANT LEAKAGE USING ELECTRICAL LEAK DETECTOR
WARNING:
Never check refrigerant leakage while the engine is running.
H
CAUTION:
Be careful of the following items so that inaccurate checks or misidentifications are avoided.
• Never allow refrigerant vapor, shop chemical vapors, cigarette smoke, or others around the vehicle.
• Always check refrigerant leakage in a low air flow environment so that refrigerant may not disperse HA
when leakage occurs.
1. Stop the engine.
2. Connect recovery/recycling/recharging equipment or manifold gauge set to A/C service valve. J
3. Check that A/C refrigerant pressure is 345 kPa (3.45 bar, 3.52 kg/cm2, 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 fill refrigerant to the specified level. K
NOTE:
Leakages may not be detected if A/C refrigerant pressure is 345 kPa (3.45 bar, 3.52 kg/cm2, 50 psi) or
less when temperature is less than 16°C (61°F). L
4. Clean area where refrigerant leakage check is performed, and check refrigerant leakage along all sur-
faces of pipe connections and A/C system components using electrical leak detector probe.
CAUTION: M
• Continue checking when a leakage is found. Always continue and complete checking along all
pipe connections and A/C system components for additional leakage.
• When a leakage is detected, clean leakage area using compressed air and check again.
• When checking leakage of cooling unit inside, always clean inside of drain hose so that the N
probe surface may not be exposed to water or dirt.
NOTE:
• Always check leakage starting from high-pressure side and continue to low-pressure side. O
• When checking leakage of cooling unit inside, operate blower fan motor for 15 minutes or more at the
maximum fan speed while the engine is stopped, and then insert electrical 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 P
refrigerant so that misidentification can be avoided.
5. Repair or replace parts where refrigerant leakage is detected. (Leakage is detected but leakage area is
unknown. GO TO 6.)
6. Start the engine and set A/C control in the following conditions.
• A/C switch ON
• Air flow: VENT (Ventilation)

Revision: 2014 December HA-79 D23

 REFRIGERANT
< BASIC INSPECTION > [QR25DE]
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold
• Fan speed: Maximum speed set
7. Run the engine at approximately 1,500 rpm for 2 minutes or more.
8. Stop the engine. Check again for refrigerant leakage. GO TO 4.
WARNING:
Never to get burned when the engine is hot.
NOTE:
• Start refrigerant leakage check immediately after the engine is
stopped.
• When refrigerant circulation is stopped, pressure on the low-
pressure side rises gradually, and after this, pressure on the
high-pressure side falls gradually.
• The higher the pressure is, the easier it is to find the refriger-
ant leakage.

SHA839E

Recycle Refrigerant INFOID:0000000010585679

WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, or
throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1. Perform lubricant return operation. Refer to HA-82, "Perform Lubricant Return Operation". (If refrigerant or
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is
detected.
2. Check gauge pressure readings of recovery/recycling/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. Never fill the equip-
ment with non-specified refrigerant.
3. Remove A/C service valve cap from the vehicle.
4. Connect recovery/recycling/recharging equipment to A/C service valve.
5. Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
6. Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated to compressor lubri-
cant, etc.
7. Refrigerant recycle operation is complete.
Charge Refrigerant INFOID:0000000010585680

WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure my irritate eyes, nose, or throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.

Revision: 2014 December HA-80 D23

 REFRIGERANT
< BASIC INSPECTION > [QR25DE]
1. Connect recovery/recycling/recharging equipment to the A/C service valve.
2. Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or A
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced. B
3. Check the airtightness of A/C system for 25 minutes or more. If pressure rises more than the specified
level, charge A/C system with approximately 200 g (0.4 lb) refrigerant and check that there is no refriger-
ant leakage. Refer to HA-78, "Leak Test".
C
CAUTION:
Check the airtightness for 15 minutes or more if the parts are replaced.
4. If parts other than compressor are replaced, fill compressor lubricant according to parts that are replaced.
D
5. Charge the specified amount of refrigerant to A/C system.
6. Check that A/C system operates normally.
7. Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose E
and low-pressure hose of recovery/recycling/recharging equipment.)
8. Install A/C service valve cap.
9. Refrigerant charge is complete. F

HA

Revision: 2014 December HA-81 D23

 LUBRICANT
< BASIC INSPECTION > [QR25DE]
LUBRICANT
Description INFOID:0000000010585681

MAINTENANCE OF LUBRICANT LEVEL

The compressor lubricant is circulating in the system together with the refrigerant. It is necessary to fill com-
pressor with lubricant when replacing A/C system parts or when a large amount of refrigerant leakage is
detected. It is important to always maintain lubricant level within the specified level. Otherwise, the following
conditions may occur.
• Insufficient lubricant amount: Stuck compressor
• Excessive lubricant amount: Insufficient cooling (caused by insufficient heat exchange)

Name : A/C system Oil Type S

Inspection INFOID:0000000010585682

If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
[Link] OIL JUDGMENT
1. Remove compressor. Refer to HA-90, "COMPRESSOR : Removal and Installation".
2. Sample a compressor oil and judge on the figure.

JSIIA0927GB

Judgement result 1>>Replace compressor only.

Judgement result 2>>Replace compressor and condenser & liquid tank assembly.
Perform Lubricant Return Operation INFOID:0000000010585683

CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera-
tion.
1. Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm
• A/C switch: ON
• Fan speed: Maximum speed set
• Intake door position: REC (Recirculation)
• Temperature setting: Full cold
2. Perform lubricant return operation for approximately 10 minutes.
3. Stop the engine.
4. Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000010585684

Fill with lubricant for the amount that is calculated according to the following conditions.
Example: Lubricant amount to be added when replacing evaporator, condenser and liquid tank [m (Imp fl
oz.)] = 55 (1.9) + 35 (1.2) + 15 (0.5) + α

Revision: 2014 December HA-82 D23

 LUBRICANT
< BASIC INSPECTION > [QR25DE]

Lubricant amount to be added to A/C system A

Conditions
m (Imp fl oz.)
Replace evaporator 55 (1.9)
Replace condenser 35 (1.2) B
Replace liquid tank 15 (0.5)
Large amount leakage 30 (1.1)
Refrigerant leakage is detected C
Small amount leakage —
Lubricant amount that is recycled together with refrigerant during recycle operation α
D
Lubricant Adjusting Procedure for Compressor Replacement INFOID:0000000010585685

1. Drain lubricant from removed compressor and measure lubricant amount.

E
1. Drain lubricant from high-pressure port and low-pressure
port while rotating magnet clutch.
2. Measure total amount of lubricant that is drained from
removed compressor. F

H
JMIIA4001ZZ

2. Drain lubricant from a new compressor that is calculated accord-

ing to the following conditions. HA

Amount to be drained (A)

[m (Imp fl oz.)] = F − (D + S + R + α) J
F : Lubricant amount that a new compressor con-
tains [180 (6.3)]
D : Lubricant amount that is drained from removed K
compressor
S : Lubricant amount that remains inside of re- JPIIA1455GB

moved compressor [20 (0.7)] L

R : Lubricant amount to be added according to com-
ponents that are removed except compressor
M
α : Lubricant amount that is recycled together with
refrigerant during recycle operation
CAUTION: N
If lubricant amount that is drained from removed compressor is less than 60 m (2.1 Imp fl oz.),
perform calculation by setting “D” as 40 m (1.4 Imp fl oz.).
O
Lubricant amount to be added to A/C system
Conditions
m (Imp fl oz.)
Replace evaporator 55 (1.9) P
Replace condenser 35 (1.2)
Replace liquid tank 15 (0.5)
Example: Lubricant amount to be drained from a new compressor when replacing compressor, condenser
and liquid tank [m (Imp fl oz.)] [D = 60 (2.1), α = 5 (0.2)]
180 (6.3) − [60 (2.1) + 20 (0.7) + 35 (1.2) + 15 (0.5) + 5 (0.2)] = 45 (1.6)
3. Install compressor and check the operation.

Revision: 2014 December HA-83 D23

 PERFORMANCE TEST
< BASIC INSPECTION > [QR25DE]
PERFORMANCE TEST
Inspection INFOID:0000000010585686

INSPECTION PROCEDURE
1. Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge.
2. Start the engine, and set to the following condition.
Test condition
Surrounding condition Indoors or in the shade (in a well-ventilated place)
Door Closed
Door glass Full open
Vehicle condition
Hood Open
Engine speed Idle speed
Temperature control switch or dial Full cold
A/C switch ON
A/C condition Air outlet VENT (Ventilation)
Intake door position REC (Recirculation)
Fan speed Maximum speed set
3. Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4. Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to-
operating pressure” are within the specified value.
5. When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to HA-86,
"Symptom Table".
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE

Inside air (Recirculating air) at blower assembly inlet

Discharge air temperature from center ventilator
Relative humidity Air temperature °C (°F)
% °C (°F)
20 (68) 4.7 – 6.7 (40 – 44)
25 (77) 8.6 – 11.1 (47 – 52)
50 – 60
30 (86) 12.6 – 15.6 (55 – 60)
35 (95) 19.0 – 22.5 (66 – 73)
20 (68) 6.7 – 8.7 (44 – 48)
25 (77) 11.1 – 13.6 (52 – 56)
60 – 70
30 (86) 15.6 – 18.6 (60 – 65)
35 (95) 22.5 – 26.0 (73 – 79)

AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE

Revision: 2014 December HA-84 D23

 PERFORMANCE TEST
< BASIC INSPECTION > [QR25DE]

Fresh air A
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
% °C (°F)
909 – 1,112 159 – 194 B
25 (77)
(9.1 – 11.1, 9.2 – 11.3, 131.8 – 161.2) (1.6 – 1.9, 1.6 – 2.0, 23.1 – 28.1)
1,073 – 1,312 211 – 259
30 (86)
(10.7 – 13.1, 10.9 – 13.4, 155.6 – 190.2) (2.1 – 2.6, 2.2 – 2.6, 30.6 – 37.6) C
50 – 70
1,445 – 1,766 247 – 300
35 (95)
(14.5 – 17.7, 14.7 – 18.0, 209.5 – 256.1) (2.5 – 3.0, 2.5 – 3.1, 35.8 – 43.5)
1,650 – 2,017 290 – 355 D
40 (104)
(16.5 – 20.2, 16.8 – 20.6, 239.3 – 292.5) (2.9 – 3.6, 3.0 – 3.6, 42.1 – 51.5)

HA

Revision: 2014 December HA-85 D23

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [QR25DE]

SYMPTOM DIAGNOSIS
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure INFOID:0000000010585671

Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer to
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how-
ever, differs from vehicle to vehicle.
Symptom Table INFOID:0000000010585672

Gauge indication Refrigerant cycle Probable cause Corrective action

Collect all refrigerant, evacuate
The pressure returns to nor-
refrigerant cycle again, and
mal soon after sprinkling wa- Overfilled refrigerant.
then refill it with the specified
ter on condenser.
amount of refrigerant.
Insufficient condenser cooling
performance.
Both high- and low-pressure sides • Poor fan rotation of radiator • Repair or replace malfunc-
are too high. Air flow to condenser is insuf- and condenser. tioning parts.
ficient. • Improper installation of air • Clean and repair condenser
guide. fins.
• Clogged or dirty condenser
fins.
When compressor is stopped,
a high-pressure reading Collect all refrigerant, evacuate
AC359A
quickly drops by approximate- refrigerant cycle again, and
ly 196 kPa (1.96 bar, 2 kg/ Air mixed in refrigerant cycle.
then refill it with the specified
cm2, 28 psi). It then gradually amount of refrigerant.
decreases.
• Low-pressure pipe is cooler
than the outlet of evapora- Expansion valve opened too
tor. much (excessive flow of refrig- Replace expansion valve.
• Low-pressure pipe is frost- erant).
ed.
High-pressure side is excessively
high and low-pressure side is too
low.
High-pressure pipe and upper
Clogged or crushed high-pres-
side of condenser become Repair or replace the malfunc-
sure pipe located between
hot, however, liquid tank does tioning parts.
compressor and condenser.
not become so hot.

AC360A

High-pressure side is too low and

low-pressure side is too high. • The readings of both sides
Malfunction in compressor sys-
become equal soon after
tem (insufficient compressor
compressor operation
pressure operation).
stops. Replace compressor.
• Damage or breakage of
• There is no temperature dif-
valve.
ference between high- and
• Malfunctioning gaskets.
low-pressure sides.
AC356A

Revision: 2014 December HA-86 D23

 REFRIGERATION SYSTEM SYMPTOMS
< SYMPTOM DIAGNOSIS > [QR25DE]
Gauge indication Refrigerant cycle Probable cause Corrective action
A
• The area around evapora-
Clogged expansion valve.
tor outlet does not become
• Breakage of temperature Eliminate foreign material from
cold.
sensor. expansion valve, or replace it.
• The area around evapora- B
• Clogging by foreign material.
tor inlet becomes frosted.
• There is a temperature dif-
Both high- and low-pressure sides ference between the areas
around outlet and inlet Malfunction in inner liquid tank Replace condenser & liquid
C
are too low.
pipes of liquid tank. (clogged strainer). tank assembly.
• Liquid tank becomes frost-
ed. D
Clogged or crushed low-pres- Repair or replace malfunction-
sure pipe. ing parts.
Evaporator becomes frosted. • Intake sensor. Refer to HAC- E
Malfunction in intake sensor or
AC353A 70, "Diagnosis Procedure".
thermo control amp..
• Check thermo control amp..
• Check for leakage.
There is a small temperature
• Collect all refrigerant, evacu-
F
difference between the high • Shortage of refrigerant.
ate refrigerant cycle again,
and low pressure pipes for re- • Leakage of refrigerant.
and then refill it with the spec-
frigerant cycle.
ified amount of refrigerant. G
Low-pressure side sometimes be-
comes negative. • Collect all refrigerant.
• Sometimes the area
• Evacuate refrigerant cycle H
around evaporator outlet • Icing caused by the mixing of
completely, and then refill it
does not become cold. water in cooler cycle.
with the specified amount of
• Sometimes the area • Deteriorated dryer in liquid
refrigerant. At this time, al-
around evaporator inlet is tank.
frosted.
ways replace condenser & HA
liquid tank assembly.
AC354A

Revision: 2014 December HA-87 D23

 NOISE
< SYMPTOM DIAGNOSIS > [QR25DE]
NOISE
Symptom Table INFOID:0000000010585673

Symptom Noise source Probable cause Corrective action

Wear, breakage, or clogging of foreign Check compressor oil. Re-
Inside of compressor
material in inner parts. fer to HA-82, "Inspection".
Check clearance between
Unusual noise from compressor Magnet clutch Contact of clutch disc with pulley. clutch disc and pulley. Refer
when A/C is ON. to HA-92, "Inspection".
Check bolts for tightness.
Compressor body Loosened compressor mounting bolts. Refer to HA-89, "Exploded
View".
Check the installation condi-
Cooler piping (pipe and Improper installation of clip and brack- tion of the cooler piping. Re-
Unusual noise from cooler piping.
flexible hose) et. fer to HA-93, "Exploded
View".
• Check for leakage.
• Collect all refrigerant,
evacuate refrigerant cycle
Shortage of refrigerant.
again, and then refill it
Unusual noise from expansion with the specified amount
Expansion valve
valve when A/C is ON. of refrigerant.
Eliminate foreign material
Wear, breakage, or clogging of foreign
from expansion valve, or re-
material in inner parts.
place it.
Check belt tension. Refer to
Loosened belt
Unusual noise from belt. — EM-152, "Inspection".
Internal compressor parts get locked Replace compressor.

Revision: 2014 December HA-88 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [QR25DE]

REMOVAL AND INSTALLATION A

COMPRESSOR
Exploded View INFOID:0000000010488941
B

REMOVAL
C

H
JMIIA4002ZZ

Compressor
HA
: N·m (kg-m, ft-lb)

DISASSEMBLY
J

O
JMIIA0746GB

Compressor unit Field coil Snap ring P

Pulley assembly Snap ring Shim
Clutch disc

: N·m (kg-m, ft-lb)

COMPRESSOR

Revision: 2014 December HA-89 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [QR25DE]
COMPRESSOR : Removal and Installation INFOID:0000000010489010

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove front fender protector LH. Refer to EXT-23, "Removal and Installation".
3. Disconnect magnet clutch connector .

: Vehicle front

JMIIA4012ZZ

4. Remove drive belt. Refer to EM-151, "Removal and Installation".

5. Remove mounting bolt , and then disconnect low-pressure
flexible hose from compressor.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA4013ZZ

6. Remove mounting bolt , and then disconnect high-pressure

flexible hose from compressor.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA4014ZZ

7. Remove mounting bolts , and then remove stay.

: Vehicle front

JMIIA4015ZZ

Revision: 2014 December HA-90 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [QR25DE]
8. Remove mounting bolts , and then remove compressor from
the vehicle. A

: Vehicle front
B

JMIIA4016ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. E
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-83, "Lubricant
Adjusting Procedure for Compressor Replacement".
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test". F
• Check tension of the drive belt after installing compressor. Refer to EM-152, "Inspection".

MAGNET CLUTCH G

MAGNET CLUTCH : Removal and Installation INFOID:0000000010599502

H
REMOVAL
1. Fix clutch disc.
2. Remove center bolt, and then remove clutch disc. HA
3. Remove snap ring using external snap ring pliers.
4. Position center pulley puller on the end of the drive shaft, and remove pulley assembly using any commer-
cially available pulley puller. J
To prevent pulley groove from being deformed, puller claws should be positioned into the edge of the pul-
ley assembly.
5. Disconnect field coil harness from compressor unit. K
6. Remove snap ring using external snap ring pliers, and then remove field coil.
INSTALLATION
L
1. Install field coil .
Be sure to align the coil’s pin with the hole in the compres-
sor’s front head.
M
2. Connect field coil harness to compressor unit.

O
JMIIA0575ZZ

Revision: 2014 December HA-91 D23

 COMPRESSOR
< REMOVAL AND INSTALLATION > [QR25DE]
3. Install pulley assembly using installer (SST: KJ99106200) (A)
and a hand press, and then install snap ring using snap ring
pliers.

JMIIA0576ZZ

4. Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand.
5. Using holder to prevent clutch disc rotation.
After tightening the bolt, check that the pulley rotates smoothly.
Break-in Operation
When replacing compressor clutch assembly, always carry out the break-in operation. This is done by engag-
ing and disengaging the clutch about thirty-times. Break-in operation raises the level of transmitted torque.
Inspection INFOID:0000000010489011

CHECK DISC TO PULLEY CLEARANCE

Check the clearance (B) between pulley assembly and clutch disc
along the entire periphery with a feeler gauge (A).

Clearance : Refer to HA-113, "Compressor".

CAUTION:
Replace compressor if specified clearance is not obtained,
replace adjusting spacer and readjust.

SJIA1918E

Revision: 2014 December HA-92 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [QR25DE]
COOLER PIPE AND HOSE
A
Exploded View INFOID:0000000010490520

HA

L
JMIIA3997GB

High-pressure pipe O-ring Condenser & liquid tank assembly M

High-pressure flexible hose Low-pressure flexible hose Compressor
Low-pressure pipe Low-pressure flexible pipe bracket Heater & cooling unit assembly
N
: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

O
: N·m (kg-m, in-lb)
: Indicates that the part is connected at points with same symbol in actual cehicle.

HIGH-PRESSURE FLEXIBLE HOSE P

HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000010490521

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".

Revision: 2014 December HA-93 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [QR25DE]
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove front wheel and tire (LH side only). Refer to WT-7, "Removal and Installation".
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation".
4. Remove mounting bolt , and then disconnect high-pressure
flexible hose from condenser inlet pipe assembly.
CAUTION:
Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.

JSIIA1908ZZ

5. Remove mounting bolt , and then disconnect high-pressure

flexible hose from compressor side.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

: Vehicle front

JMIIA4014ZZ

6. Remove high-pressure flexible hose from the vehicle.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

LOW-PRESSURE FLEXIBLE HOSE

LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation INFOID:0000000010490522

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove front wheel and tire (LH side only). Refer to WT-7, "Removal and Installation".
3. Remove front fender protector (LH side only). Refer to EXT-23, "Removal and Installation".

Revision: 2014 December HA-94 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [QR25DE]
4. Remove mounting bolt , and then disconnect low-pressure
flexible hose from low-pressure pipe. A
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air. B

JSIIA1909ZZ

D
5. Remove mounting bolt , and then disconnect low-pressure
flexible hose from compressor.
CAUTION: E
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.

: Vehicle front F

G
JMIIA4013ZZ

6. Remove low-pressure flexible hose from the vehicle.

H
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION: HA
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".
J
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation INFOID:0000000010490523 K

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large L
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL M
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove air filter assembly. Refer to EM-159, "Removal and Installation". N
3. Disconnect vacuum hose from brake booster. Refer to BR-121, "Removal and Installation".
4. Remove mounting bolt , and then disconnect high-pressure
pipe from expansion valve. O
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air. P

JSIIA1910ZZ

Revision: 2014 December HA-95 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [QR25DE]
5. Remove mounting bolt and then disconnect high-pressure
pipe from condenser outlet pipe assembly .

JMIIA4018ZZ

6. Remove fixing clips, and then remove high pressure pipe from vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

LOW-PRESSURE PIPE
LOW-PRESSURE PIPE : Removal and Installation INFOID:0000000010490524

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove mounting bolt , and then disconnect low-pressure
pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air.

JSIIA1914ZZ

3. Remove mounting bolt , and then disconnect low-pressure

pipe from low-pressure flexible hose.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JSIIA1913ZZ

Revision: 2014 December HA-96 D23

 COOLER PIPE AND HOSE
< REMOVAL AND INSTALLATION > [QR25DE]
4. Remove low-pressure pipe mounting bracket bolts , and then
remove low-pressure pipe . A

: Bracket
B

JSIIA1924ZZ

D
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. E
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

HA

Revision: 2014 December HA-97 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [QR25DE]
CONDENSER
Exploded View INFOID:0000000010490527

JMIIA4010GB

Condenser upper bracket RH Condenser side seal upper Condenser side seal lower
Outlet pipe assembly Refrigerant pressure sensor O-ring
Condenser Inlet pipe assembly Condenser lower bracket
Bracket Liquid tank Liquid tank bracket
Condenser upper bracket LH Condenser upper seal
: Always replace after every disassembly.

: N·m (kg-m, ft-lb)

: N·m (kg-m, in-lb)

CONDENSER
CONDENSER : Removal and Installation INFOID:0000000010490564

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove front grille. Refer to EXT-19, "Removal and Installation".
3. Remove radiator upper seal. Refer to the following.
• With Intelligent Key system: Refer to DLK-169, "Removal and Installation"
• Without Intelligent Key system: Refer to DLK-169, "Removal and Installation".
4. Remove AT fluid cooler mounting bolt, and then disengage AT fluid cooler fixing pawls from radiator (with
AT fluid cooler). Refer to TM-321, "Exploded View".
CAUTION:
Never damage the core surface of AT fluid cooler.
5. Remove condenser inlet pipe assembly and outlet pipe assembly from the condenser. Refer to HA-101,
"CONDENSER PIPE ASSEMBLY : Removal and Installation".

Revision: 2014 December HA-98 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [QR25DE]
6. Remove condensor upper bracket mounting bolt .
A

JSIIA1915ZZ

D
7. Remove condenser upper bracket RH by pressing the lock as
shown in the figure.
E

G
JSIIA1916ZZ

8. Remove radiator mounting bolts (LH and RH). H

HA

JSIIA1917ZZ
K
9. Remove front under cover. Refer to EXT-24, "Removal and Installation".
10. Disengage radiator shroud (lower) fixing pawls, and then remove radiator shroud (lower). Refer to CO-16,
"Exploded View". L
11. Lift up radiator, and then remove radiator from radiator mounting rubber.
12. Move the radiator to the rear direction to make enough space and take out the condenser assembly
M
upwards.

JSIIA1942ZZ

CAUTION:

Revision: 2014 December HA-99 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [QR25DE]
• Never give heavy load to the radiator.
• Never damage the core surface of condenser.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Perform lubricant adjusting procedure before installing new compressor. Refer to HA-82, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
• Check for leakages when recharging refrigerant.

LIQUID TANK
LIQUID TANK : Removal and Installation INFOID:0000000010490565

REMOVAL
1. Remove condenser assembly. Refer to HA-98, "CONDENSER : Removal and Installation".
2. Clean liquid tank and its surrounding area and then remove dust and rust from liquid tank.
CAUTION:
Be sure to clean carefully.
3. Remove mounting bolts , and then remove liquid tank .
CAUTION:
Cap or wrap the joint of the A/C piping and liquid tank with
suitable material such as vinyl tape to avoid the entry of air.

JSIIA1919ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Install liquid tank, and then install liquid tank bracket on condenser.
• Check that liquid tank bracket is securely installed at protrusion of condenser. (Check that liquid
tank bracket does not move to a position below center of liquid tank.)
• Perform lubricant adjusting procedure before installing new liquid tank. Refer to HA-82, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

REFRIGERANT PRESSURE SENSOR

REFRIGERANT PRESSURE SENSOR : Removal and Installation INFOID:0000000010490566

REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove condenser outlet pipe assembly. Refer to HA-101, "CONDENSER PIPE ASSEMBLY : Removal
and Installation".
3. Use a adjustable wrench or other tool to hold the refrigerant pressure sensor mounting block, and then
remove the refrigerant pressure sensor from the condenser.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable material such as vinyl tape to avoid the entry
of air.

Revision: 2014 December HA-100 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [QR25DE]
INSTALLATION
Note the following item, and then install in the reverse order of removal. A
CAUTION:
Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".
B
CONDENSER PIPE ASSEMBLY
CONDENSER PIPE ASSEMBLY : Removal and Installation INFOID:0000000010519429
C

REMOVAL
1. Use refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy- D
cle Refrigerant".
2. Remove bumper fascia assembly. Refer to EXT-11, "Removal and Installation".
3. Remove mounting bolt , and then disconnect condenser inlet E
pipe assembly from high-pressure flexible hose assembly .
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate- F
rial such as vinyl tape to avoid the entry of air.

JSIIA1896ZZ H

4. Remove mounting bolt , and then disconnect condenser inlet

pipe assembly from condenser assembly. HA
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.
J

JSIIA1897ZZ

L
5. Remove condenser inlet pipe assembly from vehicle.
6. Disconnect the refrigerant pressure sensor connector .
M

JSIIA1911ZZ

Revision: 2014 December HA-101 D23

 CONDENSER
< REMOVAL AND INSTALLATION > [QR25DE]
7. Remove mounting bolt , and then disconnect condenser outlet
pipe assembly from high-pressure pipe assembly .
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JMIIA4018ZZ

8. Remove mounting bolt , and then disconnect condenser outlet

pipe assembly from condenser assembly.
CAUTION:
Cap or wrap the joint of the A/C piping with suitable mate-
rial such as vinyl tape to avoid the entry of air.

JSIIA1899ZZ

9. Remove condenser outlet pipe assembly from vehicle.

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

Revision: 2014 December HA-102 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
HEATER & COOLING UNIT ASSEMBLY
A
Exploded View INFOID:0000000010491656

REMOVAL B

HA

JSIIA1938GB
K
Heater & cooling unit assembly Blower unit assembly Drain hose
Instrument stay LH Instrument stay RH Steering member L
: N·m (kg-m, ft-lb)

DISASSEMBLY M

Revision: 2014 December HA-103 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
Manual air conditioning (switch type)

JSIIA1900GB

Ventilator seal Defroster seal Ventilator door

Defroster door Center plate case Heater & cooling unit case RH
Foot lever Defroster link Foot link
Ventilator lever Main link Mode lever
Mode door motor assembly Air mix door motor assembly Mix adapter
Defroster lever Evaporator assembly Evaporator insulator
Expansion valve Expansion valve packing O-ring
Heater core Heater pipe grommet Foot duct
AC cover Evaporator pipe cover Heater pipe cover
Heater & cooling unit case LH Intake outlet packing Sub harness
Power module assembly Adapter case Foot door assembly
Inner duct case Slide door unit Air guide case
AC drain case Intake sensor assembly

Revision: 2014 December HA-104 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
: Always replace after every disassembly.
A
: N·m (kg-m, in-lb)

Manual air conditioning (dial type)

B

HA

JSIIA1943GB

N
Ventilator seal Defroster seal Ventilator door
Defroster door Center plate case Foot lever
Defroster link Defroster lever Foot link O
Ventilator lever Main link Mix lever
Mix link Air mix gear lever Evaporator assembly
Evaporator insulator Expansion valve Expansion valve packing
P

O-ring Heater core Heater pipe grommet

Thermo control amp. Foot duct AC cover
Evaporator pipe cover Heater pipe cover Heater & cooling unit case LH
Sub harness Resistance assembly Inner duct case
Foot duct assembly Adapter case Slide door unit

Revision: 2014 December HA-105 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
Air guide duct Heater & cooling unit case RH AC drain case
Intake outlet packing
: Always replace after every disassembly.

: N·m (kg-m, in-lb)

Manual cooler

JMIIA4048GB

Ventilator seal Defroster seal Ventilator door

Defroster door Center plate case Foot lever
Defroster link Defroster lever Foot link
Ventilator lever Main link Evaporator assembly
Evaporator insulator Expansion valve Expansion valve packing
O-ring grommet Thermo control amp.
Foot duct AC cover Evaporator pipe cover
Heater pipe grommet Heater & cooling unit case LH Sub harness
Resistance assembly Inner duct case Foot duct assembly

Revision: 2014 December HA-106 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
Adapter case Air guide duct Heater & cooling unit case RH
A
AC drain case Intake outlet packing
: Always replace after every disassembly.

: N·m (kg-m, in-lb) B

HEATER & COOLING UNIT ASSEMBLY

C
HEATER & COOLING UNIT ASSEMBLY : Removal and Installation INFOID:0000000010491657

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large D
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL E
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
F
2. Drain engine coolant from cooling system. Refer to CO-10, "Draining".
3. Remove wiper drive assembly. Refer to WW-49, "WIPER DRIVE ASSEMBLY : Removal and Installation"
(With Intelligent Key system) or WW-105, "WIPER DRIVE ASSEMBLY : Removal and Installation" (With-
out Intelligent Key system). G
4. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve.
CAUTION: H
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air. HA

J
JSIIA1925ZZ

5. Remove fixing clamps , and then disconnect heater hoses . K

(with manual air conditioning)
CAUTION:
• Some coolant may spill when heater hoses are discon- L
nected.
• Close off the coolant inlet and outlet on the heater pipes
(2 locations) with shop cloths.
M

JSIIA1927ZZ
N

6. Remove instrument panel assembly. Refer to IP-14, "Removal and Installation".

7. Remove blower mounting bolts . O

JSIIA1892ZZ

Revision: 2014 December HA-107 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]

8. Remove mounting nuts , mounting bolts and then remove

instrument stay .

JSIIA1928ZZ

9. Disconnect drain hose from heater & cooling unit assembly.

JSIIA1929ZZ

10. Remove mounting bolts of ground wires.

JSIIA1931ZZ

11. Remove all of harness connectors and mounting nuts necessary to allow steering column assembly to be
moved. Refer to ST-15, "Removal and Installation".
12. Move steering column assembly to secure work space.
13. Remove all of harness connectors and clips necessary to allow steering member to be removed. Move
main harness aside and secure work space so that steering member can be easily removed.

Revision: 2014 December HA-108 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
14. Remove mounting bolts , and then remove steering member from the vehicle.
A

H
JSIIA1930ZZ

CAUTION:
When removing steering member, 2 workers are required to prevent it from dropping. HA
15. Disconnect the intake door motor and blower motor connectors.
16. Remove mounting screws , and then remove blower unit
J
assembly .

JSIIA1939ZZ
M

17. Remove heater & cooling unit assembly from the vehicle.
CAUTION:
When removing heater & cooling unit assembly, 2 workers are required to prevent it from drop- N
ping.

INSTALLATION O
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing. P
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".
NOTE:
When filling radiator with engine coolant. Refer to CO-12, "Refilling".

EXPANSION VALVE

Revision: 2014 December HA-109 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
EXPANSION VALVE : Removal and Installation INFOID:0000000010491658

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove mounting bolt , and then disconnect low-pressure
pipe and high-pressure pipe from expansion valve.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air.

JSIIA1925ZZ

3. Remove mounting bolts , and then remove expansion valve.

CAUTION:
Cap or wrap the joint of the expansion valve and evaporator
with suitable material such as vinyl tape to avoid the entry
of air.

JSIIA1926ZZ

INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

EVAPORATOR
EVAPORATOR : Removal and Installation INFOID:0000000010491659

CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to HA-
82, "Perform Lubricant Return Operation".
REMOVAL
1. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to HA-80, "Recy-
cle Refrigerant".
2. Remove heater & cooling unit assembly. Refer to HA-107, "HEATER & COOLING UNIT ASSEMBLY :
Removal and Installation".
3. Disassemble heater & cooling unit assembly, and then remove evaporator assembly.
4. Disconnect intake sensor or thermo control amp.. Refer to HA-103, "Exploded View".
5. Remove expansion valve from evaporator. Refer to HA-103, "Exploded View".

INSTALLATION

Revision: 2014 December HA-110 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
Note the following items, and then install in the reverse order of removal.
CAUTION: A
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• When install the intake sensor or thermo control amp., set the same position before replacement.
• Never rotate the bracket insertion part when removing and installing the intake sensor.
B
• Perform lubricant adjusting procedure after installing new evaporator. Refer to HA-82, "Lubricant
Adjusting Procedure for Components Replacement Except Compressor".
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".
C
HEATER CORE
HEATER CORE : Removal and Installation INFOID:0000000010491660 D

REMOVAL
1. Remove heater & cooling unit assembly. Refer to HA-107, "HEATER & COOLING UNIT ASSEMBLY : E
Removal and Installation".
2. Remove heater pipe grommet .
F

JSIIA1941ZZ
HA
3. Remove mounting screws , and then remove heater pipe
cover .
J

L
JSIIA1893ZZ

4. Slide heater core to leftward (as shown in the figure). M

JSIIA1894ZZ P
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to HA-78, "Leak Test".

Revision: 2014 December HA-111 D23

 HEATER & COOLING UNIT ASSEMBLY
< REMOVAL AND INSTALLATION > [QR25DE]
NOTE:
When filling radiator with engine coolant. Refer to CO-39, "Refilling".

Revision: 2014 December HA-112 D23

 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
Compressor INFOID:0000000010491758
B

VALEO THERMAL SYSTEMS JAPAN make C

Model
DKS-17D
Type Swash plate
Displacement D
Maximum 175 (10.7)
cm3 (cu in)/rev
Cylinder bore × stroke (Max.)mm (in.) 30.5 (1.20) × 24 (0.94)
Direction of rotation Clockwise (viewed from clutch) E
Drive belt Poly V
Disc to pulley clearance 0.3 – 0.7
Standard F
mm (in) (0.012 – 0.024)

Lubricant INFOID:0000000010491759

Name A/C System Oil Type S (DH-PS)

Capacity Total in system 180 (6.3) H

m (Imp fl oz.) Compressor (service part) charging amount 180 (6.3)

Refrigerant INFOID:0000000010491760
HA

Type HFC-134a (R-134a) J

Capacity
0.50 (1.1)
kg (lb)

K
Engine Idling Speed INFOID:0000000010491761

Refer to EC-744, "General Specification".

L
Belt Tension INFOID:0000000010491762

Refer to EM-152, "Inspection".

M

Revision: 2014 December HA-113 D23