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MTC Air Conditioner Manual

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J AIR CONDITIONER
PRECAUTIONS ..................................................... . .... 5
Contaminated Refrigerant ................................... . .... 5
General Refrigerant Precautions ......................... . .... 6
Precautions for Leak Detection Dye .................... . .... 6
A/C Identification Label ....................................... . .... 7
CONNECTION ................................................. . .... 7
Precautions for Servicing Compressor ................ . ...11
Precautions for Service Equipment ..................... . ...11
ELECTRONIC LEAK DETECTOR ................... . ...11
VACUUM PUMP .............................................. . .. 12
MANIFOLD GAUGE SET ................................. . .. 12
SERVICE HOSES ............................................ . .. 12
SERVICE COUPLERS ..................................... . .. 13
REFRIGERANT WEIGHT SCALE ................... . .. 13
CHARGING CYLINDER ................................... . .. 13
PREPARATION ...................................................... . .. 14
Special Service Tools .......................................... . .. 14
Commercial Service Tools ................................... . .. 16
REFRIGERATION SYSTEM .................................. . .. 18
Refrigerant Cycle ................................................ . .. 18
REFRIGERANT FLOW .................................... . .. 18
Refrigerant System Protection ............................ . .. 18
REFRIGERANT PRESSURE SENSOR .......... . .. 18
PRESSURE RELIEF VALVE ........................... . .. 19
Component Layout .............................................. . .. 20
FRONT REFRIGERATION SYSTEM ............... . .. 20
REAR REFRIGERATION SYSTEM ................. . .. 21
Revision: January 2005
SECTION
MANUAL AIR CONDITIONER
CONTENTS
LUBRICANT ........................................................... . .. 22
LUBRICANT ..................................................... . .. 22
CHECKING AND ADJUSTING ......................... . .. 22
AIR CONDITIONER CONTROL ............................ . .. 24
Description ........................................................... . .. 24
Operation ............................................................. . .. 24
AIR MIX DOOR CONTROL .............................. . .. 24
BLOWER SPEED CONTROL .......................... . .. 24
INTAKE DOORS CONTROL ............................ . .. 24
MODE DOOR CONTROL ................................ . .. 24
DEFROSTER DOOR CONTROL ..................... . .. 24
MAGNET CLUTCH CONTROL ........................ . .. 25
SELF-DIAGNOSTIC SYSTEM ......................... . .. 25
Description of Control System ............................. . .. 26
Control Operation ................................................ . .. 26
DISPLAY SCREEN ........................................... . .. 27
TEMPERATURE DIAL (TEMPERATURE CON-
TROL) (FRONT) ............................................... . .. 27
TROL) (REAR) ................................................. . .. 27
RECIRCULATION () SWITCH .......................... . .. 27
REAR WINDOW DEFOGGER SWITCH .......... . .. 27
A/C SWITCH .................................................... . .. 27
MODE DIAL ...................................................... . .. 27
FRONT BLOWER CONTROL DIAL ................. . .. 27
REAR BLOWER CONTROL DIAL ................... . .. 27
Discharge Air Flow .............................................. . .. 28
FRONT ............................................................. . .. 28
REAR ............................................................... . .. 28
System Description .............................................. . .. 29
TROUBLE DIAGNOSIS ......................................... . .. 31
CONSULT-II Function (BCM) .............................. . .. 31
CONSULT-II BASIC OPERATION .................... . .. 31
DATA MONITOR .............................................. . .. 32
Accurate Repair ................................................... . .. 33
MTC-1
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2004 Quest

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Summary of Contents for MTC Air Conditioner

  • Page 1: Table Of Contents

    SIONER” ..............5 CHECKING AND ADJUSTING ......22 Precautions for Working with HFC-134a (R-134a) ..5 AIR CONDITIONER CONTROL ....... 24 Contaminated Refrigerant ........5 Description .............. 24 General Refrigerant Precautions ......6 Operation .............
  • Page 2 Removal and Installation ........119 Front Blower Motor Circuit ........72 FRONT BLOWER MOTOR ....... . 119 INSPECTION FLOW ......... .. 72 REAR BLOWER MOTOR ........120 SYSTEM DESCRIPTION ........73 MTC-2 Revision: January 2005 2004 Quest...
  • Page 3 INSTALLATION ..........158 Removal and Installation for Front Expansion Valve . 158 REMOVAL ............158 INSTALLATION ..........158 Removal and Installation for Rear Expansion Valve . 158 REMOVAL ............158 MTC-3 Revision: January 2005 2004 Quest...
  • Page 4 REFRIGERANT ..........163 Electronic Refrigerant Leak Detector ....160 ENGINE IDLING SPEED ........163 PRECAUTIONS FOR HANDLING LEAK BELT TENSION ..........163 DETECTOR ............160 CHECKING PROCEDURE ....... . 161 MTC-4 Revision: January 2005 2004 Quest...

  • Page 5: Precautions

    CFC-12 (R-12) refrigerant and HFC-134a (R-134a) refrigerant are not compatible. If the refrigerants are mixed compressor failure is likely to occur. Refer MTC-5, "Contaminated Refrigerant" . To determine the purity of HFC-134a (R-134a) in the vehicle and recovery tank, use Refrigerant Recovery/Recycling Recharging equipment and Refrigerant Identifier.

  • Page 6: General Refrigerant Precautions

    This refrigerant must be disposed of in accordance with all federal and local regulations. In addition, replacement of all refrigerant system components on the vehicle is recommended. If the vehicle is within the warranty period, the air conditioner warranty is void. Please contact Nissan Cus- tomer Affairs for further assistance.

  • Page 7: A/C Identification Label

    O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facil- itating piping connections. SHA815E MTC-7 Revision: January 2005 2004 Quest...

  • Page 8: O-Ring And Refrigerant Connection

    PRECAUTIONS O-RING AND REFRIGERANT CONNECTION WJIA0370E MTC-8 Revision: January 2005 2004 Quest...
  • Page 9 The new and former refrigerant connections use different O-ring configurations. Do not confuse O- rings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at or around the connection. MTC-9 Revision: January 2005 2004 Quest...
  • Page 10 After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. When installing an air conditioner in the vehicle, connect the pipes as the final stage of the opera- tion. Do not remove the seal caps of pipes and other components until just before required for connection.

  • Page 11: Precautions For Servicing Compressor

    When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compres- sor” exactly. Refer to MTC-22, "Maintenance of Lubricant Quantity in Compressor" Keep friction surfaces between clutch and pulley clean. If the surface is contaminated with lubri- cant, wipe it off by using a clean waste cloth moistened with thinner.

  • Page 12: Vacuum Pump

    Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shut- off devices (either manual or automatic) near the end of the hoses opposite the manifold gauge. RHA272D MTC-12 Revision: January 2005 2004 Quest...

  • Page 13: Service Couplers

    GI-12, "How to Read Wiring Diagrams". PG-4, "POWER SUPPLY ROUTING CIRCUIT". When you perform trouble diagnosis, refer to the following: GI-9, "How to Follow Trouble Diagnoses". GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident". MTC-13 Revision: January 2005 2004 Quest...

  • Page 14: Preparation

    NISSAN A/C System Oil Type DH- Application: HFC-134a (R-134a) vane rotary compressors (NISSAN only) Lubricity: 40 m (1.4 US fl oz, 1.4 Imp fl oz) S-NT197 — Refrigerant recovery and recycling and (ACR2005-NI) recharging ACR5 A/C Service Center WJIA0293E MTC-14 Revision: January 2005 2004 Quest...
  • Page 15 For injecting 1/4 ounce of fluorescent (J-41459) leak detection dye into A/C system. HFC-134a (R-134a) Dye injector Use with (J-41447) 1/4 ounce bot- tles SHA440F — For cleaning dye spills. (J-43872) Refrigerant dye cleaner SHA441F MTC-15 Revision: January 2005 2004 Quest...

  • Page 16: Commercial Service Tools

    — Capacity: (J-39649) 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 Commercial Service Tools EJS001RW MTC-16 Revision: January 2005 2004 Quest...
  • Page 17 Description Tool name (J-41810-NI) For checking refrigerant purity and Refrigerant identifier equipment (R- system contamination 134a) RJIA0197E Power tool Loosening bolts and nuts PBIC0190E (J-44614) Clutch disc holding tool Clutch disc holding tool WHA230 MTC-17 Revision: January 2005 2004 Quest...

  • Page 18: Refrigeration System

    The ECM deenergizes the A/C relay to disengage the magnetic compressor clutch when pressure on the high pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (28 kg/cm , 398 psi), or below about 120 kPa (1.22 kg/cm , 17.4 psi). MTC-18 Revision: January 2005 2004 Quest...

  • Page 19: Pressure Relief Valve

    When the pressure of refrigerant in the system increases to an abnormal level [more than 2,990 kPa (30.5 kg/ , 433.6 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. WJIA1342E MTC-19 Revision: January 2005 2004 Quest...

  • Page 20: Component Layout

    REFRIGERATION SYSTEM Component Layout EJS001RZ FRONT REFRIGERATION SYSTEM LJIA0085E MTC-20 Revision: January 2005 2004 Quest...

  • Page 21: Rear Refrigeration System

    Front heater and cooling unit assembly 10. Floor connector duct 11. Floor distribution duct 12. Floor duct REAR REFRIGERATION SYSTEM LJIA0086E 1. Rear overhead duct Rear heat duct Rear heater and cooling unit assembly 4. Clips MTC-21 Revision: January 2005 2004 Quest...

  • Page 22: Lubricant

    Connect recovery/recycling equipment to vehicle. Confirm refrigerant purity in supply tank using recovery/ recycling equipment and refrigerant identifier. If NG, refer to MTC-5, "Contaminated Refrigerant" Confirm refrigerant purity in vehicle A/C system using recovery/recycling equipment and refrigerant identi- fier. If NG, refer to MTC-5, "Contaminated Refrigerant"...
  • Page 23 (0.2 US fl oz, 0.2 Imp fl oz) of lubricant at this time. Do not add this 5 m (0.2 US fl oz, 0.2 Imp fl oz) of lubricant if only replacing the compressor. RHA065DD MTC-23 Revision: January 2005 2004 Quest...

  • Page 24: Air Conditioner Control

    AIR CONDITIONER CONTROL AIR CONDITIONER CONTROL PFP:27500 Description EJS001UD The front air control provides regulation of the vehicle's interior temperature. The system is based on the posi- tion of the front air controls temperature switch selected by the driver. This is done by utilizing a microcom-...

  • Page 25: Magnet Clutch Control

    If it judges compressor can be turned ON, it sends compressor ON sig- nal to IPDM E/R, via CAN communication line. Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate com- pressor.

  • Page 26: Description Of Control System

    AIR CONDITIONER CONTROL Description of Control System EJS001S3 The control system consists of input sensors, switches, the front air control (microcomputer) and outputs. The relationship of these components is shown in the figure below: WJIA1610E Control Operation EJS001S4 Front air control...

  • Page 27: Display Screen

    AIR CONDITIONER CONTROL Rear air control LJIA0024E DISPLAY SCREEN Displays the operational status of the system. TEMPERATURE DIAL (TEMPERATURE CONTROL) (FRONT) Increases or decreases the set temperature. TEMPERATURE DIAL (TEMPERATURE CONTROL) (REAR) Increases or decreases the set temperature. RECIRCULATION () SWITCH When REC switch is ON, REC switch indicator turns ON, and air inlet is set to REC.

  • Page 28: Discharge Air Flow

    AIR CONDITIONER CONTROL Discharge Air Flow EJS001S6 FRONT WJIA1037E REAR LJIA0127E MTC-28 Revision: January 2005 2004 Quest...

  • Page 29: System Description

    AIR CONDITIONER CONTROL System Description EJS001S7 SWITCHES AND THEIR CONTROL FUNCTION WJIA0531E WJIA0532E MTC-29 Revision: January 2005 2004 Quest...

  • Page 30: Can Communication System Description

    AIR CONDITIONER CONTROL CAN Communication System Description EJS001S8 Refer to LAN-6, "CAN COMMUNICATION" MTC-30 Revision: January 2005 2004 Quest...

  • Page 31: Trouble Diagnosis

    SULT-II converter to the data link connector, and turn the ignition switch ON. BBIA0336E Touch “START (NISSAN BASED VHCL)”. BCIA0029E Touch “BCM” on “SELECT SYSTEM” screen. If “BCM” is not indicated, go to GI-37, "CONSULT-II Data Link Connector (DLC) Circuit" BCIA0030E MTC-31 Revision: January 2005 2004 Quest...

  • Page 32: Data Monitor

    Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal. COMP ON SIG “ON/OFF” Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal. FAN ON SIG “ON/OFF” Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal.

  • Page 33: How To Perform Trouble Diagnosis For Quick And Accurate Repair

    TROUBLE DIAGNOSIS How to Perform Trouble Diagnosis for Quick and Accurate Repair EJS001SA WORK FLOW SHA900E MTC-52, "Operational Check" SYMPTOM TABLE Symptom Reference Page MTC-54, "Power Supply and A/C system does not come on. Go to Trouble Diagnosis Procedure for A/C System.
  • Page 34 TROUBLE DIAGNOSIS Symptom Reference Page Noise Go to Trouble Diagnosis Procedure for Noise. MTC-109, "Noise" MTC-110, "Self- Self-diagnosis cannot be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis. diagnosis" MTC-34 Revision: January 2005 2004 Quest...

  • Page 35: Component Parts And Harness Connector Location

    TROUBLE DIAGNOSIS Component Parts and Harness Connector Location EJS001SB ENGINE COMPARTMENT WJIA1604E MTC-35 Revision: January 2005 2004 Quest...

  • Page 36: Front Passenger Compartment

    TROUBLE DIAGNOSIS FRONT PASSENGER COMPARTMENT WJIA0481E MTC-36 Revision: January 2005 2004 Quest...

  • Page 37: Rear Passenger Compartment

    TROUBLE DIAGNOSIS REAR PASSENGER COMPARTMENT LJIA0123E MTC-37 Revision: January 2005 2004 Quest...

  • Page 38: Schematic

    TROUBLE DIAGNOSIS Schematic EJS001SC WJWA0259E MTC-38 Revision: January 2005 2004 Quest...

  • Page 39: Wiring Diagram -A/C,M

    TROUBLE DIAGNOSIS Wiring Diagram —A/C,M— EJS001SD WJWA0260E MTC-39 Revision: January 2005 2004 Quest...
  • Page 40 TROUBLE DIAGNOSIS WJWA0064E MTC-40 Revision: January 2005 2004 Quest...
  • Page 41 TROUBLE DIAGNOSIS WJWA0265E MTC-41 Revision: January 2005 2004 Quest...
  • Page 42 TROUBLE DIAGNOSIS WJWA0266E MTC-42 Revision: January 2005 2004 Quest...
  • Page 43 TROUBLE DIAGNOSIS WJWA0176E MTC-43 Revision: January 2005 2004 Quest...
  • Page 44 TROUBLE DIAGNOSIS WJWA0261E MTC-44 Revision: January 2005 2004 Quest...
  • Page 45 TROUBLE DIAGNOSIS WJWA0262E MTC-45 Revision: January 2005 2004 Quest...
  • Page 46 TROUBLE DIAGNOSIS WJWA0263E MTC-46 Revision: January 2005 2004 Quest...
  • Page 47 TROUBLE DIAGNOSIS WJWA0264E MTC-47 Revision: January 2005 2004 Quest...

  • Page 48: Front Air Control Terminals And Reference Value

    0 - 5V Front air mix door motor feedback Defroster door motor CCW Counterclockwise rotation Battery voltage Defroster door motor CW Clockwise rotation Battery voltage Sensor return 0 - 5V Power supply for BAT Battery voltage MTC-48 Revision: January 2005 2004 Quest...
  • Page 49 Front blower motor OFF Battery voltage Front blower speed 2 Front blower motor ON 0 - 5V Front blower motor OFF Battery voltage Front blower speed 3 Front blower motor ON 0 - 5V MTC-49 Revision: January 2005 2004 Quest...

  • Page 50: A/C System Self-Diagnosis Function

    The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. Refer to applicable sections (items) for details. Fault codes (if any are present) will be displayed in the ambient temperature display area. Refer to MTC-51, "SELF-DIAGNOSIS CODE CHART" WJIA0486E MTC-50...
  • Page 51 BCM not responding to A/C request CLUTCH" BCM not responding to rear defroster request GW-84, "REAR WINDOW DEFOGGER" MTC-62, "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR Air mix door motor (front) circuit failure MOTOR (FRONT)" In-vehicle sensor circuit out of range (low) ATC-120, "In-vehicle Sensor Circuit"...

  • Page 52: Operational Check

    WJIA0488E Confirm that discharge air comes out according to the air distri- bution table. Refer to MTC-28, "Discharge Air Flow" Mode door position is checked in the next step. If NG, go to trouble diagnosis procedure for MTC-57, "Mode Door Motor Circuit"...

  • Page 53: Checking Temperature Decrease

    Check for cold air at appropriate discharge air outlets. If NG, listen for sound of air mix door motor operation if OK, go to trouble diagnosis procedure for MTC-100, "Insufficient Cooling" . If air mix door motor appears to be malfunctioning, go to MTC-62, "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR...

  • Page 54: Power Supply And Ground Circuit For Front Air Control

    TROUBLE DIAGNOSIS Power Supply and Ground Circuit for Front Air Control EJS001SH SYMPTOM: A/C system does not come on. INSPECTION FLOW WJIA1027E MTC-54, "Power Supply and Ground MTC-52, "Operational Check". Circuit for Front Air Control" MTC-54 Revision: January 2005 2004 Quest...

  • Page 55: Component Description

    Self-diagnostic functions are also built into the front air control to pro- vide quick check of malfunctions in the air conditioner system. LJIA0126E Potentio Temperature Control (PTC) The PTC is built into the front air control.
  • Page 56 Check continuity between front air control harness connector M49 terminal 1 (B) and ground. Continuity should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> Repair harness or connector. WJIA1588E MTC-56 Revision: January 2005...

  • Page 57: Mode Door Motor Circuit

    Air outlet does not change. Mode door motor does not operate normally. INSPECTION FLOW WJIA1611E MTC-28, "Discharge Air Flow". MTC-52, "Operational Check". MTC-50, "A/C System Self-diagno- Function". MTC-51, "SELF-DIAGNOSIS CODE MTC-58, "DIAGNOSTIC PROCE- MTC-51, "SELF-DIAGNOSIS CODE CHART". DURE FOR MODE DOOR CHART"...

  • Page 58: System Description

    Motor rotation is conveyed to a link which activates the mode door. WJIA0424E DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 92 is present. Yes or No >> GO TO 2. >> GO TO 3. MTC-58 Revision: January 2005 2004 Quest...
  • Page 59 M304 terminal 3 (W/G) and front air control harness connector M49 terminal 2 (W/G). Continuity should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> Repair or replace harness as necessary. LJIA0029E CHECK PBR GROUND REFERENCE CIRCUIT Disconnect the front air control harness connector.
  • Page 60 16 (LG) and ground. Cycle mode switch through all modes. 0V - 5V (Approx.) should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> GO TO 7. LJIA0032E CHECK PBR FEEDBACK CIRCUIT Disconnect the mode door motor harness connector and front air control harness connector.

  • Page 61: Air Mix Door Motor Circuit

    Discharge air temperature does not change. Air mix door motor does not operate. INSPECTION FLOW WJIA1612E MTC-52, "Operational Check". MTC-50, "A/C System Self-diagno- MTC-51, "SELF-DIAGNOSIS CODE Function". CHART". MTC-62, "DIAGNOSTIC PROCE- MTC-116, "FRONT AIR CONTROL" DURE FOR AIR MIX DOOR MOTOR (FRONT)".

  • Page 62: System Description

    WJIA0496E WJIA0498E DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (FRONT) CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 22 is present. Yes or No >> GO TO 2. >> GO TO 3. MTC-62 Revision: January 2005 2004 Quest...
  • Page 63 M39 terminal 3 (W/G) and front air control harness connector M49 terminal 2 (W/G). Continuity should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> Repair or replace harness as necessary. WJIA0537E MTC-63...

  • Page 64: Diagnostic Procedure For Air Mix Door Motor (Rear)

    18 (Y/B) and ground. Rotate front temperature dial through complete range. 0V - 5V (Approx.) should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> GO TO 7. LJIA0041E CHECK PBR FEEDBACK CIRCUIT Disconnect the air mix door motor (front) harness connector and front air control harness connector.
  • Page 65 B146 terminal 3 (W/G) and front air control harness con- nector M49 terminal 2 (W/G). Continuity should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> Repair or replace harness as necessary. LJIA0051E MTC-65...
  • Page 66 42 (G/B) and ground. Rotate rear temperature dial through complete range. 0V - 5V (Approx.) should exist. OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> GO TO 7. LJIA0053E CHECK PBR FEEDBACK CIRCUIT Disconnect the air mix door motor (rear) harness connector and front air control harness connector.

  • Page 67: Intake Door Motor Circuit

    TROUBLE DIAGNOSIS Intake Door Motor Circuit EJS001SK SYMPTOM: Intake door does not change. Intake door motor does not operate normally. INSPECTION FLOW WJIA0499E MTC-52, "Operational Check". MTC-50, "A/C System Self-diagno- MTC-51, "SELF-DIAGNOSIS CODE Function". CHART". MTC-67 Revision: January 2005 2004 Quest...

  • Page 68: System Description

    DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR (DRIVER) CHECK RESULT FROM FRONT AIR CONTROL SELF-DIAGNOSIS Self-diagnosis code 82 is present. Yes or No >> GO TO 2. >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" MTC-68 Revision: January 2005 2004 Quest...

  • Page 69: Diagnostic Procedure For Intake Door Motor (Passenger)

    Self-diagnosis code 72 is present. Yes or No >> GO TO 2. >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" CHECK POWER SUPPLY CIRCUIT FOR INTAKE DOOR MOTOR (PASSENGER) Disconnect front air control connector and intake door motor (passenger) connector.

  • Page 70: Defroster Door Motor Circuit

    TROUBLE DIAGNOSIS Defroster Door Motor Circuit EJS001SL SYMPTOM: Defroster door does not change. Defroster door does not operate normally. INSPECTION FLOW WJIA1614E MTC-50, "A/C System Self-diagnosis MTC-51, "SELF-DIAGNOSIS CODE MTC-52, "Operational Check" Function" CHART" MTC-51, "SELF-DIAGNOSIS CODE CHART" MTC-33, MTC-116, "FRONT AIR CONTROL"...

  • Page 71: System Description

    Self-diagnosis code 62 is present. OK or NG >> GO TO 2. >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" CHECK POWER SUPPLY CIRCUITS FOR DEFROSTER DOOR MOTOR Disconnect front air control connector and defroster door motor connector.

  • Page 72: Front Blower Motor Circuit

    Front Blower Motor Circuit EJS001SM SYMPTOM: Blower motor operation is malfunctioning. INSPECTION FLOW WJIA1615E MTC-52, "Operational Check". MTC-50, "A/C System Self-diagno- MTC-51, "SELF-DIAGNOSIS CODE Function". CHART". MTC-74, "DIAGNOSTIC PROCE- MTC-33, "SYMPTOM TABLE" MTC-116, "FRONT AIR CONTROL" DURE FOR BLOWER MOTOR".

  • Page 73: System Description

    TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts Front air control Front blower switch Front blower motor resistor Front blower motor Front blower motor relay System Operation WJIA1616E Blower Speed Control Specification WJIA0441E MTC-73 Revision: January 2005 2004 Quest...

  • Page 74: Diagnostic Procedure For Blower Motor

    Select any front blower motor speed except OFF. Check voltage between front blower motor harness connector M62 terminal + (W/L) and ground. Battery voltage should exist. OK or NG >> GO TO 11. >> GO TO 4. WJIA0326E MTC-74 Revision: January 2005 2004 Quest...
  • Page 75 TROUBLE DIAGNOSIS CHECK FRONT BLOWER MOTOR RELAY Refer to MTC-78, "Front Blower Motor Relay" OK or NG >> GO TO 5. >> Replace front blower motor relay. CHECK FRONT BLOWER MOTOR POWER FROM RELAY TO FRONT BLOWER MOTOR Reconnect front blower motor harness connector.
  • Page 76 >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" CHECK FRONT BLOWER MOTOR RESISTOR Refer to MTC-79, "Front Blower Motor Resistor" OK or NG >> GO TO 14. >> Replace front blower motor resistor. Refer to MTC-137, "Removal and Installation"...
  • Page 77 Ground WJIA0969E OK or NG >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" >> GO TO 15. CHECK FRONT BLOWER MOTOR GROUND CIRCUIT TO FRONT BLOWER MOTOR RESISTOR Disconnect front blower motor and front blower motor resistor harness connector.

  • Page 78: Component Inspection

    Ensure that there are no foreign particles inside the blower unit. Apply 12 volts to terminal + and ground to terminal - and verify that the motor operates freely and quietly. LJIA0081E Front Blower Switch Check continuity between terminals at each switch position. WJIA0508E MTC-78 Revision: January 2005 2004 Quest...
  • Page 79 TROUBLE DIAGNOSIS Front Blower Motor Resistor Check continuity between terminals. There will be resistance, but there should not be an open or short between any two terminals. WJIA0971E MTC-79 Revision: January 2005 2004 Quest...

  • Page 80: Rear Blower Motor Circuit

    TROUBLE DIAGNOSIS Rear Blower Motor Circuit EJS001SN SYMPTOM: Blower motor operation is malfunctioning. INSPECTION FLOW WJIA1617E MTC-52, "Operational Check" MTC-89, "Rear Blower Switch MTC-33, "SYMPTOM TABLE" (Front)" MTC-80 Revision: January 2005 2004 Quest...

  • Page 81: System Description

    Blower motor rotates normally when rear blower switch (front) is set at 1 - 4 speed. OK or NG >> GO TO 2. >> Refer to MTC-83, "Trouble Diagnosis Procedure For Rear Blower Motor (1 - 4 Speed)" CHECK REAR BLOWER SWITCH (FRONT) Refer to MTC-89, "Rear Blower Switch (Front)"...
  • Page 82 TROUBLE DIAGNOSIS CHECK REAR BLOWER SWITCH (REAR) Refer to MTC-89, "Rear Blower Switch (Rear)" OK or NG >> GO TO 4. >> Replace rear blower switch (rear). Refer to MTC-116, "REAR AIR CONTROL" CHECK CIRCUIT CONTINUITY Disconnect rear blower switch (front) harness connector and rear blower switch (rear) harness connector.
  • Page 83 Rear blower motor does not rotate when rear blower switch (front) is set at 1 - 4 speed. Inspection Flow WJIA1620E MTC-52, "Operational Check" MTC-83, "Trouble Diagnosis Proce- MTC-33, "SYMPTOM TABLE" dure For Rear Blower Motor (1 - 4 Speed)"...
  • Page 84 >> GO TO 4. LJIA0099E CHECK REAR BLOWER MOTOR RELAY Refer to MTC-89, "Rear Blower Motor Relay" OK or NG >> GO TO 5. >> Replace rear blower motor relay. CHECK REAR BLOWER MOTOR POWER FROM RELAY TO REAR BLOWER MOTOR Reconnect rear blower motor harness connector.
  • Page 85 Check continuity between rear blower motor harness connector B134 terminal + (L/R) and ground. Continuity should not exist. OK or NG >> Check rear blower motor. Refer to MTC-90, "Rear Blower Motor" >> Repair harness or connector. LJIA0104E MTC-85 Revision: January 2005...
  • Page 86 >> Replace rear blower motor. Refer to MTC-120, "REAR BLOWER MOTOR" CHECK REAR BLOWER SWITCH (FRONT) Refer to MTC-89, "Rear Blower Switch (Front)" OK or NG >> GO TO 15. >> Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL"...
  • Page 87 (rear) connector B141 terminals 9 (LG), 6 (L/B), 8 (LG/B), and 7 (G). Terminal No. Continuity Rear blower switch (front) Rear blower switch (rear) LJIA0110E Should exist OK or NG >> GO TO 18. >> Repair harness or connector. MTC-87 Revision: January 2005 2004 Quest...
  • Page 88 TROUBLE DIAGNOSIS CHECK REAR BLOWER SWITCH (FRONT) Refer to MTC-89, "Rear Blower Switch (Front)" OK or NG >> GO TO 19. >> Replace rear blower switch (front). Refer to MTC-116, "FRONT AIR CONTROL" CHECK REAR BLOWER SWITCH (REAR) Refer to MTC-89, "Rear Blower Switch (Rear)"...

  • Page 89: Component Inspection

    WJIA0973E Rear Blower Switch (Rear) Check continuity between terminals at each switch position. LJIA0113E Rear Blower Switch (Front) Check continuity between terminals at each switch position. LJIA0114E MTC-89 Revision: January 2005 2004 Quest...
  • Page 90 LJIA0115E Rear Blower Motor Resistor Check continuity between terminals. There will be resistance, but there should not be an open or short between any two terminals. LJIA0116E MTC-90 Revision: January 2005 2004 Quest...

  • Page 91: Rear Air Control Circuit

    Rear Air Control Circuit EJS001SO SYMPTOM: Temperature cannot be adjusted from the rear air control. INSPECTION FLOW WJIA0519E MTC-52, "Operational Check". MTC-50, "A/C System Self-diagno- MTC-51, "SELF-DIAGNOSIS CODE Function". CHART". MTC-91, "Rear Air Control Circuit". MTC-64, "DIAGNOSTIC PROCE- DURE FOR AIR MIX DOOR MOTOR (REAR)".

  • Page 92: System Description

    CHECK OPERATION FROM FRONT AIR CONTROL Does rear temperature/mode operate normally from front air control? Yes or No >> GO TO 2. >> Refer to MTC-64, "DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR (REAR)" MTC-92 Revision: January 2005 2004 Quest...
  • Page 93 Check continuity between rear air control harness connector B142 terminals 2 (W/G) and 4 (Y) and ground. Continuity should not exist. OK or NG LJIA0122E >> Replace rear air control. Refer to MTC-116, "REAR AIR CONTROL" >> Repair harness or connector. MTC-93 Revision: January 2005 2004 Quest...

  • Page 94: Magnet Clutch Circuit

    TROUBLE DIAGNOSIS Magnet Clutch Circuit EJS001SP SYMPTOM: Magnet clutch does not engage. INSPECTION FLOW WJIA1619E MTC-52, "Operational Check" MTC-50, "A/C System Self-diagnosis MTC-51, "SELF-DIAGNOSIS CODE Function". CHART". MTC-111, "Ambient Sensor Circuit". MTC-113, "Intake Sensor Circuit". MTC-116, "FRONT AIR CONTROL" MTC-94...

  • Page 95: System Description

    SYMPTOM: Magnet clutch does not engage when A/C switch is ON. WJIA0472E CHECK INTAKE SENSOR CIRCUIT Check intake sensor. Refer to MTC-50, "A/C System Self-diagnosis Function" OK or NG >> GO TO 2. >> Malfunctioning intake sensor. Refer to MTC-113, "Intake Sensor Circuit"...
  • Page 96 >> Replace IPDM E/R. Refer to PG-27, "Removal and Installation of IPDM E/R" >> Replace magnet clutch. Refer to MTC-149, "Removal and Installation for Compressor Clutch" SJIA0197E CHECK BCM INPUT (COMPRESSOR ON) SIGNAL Check compressor ON/OFF signal. Refer to MTC-31, "CONSULT-II Function (BCM)"...
  • Page 97 >> If the voltage is approx. 0V when A/C switch is OFF, replace BCM. CHECK REFRIGERANT PRESSURE SENSOR WITH CONSULT-II Start engine. Check voltage of refrigerant pressure sensor. Refer to MTC-31, "CONSULT-II Function (BCM)" WITHOUT CONSULT-II Start engine. Check voltage between ECM harness connector F54 terminal 70 (W) and ground.
  • Page 98 TROUBLE DIAGNOSIS CHECK BCM INPUT (FAN ON) SIGNAL Check FAN ON/OFF signal. Refer to MTC-31, "CONSULT-II Func- tion (BCM)" FAN CONTROL SWITCH ON : FAN ON SIG ON FAN CONTROL SWITCH OFF : FAN ON SIG OFF OK or NG >>...

  • Page 99: Component Inspection

    TROUBLE DIAGNOSIS CHECK CAN COMMUNICATION Check CAN communication. Refer to MTC-30, "CAN Communication System Description" BCM – ECM ECM – IPDM E/R ECM – Front air control OK or NG >> Inspection End. >> Repair or replace malfunctioning part(s). COMPONENT INSPECTION Refrigerant Pressure Sensor The refrigerant pressure sensor is attached to the condenser.

  • Page 100: Insufficient Cooling

    TROUBLE DIAGNOSIS Insufficient Cooling EJS001SQ SYMPTOM: Insufficient cooling INSPECTION FLOW WJIA1029E MTC-52, "Operational Check". MTC-50, "A/C System Self-diagno- MTC-51, "SELF-DIAGNOSIS CODE Function". CHART". EC-472, "DTC P1217 ENGINE MTC-5, "Contaminated Refrigerant". *6 .MTC-101, "PERFORMANCE TEST OVER TEMPERATURE" DIAGNOSES" MTC-104, "Test Reading"...

  • Page 101: Performance Test Diagnoses

    TROUBLE DIAGNOSIS PERFORMANCE TEST DIAGNOSES WJIA0533E MTC-101 Revision: January 2005 2004 Quest...
  • Page 102 TROUBLE DIAGNOSIS MTC-104, "PERFORMANCE MTC-104, "PERFORMANCE MTC-105, "Trouble Diagnoses for CHART". CHART". Unusual Pressure". MTC-61, "Air Mix Door Motor Cir- cuit". MTC-102 Revision: January 2005 2004 Quest...
  • Page 103 TROUBLE DIAGNOSIS WJIA0534E MTC-149, "Removal and Installation MTC-72, "Front Blower Motor Cir- EM-14, "Checking Drive Belts". for Compressor Clutch". cuit". MTC-103 Revision: January 2005 2004 Quest...

  • Page 104: Performance Chart

    35 (95) (14.2 - 17.4, 202.0 - 247.5) (2.8 - 3.5, 39.8 - 49.8) 1,510 - 1,844 343 - 422 40 (104) (15.4 - 18.8, 219.0 - 267.4) (3.5 - 4.3, 49.8 - 61.2) MTC-104 Revision: January 2005 2004 Quest...

  • Page 105: Trouble Diagnoses For Unusual Pressure

    Upper side of condenser and High-pressure tube or parts malfunctioning parts. high-pressure side are hot, located between compressor however, liquid tank is not so and condenser are clogged or Check lubricant for contami- hot. crushed. nation. AC360A MTC-105 Revision: January 2005 2004 Quest...
  • Page 106 Check lubricant for contami- the evaporator outlet. nation. Check intake sensor circuit. Refer to MTC-113, "Intake Air flow volume is too low. Evaporator is frozen. Sensor Circuit" Replace compressor. MTC-106 Revision: January 2005...
  • Page 107 (not shop air). AC362A If either of the above meth- ods cannot correct the mal- function, replace expansion valve. Replace liquid tank. Check lubricant for contami- nation. MTC-107 Revision: January 2005 2004 Quest...

  • Page 108: Insufficient Heating

    TROUBLE DIAGNOSIS Insufficient Heating EJS001SR SYMPTOM: Insufficient heating INSPECTION FLOW WJIA1030E MTC-52, "Operational Check". MTC-61, "Air Mix Door Motor Cir- MTC-50, "A/C System Self-diagno- cuit". Function". MTC-50, "A/C System Self-diagno- MTC-72, "Front Blower Motor Cir- EC-187, "DTC P0117, P0118 ECT Function".

  • Page 109: Noise

    TROUBLE DIAGNOSIS Noise EJS001SS SYMPTOM: Noise INSPECTION FLOW WJIA0473E MTC-109 Revision: January 2005 2004 Quest...

  • Page 110: Self-Diagnosis

    INSPECTION FLOW WJIA0525E MTC-54, "Power Supply and Ground MTC-111, "Ambient Sensor Circuit". MTC-113, "Intake Sensor Circuit". Circuit for Front Air Control". MTC-61, "Air Mix Door Motor Cir- MTC-52, "Operational Check". MTC-33, "SYMPTOM TABLE". cuit". MTC-110 Revision: January 2005 2004 Quest...

  • Page 111: Ambient Sensor Circuit

    Disconnect ambient sensor connector. Turn ignition switch ON. Check voltage between ambient sensor harness connector E1 terminal 1 (O/B) and ground. Approx. 5V OK or NG >> GO TO 2. >> GO TO 4. WJIA0977E MTC-111 Revision: January 2005 2004 Quest...
  • Page 112 MTC-113, "Ambient Sensor" OK or NG >> 1. Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" 2. Go to self-diagnosis MTC-50, "A/C System Self-diagnosis Function" and perform self-diagno- sis. >> 1. Replace ambient sensor. 2. Go to self-diagnosis MTC-50, "A/C System Self-diagnosis Function"...

  • Page 113: Component Inspection

    WJIA0482E DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR SYMPTOM: Intake sensor circuit is open or shorted. (56 or 57 is indi- cated on front air control as a result of conducting Self-diagnosis). WJIA0464E MTC-113 Revision: January 2005 2004 Quest...
  • Page 114 MTC-115, "Intake Sensor" OK or NG >> 1. Replace front air control. Refer to MTC-116, "FRONT AIR CONTROL" 2. Go to self-diagnosis MTC-50, "A/C System Self-diagnosis Function" and perform self-diagno- sis. >> 1. Replace intake sensor. 2. Go to self-diagnosis MTC-50, "A/C System Self-diagnosis Function"...

  • Page 115: Component Inspection

    95.8 5 (41) 74.9 10 (50) 58.9 15 (59) 46.7 20 (68) 37.3 25 (77) 30.0 30 (86) 24.2 35 (95) 19.7 40 (104) 16.1 45 (113) 13.2 WJIA0978E If NG, replace intake sensor. MTC-115 Revision: January 2005 2004 Quest...

  • Page 116: Control Unit

    Remove the rear air control from the headliner, located over the sliding door, RH. Disconnect the rear air control electrical connector and remove the rear air control. LJIA0030E Installation Installation is in the reverse order of removal. MTC-116 Revision: January 2005 2004 Quest...

  • Page 117: Ambient Sensor

    The ambient sensor is located behind the front bumper opening, in front of the condenser. Release the ambient sensor clip and then remove the ambient sensor. Installation is in the reverse order of removal. WJIA0341E MTC-117 Revision: January 2005 2004 Quest...

  • Page 118: Intake Sensor

    Disconnect the intake sensor electrical connector. Twist and pull the intake sensor to remove the intake sensor from the front heater and cooling unit assem- bly. INSTALLATION Installation is in the reverse order of removal. MTC-118 Revision: January 2005 2004 Quest...

  • Page 119: Blower Motor

    Heater core and evaporator case Removal Remove the combination meter. Refer to IP-12, "Combination Meter" Remove the defroster duct. Refer to MTC-142, "DEFROSTER DUCT" Remove the front blower motor. Installation Installation is in the reverse order of removal. MTC-119 Revision: January 2005...

  • Page 120: Rear Blower Motor

    Remove the rear lower finisher assembly RH. Refer to EI-32, "RIGHT SIDE AND REAR" Disconnect the blower motor electrical connector. Remove the three screws and remove the blower motor. LJIA0056E Installation Installation is in the reverse order of removal. MTC-120 Revision: January 2005 2004 Quest...

  • Page 121: In-Cabin Microfilter

    The direction arrow is LJIA0058E printed on the side of the in-cabin microfilters. Install the in-cabin microfilter cover. Install the glove box assembly. Refer to IP-13, "Instrument Lower Panel RH and Glove Box" MTC-121 Revision: January 2005 2004 Quest...

  • Page 122: Heater & Cooling Unit Assembly

    Front Heater and Cooling Unit Assembly LJIA0067E High/low pressure pipe High/low pressure pipe bracket Front heater and cooling unit assembly Front heater core pipe and hose Front heater core pipe brackets Heater pump assembly MTC-122 Revision: January 2005 2004 Quest...

  • Page 123: Removal And Installation

    EJS001T6 FRONT HEATER AND COOLING UNIT ASSEMBLY Discharge the refrigerant from the A/C system. Refer to MTC-144, "Discharging Refrigerant" Drain the coolant from the engine cooling system. Refer to MA-14, "DRAINING ENGINE COOLANT" Remove the cowl top extension. Refer to EI-18, "COWL TOP"...

  • Page 124: Rear Heater And Cooling Unit Assembly

    Fill the engine cooling system with the specified coolant mixture. Refer to MA-15, "REFILLING ENGINE COOLANT" Recharge the A/C system. Refer to MTC-144, "Evacuating System and Charging Refrigerant" REAR HEATER AND COOLING UNIT ASSEMBLY Discharge the refrigerant from the A/C system. Refer to MTC-144, "Discharging Refrigerant"...

  • Page 125: Heater Core

    HEATER CORE HEATER CORE PFP:27140 Components EJS001U4 Front Heater and Cooling Unit Assembly LJIA0017E Front blower motor Blower motor side cover Blower motor case Heater core and evaporator case MTC-125 Revision: January 2005 2004 Quest...

  • Page 126: Removal And Installation

    Rear blower motor resistor Removal and Installation EJS001T7 FRONT HEATER CORE Remove the front heater and cooling unit assembly. Refer to MTC-123, "FRONT HEATER AND COOL- ING UNIT ASSEMBLY" Remove the blower motor side cover. Remove the front blower motor. MTC-126...

  • Page 127: Rear Heater Core

    EI-30, "Removal and Installation" Disconnect the rear heater core hoses from the rear heater core. LJIA0069E Remove the rear heater core bracket. Remove the rear heater core. LJIA0071E Installation is in the reverse order of removal. MTC-127 Revision: January 2005 2004 Quest...

  • Page 128: Heater Pump

    Do not disassemble the heater pump, replace the heater pump as an assembly. LJIA0036E INSTALLATION Installation is in the reverse order of removal. CAUTION: Do not disassemble the heater pump, replace the heater pump as an assembly. MTC-128 Revision: January 2005 2004 Quest...

  • Page 129: Defroster Door Motor

    Intake sensor REMOVAL Remove the front heater and cooling unit assembly. Refer to MTC-123, "FRONT HEATER AND COOL- ING UNIT ASSEMBLY" Remove the steering member from the front heater and cooling unit assembly. Disconnect the defroster door motor electrical connector.

  • Page 130: Intake Door Motor

    INTAKE DOOR MOTOR INTAKE DOOR MOTOR PFP:27730 Components EJS001U5 Intake Door Motor (Driver) - Front Heater and Cooling Unit Assembly WJIA0446E Intake door motor (driver) Air mix door motor (front) Front heater and cooling unit assembly MTC-130 Revision: January 2005 2004 Quest...

  • Page 131: Removal And Installation

    Remove the center console trim panel. Refer to IP-10, "Removal and Installation" Disconnect the intake door motor electrical connector. Remove the three screws and remove the intake door motor. Installation is in the reverse order of removal. LJIA0082E MTC-131 Revision: January 2005 2004 Quest...

  • Page 132: Passenger Side

    INTAKE DOOR MOTOR PASSENGER SIDE Remove the front heater and cooling unit assembly. Refer to MTC-123, "FRONT HEATER AND COOL- ING UNIT ASSEMBLY" Remove the steering member from the front heater and cooling unit assembly. Disconnect the intake door motor electrical connector.

  • Page 133: Mode Door Motor

    Intake sensor REMOVAL Remove the instrument lower panel RH and glove box. Refer to IP-13, "Instrument Lower Panel RH and Glove Box" Remove the center console trim panel. Refer to IP-10, "Removal and Installation" MTC-133 Revision: January 2005 2004 Quest...

  • Page 134: Installation

    MODE DOOR MOTOR Disconnect the mode door motor electrical connector. Remove the three screws and remove the mode door motor. LJIA0083E INSTALLATION Installation is in the reverse order of removal. MTC-134 Revision: January 2005 2004 Quest...

  • Page 135: Air Mix Door Motor

    Removal and Installation EJS001TZ AIR MIX DOOR MOTOR (FRONT) Remove the lower driver instrument panel. Refer to IP-12, "Instrument Lower Panel LH" Remove the center console trim panel. Refer to IP-10, "Removal and Installation" MTC-135 Revision: January 2005 2004 Quest...

  • Page 136: Air Mix Door Motor (Rear)

    EI-32, "RIGHT SIDE AND REAR" Disconnect the rear air mix door motor electrical connector. Remove the three screws and remove the rear air mix door motor. Installation is in the reverse order of removal. LJIA0021E MTC-136 Revision: January 2005 2004 Quest...

  • Page 137: Front Blower Motor Resistor

    Remove the center console trim panel. Refer to IP-10, "Removal and Installation" Disconnect the front blower motor resistor electrical connector. Remove the two screws and remove the front blower motor resistor. INSTALLATION Installation is in the reverse order of removal. MTC-137 Revision: January 2005 2004 Quest...

  • Page 138: Rear Blower Motor Resistor

    Remove the rear lower finisher assembly RH. Refer to EI-32, "RIGHT SIDE AND REAR" Disconnect the rear blower motor resistor electrical connector. Remove the two screws and remove the rear blower motor resistor. INSTALLATION Installation is in the reverse order of removal. MTC-138 Revision: January 2005 2004 Quest...

  • Page 139: Ducts And Grilles

    DUCTS AND GRILLES DUCTS AND GRILLES PFP:27860 Components EJS001U7 Ducts - Front Heater and Cooling Unit Assembly LJIA0085E MTC-139 Revision: January 2005 2004 Quest...
  • Page 140 Front heater and cooling unit assembly 10. Floor connector duct 11. Floor distribution duct 12. Floor duct Ducts - Rear Heater and Cooling Unit Assembly LJIA0086E Rear overhead duct Rear floor duct Rear heater and cooling unit assembly Clips MTC-140 Revision: January 2005 2004 Quest...
  • Page 141 DUCTS AND GRILLES Grilles LJIA0087E Overhead console Overhead console front grilles Overhead console rear grilles LH side demister grille LH ventilator grille Center ventilator grille MTC-141 Revision: January 2005 2004 Quest...

  • Page 142: Removal And Installation

    10. Cluster lid C Removal and Installation EJS001TF DEFROSTER NOZZLE Remove the front heater and cooling unit assembly. Refer to MTC-123, "FRONT HEATER AND COOL- ING UNIT ASSEMBLY" Remove the defroster nozzle. Installation is in the reverse order of removal. FRESH AIR DUCT Remove the front heater and cooling unit assembly.

  • Page 143: Grilles

    Remove the interior trim panel as necessary that contains the grille to be removed. Refer to EI-30, "BODY SIDE TRIM" EI-36, "HEADLINING" Remove the grille from the interior trim panel. Installation is in the reverse order of removal. MTC-143 Revision: January 2005 2004 Quest...

  • Page 144: Refrigerant Lines

    Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. Evacuating System and Charging Refrigerant WJIA0375E Shut-off valve A/C service valve Recovery/recycling equipment Refrigerant container (HFC-134a) Weight scale (J-39650) Evacuating vacuum pump (J-39699) Manifold gauge set (J-39183) MTC-144 Revision: January 2005 2004 Quest...
  • Page 145 REFRIGERANT LINES WJIA0530E MTC-22, "CHECKING AND MTC-159, "Checking for Refrigerant MTC-5, "Contaminated Refrigerant". ADJUSTING" Leaks". MTC-159, "Checking for Refrigerant MTC-101, "PERFORMANCE TEST Leaks". DIAGNOSES". MTC-145 Revision: January 2005 2004 Quest...

  • Page 146: Components

    REFRIGERANT LINES Components EJS001TH Front A/C Compressor and Condenser WJIA0370E MTC-146 Revision: January 2005 2004 Quest...
  • Page 147 Low-pressure flexible hose High-pressure flexible hose Shaft seal Condenser Liquid tank 10. Pressure relief valve 11. Compressor 12. Expansion valve (front) 13. High/low pressure pipe Rear A/C LJIA0016E NOTE: Refer to MTC-7, "Precautions for Refrigerant Connection" MTC-147 Revision: January 2005 2004 Quest...

  • Page 148: Removal And Installation For Compressor

    Compressor Mounting WJIA0371E Stud Compressor REMOVAL Discharge the refrigerant. Refer to MTC-144, "HFC-134a (R-134a) Service Procedure" Remove the drive belt. Refer to MA-12, "Drive Belts" Remove the coolant pipe bracket bolt. Remove the compressor mounting stud. Disconnect the compressor connector.

  • Page 149: Removal And Installation For Compressor Clutch

    Snap ring Thermal protector (built in) Compressor REMOVAL Remove the A/C compressor. Refer to MTC-148, "Removal and Installation for Compressor" Remove the center bolt while holding the clutch disc stationary using Tool as shown. Tool number : J-44614 Remove the clutch disc.

  • Page 150: Inspection

    Coil Check magnet coil for loose connections or any cracked insulation. INSTALLATION Install the magnet coil. CAUTION: Be sure to align the magnet coil pin with the hole in the compressor front head. WHA213 MTC-150 Revision: January 2005 2004 Quest...
  • Page 151 Press the clutch disc down by hand. WHA184 Install the clutch pulley bolt using Tool, to prevent the clutch disc from turning and tighten the bolt to specification. Refer to MTC- 146, "Components" Tool number : J-44614 CAUTION: After tightening the clutch pulley bolt, check that the clutch pulley rotates smoothly.

  • Page 152: Break-In Operation

    EJS001TK REMOVAL Discharge the refrigerant. Refer to MTC-144, "HFC-134a (R-134a) Service Procedure" CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove the low-pressure flexible hose. Refer to MTC-146, "Components"...

  • Page 153: Removal And Installation For High-Pressure Pipe

    Remove the windshield washer fluid bottle filler neck. Reposition the coolant reservoir tank aside. Reposition the power steering fluid reservoir aside. Discharge the refrigerant. Refer to MTC-144, "HFC-134a (R-134a) Service Procedure" Remove the high-pressure pipe. Refer to MTC-146, "Components" CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air.

  • Page 154: Removal And Installation For Condenser

    REFRIGERANT LINES Removal and Installation for Condenser EJS001TP REMOVAL Discharge the refrigerant. Refer to MTC-144, "HFC-134a (R-134a) Service Procedure" Remove the radiator. Refer to CO-11, "RADIATOR" CAUTION: Be careful not to damage the core surface of the condenser and the radiator.

  • Page 155: Removal And Installation For Front Evaporator

    Blower motor case Heater core and evaporator case REMOVAL Remove the front heater and cooling unit assembly. Refer to MTC-123, "FRONT HEATER AND COOL- ING UNIT ASSEMBLY" Remove the blower motor side cover. Remove the front blower motor. Remove the heater core and evaporator case bottom cover.

  • Page 156: Installation

    Replace the O-rings on the low-pressure flexible hose and the high-pressure pipe with new ones. Apply compressor oil to the O-rings before installing them. When installing the in-cabin microfilters, face the microfilters according to the air flow direction arrow printed on the side of the filters. MTC-156 Revision: January 2005 2004 Quest...

  • Page 157: Removal And Installation For Rear Evaporator

    Blower motor case Rear blower motor resistor REMOVAL Remove the rear heater and cooling unit assembly from the vehicle. Refer to MTC-124, "REAR HEATER AND COOLING UNIT ASSEMBLY" Remove the rear blower motor. Remove the rear blower motor resistor. MTC-157...

  • Page 158: Installation

    Removal and Installation for Front Expansion Valve EJS001UE REMOVAL Discharge the refrigerant. Refer to MTC-144, "HFC-134a (R-134a) Service Procedure" Remove the front heater and cooling unit assembly. Refer to MTC-123, "FRONT HEATER AND COOL- ING UNIT ASSEMBLY" Remove the cooler grommet.

  • Page 159: Checking For Refrigerant Leaks

    : 4 N·m (0.4 kg-m, 35 in-lb) A/C refrigerant pipe to expansion valve bolt : Refer to MTC-146, "Components" CAUTION: Replace the O-rings on the A/C refrigerant pipes with new ones, then apply compressor oil to them when installing them.

  • Page 160: Electronic Refrigerant Leak Detector

    SHA196FA Position the probe approximately 5 mm (3/16 in) away from the point to be checked as shown. SHA707EA When checking for leaks, circle each fitting completely with the probe as shown. SHA706E MTC-160 Revision: January 2005 2004 Quest...

  • Page 161: Checking Procedure

    16 C (61 F). If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. Refer to MTC-144, "HFC-134a (R-134a) Service Procedure" NOTE: At temperatures below 16 C (61 F), leaks may not be detected since the system may not reach 345 kPa (3.52 kg/cm...

  • Page 162: Revision: January

    16. Evacuate and recharge the A/C system and perform the leak test to confirm that there are no refrigerant leaks. 17. Conduct the Operational Check to ensure system works properly. Refer to MTC-52, "Operational Check" MTC-162 Revision: January 2005 2004 Quest...

  • Page 163: Service Data And Specifications (Sds)

    Part number KLH00-PAGS0 Total in system 220 (7.44, 7.7) Capacity (US fl oz, lmp fl oz) Compressor (service part) charging amount Refer to MTC-22, "CHECKING AND ADJUSTING" REFRIGERANT Type HFC-134a (R-134a) Capacity 50 (1.98 0.11) g (lb) ENGINE IDLING SPEED Refer to EC-35, "Idle Speed and Ignition Timing Check"...
  • Page 164 SERVICE DATA AND SPECIFICATIONS (SDS) MTC-164 Revision: January 2005 2004 Quest...

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