Haima S5 User manual

Table of Contents

Volume III A/C, Restraint System, Body

Accessories and Electrical System

Chapter 16 A/C System ························································································· 3A-1

Chapter 17 Airbags and Restraint System···································································· 3B-1

Chapter 18 Body and Accessories············································································· 3C-1

Chapter 19 Electrical System ·················································································· 3D-1

A/C System3A-1

Chapter 16 A/C System

Table of Contents

Fault Diagnosis ·································································································· 3A-2

Introduction ······································································································ 3A-2

Fault Diagnosis Index ·························································································· 3A-2

Fault Symptom Diagnosis······················································································ 3A-3

Maintenance Warning and Instruction········································································ 3A-17

Treatment of the refrigerant···················································································· 3A-17

Storage of the refrigerant······················································································· 3A-17

Treatment of the compressor oil··············································································· 3A-17

Maintenance Procedures for Refrigeration System························································· 3A-17

Installing the manifold gauge·················································································· 3A-17

Recovering the refrigerant ····················································································· 3A-18

Refrigerant filling ······························································································· 3A-18

Adding the refrigerant ·························································································· 3A-20

Recovering the used R134a refrigerant ······································································ 3A-20

Adding fresh R134a refrigerant ··············································································· 3A-20

Checking the refrigerant························································································ 3A-20

Refrigeration System Performance Test······································································ 3A-20

Basic System····································································································· 3A-23

Structure View ··································································································· 3A-23

Removal/Installation of HVAC Assembly ··································································· 3A-23

Disassembly/Assembly of HVAC············································································· 3A-24

Removal/Installation of Air Flow Mode Main Linkage ··················································· 3A-25

Installation Instruction for Air Flow Mode Main Linkage ················································ 3A-25

Removal/Installation of A/C Compressor···································································· 3A-25

Removal/Installation of Condenser ··········································································· 3A-26

Checking the Condenser ······················································································· 3A-26

Removal/Installation of Refrigeration Pipeline ····························································· 3A-27

Removal/Installation of Blower Motor······································································· 3A-27

Removal/Installation of Resistor·············································································· 3A-27

Removal/Installation of Ambient Temperature Sensor····················································· 3A-28

Checking the Ambient Temperature Sensor ································································· 3A-28

Removal/Installation of Interior Temperature Sensor ······················································ 3A-28

Removal/Installation of A/C Controller······································································ 3A-29

A/C System3A-2

Fault Diagnosis

Introduction

 Refer to the Section Gl, read and comprehend

the basic flow of fault diagnosis and conduct

each step correctly.

 When performing the fault diagnosis marked

with (★), please shake the harness and the

connector to check the connector pin for poor

contact that causes the intermittent failure.

If it is poorly contacted, please check to

confirm each connector, wire and wiring

harness are correctly connected without any

damage.

 The inspection (steps) parts are illustrated

according to different line faults. Determine

the fault symptom based on the following

table and then troubleshoot the corresponding

parts.

Fault Diagnosis Index

SN. Fault Symptom

1 Insufficient or no air intake based on the air flow mode

2

No air intake in each different air flow mode

No change of the air inflow after the fan speed is changed

3 No change of the air flow mode

4 Abnormal/no air circulation

5 The exhaust gas temperature does not change.

6 Blowers malfunction

7 Electromagnetic clutch is not engaged.

8 Inadequate refrigeration.

9 No cool air out

10 Inadequate heating.

11 There is noise under A/C operation.

A/C System3A-3

Fault Symptom Diagnosis

1 Insufficient or no air intake based on the air flow mode

Fault Diagnosis Hint:

① Blowing face mode system fault:

Step 1-4

② Blowing foot mode system fault:

Step 5

③ DEFROSTER mode system fault:

Step 6-8

Step Inspection Operation

Yes Go to the next step.

1

Is there any normal

resistance can be felt when

operating the air flow mode

control knob?

Is it able to be operated to

each position?

No

Conduct the steps listed under the No.3 Fault Diagnosis

Index.

Yes Go to the step 5.

2

Can the air be vented under

the VENT mode?

No Go to the next step.

Yes Remove the obstruction and go to the step 9.

3 Is the air vent blocked?

No Go to the next step.

Yes

Check the pipeline for any blockage, distortion or leakage

and then go to the step 9.

4

Is the vent pipeline on the

instrument panel is properly

installed?

No

Install the pipeline securely in place and then go to the step

9.

Yes Go to the next step.

5

Can the air be vented under

the HEAT mode?

No

Check the air vent for any blockage and then go to the step

9.

Yes It operates normally, so recheck the fault symptom.

6

Can the air be vented under

the DEFROSTER mode?

No Go to the next step.

Yes Remove the obstruction and then go to the step 9.

7 Is the air vent blocked?

No Go to the next step.

Yes

Check the pipeline for any blockage, distortion or leakage

and then go to the next step.

8

Is the defroster pipeline is

properly installed?

No

Install the pipeline securely in place and then go to the next

step.

Yes

End the fault diagnosis and explain the repair details to the

customer.

9 Can the air be vented?

No

If the fault reoccurs, recheck the fault symptom and start

from the step 1.

A/C System3A-4

2

No air intake in each different air flow mode

No change of the air inflow after the fan speed is changed

Fault Diagnosis Hint:

① Fault of the blower relay, the blower motor, the resistance or the fan switch

Step 1

② Fault of the blower unit

Step 2-4

Step Inspection Operation

Yes Go to the next step.

1

Check the following systems and

electrical parts:

blower relay, blower motor, resistance,

electronic fan switch.

Are they normal?

No

Repair or replace the faulty parts and then go

to the step 5.

Yes Go to the step 4.

2

Turn the ignition switch to ON position

Turn on the fan switch to enable the

interior air circulation

Is the fan of the blower unit rotating

smoothly?

No Go to the next step.

Yes Go to the next step.

3

Check whether the fan of the blower unit

is normal?

Is the fan interfering with the fan frame?

Are there any foreign matters or obstacles

in the fan?

No

Remove the foreign matters, repair or replace

the fan and the fan frame, and then go to the

step 5.

Yes Remove the obstacles and go to the next step.

4

Is the air inlet/vent of the blower unit

blocked?

No

Check the passage between the blower unit

and the heater unit for any blockage and then

go to the next step.

Yes

End the fault diagnosis and explain the repair

details to the customer.

5 Can the air be vented?

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

3 No change of the air flow mode

Fault Diagnosis Hint:

1) Fault of the air flow mode linkage, crank, rod, cable and cable clip.

Step 1, 2

2) Fault of the climate control unit gear rack and the air flow mode cable.

Step 3

3) Fault of one or more heater unit openings.

Step 4,5

Step Inspection Operation

Yes Go to the next step.

1

Check the air flow mode linkage, crank, rod

and cable clip.

Are the linkage and the crank lubricated?

Are all the linkage, crank and rod installed in

place?

Is the cable clip distorted?

No

Apply the grease or install the linkage,

crank and rod securely in place; repair

or replace the cable clip and then go to

the step 6.

A/C System3A-5

Are the above items normal?

Yes Go to the next step.

2

Is the air flow mode cable securely fixed?

Does it match correctly with the air flow mode

linkage of the heater unit?

No

Adjust the air flow model cable or

install it correctly, and then go to the

step .6.

Yes

Remove the obstruction and then go to

the step 9.

3

Check the climate control unit.

Is the gear rack engaged normally?

Is the air flow mode cable correctly installed

on the gear rack?

Are the above items normal?

No Go to the next step.

Yes

Remove the obstacles and then go to

the step 6.

4

Are there any obstacles at each opening of the

heater unit?

No Go to the next step.

Yes

Check each opening for any crack or

damage and then go to the next step.

5

Are all the openings of the heater unit correctl

y

and securely installed?

No

Install the openings securely in place

and then go to the next step.

Yes

End the fault diagnosis and explain the

repair details to the customer.

6 Does the air flow mode change?

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

4 Abnormal/no air circulation

Fault Diagnosis Hint:

① Fault of the blower unit intake linkage, crank, cable and cable clip

Step 1、2

② Fault of the intake cable of the climate control unit

Step 3

③ Fault of the blower unit air inlet

Step 4、5

Step Inspection Operation

Yes Go to the next step.

1

Check the blower unit intake linkage, intake

crank and cable clip.

Are the linkage and the crank lubricated?

Are the linkage and the crank correctly and

securely installed?

Is the cable clip distorted?

Are the above items normal?

No

Apply the grease or install the linkage

and crank correctly and securely in place,

or replace the cable clip, and then go to

the step 6.

Yes Go to the next step.

2

Check the internal and external circulation

motor drive harness is correctly plugged into

the drive motor?

No

Inside and outside the loop stepper motor

driver adjust the harness to ensure proper

connection with the stepper motor, and

then go to the step .6.

Yes Go to the next step.

3

Air conditioning inside and outside the loop

button on the manipulator is damaged?

No

Replace the controller assembly, and then

go to the step 6.

Yes

Remove the obstacles, and then go to the

step 6.

4

Are there any obstacles at the air inlet of the

blower unit?

No Go to the next step.

A/C System3A-6

Yes

Check the air inlet for any crack or

damage and then go to the next step.

5

Is the air inlet of the blower unit correctly an

d

securely installed?

No

Install the air inlet securely in place and

then go to the next step.

Yes

End the fault diagnosis and explain the

repair details to the customer.

6 Is there any air circulation?

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

5 The exhaust gas temperature does not change.

Fault Diagnosis Hint:

1) Fault of the air mixing linkage, crank, pull rod, cold and warm the stepper motor of the heater

unit

Step 2、3

2) Cold and warm air-conditioning knob actuator failure.

Step 4

3) HVAC air mix door catching.

Step 5、6

Step Inspection Operation

Yes Go to the next step.

1 Is the coolant preheated?

No

Preheat the engine and then go to the

step 7.

Yes Go to the next step.

2

Check the air mixing linkage, crank, pull

rod and cold and warm the stepper motor

of the heater unit.

Are the linkage and the crank lubricated?

Are the linkage, crank and pull rod

securely installed in place?

Whether Cold and warm the stepper motor

damage?

Are the above items normal?

No

Apply the grease or install the linkage,

crank and pull rod correctly and

securely in place, or replace the the

stepper motor, and then go to the step

6.

Yes

Adjust air mix motor drive harness to

ensure proper connection with the

drive motor,and then go to the step 7.

3

Air mix motor drive harness is correctly

plugged into the drive motor?

No Go to the next step.

Yes

Replace the air conditioning

manipulators, and then go to the step 7.

4

Check the climate control unit.

Cold and warm air conditioning knobs

manipulator is damaged?

No Go to the next step.

Yes

Repair or replace the HVAC air mixing

damper, and then go to the step 7.

5

Whether HVAC air mixing damper

catching?

No Go to the next step.

Yes

Check the air mixing port for any crack

or damage and then go to the next step.

6

Is the air mixing port of the heater unit

correctly and securely installed?

No

Install the air mixing port correctly and

securely in place and then go to the

next step.

Yes

End the fault diagnosis and explain the

repair details to the customer.

7

Does it operate normally at each

temperature setting?

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

A/C System3A-7

6 Blowers malfunction

Fault Diagnosis Hint:

1. Blower motor wiring fault. Step 1.2.3.4.5

2. Fan speed control module failure. Step 6.7.8

3. Speed control knob switch failure. Step 9

4. blower motor failure. Step 10

Step Inspection Operation

Yes Go to the next step.

1

Check the blower motor power supply is

normal?

No Go to the step 3.

Yes Go to the next step.

2

Check the blower motor ground circuit is

normal?

No Go to the step 10.

Yes Go to the next step.

3

Check the blower relay power supply

voltage is normal?

No

Check the power supply circuit,

troubleshooting,go to the step 11.

Yes Go to the next step.

4 Check the blower relay is normal?

No

Replace the blower relay, go to the step

11

Yes Go to the next step.

5 Check the fuse is normal?

No Replace the fuse, go to the step 11

Yes Go to the next step.

6

Check the circuit between the blower fan

speed control module is turned on?

No

Replace the blower fan speed control

module, go to the step 11

Yes Go to the next step.

7

Check the circuit between the blower

motor and fan speed control module is

continuity?

No

Repair harness or connector, go to the

step 11

Yes Go to the next step.

8

Check the circuit between the blower

motor and fan speed control module is

continuity?

No

Repair harness or connector, go to the

step 11

Yes Go to the next step.

9

Check the speed control knob switch is

normal?

No

Repair grounding switch harness

connector or replace the air

conditioning manipulators, go to the

step 11

Yes Go to the next step.

10 Check that the blower motor normal?

No

Remove the blower motor, blower

motor, smooth rotation is determined,

go to the next step.

Yes

Troubleshooting end, explain to the

customer repair the situation.

11

Open the blower speed control knob, a

normal amount of wind, and the wind

speed can be adjusted.

No

If obstacles happen again, to re-

examine the failure symptoms, and

then start from step 1.

7 Electromagnetic clutch can not be combined

Fault Diagnosis Hint:

1. Compressor wiring fault. Step 1 . 3

A/C System3A-8

2. Failure of the compressor itself. Step 2

3. Fuse failure. Step 3

4. Compressor input signal failure. Step 4.5.6.7

5. Cooling fan failure. Step 8

Step Inspection Operation

Yes Go to the next step.

1

Check the power of the electromagnetic

clutch is normal?

No Go to the step 4

Yes Go to the next step.

2

Check the electromagnetic clutch circuit is

normal?

No

Replace the compressor, go to the step

9

Yes Go to the next step.

3 Check the fuse is normal?

No Replace the fuse, go to the step 9

Yes Go to the next step.

4 Check the ECU input signal is normal?

No

Repair or replace the faulty parts, go to

the step 9

Yes Go to the next step.

5

Check the refrigerant pressure sensor is

normal?

No

Repair or replace the pressure sensor,

go to the step 9.

Yes Go to the next step.

6

Circuit continuity check A / C button.

No

Repair harness or replace air

conditioning controller,go to the step 9.

Yes Go to the next step.

7

Check the speed control knob circuit

continuity.

No

Repair harness or replace air

conditioning controller,go to the step 9.

Yes Go to the next step.

8

Check that the cooling fan can work

properly.

No

Repair or replace the cooling fan, go to

the next step.

Yes

Troubleshooting end, explain to the

customer repair the situation.

9

Ignition, press the A / C switch, confirm

whether the normal electromagnetic clutch

combination?

No

If obstacles happen again, to re-

examine the failure symptoms, and

then start from step 1.

8 Inadequate refrigeration.

Fault Diagnosis Hint:

1. Fault of the drive belt

Step 2

2. Fault of the blower unit or condenser

Step 4-5

3. Fault of the receiver/dryer or expansion valve

Step 8-9

4. Fault of the refrigeration pipeline

Step 10-11

5. Fault of the A/C compressor system or insufficient compressor oil

Step 15,-16

6. Too much compressor oil or the fault of expansion valve or heater unit linkage or air mixing

linkage

Step 17-19

A/C System3A-9

Step Inspection Operation

Yes

It operates normally (recheck the fault

symptom)

1

Perform the refrigeration system

performance test.

Refer to the maintenance procedures of the

refrigeration system to perform the

performance test.

Does it operate normally?

No Go to the next step.

Yes Go to the next step.

2

Is the drive belt normal?

Refer to Checking the Drive Belt, Drive

Belt, Section B.

No

Adjust or replace the drive belt and

then go to the step 20.

Refer to Adjusting the Drive Belt,

Drive Belt, Section B.

Yes Go to the next step.

3

Check the refrigerant pressure at the

high/low pressure end. Is the pressure

within the limit?

No Go to the step 6.

Yes

Remove the obstruction and then go to

the step 20.

(In the evaporator unit, if the air does

not arrive at the evaporator, the heat

exchange cannot generate and the

refrigerant pressure shall rise;

therefore, the obstruction should be

removed timely)

4 Is the blower air inlet blocked?

No Go to the next step.

Yes

Adjust the refrigerant to the specified

volume and then go to the step 20.

(excessive refrigerant)

5

Does the condenser operate normally?

Refer to Checking the Condenser, Basic

System.

No

Replace the condenser or repair and

clean the condenser cooling fin, and

then go to the step 20.

Yes Go to the next step.

6

Is the refrigerant pressure both at the high

end and low end below the standard?

No Go to the step 14.

Yes Go to the next step.

7

When the A/C compressor is turned on,

can the pressure at the high end increase

immediately to the specified value and

then decrease and become stable? (Is there

any negative pressure at the low pressure

end?)

No Go to the step 10.

Yes Go to the next step.

8

Turn off the A/C switch to stop the A/C for

10min.

Start the engine.

Turn on both the A/C switch and the fan

switch.

Is there still fault when the A/C

compressor is turned on?

No

Replace the receiver/dryer and then go

to the step 20.

(It is necessary to replace it because

there is water mixed into the

receiver/dryer.)

Yes

Replace the expansion valve and then

go to the step 20. (The replacement is

necessary, because the valve is closed

too much)

9

Is thermal sensing tube of the expansion

valve in the evaporator unit installed

correctly and securely?

No

Install thermal sensing tube of the

expansion valve in the evaporator unit

correctly and securely and then go to

the step 20.

A/C System3A-10

Yes Go to the next step.

10

Check the refrigeration pipeline.

Is the conduit damaged or fissured?

Is there any greasy dirt on the conduit

connector? (By visual inspection)

Is there any leakage on the conduit

connector?

Is there any leakage at the connection pipe

of the condenser?

Is there any leakage at the connection pipe

of the receiver/dryer?

Is there any leakage at the connection pipe

of the A/C compressor?

Is there any leakage at the connection pipe

of the evaporator unit?

Perform the air leak detection by using the

air leak detector.

Are the above items normal?

No

If the conduit or A/C parts are

damaged or fissured, replace them and

then go to the step 20; if not, go to the

step 13.

Yes

Adjust the compressor oil and the

refrigerant to the specified volume and

then go to the step 20.

11

Is there any leakage at the connections of

the pipeline of the evaporator unit?

No

If the pipeline is damaged or fissured,

replace it, and then go to the step 20; if

not, go to the next step.

Yes

Tighten the connector to the specified

torque, adjust the compressor oil and

the refrigerant to the specified volume

and then go to the step 20.

12

Does the pipeline connector of the

evaporator core in the evaporator unit

become loose?

No

Replace the O-ring on the conduit,

adjust the compressor oil and the

refrigerant to the specified volume and

then go to the step 20.

Yes

Tighten the connector to the specified

torque, adjust the compressor oil and

the refrigerant to the specified volume

and then go to the step 20.

13 Does the conduit connector become loose?

No

Replace the O-ring on the conduit,

adjust the compressor oil and the

refrigerant to the specified volume and

then go to the step 20.

Yes

Go to the next step (if nearly no

increase of pressure)

14

Is there nearly no increase of pressure at

the high pressure end of the A/C

refrigeration system?

No Go to the step 17

Yes Go back to the step 3.

15

Is there any increase of pressure at the high

pressure end under the high speed

operation of the engine?

No Go to the next step.

Yes

End the fault diagnosis and explain to

the customer that the fault is caused by

insufficient compressor oil.

16

Is there any increase of pressure at the high

pressure end when the compressor oil is

added to the specified volume?

No

Replace the A/C compressor and then

go to the step 20 (A/C compressor

fault)

Yes Go to the step 19.

17

Is the refrigerant pressure relatively high

only at the low pressure end?

No Go to the next step.

18

Are the air mixing linkage, crank and pull

rod of the heater control unit installed Yes Adjust the compressor oil to the

specified volume and then go to the

A/C System3A-11

step 20. (A/C compressor oil volume

exceeds the specified)

correctly?

No

Repair or install the linkage, crank and

pull rod and then go to the step 20.

Yes

Repair the expansion valve and then go

to the next step. (The replacement is

necessary, because the expansion valve

is opened too much)

19

Is thermal sensing tube of the expansion

valve in the evaporator unit installed

correctly and securely?

No

Install thermal sensing tube securely

and then go to the next step.

Yes

End the fault diagnosis and explain the

repair details to the customer.

20

Can the cool air be vented?

(Is the result of the refrigeration system

performance test normal?)

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

9 No cool air out

Fault Diagnosis Hint:

① Fault of the A/C switch indicator lamp Step 3-5

② Fault of PCM A/C turn-off control system and the cooling system

Step 6, 22

③ Fault of the A/C amplifier, A/C switch, potentiometer

Step 8-14

④ PCM(A/C signal) system fault

Step 15,16

⑤ Fault of the refrigerant pressure switch and the cooling system

Step 17-19

⑥ PCM (IG1 signal) system fault

Step 20,21

⑦ Compressor system fault

Step 23,24

⑧ A/C relay system fault

Step 25-27

Step Inspection Operation

Yes Go to the next step.

1 Can the cool air vented?

No

Conduct the step 1 listed in the Fault

Diagnosis Index 1 and 2.

Yes

Conduct the step 1 listed in the Fault

Diagnosis Index 6.

2

Start the engine.

Turn on both the A/C switch and the fan

switch simultaneously.

Does the A/C compressor operate normally?

No Go to the next step.

Yes Go to the step 6.

3

Does the A/C switch indicator lamp come

on?

No Go to the next step.

Yes Go to the next step.

*4

Turn the ignition switch to the ON position.

Test the voltage (IG2) signal of the Pin C of

the A/C switch.

Is the voltage about 12V?

No

Repair the harness between the fuse

box and the A/C switch and then go to

the step 28.

*5

Turn on both the A/C switch and the fan

switch simultaneously.

Yes

Check the A/C switch and then go to

the step 28.

A/C System3A-12

Test the voltage (A/C signal) of the Pin A of

the A/C switch.

Is the voltage about 12V?

No

Repair the harness between the A/C

switch box and the fan switch and then

go to the step 28.

Yes Go to the step 15

*7

Turn the ignition switch to the LOCK

position.

Disconnect the refrigerant pressure switch.

Turn the ignition switch to the ON position.

Set the fan speed at the position 1.

Test the refrigerant pressure switch

connector (at the wiring harness side)

The voltage of the following pin:

·Pin A (A/C signal)

Is the voltage about 12V when the A/C

switch is turned off? Is the voltage is 0V

when the A/C switch is turned on?

No

Connect the refrigerant pressure switch

connector and then go to the next step.

Yes

Stop the short circuit and then go the

next step.

*8

Turn the ignition switch to the LOCK

position.

Disconnect the A/C amplifier connector.

Start the engine

Turn on both the A/C switch and the fan

switch simultaneously.

Is there any cool air vented out when the Pin

B and C of the A/C amplifier connector is

short circuited?

No

Stop the short circuit and then go to the

step 13.

Yes Go to the next step.

*9

Turn the ignition switch to the ON position.

Test if the voltage of the Pin C (IG2 signal)

of the A/C amplifier connector is about

12V.

No

Repair the harness between the fuse

box and the A/C amplifier and then go

to the step 28.

Yes

Repair the harness between the

refrigerant pressure switch box and the

A/C amplifier and then go to the step

28.

*10

Test if the voltage of the Pin B (A/C signal)

of the A/C amplifier connector is about

12V.

No Go to the next step.

Yes Go to the next step.

11

Is the potentiometer normal?

Refer to Checking the Potentiometer,

Control System.

No

Replace the potentiometer and then go

to the step 28.

Yes

Repair the harness between the A/C

amplifier and the potentiometer and

then go to the step 28.

12

Is the amplifier normal?

Refer to Checking the A/C Amplifier,

Control System.

No

Replace the A/C amplifier and then go

to the step 28.

Yes Go to the next step.

*13

Turn the ignition switch to the LOCK

position.

Check the continuity between the Pin B

(A/C signal) of the A/C amplifier connector

and the following refrigerant pressure

switch connector pin (A/C signal).

Are they in continuity?

No

Repair the wiring harness between the

refrigerant pressure switch box and the

A/C amplifier and then go to the step

28.

Yes

Check the wiring harness between the

A/C amplifier and the A/C breaker and

then go to the step 28.

*14

Turn the ignition switch to the ON position.

Turn on the A/C switch。

Turn off the fan switch.

Is the Pin B (A/C signal) of the A/C switch

connector about 12V?

No

Check the A/C switch and then go to

the step 28.

*15 Is the voltage of the Pin B (A/C signal) of

Yes Go to the step 17

A/C System3A-13

the refrigerant pressure switch connector

about 12V?

No Go to the next step.

Yes

Repair the wiring harness between the

PCM and the refrigerant pressure

switch and then go to the step 28.

*16

Is the voltage of the Pin 1P (A/C signal) of

the PCM connector (22-core) about 12V?

No

Check the PCM and then go to the step

28.

Yes Go to the next step.

17

Is there any cool air out when the following

pins of the refrigerant pressure switch

connector are short circuited?

Pins A-B (A/C signal)

No

Stop the short circuit and reconnect the

refrigerant pressure switch connector,

and then go to the step 20.

Yes

Stop the short circuit and reconnect the

refrigerant pressure switch connector,

and then go to the step 20.

18

Is the refrigerant pressure normal?

Refer to Checking the Refrigerant Filling,

Refrigeration System Maintenance

Procedure.

No Go to the next step.

Yes

Check the refrigerant pressure switch

and then go to the step 28.

19

Is the refrigerant metering normal?

Refer to Checking the Refrigerant Filling,

Refrigeration System Maintenance

Procedure.

No

Adjust the refrigerant to the specified

value and then go to the step 28.

Yes

Stop the short circuit and then go the

next step.

*20

Does the electromagnetic clutch operate

when the Pin B (IG1 signal) of the A/C

relay connector is grounded?

No Go to the step 22

Yes Go to the next step.

*21

Turn off the A/C switch.

Is the voltage of the Pin 1S (IG1) of the

PCM connector (22-core) about 12V?

No

Repair the wiring harness between A/C

relay and the PCM and then go to the

step 28.

Yes

Check the operation of the refrigerant

system. Refer to Checking the Control

of the CONDENSER fan, Cooling Fan

Control, System Inspection, Section F.

*22

Check the following input signal

components:

engine coolant temperature sensor,

transmission gear switch, neutral switch,

power steering switch, crank angle position

sensor, accelerator pedal position sensor and

PCM wiring harness (A/C – cutoff control)

Are they normal?

No

Replace the input signal components

and then go to the step 28.

Yes Go to the next step.

*23

Is the voltage of the Pin A (A/C control

signal) of the electromagnetic clutch

thermal protector about 12V?

No Go to the step 25

Yes

Replace thermal protector and then go

to the step 28.

*24

Is the electromagnetic clutch normal?

Refer to Checking the Electromagnetic

Clutch, Control System.

No

Replace the electromagnetic clutch coil

and then go to the step 28.

Yes Go to the next step.

*25 Is the A/C relay power fuse normal?

No

Check whether the circuit with a blown

fuse is short circuited to the ground.

Repair or replace accordingly. Install a

fuse of the appropriate rating.

Yes Go to the next step.

*26

Turn the ignition switch to the ON position.

Is the voltage of the following pins of the

A/C relay unit about 12V?

Pin A (IG1 signal)

Pin C (A/C control signal)

No

Repair the harness between the A/C

relay and the fuse box and then go to

the step 28.

*27

Is the voltage of the Pin D (A/C control

signal) of the A/C relay unit about 12V? Yes Repair the harness between the A/C

relay and thermal protector and then go

A/C System3A-14

to the next step.

No

Check the A/C relay and then go to the

next step.

Yes

End the fault diagnosis and explain the

repair details to the customer.

*28

Is there any cool air out? (Is the result of the

refrigeration system performance test

normal?)

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

10

Inadequate heating

Fault Diagnosis Hint:

1. Cold and warm mixing damper failure. Step 4

2. Duct leakage failure. Step 6

Step Inspection Operation

Yes

Exclude leakage, go to the step 4

1

Check the engine coolant leaks?

No Go to the next step.

Yes Go to the next step.

2 Check the radiator tank cap is normal?

No Troubleshooting,go to the step 4

Yes Go to the next step.

3

Check the engine coolant water sound

normal?

No Troubleshooting,go to the step 4

Yes

End the fault diagnosis and explain the

repair details to the customer.

4

After the engine is warm, the temperature

control knob rotation Xeon hot location,

check the warm air flow from the outlet?

No Go to the next step.

Yes Go to the next step.

5

Check the mix door motor and wiring

normal?

No

Adjust or replace the door motor, repair

wiring harness,go to the step 4.

Yes Go to the next step.

6

Check the air conditioning system and the

outlet duct leaks?

No Troubleshooting,go to the step 4

Yes

Reinstall the warm water pipes to be

installed smoothly, go to the step 4

7

Visually inspect the condition of the warm

water pipe installation, Whether twisted,

crushed, etc.?

No Go to the next step.

Yes Go to the next step.

8

Check the heater inlet and outlet

temperature is normal?

No

Check the cooling system again, after

performing the procedure to replace the

heater core.

Yes

End the fault diagnosis and explain the

repair details to the customer.

9

Replace the heater core, check the fault

disappears.

No

If obstacles happen again, to re-

examine the failure symptoms, and

then start from step 1.

11 There is noise under A/C operation.

Fault Diagnosis Hint:

1. Operating noise of the electromagnetic clutch

Step 4

2. Noise from the A/C compressor blades

A/C System3A-15

Step 5-13

3. Noise from the A/C compressor slipping

Step 14-17

4. Interference noise of the hose or refrigeration pipeline

Step 18

Step Inspection Operation

Yes Go to the step 5

1

Is there any tinkle, crackle, beep and

buzzer? (Is the noise from the A/C

compressor blades?)

No Go to the next step.

Yes Go to the step 14

2

Is there any grating and whir? (Is the noise

from the A/C compressor slipping)?

No Go to the next step.

Yes Go to the step 18

3 Is there any clash and chatter (babble)?

No Go to the next step.

Yes

Adjust the clearance between the

electromagnetic clutch pressure plate and the

compressor belt pulley and then go to the

step 19.

Refer to Adjusting the Electromagnetic

Clutch, Control System.

4

Is there any click sound? (the operating

noise of the electromagnetic clutch)

No

The condition is normal (recheck the fault

symptom)

Yes Go to the next step.

5

Does the noise last for more than 3s after

the A/C compressor is turned on?

No

The condition is normal (the noise only

occurs in 2~3s after the A/C compressor is

turned on)

Yes Go to the next step.

6

Is the idle speed normal?

·Refer to the Idle Speed Adjustment, Engine

Adjustment, Section F.

No

Adjust the idle speed and then go to the step

19.

Yes Go to the step 10

7

Is the refrigerant volume normal?

·Refer to Checking the Refrigerant Filling,

Refrigeration System Maintenance

Procedure.

No Go to the next step.

Yes Go to the next step.

8

Check the refrigerant pipeline.

Is there any damage and crack of the

pipeline?

Is there any greasy dirt at the pipeline

connection? (By visual inspection)

Is there any leakage at the pipeline

connection?

Is there any leakage at the connection pipe

of the condenser?

Is there any leakage at the connection pipe

of the receiver/dryer?

Is there any leakage at the connection pipe

of the A/C compressor?

Is there any leakage at the connection pipe

of the evaporator unit?

Perform the air leak detection by using the

air leak detector.

Are the above items normal?

No

If the pipeline or A/C parts are damaged or

fissured, replace them, and then go to the

step 19. If there is air leakage, repair or

replace the connector, replace the

receiver/dryer and then go to the step 19.

9

Is there any leakage at the connections of

the pipeline of the evaporator unit?

Yes

Adjust the refrigerant to the specified

volume and then go to the step 19.

A/C System3A-16

No

If the pipeline or A/C parts are damaged or

fissured, replace them, and then go to the

step 19. If there is air leakage, repair or

replace the connector, replace the

receiver/dryer and then go to the step 19.

Yes Go to the next step.

10

Add the 20ml{20cc.0.8fl oz} compressor

oil.

Can any noise be heard under the high

operation of the engine?

No

End the fault diagnosis and explain the

repair details to the customer.

Yes Go to the next step.

11

Drain the compressor oil.

Is there any metallic particulate pollutant?

No

Replace the A/C compressor and then go to

the step 19.

Yes

Replace the entire A/C system (except for

the heater) and then go to the step 19.

12

Is the compressor oil whitened or be mixed

with water?

No Go to the next step.

Yes

Replace the A/C compressor and the

receiver/dryer (because the A/C compressor

may be worn and the receiver/dryer may be

blocked, it is necessary to replace them) and

then go to the step 19.

13

Is there any click sound? (the operating

noise of the electromagnetic clutch)

No

The condition is normal and recheck the

fault symptom.

Yes

Replace the A/C compressor, and then go to

the step 19.(A/C compressor drain valve is

kept open)

.14

Can you hear any noise right after the A/C

compressor stops?

No Go to the next step.

Yes Go to the next step.

15

Is the drive belt normal?

Refer to Checking the Drive Belt, Drive

Belt, Section B.

No

Adjust or replace the drive belt and then go

to the step 19.

Yes

Remove the sundries and greasy dirt or

replace the drive belt, and then go to the step

19.

16

Is the drive belt worn? Is there any attached

sundries? Is there any greasy dirt?

No Go to the next step.

Yes

Replace the A/C compressor (except for the

electromagnetic clutch pressure plate, the

belt pulley and the coil) and then go to the

step 19.

17

Is the electromagnetic clutch normal?

Refer to Checking the Electromagnetic

Clutch, Control System.

No

Replace the electromagnetic clutch and then

go to the step 19.

Yes

Visually check the A/C compressor and

replace relevant parts when necessary, and

then go to the next step.

18 Is the noise from the A/C compressor?

No

If the noise is caused by the refrigerant

pipeline, repair the loosened or missed clips

and tighten the screws, and then go the next

step.

Yes

End the fault diagnosis and explain the

repair details to the customer. .

19

Does the noise stop out of the A/C

compressor?

No

If the fault reoccurs, recheck the fault

symptom and start from the step 1.

A/C System3A-17

Maintenance Warning and

Instruction

Treatment of the refrigerant

1. Please avoid inhaling the air containing the

refrigerant or lubricant vapor, for these gases

may cause irritation to eyes, nose and throat.

For environmental concerns, we strongly

recommend that the recovery/recycling/filling

equipment be adopted for R134a emission

from the A/C system. If an accidental leak in

the system may occur, please ensure the work

area is well ventilated before continuing the

maintenance.

2. Do not use the compressed air method to

perform the pressure or leak test for the

R134a maintenance equipment and/or the

vehicle A/C system. The mixture of R134a

and air at certain proportion is flammable

when the pressure is increased; if ignited, it

shall cause personal injury or property

damage. For other health and safety

information, please obtain from the

refrigerant supplier.

3. Do not let the refrigerant leak near an open

flame or other sources of heat. The refrigerant

will produce toxic gases when it is exposed to

the heat sources such as cigarettes or heaters.

If the operation may cause leakage, be sure to

avoid the above-mentioned heat sources and

maintain good ventilation.

4. Handling refrigerant is dangerous. Dripping a

drop of refrigerant on the skin will cause

localized frostbite; therefore, be sure to wear

gloves and goggles. If the refrigerant is

splashed into eyes, rinse with water

immediately and then go to the doctor.

Storage of the refrigerant

There is high pressure inside the refrigerant

reservoir. It may explode when being exposed to

the heat source, making metal fragments and

refrigerant splashing in all directions, which would

cause personal injury. The refrigerant should be

stored in the places with the temperature below 40

℃{1040F).

Treatment of the compressor oil

1. Only the PAG 105# compressor oil can be

adopted for this vehicle and other kinds of oil

may cause damage to the A/C compressor.

2. Don’t let the PAG 105# compressor oil drop

on the vehicle body, or else the paint may

come off. If it drops on the vehicle body

accidentally, wiper it off immediately.

3. The PAG 105 # compressor oil is of higher

moisture absorption capacity than the

previously used mineral oil. The moisture

mixed into the compressor oil may cause

damage to the refrigeration system; therefore,

after the refrigeration system components are

removed, you should close the lid

immediately to prevent any moisture from

entering.

Maintenance Procedures for

Refrigeration System

Installing the manifold gauge

1. Close the valve on the SST(49C061001)

completely.

2. Connect the SST(49C061002, 49C061003)

and the SST(49C061001) respectively with

the low pressure port and the high pressure

port.

3. Connect the ends of the SST(49C061006A,

49C061007) and the SST(49C061002,

49C061003).

4. Connect the SST(49C061006A, 49C061007)

with the filler port.

ATMOS GU10 compressor oil

Time

Mineral oil

Moisture absorption capacity

Cover

Filler port at the

low pressure en

d

Filler port at the high

p

ressure en

d

A/C System3A-18

Recovering the refrigerant

Warning:

1. Please avoid inhaling the air containing the

refrigerant or lubricant vapor, for these gases

may cause irritation to eyes, nose and throat.

For environmental concerns, we strongly

recommend that the recovery/recycling/filling

equipment be adopted for R134a emission

from the A/C system. If an accidental leak in

the system may occur, please ensure the work

area is well ventilated before continuing the

maintenance.

2. Connect the R134Ra

recovery/recycling/filling equipment with the

vehicle and operate it as per the

manufacturer’s instruction book.

Refrigerant filling

Warning:

Please avoid inhaling the air containing the

refrigerant or lubricant vapor, for these gases may

cause irritation to eyes, nose and throat. For

environmental concerns, we strongly recommend

that the recovery/recycling/filling equipment be

adopted for R134a emission from the A/C system.

If an accidental leak in the system may occur,

please ensure the work area is well ventilated

before continuing the maintenance.

Caution:

Please fill the system with proper amount of

refrigerant, for the excessive refrigerant will

reduce the operating efficiency of the A/C and

damage the refrigeration cycle system.

Recovering the used R134a refrigerant

Connect the R134Ra

recovery/recycling/filling equipment with the

vehicle and operate it as per the manufacturer’s

instruction book.

Adding fresh R134a refrigerant

1. Install the SST(manifold gauge) (Refer to

Installing the Manifold Gauge).

2. Connect the pin plug of the SST(49C061004)

with the bleeder valve of the

SST(49C061001).

3. Connect the SST(49C061005) with the central

port of the SST(49C061001).

4. Connect the SST(49C061005) with the

vacuum pump.

5. Connect the SST(49C061004) with the

refrigerant reservoir.

6. Put the refrigerant reservoir on the scale.

Specified refrigerant capacity:

600g{21. 20z)

675g{23. 80z): in extremely hot areas

7. Open all the valves of the ST(49C061001).

Caution:

Close the SST valves immediately after turning off

the vacuum pump; otherwise, the oil in the vacuum

pump will return to the refrigeration cycle system,

resulting in the decreased efficiency of the A/C

system.

8. Operate the vacuum pump for 15min.

9. Confirm the reading of the high and low

pressure ends of the SST(49C061001) is －

101kPa{ － 760mmHg, － 29.9inHg). Close

each valve of the SST(49C061001).

Closed

Pin plug

Vacuum pump

Scale

Refrigerant

reservoi

r

Bleeder valve

A/C System3A-19

10. Turn off the vacuum pump and wait for 5min.

11. Check the reading of the high and low

pressure ends of the SST(49C061001). If the

value changes, check for any leak and start

from the step 7. If there is no change, go to

the step 12.

12. Open the valves of the refrigerant reservoir.

13. Weigh the reservoir.

Warning:

1) If the refrigeration system is filled with

excessive refrigerant or when there is any

leakage, the refrigerant would dissipate into

the atmosphere. In order to prevent the

damage to the ozone layer caused by the

accidental leakage, please perform the

correct steps for checking the leakage and

only add proper amount of refrigerant.

2) It is dangerous to operate the engine when

filling the system with refrigerant with the

high pressure valve of the reservoir open.

The pressure in the reservoir would increase

resulting in explosion, making metal

fragments and refrigerant splashing in all

directions, which would cause personal

injury; therefore, don’t open the high

pressure valve when the engine is operating.

14. Open the high pressure valve of the

SST(49C061001).

15. When the reading of the low pressure end

increases to 0.098MPa{1.0kgf/ cm2,14psi},

close the high pressure valve of the

SST(49c061001).

16. Use the SST(refrigerant leak detector) to

check the cooling pipe/hose for any leak. If

there is no leak, go to the step 17; if there is

leak due to the insecurely connected

connector, tighten the connector and recheck

for any leak. If the leak still exists, drain off

the refrigerant and repair the connector. Refill

the refrigerant from the step 7. If there is no

leak after the connector is tightened, go to the

step 17.

Warning:

It is dangerous to operate the engine when filling

the system with refrigerant with the high pressure

valve of the reservoir open. The pressure in the

reservoir would increase resulting in explosion,

making metal fragments and refrigerant splashing

in all directions, which would cause personal

injury; therefore, don’t open the high pressure

valve when the engine is operating.

17. Open the high pressure valve of the

SST(49C061001) and start to fill until the

weight of the reservoir is reduced by 300g110.

60zl compared to the weight obtained in the

step 13.

18. Close the high pressure valve of the

SST(49C061001).

Warning:

It is dangerous to operate the engine when filling

the system with refrigerant with the high

pressure valve of the reservoir open. The

pressure in the reservoir would increase resulting

in explosion, making metal fragments and

refrigerant splashing in all directions, which

would cause personal injury; therefore, don’t

open the high pressure valve when the engine is

operating.

19. Start the engine and turn on the A/C

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