Haima S5 1.5T User manual

Type
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:
Blowing face mode system fault:
Step 1-4
Blowing foot mode system fault:
Step 5
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:
Fault of the blower relay, the blower motor, the resistance or the fan switch
Step 1
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:
Fault of the blower unit intake linkage, crank, cable and cable clip
Step 12
Fault of the intake cable of the climate control unit
Step 3
Fault of the blower unit air inlet
Step 45
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 23
2) Cold and warm air-conditioning knob actuator failure.
Step 4
3) HVAC air mix door catching.
Step 56
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:
Fault of the A/C switch indicator lamp Step 3-5
Fault of PCM A/C turn-off control system and the cooling system
Step 6, 22
Fault of the A/C amplifier, A/C switch, potentiometer
Step 8-14
PCM(A/C signal) system fault
Step 15,16
Fault of the refrigerant pressure switch and the cooling system
Step 17-19
PCM (IG1 signal) system fault
Step 20,21
Compressor system fault
Step 23,24
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
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
O
p
en
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Haima S5 1.5T User manual

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