RM35X0E _58 Vehicle Interior _079316 HEATING / AIR CONDITIONING _0386653 AIR CONDITIONING SYSTEM(for Manual Cooler System) G

HEATING / AIR CONDITIONING AIR CONDITIONING SYSTEM(for Manual Cooler System) ON-VEHICLE INSPECTION

PROCEDURE

Hide Display 1. COOLING PERFORMANCE TEST

Install the air conditioning tool set to the vehicle.

Set the vehicle to the following conditions. [*1]

Item	Condition
Vehicle Body	Vehicle stopped in shade
Door	Fully open
Temperature switch	On
Fresh/recirculation Mode Control Damper Position	Recirculation
Air Vent Damper Position	FACE
Set Temperature	MAX COLD
Blower Speed	HI
Air Conditioning Air Inlet Temperature*2	25 to 34°C (77 to 93.2°F)
Condenser Pressure (Gauge High Pressure Side)*3	1.37 to 1.57 MPaG (14 to 16 kgf/cm²)

HINT:: *2: This inspection can be judged correctly only if the air inlet temperature is within a range of 25 to 34°C (77 to 93.2°F). Therefore, postpone the test if the temperature is low.; If the condenser pressure (gauge high pressure side) is high, splash the condenser with water to lower the pressure. Conversely, if the condenser pressure is low, cover the front of the condenser to raise the pressure.

Place a wet and dry bulb thermometer at the air inlet (necessary for measuring the humidity), and insert its dry bulb at the center of the air vent to measure.

Operate the air conditioning in the conditions of [*1], and allow the temperature at the air vent to stabilize. (Approximately 5 to 6 minutes)

Measure the wet and dry temperatures of the air inlet and the temperature of the air vent.

Map the measurement values of the air inlet to the psychometric diagram to find the relative humidity.

3.135,4.49 3.406,4.719 0.271,0.229 10 false *b 3.323,2.021 3.594,2.25 0.271,0.229 10 false *c 2.375,2.635 2.646,2.865 0.271,0.229 10 false *d 4.688,0.656 4.958,0.885 0.271,0.229 10 false *d 0.24,0.219 0.51,0.448 0.271,0.229 10 false *a

*a	Psychrometric Diagram	*b	Dry Bulb Temperature (°C)
*c	Wet Bulb Temperature (°C)	*d	Relative Humidity (%)

1.188,3.167 1.49,3.354 0.302,0.188 10 *b 0.677,0.677 1,0.906 0.323,0.229 10 *c 0.104,0.115 0.427,0.344 0.323,0.229 10 *a

*a	Example
*b	Dry Bulb Temperature (°C)
*c	Wet Bulb Temperature (°C)

One way of finding the relative humidity is to find the intersection point of the wet and dry bulb temperatures, 19.5°C and 25°C, respectively, of the wet and dry bulb thermometer set at the air inlet. In this case, the relative humidity is 60%.

Check the cooling performance by mapping the relative humidity and the difference between the measured dry bulb temperatures of the air inlet and air vent in the standard performance chart.

1.406,1.656 1.615,1.99 0.208,0.333 10 false *b 3.906,3.375 4.115,3.656 0.208,0.281 10 false *c 0.167,0.167 0.375,0.5 0.208,0.333 10 false *a

*a	Standard Performance Chart	*b	Air Inlet/Air Vent Temperature Difference (°C)
*c	Relative Humidity (%)	-	-

Standard:: Must be within the range between the diagonal lines in the chart

0.177,0.24 0.49,0.438 0.313,0.198 10 *a 2.125,2.948 2.469,3.219 0.344,0.271 10 *c 0.167,1.552 0.479,1.75 0.313,0.198 10 *b 2.313,1.396 2.625,1.594 0.313,0.198 10 *d

*a	Example
*b	Air inlet/air vent temperature difference (°C)
*c	Relative humidity (%)
*d	Intersection

One example of how to check the cooling performance using a standard performance chart is to find the intersection point of the relative humidity (60%) and the difference in dry bulb temperatures at the air inlet and vent (17°C). In this example, the cooling performance is inside the standard range.

Hide Display 2.CHECK REFRIGERANT GAS PRESSURE

Check refrigerant pressure using gauge

2.99,2.417 3.156,2.417 3.156,2.417 3.156,2.729 false 3.333,2.896 3.5,2.896 3.5,2.896 3.5,3.063 false 3.469,3.396 3.635,3.396 3.635,3.396 3.635,3.229 false 3.729,3.802 3.896,3.802 3.896,3.802 3.896,3.635 false 3.583,1.667 4.167,2.063 false 4.75,2.521 5.333,2.917 false 0.229,3.135 2.219,3.333 1.99,0.198 10 false 200 (2.0, 29) 0.229,2.448 2.219,2.646 1.99,0.198 10 false 300 (3.1, 44) 0.229,1.75 2.219,1.948 1.99,0.198 10 false 400 (4.1, 58) 0.229,1.073 2.219,1.271 1.99,0.198 10 false 500 (5.1, 73) 1.375,4.24 3.365,4.438 1.99,0.198 10 false 500 (5.1, 73) 2.552,4.24 4.542,4.438 1.99,0.198 10 false 1000 (10.2, 145) 3.833,4.24 5.823,4.438 1.99,0.198 10 false 1500 (15.3, 218) 5.104,4.24 7.094,4.438 1.99,0.198 10 false 2000 (20.4, 290) 1.229,3.552 3.219,3.75 1.99,0.198 10 false 140 (1.4, 20) 1.302,3.146 3.292,3.344 1.99,0.198 10 false 200 (2.0, 29) 1.229,2.969 3.219,3.167 1.99,0.198 10 false 220 (2.2, 32) 1.24,2.635 3.229,2.833 1.99,0.198 10 false 270 (2.8, 39) 1.958,2.323 3.948,2.521 1.99,0.198 10 false 1060 (10.8, 154) 2.313,2.802 4.302,3 1.99,0.198 10 false 1200 (12.2, 174) 2.448,3.313 4.438,3.51 1.99,0.198 10 false 1250 (12.7, 181) 2.708,3.708 4.698,3.906 1.99,0.198 10 false 1320 (13.5, 191) 1.021,0.573 1.333,0.771 0.313,0.198 10 false *a 6.292,4.094 6.604,4.292 0.313,0.198 10 false *b 3.427,1.542 3.74,1.74 0.313,0.198 10 false *c 5.365,2.875 5.677,3.073 0.313,0.198 10 false *d

*a	Pressure on Low Pressure Side kPa (kgf/cm², psi)	*b	Pressure on High Pressure Side kPa (kgf/cm², psi)
*c	Blower High Zone	*d	Blower Low Zone

Install the air conditioning tool set.

ii.

Set the vehicle to the following conditions. [*3]

Measurement Condition:
Item	Condition
Vehicle Condition	Engine running
Doors	Fully closed (windows also fully closed)
Temperature switch	On
Recirculation/fresh Control Switch	Recirculation
Set Temperature	MAX COLD
Blower Speed	HI
Air Conditioning Air Inlet Temperature	25 to 35°C (77 to 95°F)

iii.

In conditions [*3], read the gauge and check the numerical value.

0.906,1.813 1.219,1.969 0.313,0.156 10 false *a 2.396,1.813 2.708,1.969 0.313,0.156 10 false *b

*a	LO
*b	HI

Normal

Specified Condition:

Gauge Reading
Pressure Side	Refrigerant Volume
Low	150 to 250 kPa (1.5 to 2.5 kgf/cm², 22 to 36 psi)
High	1370 to 1570 kPa (14.0 to 16.0 kgf/cm², 199 to 228 psi)

HINT:: The illustration shows the gauges when the refrigerant gas volume is normal.

During malfunction

(a)

0.917,1.719 1.125,1.958 0.208,0.24 10 *a 2.323,1.719 2.531,1.958 0.208,0.24 10 *b

*a	LO
*b	HI

Symptom 1: During cooling operation, pressure on low pressure side cycles between normal and vacuum.

Standard Value Measurement Result
Symptom	The air conditioning system works intermittently
Cause	Moisture in the cooling system freezes at the cooler expansion valve orifice and temporarily prevents refrigerant gas from circulating. The condition, however, is restored to normal after the ice is melted.
Diagnosis	· Cooler dryer is overly saturated · Moisture in the cooling system freezes at the cooler expansion valve orifice and blocks circulation of the refrigerant gas
Action Taken	· Replace the cooler dryer · Remove moisture from cycle by repeatedly evacuating air · Add an appropriate volume of new refrigerant gas

HINT:: The illustration shows the gauges when moisture has got into the cooling system.

(b)

0.938,1.719 1.219,1.969 0.281,0.25 10 *a 2.354,1.719 2.635,1.969 0.281,0.25 10 *b

*a	LO
*b	HI

Symptom 2: The pressure on both the low and high pressure sides is low.

Standard Value Measurement Result
Symptoms	· Cooling is not working well · Coolant performance is insufficient
Cause	There is a gas leak somewhere in the cooling system
Diagnosis	· Insufficient refrigerant gas volume · Refrigerant gas leak
Action Taken	· Check for refrigerant gas leak and repair if necessary (201902,999999,_58,_079316,_0384873,RM100000001GISI,) · Add an appropriate volume of new refrigerant gas · If the pressure readout value when the gauge is connected is near 0, check for leaking points, make necessary repairs, and then evacuate the air conditioning system

HINT:: The illustration shows the gauges when cooling is not working well.

(c)

0.927,1.729 1.125,1.948 0.198,0.219 10 *a 2.344,1.729 2.542,1.948 0.198,0.219 10 *b

*a	LO
*b	HI

Symptom 3: The pressure on both the low and high sides is low, which causes condensation on the pipe from the cooler condenser assembly to the A/C unit.

Standard Value Measurement Result
Symptoms	Cooling is not working well
Cause	Dust in the cooler condenser core blocks the flow of refrigerant gas
Diagnosis	Blockage of cooler condenser core
Action Taken	Replace the cooler condenser assembly

HINT:: The illustration shows the gauges when cooling by refrigerant gas is not working well.

(d)

0.917,1.75 1.156,2 0.24,0.25 10 *a 2.365,1.75 2.604,2 0.24,0.25 10 *b

*a	LO
*b	HI

Symptom 4: The pressure on both the low and high sides is low, that causes frost or condensation on the pipe before and after the cooler condenser core or cooler expansion valve.

Standard Value Measurement Result
Symptoms	Cooling is not functioning (also functioning occasionally)
Cause	· The flow of refrigerant gas is blocked by moisture or dust in the cooling system · The flow of refrigerant gas is impaired by refrigerant gas leak from the cooler expansion valve
Diagnosis	Refrigerant gas cannot circulate
Action Taken	· Check the cooler expansion valve · Remove dust in the cooler expansion valve with an air gun · Replace the cooler condenser assembly · Evacuate the air conditioning system, and then add an appropriate volume of new refrigerant gas · If there is a refrigerant gas leak from the cooler expansion valve, replace the valve

HINT:: The illustration shows the gauges when refrigerant gas does not circulate.

(e)

0.917,1.74 1.177,2 0.26,0.26 10 *a 2.344,1.74 2.604,2 0.26,0.26 10 *b

*a	LO
*b	HI

Symptom 5: The pressure on both the low and high pressure sides is high.

Standard Value Measurement Result
Symptoms	Cooling is not working well
Cause	· The flow of refrigerant gas is blocked by moisture or dust in the cooling system · The flow of refrigerant gas is impaired by refrigerant gas leak from the cooler expansion valve
Diagnosis	· Excessive refrigerant gas volume · Cooling of cooler condenser core is insufficient
Action Taken	· Clean the cooler condenser core fin · Check the operation of the condenser fan · Adjust the refrigerant gas volume

HINT:: The illustration shows the gauges when the refrigerant gas volume is excessive or cooling of the cooler condenser core is insufficient.

(f)

0.917,1.802 1.135,2 0.219,0.198 10 *a 2.333,1.802 2.552,2 0.219,0.198 10 *b

*a	LO
*b	HI

Symptom 6: The pressure on both the low and high pressure sides is high, and the low pressure line is too hot to touch.

Standard Value Measurement Result
Symptoms	Cooling is not functioning
Cause	Air in refrigeration system
Diagnosis	· Air is in the refrigeration system · Evacuation of the air conditioning system is insufficient
Action Taken	· Check if the compressor oil is dirty or insufficient · Evacuate the air conditioning system, and then add an appropriate volume of new refrigerant gas

HINT:: ·

Notes: The gauge indicates when the cooling system is open without the system being evacuated and filled with refrigerant gas.

·

The illustration shows the gauges when air has got into the refrigerant system.

(g)

0.924,1.771 1.132,2.0 0.208,0.229 10 *a 2.334,1.771 2.542,1.986 0.208,0.215 10 *b

*a	LO
*b	HI

Symptom 7: The pressure on both the low and high pressure sides is high, and frost or condensation is forming on the low pressure side.

Standard Value Measurement Result
Symptoms	Cooling is not working well
Cause	Trouble with the cooler expansion valve
Diagnosis	· Refrigerant gas volume is excessive on the low pressure pipe line · Cooler expansion valve opened too far
Action Taken	Replace the cooler expansion valve

HINT:: The illustration shows the gauges when the cooler expansion valve is improper.

(h)

0.946,1.787 1.163,2.003 0.217,0.217 10 *a 2.321,1.787 2.538,2.003 0.217,0.217 10 *b

*a	LO
*b	HI

Symptom 8: The pressure on the low pressure side is high and the pressure on the high pressure side is low.

Standard Value Measurement Result
Symptoms	Cooling is not functioning
Cause	Compression leak inside the compressor with magnet clutch assembly
Diagnosis	· Compression malfunction · Valve leak or damaged sliding parts
Action Taken	Repair or replace the compressor with magnet clutch assembly

HINT:: The illustration shows the gauges when the compression in the compressor with magnet clutch assembly is poor.

(i)

0.938,1.792 1.25,1.948 0.313,0.156 10 false *a 2.396,1.802 2.708,1.958 0.313,0.156 10 false *b

*a	LO
*b	HI

Symptom 9: The pressure is the same on both the low and high pressure sides.

Standard Value Measurement Result
Symptoms	Cooling is not functioning
Cause	Trouble with the compressor with magnet clutch assembly
Diagnosis	Compressor with magnet clutch assembly does not rotate
Action Taken	Repair or replace the compressor with magnet clutch assembly

HINT:: The illustration shows the gauges when the compressor with magnet clutch assembly is malfunctioning.

Hide Display 88460 3.CHECK COOLER CONDENSER ASSEMBLY

When the fins of the cooler condenser assembly are dirty, clean with water and dry with compressed air.

NOTICE:: ·

Do not damage the cooler condenser assembly fins.

·

When the cooler condenser assembly fins are bent, use a screwdriver or pliers to straighten them.

Hide Display 4. CHECK FOR REFRIGERANT GAS LEAK

Using a gas leak detector, check for refrigerant gas leaks from connections on the pipe line.

If refrigerant gas is leaking from a connection on the pipe line, check the tightening torque of the joint.