NO.7 NO COOL AIR [MANUAL AIR CONDITIONER]

7	No cool air
DESCRIPTION	• Magnetic clutch does not operate
POSSIBLE CAUSE	• Malfunction in PCM A/C cut control system • Open or short circuit in wiring harness between evaporator temperature sensor and climate control unit • Malfunction in evaporator temperature sensor (internal circuit malfunction) • Malfunction in climate control unit • Malfunction in refrigerant pressure sensor • Malfunction in PCM (A/C signal) • Malfunction in PCM (IG1 signal) • Malfunction in A/C compressor • Malfunction in A/C relay • Malfunction in evaporator temperature sensor • Malfunction in front body control module (FBCM) • Improper refrigerant charging amount • Open circuit in wiring harness between front body control module (FBCM) and climate control unit • Malfunction in CAN communication

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged.

STEP	INSPECTION	ACTION
1	CHECK MALFUNCTION SYMPTOMS Note • Without i-stop, go to the next step. • Is malfunctions occur in only when operating the i-stop?	Yes	Perform the i-stop troubleshooting. (See FOREWORD [SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See FOREWORD [SKYACTIV-D 2.2].)
No	Go to the next step.
2	INSPECT FUSE • Are A/C relay power supply fuses okay?	Yes	Go to the next step.
No	Replace fuse, then go to Step 16. If fuse burns out immediately, go to the next step.
3	INSPECT AIR BLOW OUT • Does air blow out?	Yes	Go to the next step.
No	Go to Step 1 of troubleshooting indexes No.1 and 2.
4	INSPECT A/C COMPRESSOR OPERATION • Start engine. • Turn A/C switch and fan switch on. • Does A/C compressor operate?	Yes	Go to Step 1 of troubleshooting index No.6.
No	Go to the next step.
5	INSPECT FOR DTC IN PCM AND FRONT BODY CONTROL MODULE (FBCM) • Inspect for DTCs related to the PCM and front body control module (FBCM) on-board diagnostic system. • Are any DTCs displayed?	Yes	Go to appropriate inspection procedure.
No	Go to the next step.
6	DETERMINE IF MALFUNCTION CAUSE IS A/C REQUEST SIGNAL OR A/C RELAY OPERATIONAL MALFUNCTION • Access PCM PID ACCS using the M-MDS. • Start the engine and idle it. • Turn the PID ACCS to ON from OFF using the M-MDS simulation function. • Is the A/C magnetic clutch engaged?	Yes	Go to the next step.
No	Go to Step 11.
7*	SIGNAL INSPECTION FROM EVAPORATOR TEMPERATURE SENSOR TO CLIMATE CONTROL UNIT • Remove the climate control unit. • Reconnect the climate control unit connector. • Measure the climate control unit terminal H voltage. (See CLIMATE CONTROL UNIT INSPECTION [MANUAL AIR CONDITIONER].) • Is the voltage within the specified?	Yes	Go to Step 9.
No	Go to the next step.
8	INSPECT EVAPORATOR TEMPERATURE SENSOR • Inspect the evaporator temperature sensor. (See EVAPORATOR TEMPERATURE SENSOR INSPECTION [MANUAL AIR CONDITIONER].) • Is the evaporator temperature sensor normal?	Yes	Inspect and repair for open or short circuit between evaporator temperature sensor and climate control unit.
No	Replace the evaporator temperature sensor. (See A/C UNIT DISASSEMBLY/ASSEMBLY.)
9	INSPECT REFRIGERANT PRESSURE SENSOR • Inspect refrigerant pressure sensor. (See REFRIGERANT PRESSURE SENSOR INSPECTION [MANUAL AIR CONDITIONER].) • Is the refrigerant pressure sensor normal?	Yes	Go to the next step.
No	Repair or replace malfunctioning part according to inspection result, then go to Step 17.
10	CONTINUITY INSPECTION BETWEEN CLIMATE CONTROL UNIT AND INSTRUMENT CLUSTER • Inspect for open or short circuit between climate control unit terminal K and front body control module (FBCM) terminal 2J. Is there any open or short circuit detected?	Yes	Repair for open or short circuit.
No	Replace the climate control unit.(A/C switch malfunction or climate control unit does not determine A/C request or transmit the A/C request signal.) (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
11	INSPECT TO SEE WHETHER MALFUNCTION (LACK OF CONTINUITY) IS IN A/C CONTROL SIGNAL CIRCUIT (BETWEEN A/C RELAY AND PCM) OR ELSEWHERE • Does cool air blow out when terminal E of A/C relay connector (A/C control signal) is grounded?	Yes	Release short, then go to the next step.
No	Go to Step 13.
12*	INSPECT TO SEE WHETHER MALFUNCTION (LACK OF CONTINUITY) IS IN PCM OR WIRING HARNESS (BETWEEN A/C RELAY AND PCM) • Test voltage at the A/C relay control signal terminal of PCM. • Is voltage approx. 12 V?	Yes	Inspect PCM, then go to Step 17.
No	Repair wiring harness between A/C relay and PCM, then go to Step 17.
13*	INSPECT TO SEE WHETHER MALFUNCTION IS IN MAGNETIC CLUTCH OR ELSEWHERE • Test voltage at the following terminal of magnetic clutch. ― Terminal A (magnetic clutch operation signal) • Is voltage approx. 12 V?	Yes	Go to the next step.
No	Go to Step 15.
14	INSPECT MAGNETIC CLUTCH CLEARANCE • Inspect the magnetic clutch clearance. (See MAGNETIC CLUTCH ADJUSTMENT [MANUAL AIR CONDITIONER].) • Is the magnetic clutch clearance normal?	Yes	Inspect and repair the magnetic clutch, then go to Step 17. (See MAGNETIC CLUTCH INSPECTION [MANUAL AIR CONDITIONER].)
No	Adjust the magnetic clutch clearance, then go to Step 17. (See MAGNETIC CLUTCH ADJUSTMENT [MANUAL AIR CONDITIONER].)
15	INSPECT WIRING HARNESS BETWEEN FUSE BLOCK AND A/C RELAY FOR LACK OF CONTINUITY • Test voltages at following terminals of A/C relay. ― Terminal A (A/C relay control signal) ― Terminal C (A/C control signal) • Are voltages approx. 12 V?	Yes	Go to the next step.
No	Repair wiring harness between fuse block and A/C relay, then go to Step 17.
16	INSPECT TO SEE WHETHER MALFUNCTION IS IN A/C RELAY OR WIRING HARNESS (BETWEEN A/C RELAY AND MAGNETIC CLUTCH) • Test voltage at the following terminal of A/C relay. ― Terminal D (magnetic clutch operation signal) • Is voltage approx. 12 V?	Yes	Inspect wiring harness between A/C relay and magnetic clutch. • If above wiring harness is OK, go to the next step. • If above wiring harness malfunctions, repair wiring harness, then go to the next step.
No	Replace A/C relay, then go to the next step.
17	CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Does cool air blow out? (Are the results of refrigerant system performance test okay?)	Yes	Troubleshooting completed. Explain repairs to customer.
No	Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.

STEP

INSPECTION

ACTION

CHECK MALFUNCTION SYMPTOMS

Note

• Without i-stop, go to the next step.

• Is malfunctions occur in only when operating the i-stop?

Yes

Perform the i-stop troubleshooting.

(See FOREWORD [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

(See FOREWORD [SKYACTIV-D 2.2].)

Go to the next step.

INSPECT FUSE

• Are A/C relay power supply fuses okay?

Yes

Go to the next step.

Replace fuse, then go to Step 16. If fuse burns out immediately, go to the next step.

INSPECT AIR BLOW OUT

• Does air blow out?

Yes

Go to the next step.

Go to Step 1 of troubleshooting indexes No.1 and 2.

INSPECT A/C COMPRESSOR OPERATION

• Start engine.

• Turn A/C switch and fan switch on.

• Does A/C compressor operate?

Yes

Go to Step 1 of troubleshooting index No.6.

Go to the next step.

INSPECT FOR DTC IN PCM AND FRONT BODY CONTROL MODULE (FBCM)

• Inspect for DTCs related to the PCM and front body control module (FBCM) on-board diagnostic system.

• Are any DTCs displayed?

Yes

Go to appropriate inspection procedure.

Go to the next step.

DETERMINE IF MALFUNCTION CAUSE IS A/C REQUEST SIGNAL OR A/C RELAY OPERATIONAL MALFUNCTION

• Access PCM PID ACCS using the M-MDS.

• Start the engine and idle it.

• Turn the PID ACCS to ON from OFF using the M-MDS simulation function.

• Is the A/C magnetic clutch engaged?

Yes

Go to the next step.

Go to Step 11.

SIGNAL INSPECTION FROM EVAPORATOR TEMPERATURE SENSOR TO CLIMATE CONTROL UNIT

• Remove the climate control unit.

• Reconnect the climate control unit connector.

• Measure the climate control unit terminal H voltage. (See CLIMATE CONTROL UNIT INSPECTION [MANUAL AIR CONDITIONER].)

• Is the voltage within the specified?

Yes

Go to Step 9.

Go to the next step.

INSPECT EVAPORATOR TEMPERATURE SENSOR

• Inspect the evaporator temperature sensor. (See EVAPORATOR TEMPERATURE SENSOR INSPECTION [MANUAL AIR CONDITIONER].)

• Is the evaporator temperature sensor normal?

Yes

Inspect and repair for open or short circuit between evaporator temperature sensor and climate control unit.

Replace the evaporator temperature sensor. (See A/C UNIT DISASSEMBLY/ASSEMBLY.)

INSPECT REFRIGERANT PRESSURE SENSOR

• Inspect refrigerant pressure sensor. (See REFRIGERANT PRESSURE SENSOR INSPECTION [MANUAL AIR CONDITIONER].)

• Is the refrigerant pressure sensor normal?

Yes

Go to the next step.

Repair or replace malfunctioning part according to inspection result, then go to Step 17.

CONTINUITY INSPECTION BETWEEN CLIMATE CONTROL UNIT AND INSTRUMENT CLUSTER

• Inspect for open or short circuit between climate control unit terminal K and front body control module (FBCM) terminal 2J.

Is there any open or short circuit detected?

Yes

Repair for open or short circuit.

Replace the climate control unit.(A/C switch malfunction or climate control unit does not determine A/C request or transmit the A/C request signal.) (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

INSPECT TO SEE WHETHER MALFUNCTION (LACK OF CONTINUITY) IS IN A/C CONTROL SIGNAL CIRCUIT (BETWEEN A/C RELAY AND PCM) OR ELSEWHERE

• Does cool air blow out when terminal E of A/C relay connector (A/C control signal) is grounded?

Yes

Release short, then go to the next step.

Go to Step 13.

12*

INSPECT TO SEE WHETHER MALFUNCTION (LACK OF CONTINUITY) IS IN PCM OR WIRING HARNESS (BETWEEN A/C RELAY AND PCM)

• Test voltage at the A/C relay control signal terminal of PCM.

• Is voltage approx. 12 V?

Yes

Inspect PCM, then go to Step 17.

Repair wiring harness between A/C relay and PCM, then go to Step 17.

13*

INSPECT TO SEE WHETHER MALFUNCTION IS IN MAGNETIC CLUTCH OR ELSEWHERE

• Test voltage at the following terminal of magnetic clutch.

― Terminal A (magnetic clutch operation signal)

• Is voltage approx. 12 V?

Yes

Go to the next step.

Go to Step 15.

INSPECT MAGNETIC CLUTCH CLEARANCE

• Inspect the magnetic clutch clearance. (See MAGNETIC CLUTCH ADJUSTMENT [MANUAL AIR CONDITIONER].)

• Is the magnetic clutch clearance normal?

Yes

Inspect and repair the magnetic clutch, then go to Step 17. (See MAGNETIC CLUTCH INSPECTION [MANUAL AIR CONDITIONER].)

Adjust the magnetic clutch clearance, then go to Step 17. (See MAGNETIC CLUTCH ADJUSTMENT [MANUAL AIR CONDITIONER].)

INSPECT WIRING HARNESS BETWEEN FUSE BLOCK AND A/C RELAY FOR LACK OF CONTINUITY

• Test voltages at following terminals of A/C relay.

― Terminal A (A/C relay control signal)

― Terminal C (A/C control signal)

• Are voltages approx. 12 V?

Yes

Go to the next step.

Repair wiring harness between fuse block and A/C relay, then go to Step 17.

INSPECT TO SEE WHETHER MALFUNCTION IS IN A/C RELAY OR WIRING HARNESS (BETWEEN A/C RELAY AND MAGNETIC CLUTCH)

• Test voltage at the following terminal of A/C relay.

― Terminal D (magnetic clutch operation signal)

• Is voltage approx. 12 V?

Yes

Inspect wiring harness between A/C relay and magnetic clutch.

• If above wiring harness is OK, go to the next step.

• If above wiring harness malfunctions, repair wiring harness, then go to the next step.

Replace A/C relay, then go to the next step.

CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR

• Does cool air blow out? (Are the results of refrigerant system performance test okay?)

Yes

Troubleshooting completed. Explain repairs to customer.

Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.