REFRIGERANT SYSTEM INEFFECTIVE [FULL-AUTO AIR CONDITIONER]

id0703c1005500

DESCRIPTION

•  Insufficient cooled-airflow even if airflow temperature setting is MAX COLD •  Excessive time required to cool to set temperature

POSSIBLE CAUSE

Note •  If the engine coolant temperature increases due to a cooling system malfunction, the fail-safe function disables the A/C operation. •  i-stop system operation malfunction (A/C system operation malfunction while i-stop function is operating) •  Blower unit or air filter clogging •  Drive belt malfunction •  Refrigerant pressure sensor malfunction •  Cooling fan operation malfunction •  Condenser fin clogging •  Expansion valve malfunction •  Insufficient compressor oil •  Poor installation of air mix link and air mix door for front A/C unit •  Poor installation of air mix link and air mix door for rear A/C unit •  Air mix actuator malfunction •  System piping malfunction ―  Crushed piping ―  Gas leakage from connecting area (improper installation, O-ring malfunction) •  Condenser malfunction •  Poor A/C compressor compression •  Evaporative temperature sensor malfunction •  Poor evaporator temperature sensor installation

Diagnostic Procedure

Step	Inspection		Action
1	CHECK MALFUNCTION SYMPTOMS •  Does the malfunction symptom occur only while i-stop function is operating?	Yes	Perform the i-stop troubleshooting. (See FOREWORD [SKYACTIV-G 2.5].) (See FOREWORD [PCM (SKYACTIV-D 2.2)].)
		No	Go to the next step.
2	INSPECT BLOWER UNIT AND AIR FILTER •  Are the blower unit intake and air filter clogged? (See AIR FILTER INSPECTION.)	Yes	Remove the cause of the clogging. Replace the air filter if it is clogged. (See AIR FILTER REMOVAL/INSTALLATION.) After performing the repair, go to Step 17.
		No	Go to the next step.
3	INSPECT REFRIGERANT PRESSURE •  Inspect the refrigerant pressure. (See REFRIGERANT PRESSURE CHECK.) •  Is the refrigerant pressure normal?	Yes	Go to the next step.
		No	Record the inspection results. •  If the refrigerant pressures on the high pressure and low pressure side are both high, go to Step 7. •  If the refrigerant pressures on the high pressure and low pressure sides are almost same, go to Step 10. •  If the refrigerant pressures on the high pressure and low pressure sides are both low, go to Step 12. •  If vacuum on the low pressure side and the refrigerant pressure on the high pressure side is extremely low, go to Step 13. •  If the refrigerant pressure on the high pressure side is low and the refrigerant pressure on the low pressure side is high, replace the A/C compressor, then go to Step 17. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) •  If the refrigerant pressure condition is under any condition other than the above, go to Step 15.
4	PERFORM AIR-CONDITIONING SYSTEM PERFORMANCE TEST •  Perform the air-conditioning system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.) •  Is the airflow temperature within the specified range?	Yes	Go to Step 17.
		No	Go to the next step.
5	INSPECT DRIVE BELT •  Inspect the drive belt. (See DRIVE BELT INSPECTION [SKYACTIV-G 2.5].) (See DRIVE BELT INSPECTION [SKYACTIV-D 2.2].) •  Is the drive belt condition normal?	Yes	Go to the next step.
		No	After adjusting the drive belt tension, go to the next step. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
6	INSPECT A/C PRESSURE SENSOR •  Inspect the A/C pressure sensor. (See REFRIGERANT PRESSURE SENSOR INSPECTION.) •  Is the A/C pressure sensor normal?	Yes	Go to the next step.
		No	Replace the refrigerant pressure sensor. (See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION.) After performing the repair, go to Step 17.
7	INSPECT COOLING FAN •  Verify the cooling fan operation. (See COOLING FAN MOTOR INSPECTION [SKYACTIV-G 2.5].) (See COOLING FAN MOTOR INSPECTION [SKYACTIV-D 2.2].) •  Is the cooling fan operation normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning location according to the inspection results. After performing the repair, go to Step 17.
8	INSPECT CONDENSER •  Inspect the condenser. (See CONDENSER INSPECTION [SKYACTIV-G 2.5].) (See CONDENSER INSPECTION [SKYACTIV-D 2.2].) •  Is it normal?	Yes	Go to the next step.
		No	Repair or replace the malfunctioning location according to the inspection results. (See CONDENSER REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See CONDENSER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) After performing the repair, go to Step 17.
9	INSPECT SYSTEM PIPING •  Is the hose on the low pressure side hot to the touch?	Yes	Replace the refrigerant. After vacuum discharging for 1 h and charging with refrigerant to the specified level, go to Step 17. (See REFRIGERANT CHARGING.)
		No	Replace the refrigerant. After vacuum discharging for 15 min and charging with refrigerant to the specified level, go to Step 17. (See REFRIGERANT CHARGING.)
10	INSPECT EXPANSION VALVE •  Remove the expansion valve and verify its condition. (See FRONT EXPANSION VALVE REMOVAL/INSTALLATION.) (See REAR EXPANSION VALVE REMOVAL/INSTALLATION.) •  Is there refrigerant leakage or valve clogging?	Yes	If there is foreign matter clogging the valve, remove the foreign matter. If there is refrigerant leakage or clogging, replace the expansion valve. (See FRONT EXPANSION VALVE REMOVAL/INSTALLATION.) (See REAR EXPANSION VALVE REMOVAL/INSTALLATION.) Go to Step 17.
		No	Go to the next step.
11	INSPECT VOLTAGE AT CLIMATE CONTROL UNIT TERMINAL •  Measure the voltage at the following terminals (vehicle wiring harness side). (See FRONT CLIMATE CONTROL UNIT INSPECTION.) ―  Front climate control unit terminal 2I ―  Front climate control unit terminal 2K ―  Rear climate control unit terminal S •  Is the voltage normal?	Yes	After adjusting the compressor oil to the specified level, go to Step 17. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
		No	Verify the air mix link and air mix door installation conditions on the side where the voltage is not normal. (See FRONT A/C UNIT DISASSEMBLY/ASSEMBLY.) (See REAR A/C UNIT DISASSEMBLY/ASSEMBLY.) Securely and correctly installed to positions Replace the air mix actuator. (See FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.) (See REAR AIR MIX ACTUATOR REMOVAL/INSTALLATION.) Not securely and correctly installed to positions Repair the air mix link and air mix door installation conditions. (See FRONT A/C UNIT DISASSEMBLY/ASSEMBLY.) (See REAR A/C UNIT DISASSEMBLY/ASSEMBLY.) Go to Step 17.
12	INSPECT SYSTEM PIPING •  Verify if there is gas leakage from the system piping using the gas leak tester. •  Is the system piping normal?	Yes	Replace the crushed system piping or the malfunctioning location. (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) Go to Step 17.
		No	Replace the O-ring of the malfunctioning location (system piping connecting area). Or replace the malfunctioning location of the system piping. (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) Go to Step 17.
13	INSPECT REFRIGERANT PRESSURE •  Does the refrigerant pressure on the low pressure side vary between the vacuum and normal range?	Yes	Replace the condenser (moisture has penetrated engine coolant). (See CONDENSER REMOVAL/INSTALLATION [SKYACTIV-G 2.5].) (See CONDENSER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) Go to Step 17.
		No	Go to the next step.
14	INSPECT EXPANSION VALVE •  Remove the expansion valve and verify its condition. (See FRONT EXPANSION VALVE REMOVAL/INSTALLATION.) (See REAR EXPANSION VALVE REMOVAL/INSTALLATION.) •  Is there refrigerant leakage or valve clogging?	Yes	If there is foreign matter clogging the valve, remove the foreign matter. If there is refrigerant leakage or clogging, replace the expansion valve. (See FRONT EXPANSION VALVE REMOVAL/INSTALLATION.) (See REAR EXPANSION VALVE REMOVAL/INSTALLATION.) Go to Step 17.
		No	Install the expansion valve, then go to Step 17.
15	INSPECT EVAPORATOR TEMPERATURE SENSOR •  Inspect the evaporator temperature sensor. (See EVAPORATOR TEMPERATURE SENSOR INSPECTION.) •  Is the evaporative temperature sensor normal?	Yes	Verify the evaporator temperature installation condition and repair the installation position. (See EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION.) Go to the next step.
		No	Replace the evaporative temperature sensor. (See EVAPORATOR TEMPERATURE SENSOR REMOVAL/INSTALLATION.) After replacement, go to Step 17.
16	INSPECT VOLTAGE AT CLIMATE CONTROL UNIT TERMINAL •  Measure the voltage at the following terminals (vehicle wiring harness side). (See FRONT CLIMATE CONTROL UNIT INSPECTION.) ―  Front climate control unit terminal 2I ―  Front climate control unit terminal 2K ―  Rear climate control unit terminal S •  Is the voltage normal?	Yes	Go to the next step.
		No	Verify the air mix link and air mix door installation conditions on the side where the voltage is not normal. (See FRONT A/C UNIT DISASSEMBLY/ASSEMBLY.) (See REAR A/C UNIT DISASSEMBLY/ASSEMBLY.) Securely and correctly installed to positions Replace the air mix actuator. (See FRONT AIR MIX ACTUATOR REMOVAL/INSTALLATION.) (See REAR AIR MIX ACTUATOR REMOVAL/INSTALLATION.) Not securely and correctly installed to positions Repair the air mix link and air mix door installation conditions. (See FRONT A/C UNIT DISASSEMBLY/ASSEMBLY.) (See REAR A/C UNIT DISASSEMBLY/ASSEMBLY.) Go to the next step.
17	VERIFY THAT MALFUNCTION SYMPTOM DOES NOT RECUR AFTER REPAIR •  If refrigerant was discharged during inspection and not recharged, perform vacuum discharging and charge with new refrigerant to the specified level. (See REFRIGERANT CHARGING.) •  Is there cool airflow (is the result of refrigerant system performance test normal?)? (See REFRIGERANT SYSTEM PERFORMANCE TEST.)	Yes	Troubleshooting completed. Explain repairs to customer.
		No	Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.