HEATING NOT FUNCTIONING EFFECTIVELY [FULL-AUTO AIR CONDITIONER]


id0703c1702200

Warning
<<High voltage>>
•  If the necessary measures are not taken before servicing an electric vehicle, it could cause electrical shock and result in serious injury or, in the worst case, death. Before servicing the electric vehicle, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and implement the necessary measures. (See HIGH VOLTAGE SERVICE CAUTIONS.)

Malfunction symptom

Heating not functioning effectively

Details
•  Insufficient warmed-airflow even if airflow temperature setting is MAX HOT
•  It takes time for airflow to be warmed to set temperature
Possible Cause
Note
•  The electric compressor does not operate during heating operation when the ambient temperature is -20 °C {-4 °F} or less or 25 °C {77 °F} or more. When the temperature is -20 °C {-4 °F} or less, heating is performed using the PTC heater.
•  Air mix actuator malfunction
•  Blower unit or air filter clogging
•  Blower system malfunction
•  Cooling fan operation malfunction
•  Active air shutter malfunction
•  Malfunction of 2way valve for refrigerant
•  Malfunction of 3way valve for refrigerant
•  PTC heater malfunction
•  Heat pump control unit malfunction
Caution
•  Because the heat pump system does not operate at an ambient temperature of -20 °C or less, remove any snow and frost from the front end of the vehicle before starting the diagnosis.


Diagnostic Procedure

Warning
<<High voltage>>
•  If necessary measures such as wearing the correct protective gear are not taken when inspecting or removing/installing the high voltage parts, it could cause electrical shock and result in serious injury or, in the worst case, death.
•  Before inspecting or removing/installing the high voltage parts, refer to [HIGH VOLTAGE SERVICE CAUTIONS] in the general information and [High Voltage Part Inspection and Removal/Installation Notes] of the high voltage system service cautions and implement the necessary measures and preparations. (See HIGH VOLTAGE SERVICE CAUTIONS.) (See HIGH VOLTAGE SYSTEM SERVICE CAUTIONS.)

Step

Inspection

Action

1
INSPECT AIR MIX ACTUATOR
•  Inspect the air mix actuator.
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
2
INSPECT BLOWER UNIT AND AIR FILTER
•  Are the blower unit intake and air filter clogged?
Yes
Remove the cause of the clogging.
Replace the air filter if it is clogged.
After repair, perform the repair completion verification.
No
Go to the next step.
3
VERIFY BLOWER MOTOR OPERATION
•  Switch the main power ON (READY off or on).
•  Set the airflow volume control dial to ON.
•  Does the blower motor operate and does air flow from the vent?
Yes
Go to the next step.
No
Go to the following malfunction symptom item.
4
INSPECT COOLING FAN OPERATION
•  Inspect the cooling fan control.
•  Is the cooling fan operation normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
5
INSPECT ACTIVE AIR SHUTTER
•  Inspect the applicable part.
•  Is the active air shutter normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
6
INSPECT REFRIGERANT PRESSURE
•  Inspect the refrigerant pressure.
•  Is the active air shutter normal?
Yes
Go to the next step.
No
Perform malfunction diagnosis according to the symptom troubleshooting for [AIR FROM VENTS NOT COLD ENOUGH] of the climate control system.
7
VERIFY HIGH VOLTAGE BATTERY TEMPERATURE
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Display the following PIDs using the M-MDS.
BECM
―  [HV_BATT_TEMP_MAX]
•  Is PID [HV_BATT_TEMP_MAX] 40 °C {104 °F} or more?
Yes
Go to the next step.
No
Go to Step 9.
8
PERFORM HIGH VOLTAGE BATTERY COOLING
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Select the following menu and perform the forced operation of the high voltage battery cooling system for 5 min.
1.  Press [Start] to start the vehicle identification.
2.  Press the [Toolbox] tab.
3.  Press the [Work Support] icon.
4.  Press [EV].
5.  Press [Run] for Compulsory operating Air Conditioner.
6.  Select [Cooling for drive battery] and press [Next].
•  Display the following PIDs using the M-MDS.
BECM
―  [HV_BATT_TEMP_MAX]
•  Is PID [HV_BATT_TEMP_MAX] 40 °C {104 °F} or more?
Yes
Perform the inspection content in Step 8 until the temperature of the high voltage battery is 40 °C {104 °F} or less.
No
Go to the next step.
9
VERIFY OPERATION OF 2WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Using the M-MDS, select the service support item [Self-Diagnosing Air Conditioner control valves] and inspect the 2way valve for refrigerant.
Note
•  Because [Self-Diagnosing Air Conditioner control valves] cannot be performed if the ambient temperature is 15°C {59 °F} or less or 40 °C {104 °F} or more, go to Step 10 and inspect the 2way valve for refrigerant.
1.  Press [Start] to start the vehicle identification.
2.  Press the [Toolbox] tab.
3.  Press the [Work Support] icon.
4.  Press [EV].
5.  Press [Run] for Self-Diagnosing Air Conditioner control valves.
6.  Select [2-way valve] and press [Next].
•  Is [Normal] displayed as the diagnosis result?
Yes
Go to step 11.
No
If [Abnormal] is displayedIf [Incomplete] is displayed
•  Repair or replace the malfunctioning location and perform the repair completion verification.
•  Go to the next step.
10
VERIFY OPERATION OF 2WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Access the HP simulation item [2_WAY_VLV] using the M-MDS.
•  Switch the main power ON (READY on)
•  Turn the [2_WAY_VLV] PID to ON from OFF using the M-MDS simulation function.
•  is operation sound heard?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
11
VERIFY OPERATION OF 3WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Using the M-MDS, select the service support item [Self-Diagnosing Air Conditioner control valves] and inspect the 3way valve for refrigerant.
Note
•  Because [Self-Diagnosing Air Conditioner control valves] cannot be performed if the ambient temperature is 15°C {59 °F} or less or 40 °C {104 °F} or more, go to Step 12 and inspect the 3way valve for refrigerant.
1.  Press [Start] to start the vehicle identification.
2.  Press the [Toolbox] tab.
3.  Press the [Work Support] icon.
4.  Press [EV].
5.  Press [Run] for Self-Diagnosing Air Conditioner control valves.
6.  Select [3-way valve] and press [Next].
•  Is [Normal] displayed as the diagnosis result?
Yes
Go to step 13.
No
If [Abnormal] is displayedIf [Incomplete] is displayed
•  Repair or replace the malfunctioning location and perform the repair completion verification.
•  Go to the next step.
12
VERIFY OPERATION OF 3WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Access the HP simulation item [3_WAY_VLV] using the M-MDS.
•  Switch the main power ON (READY on)
•  Turn the [3_WAY_VLV] PID to ON from OFF using the M-MDS simulation function.
•  is operation sound heard?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
13
VERIFY PTC HEATER OPERATION
•  Switch the main power ON (READY on)
•  Switch the A/C OFF.
•  Using the M-MDS, select the service support item [Compulsory operating Air Conditioner] and inspect the PTC heater.
―  Press [Start] to start the vehicle identification.
―  Press the [Toolbox] tab.
―  Press the [Work Support] icon.
―  Press [EV].
―  Press [Run] for [Compulsory operating Air Conditioner].
―  Select [Heating for only PTC heater] and press [Next].
•  Does warm air flow from the vent when [Heating for only PTC heater] is selected and the PTC heater is operated?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
14
INSPECTION OF PERFORMANCE OF [HEATING FOR ONLY HEAT PUMP] AND INSPECTION OF REFRIGERANT PRESSURE
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON (READY on)
•  Turn the A/C off.
•  Using the M-MDS, select the service support item [Compulsory operating Air Conditioner].
•  Select [Heating for only heat pump], and inspect the heating performance (airflow temperature) and the refrigerant pressure when the heat pump is operated.
―  Press [Start] to start the vehicle identification.
―  Press the [Toolbox] tab.
―  Press the [Work Support] icon.
―  Press [EV].
―  Press [Run] for Compulsory operating Air Conditioner.
―  Select [Heating for only heat pump] and press [Next].
•  Is the heating performance and the refrigerant pressure normal?
Yes
Explain to the customer that the normal heating performance is delivered without a problem.
No
Record the inspection results.
•  If the refrigerant pressures on the high pressure and low pressure side are both high, go to Step 15.
•  If the refrigerant pressure values on the high pressure and low pressure sides are both low, go to Step 20.
•  If the refrigerant pressure value on the low pressure side is initially normal, but it becomes a negative value after some time, perform vacuum discharging for 1 hour, charge the specified amount of the refrigerant, then perform the repair completion verification.
•  If the refrigerant pressure on the high pressure side is constantly negative, go to Step 21.
•  If the refrigerant pressure on the high pressure side is low and the refrigerant pressure on the low pressure side is high, go to Step 22.
•  If the refrigerant pressure values on the high pressure and low pressure sides are both normal, go to Step 30.
•  If the refrigerant pressure on the high pressure side is normal and the refrigerant pressure on the low pressure side is high, go to Step 30.
•  If the refrigerant pressure on the high pressure side is high and the refrigerant pressure on the low pressure side is normal, go to Step 30.
•  If the refrigerant pressure on the high pressure side is low and the refrigerant pressure on the low pressure side is normal, go to Step 30.
•  If the electric compressor does not operate, go to the following malfunction symptom item.
15
INSPECT REFRIGERNAT PRESSURE SENSOR No.2
•  Inspect the refrigerant pressure sensor No.2.
•  Is the refrigerant pressure sensor normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
16
INSPECT TEMPERATURE SENSOR OF REFRIGERANT LINE FOR CONDENSER OUTLET
•  Inspect the temperature sensor of refrigerant line for condenser outlet.
•  Is the temperature sensor of refrigerant line for condenser outlet normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
17
INSPECT TEMPERATURE SENSOR OF REFRIGERANT LINE FOR EVAPORATOR OUTLET
•  Inspect the temperature sensor of refrigerant line for evaporator outlet.
•  Is the temperature sensor of refrigerant line for evaporator outlet normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
18
INSPECT AMBIENT TEMPERATURE SENSOR
•  Inspect the ambient temperature sensor.
•  Is the ambient temperature sensor normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
19
INSPECT PASSENGER COMPARTMENT TEMPERATURE SENSOR
•  Is the cabin temperature sensor normal?
Yes
Replace the refrigerant.
After vacuum discharging for 15 min and charging with refrigerant to the specified level, perform the repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
20
INSPECT SYSTEM PIPING
•  Inspect the system piping for gas leakage using the gas leak tester.
•  Is the system piping normal?
Yes
Replace the high voltage battery and perform the repair completion verification.
No
Replace the O-ring of the malfunctioning location (system piping connecting area). Or replace the malfunctioning location of the system piping and perform the repair completion verification.
21
INSPECT REFRIGERANT PRESSURE
•  Warm the orifice for 5 min using a dryer, and inspect the refrigerant pressure again to verify change in the refrigerant pressure.
•  Is the refrigerant pressure initially normal and then it becomes a negative value after some time?
Yes
Replace the refrigerant.
After vacuum discharging for 1 hour, charge the refrigerant to the specified level, then perform the repair completion verification.
No
Replace the orifice and perform the repair completion verification.
22
VERIFY OPERATION OF 2WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Using the M-MDS, select the service support item [Self-Diagnosing Air Conditioner control valves] and inspect the 2way valve for refrigerant.
Note
•  Because [Self-Diagnosing Air Conditioner control valves] cannot be performed if the ambient temperature is 15°C {59 °F} or less or 40 °C {104 °F} or more, go to Step 23 and inspect the 2way valve for refrigerant.
1.  Press [Start] to start the vehicle identification.
2.  Press the [Toolbox] tab.
3.  Press the [Work Support] icon.
4.  Press [EV].
5.  Press [Run] for Self-Diagnosing Air Conditioner control valves.
6.  Select [2-way valve] and press [Next].
•  Is [Normal] displayed as the diagnosis result?
Yes
Go to step 24.
No
If [Abnormal] is displayedIf [Incomplete] is displayed
•  Repair or replace the malfunctioning location and perform the repair completion verification.
•  Go to the next step.
23
VERIFY OPERATION OF 2WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Access the HP simulation item [2_WAY_VLV] using the M-MDS.
•  Switch the main power ON (READY on)
•  Turn the [2_WAY_VLV] PID to ON from OFF using the M-MDS simulation function.
•  is operation sound heard?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
24
VERIFY OPERATION OF 3WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Using the M-MDS, select the service support item [Self-Diagnosing Air Conditioner control valves] and inspect the 3way valve for refrigerant.
Note
•  Because [Self-Diagnosing Air Conditioner control valves] cannot be performed if the ambient temperature is 15°C {59 °F} or less or 40 °C {104 °F} or more, go to Step 25 and inspect the 3way valve for refrigerant.
1.  Press [Start] to start the vehicle identification.
2.  Press the [Toolbox] tab.
3.  Press the [Work Support] icon.
4.  Press [EV].
5.  Press [Run] for Self-Diagnosing Air Conditioner control valves.
6.  Select [3-way valve] and press [Next].
•  Is [Normal] displayed as the diagnosis result?
Yes
Go to step 26.
No
If [Abnormal] is displayedIf [Incomplete] is displayed
•  Repair or replace the malfunctioning location and perform the repair completion verification.
•  Go to the next step.
25
VERIFY OPERATION OF 3WAY VALVE FOR REFRIGERANT
•  Connect the M-MDS to the DLC-2.
•  Switch the main power ON.
•  Access the HP simulation item [3_WAY_VLV] using the M-MDS.
•  Switch the main power ON (READY on)
•  Turn the [3_WAY_VLV] PID to ON from OFF using the M-MDS simulation function.
•  is operation sound heard?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
26
INSPECT TEMPERATURE SENSOR OF REFRIGERANT LINE FOR CONDENSER OUTLET
•  Inspect the temperature sensor of refrigerant line for condenser outlet.
•  Is the temperature sensor of refrigerant line for condenser outlet normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
27
INSPECT TEMPERATURE SENSOR OF REFRIGERANT LINE FOR EVAPORATOR OUTLET
•  Inspect the temperature sensor of refrigerant line for evaporator outlet.
•  Is the temperature sensor of refrigerant line for evaporator outlet normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
28
INSPECT AMBIENT TEMPERATURE SENSOR
•  Inspect the ambient temperature sensor.
•  Is the ambient temperature sensor normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
29
INSPECT PASSENGER COMPARTMENT TEMPERATURE SENSOR
•  Is the cabin temperature sensor normal?
Yes
Replace the electric compressor.
After replacing the part, perform repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
30
INSPECT AIR INTAKE ACTUATOR
•  Inspect the air intake actuator.
•  Is the air intake actuator normal?
Yes
Go to the next step.
No
Replace the air intake actuator and perform the repair completion verification.
31
INSPECT TEMPERATURE SENSOR OF REFRIGERANT LINE FOR CONDENSER OUTLET
•  Inspect the temperature sensor of refrigerant line for condenser outlet.
•  Is the temperature sensor of refrigerant line for condenser outlet normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
32
INSPECT TEMPERATURE SENSOR OF REFRIGERANT LINE FOR EVAPORATOR OUTLET
•  Inspect the temperature sensor of refrigerant line for evaporator outlet.
•  Is the temperature sensor of refrigerant line for evaporator outlet normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
33
INSPECT AMBIENT TEMPERATURE SENSOR
•  Inspect the ambient temperature sensor.
•  Is the ambient temperature sensor normal?
Yes
Go to the next step.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
34
INSPECT PASSENGER COMPARTMENT TEMPERATURE SENSOR
•  Is the cabin temperature sensor normal?
Yes
Replace the electronic compressor.
After replacing the part, perform repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
35
INSPECT CONDENSER
•  Inspect the condenser.
•  Is the condenser normal?
Yes
Replace the refrigerant.
After vacuum discharging for 15 min and charging with refrigerant to the specified level, perform the repair completion verification.
No
Repair or replace the malfunctioning location and perform the repair completion verification.
Repair completion verification
VERIFY THAT MALFUNCTION DOES NOT RECUR AFTER REPAIRS
•  Is there warm airflow (is result of refrigerant system performance (airflow temperature) test normal?)?
Yes
Troubleshooting completed (explain repair contents to customer).
No
Refer to the controller area network (CAN) malfunction diagnosis flow to inspect for a CAN communication error.
If the CAN communication is normal, perform the diagnosis from Step 1.