HEATING NOT FUNCTIONING EFFECTIVELY [FULL-AUTO AIR CONDITIONER]
id0703c1702200
Malfunction symptom |
Heating not functioning effectively |
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Details
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• Insufficient warmed-airflow even if airflow temperature setting is MAX HOT
• It takes time for airflow to be warmed to set temperature
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Possible Cause
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• 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
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Diagnostic Procedure
Step |
Inspection |
Action |
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1
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INSPECT AIR MIX ACTUATOR
• Inspect the air mix actuator.
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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2
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INSPECT BLOWER UNIT AND AIR FILTER
• Are the blower unit intake and air filter clogged?
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Yes
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Remove the cause of the clogging.
Replace the air filter if it is clogged.
After repair, perform the repair completion verification.
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No
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Go to the next step.
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3
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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?
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Yes
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Go to the next step.
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No
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Go to the following malfunction symptom item.
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4
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INSPECT COOLING FAN OPERATION
• Inspect the cooling fan control.
(See COOLING FAN MOTOR INSPECTION.)
• Is the cooling fan operation normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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5
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INSPECT ACTIVE AIR SHUTTER
• Inspect the applicable part.
• Is the active air shutter normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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6
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INSPECT REFRIGERANT PRESSURE
• Inspect the refrigerant pressure.
(See REFRIGERANT PRESSURE CHECK.)
• Is the active air shutter normal?
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Yes
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Go to the next step.
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No
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Perform malfunction diagnosis according to the symptom troubleshooting for [AIR FROM VENTS NOT COLD ENOUGH] of the climate control system.
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7
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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.
(See PID/DATA MONITOR INSPECTION.)
BECM
• Is PID [HV_BATT_TEMP_MAX] 40 °C {104 °F} or more?
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Yes
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Go to the next step.
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No
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Go to Step 9.
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8
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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.
• Display the following PIDs using the M-MDS.
(See PID/DATA MONITOR INSPECTION.)
BECM
• Is PID [HV_BATT_TEMP_MAX] 40 °C {104 °F} or more?
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Yes
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Perform the inspection content in Step 8 until the temperature of the high voltage battery is 40 °C {104 °F} or less.
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No
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Go to the next step.
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9
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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.
• Is [Normal] displayed as the diagnosis result?
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Yes
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Go to step 11.
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No
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If [Abnormal] is displayedIf [Incomplete] is displayed
• Repair or replace the malfunctioning location and perform the repair completion verification.
• Go to the next step.
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10
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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.
(See SIMULATION INSPECTION.)
• 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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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11
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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.
• Is [Normal] displayed as the diagnosis result?
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Yes
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Go to step 13.
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No
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If [Abnormal] is displayedIf [Incomplete] is displayed
• Repair or replace the malfunctioning location and perform the repair completion verification.
• Go to the next step.
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12
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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.
(See SIMULATION INSPECTION.)
• 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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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13
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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.
• Does warm air flow from the vent when [Heating for only PTC heater] is selected and the PTC heater is operated?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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14
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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.
(See REFRIGERANT PRESSURE CHECK.)
• Is the heating performance and the refrigerant pressure normal?
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Yes
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Explain to the customer that the normal heating performance is delivered without a problem.
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No
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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.
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15
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INSPECT REFRIGERNAT PRESSURE SENSOR No.2
• Inspect the refrigerant pressure sensor No.2.
• Is the refrigerant pressure sensor normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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16
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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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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17
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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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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18
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INSPECT AMBIENT TEMPERATURE SENSOR
• Inspect the ambient temperature sensor.
• Is the ambient temperature sensor normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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19
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INSPECT PASSENGER COMPARTMENT TEMPERATURE SENSOR
• Inspect the cabin temperature sensor.
• Is the cabin temperature sensor normal?
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Yes
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Replace the refrigerant.
After vacuum discharging for 15 min and charging with refrigerant to the specified level, perform the repair completion verification.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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20
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INSPECT SYSTEM PIPING
• Inspect the system piping for gas leakage using the gas leak tester.
(See REFRIGERANT CHARGING.)
• Is the system piping normal?
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Yes
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Replace the high voltage battery and perform the repair completion verification.
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No
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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.
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21
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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?
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Yes
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Replace the refrigerant.
After vacuum discharging for 1 hour, charge the refrigerant to the specified level, then perform the repair completion verification.
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No
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Replace the orifice and perform the repair completion verification.
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22
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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.
• Is [Normal] displayed as the diagnosis result?
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Yes
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Go to step 24.
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No
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If [Abnormal] is displayedIf [Incomplete] is displayed
• Repair or replace the malfunctioning location and perform the repair completion verification.
• Go to the next step.
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23
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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.
(See SIMULATION INSPECTION.)
• 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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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24
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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.
• Is [Normal] displayed as the diagnosis result?
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Yes
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Go to step 26.
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No
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If [Abnormal] is displayedIf [Incomplete] is displayed
• Repair or replace the malfunctioning location and perform the repair completion verification.
• Go to the next step.
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25
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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.
(See SIMULATION INSPECTION.)
• 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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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26
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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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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27
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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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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28
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INSPECT AMBIENT TEMPERATURE SENSOR
• Inspect the ambient temperature sensor.
• Is the ambient temperature sensor normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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29
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INSPECT PASSENGER COMPARTMENT TEMPERATURE SENSOR
• Inspect the cabin temperature sensor.
• Is the cabin temperature sensor normal?
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Yes
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Replace the electric compressor.
After replacing the part, perform repair completion verification.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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30
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INSPECT AIR INTAKE ACTUATOR
• Inspect the air intake actuator.
• Is the air intake actuator normal?
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Yes
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Go to the next step.
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No
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Replace the air intake actuator and perform the repair completion verification.
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31
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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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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32
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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?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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33
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INSPECT AMBIENT TEMPERATURE SENSOR
• Inspect the ambient temperature sensor.
• Is the ambient temperature sensor normal?
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Yes
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Go to the next step.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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34
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INSPECT PASSENGER COMPARTMENT TEMPERATURE SENSOR
• Inspect the cabin temperature sensor.
• Is the cabin temperature sensor normal?
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Yes
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Replace the electronic compressor.
After replacing the part, perform repair completion verification.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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35
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INSPECT CONDENSER
• Inspect the condenser.
(See CONDENSER INSPECTION.)
• Is the condenser normal?
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Yes
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Replace the refrigerant.
After vacuum discharging for 15 min and charging with refrigerant to the specified level, perform the repair completion verification.
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No
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Repair or replace the malfunctioning location and perform the repair completion verification.
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Repair completion verification
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VERIFY THAT MALFUNCTION DOES NOT RECUR AFTER REPAIRS
• Is there warm airflow (is result of refrigerant system performance (airflow temperature) test normal?)?
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Yes
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Troubleshooting completed (explain repair contents to customer).
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No
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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.
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