NO.6 AIR FROM VENTS NOT COLD ENOUGH [FULL-AUTO AIR CONDITIONER]

id0702c1812500

6

Air from vents not cold enough

DESCRIPTION

•  Magnetic clutch operates but A/C system malfunctions.

POSSIBLE CAUSE

Note

•  If the engine coolant temperature increases due to a cooling system malfunction, the fail-safe function disables the A/C operation.

•  Drive belt malfunction (Step 4)

•  Refrigerant pressure switch malfunction (ZJ, ZY) (Step 6)

•  Refrigerant pressure sensor malfunction (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)) (Step 5)

•  Cooling fan system malfunction (Step 8)

•  Condenser or related part malfunction (Step 9)

•  A/C unit or condenser malfunction (Steps 12, 13, 20)

•  Receiver/drier or expansion valve malfunction (valve closes too much) (Steps 11, 20)

•  Malfunction in refrigerant lines (Steps 14—19)

•  Over filling of compressor oil, malfunction in expansion valve or A/C unit air mix link system (Step 22)

•  Evaporative temperature sensor malfunction (Step 21)

Diagnostic procedure

STEP	INSPECTION		ACTION
1	INSPECT PCM, INSTRUMENT CLUSTER AND CLIMATE CONTROL UNIT FOR DTC • Retrieve the PCM and instrument cluster DTC using the M-MDS. • Retrieve the climate control unit DTC using the A/C Operation Check Mode. (See ON-BOARD DIAGNOSTIC TEST [ZJ, ZY].) (See ON-BOARD DIAGNOSTIC TEST [MZ-CD 1.4 DI Turbo].) (See ON-BOARD DIAGNOSTIC TEST [MZ-CD 1.6 (Y6)].) (See DTC DISPLAY [FULL-AUTO AIR CONDITIONER].) (See DTC INSPECTION [INSTRUMENT CLUSTER].) • Are there DTC displayed?	Yes	Go to the applicable DTC troubleshooting procedures. (See DTC TABLE [ZJ, ZY].) (See DTC TABLE [MZ-CD 1.4 DI Turbo].) (See DTC TABLE [MZ-CD 1.6 (Y6)].) (See DTC TABLE [FULL-AUTO AIR CONDITIONER].) (See DTC TABLE [INSTRUMENT CLUSTER].)
1		No	Go to the next step.
2	INSPECT REFRIGERANT PRESSURE TO LOCATE MALFUNCTION • Perform refrigerant pressure check. (See REFRIGERANT PRESSURE CHECK.) • Is the refrigerant pressure normal?	Yes	Go to the next step.
2		No	Record the inspection result. • If the refrigerant high-pressure and low-pressure values are both high, go to Step 8. • If the refrigerant high-pressure and low-pressure values are approximately the same, go to Step 11. • If the refrigerant high-pressure and low-pressure values are both low, go to Step 13. • If there is a vacuum on the low pressure side and extremely low pressure on the high pressure side, go to Step 19. • If there is low pressure on the high pressure side and high pressure on the low pressure side, replace the A/C compressor, then go to Step 23. (See A/C COMPRESSOR REMOVAL/INSTALLATION.) • If the refrigerant pressure is other than above condition, go to Step 21.
3	INSPECT REFRIGERANT SYSTEM PERFORMANCE • Perform refrigerant system performance test. (See REFRIGERANT SYSTEM PERFORMANCE TEST.) • Is the operation normal?	Yes	Operation is normal (Recheck malfunction symptoms.).
3		No	Go to the next step.
4	INSPECT DRIVE BELT • Inspect the drive belt. (See DRIVE BELT INSPECTION [ZJ, ZY].) (See DRIVE BELT INSPECTION [MZ-CD 1.4 DI Turbo].) (See DRIVE BELT INSPECTION [MZ-CD 1.6 (Y6)].) • Is it normal?	Yes	Go to the next step (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)). Go to Step 6 (ZJ, ZY).
4		No	Adjust or replace the drive belt, then the next step (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)). (See DRIVE BELT REPLACEMENT [MZ-CD 1.4 DI Turbo].) (See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].) Adjust or replace the drive belt, then the go to step 6 (ZJ, ZY). (See DRIVE BELT REMOVAL/INSTALLATION [ZJ, ZY].)
5	INSPECT REFRIGERANT PRESSURE SENSOR • Inspect the refrigerant pressure sensor. (See REFRIGERANT PRESSURE SENSOR INSPECTION [FULL-AUTO AIR CONDITIONER].) • Is it normal?	Yes	Go to the step 8.
5		No	Repair or replace malfunctioning part according to inspection result, then go to Step 23. (See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)
6	INSPECT REFRIGERANT PRESSURE SWITCH • Inspect the refrigerant pressure switch. (See REFRIGERANT PRESSURE SWITCH INSPECTION [MANUAL AIR CONDITIONER].) • Is it normal?	Yes	Go to the step 8.
6		No	Replace the refrigerant pressure switch, then go to Step 23. (See REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
7	INSPECT REFRIGERANT PRESSURE SWITCH RELATED HARNESS • Inspect following refrigerant pressure switch wiring harness (open or short circuit) and connectors (corrosion, pulled out pins). ― PCM terminal 1AC and refrigerant pressure switch terminal A ― PCM terminal 1AO and refrigerant pressure switch terminal B ― Refrigerant pressure switch terminal C/D and ground • Is it normal?	Yes	Go to the next step.
7		No	Repair or replace malfunctioning part according to inspection result, then go to Step 22.
8	INSPECT COOLING FAN OPERATION • Verify the cooling fan operation. (See COOLING FAN MOTOR INSPECTION [ZJ, ZY].) (See FAN MOTOR INSPECTION [MZ-CD 1.4 DI Turbo].) (See COOLING FAN MOTOR INSPECTION [MZ-CD 1.6 (Y6)].) • Is the cooling fan operation normal?	Yes	Go to the next step.
8		No	Repair or replace the malfunctioning location according to the inspection results. Then go to Step 23.
9	VISUALLY INSPECT CONDENSER • Is the condenser fin clogged or obstructed by foreign material?	Yes	Remove the foreign material. Repair the condenser fin. Then go to Step 23.
9		No	Go to the next step.
10	CHECK REFRIGERATION SYSTEM FOR OVERCHARGE OR AIR CONTAMINATION • Is the low side line hot to the touch?	Yes	Recover refrigerant. Evacuate system for one hour. Refill with correct amount of refrigerant, and go to step 23.
10		No	Recover refrigerant, evacuate for 15 minutes, refill with correct amount and go to step 23.
11	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR ELSEWHERE • Compare the refrigerant pressure of the low pressure side with the high pressure side at Step 2. • Is there little difference between the high pressure side and low pressure side readings (refer to graph in REFRIGERANT PRESSURE CHECK procedure)? (See REFRIGERANT PRESSURE CHECK.)	Yes	Replace the expansion valve. After performing the following servicing, go to Step 23. • Adjust the compressor oil to the specified level. • After discharging, charge with new refrigerant to the specified level.
11		No	Go to the next step.
12	INSPECT AIR MIX DOOR RELATED PART INSTALLATION • Measure the climate control unit terminal 1M voltage when the temperature control dials are set to MAX COLD and MAX HOT by control panel. • Are voltages normal?	Yes	Adjust the compressor oil to the specified amount, then go to Step 23. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)
12		No	• Inspect the air mix link, air mix crank, air mix wire and air mix rod of the A/C unit correctly and securely installed to their positions. (See A/C UNIT REMOVAL/INSTALLATION.) • Repair or install correctly for suspect part according to inspection result, then go to Step 23.
13	INSPECT A/C UNIT FOR BLOCKAGE • Is the A/C unit intake and air filter clogged?	Yes	Remove the cause of the clogging. Replace the air filter if it is clogged. Then go to Step 23.
13		No	Go to the next step.
14	CHECK TO SEE WHETHER MALFUNCTION IS REFRIGERANT LINE LEAKAGE OR ELSEWHERE • Verify if there is gas leakage from the system hoses using the gas leak tester. • Is there gas leakage?	Yes	If there is leakage from a system hose connection area, go to Step 13. If there is leakage other than from a system hose connection area, go to Step 15.
14		No	Go to the next step.
15	VISUALLY INSPECT REFRIGERANT LINE • Is a system hose crushed?	Yes	Replace the crushed system hose. (See REFRIGERANT LINE REMOVAL/INSTALLATION.) After performing the following servicing, go to Step 23. • Adjust the compressor oil to the specified level. • After discharging, charge with new refrigerant to the specified level.
15		No	Go to Step 22.
16	CHECK TO SEE WHETHER MALFUNCTION IS IN REFRIGERANT LINE JOINT LOOSE OR O-RING • Tighten the system hose connection area to the specified torque. (See REFRIGERANT LINE REMOVAL/INSTALLATION.) • Has the leakage stopped?	Yes	Go to the next step.
16		No	Go to Step 15.
17	VISUALLY INSPECT REFRIGERANT LINE • Is a system hose crushed?	Yes	Replace the crushed system hose. (See REFRIGERANT LINE REMOVAL/INSTALLATION.) After performing the following servicing, go to Step 23. • Adjust the compressor oil to the specified level. • After discharging, charge with new refrigerant to the specified level.
17		No	Adjust the compressor oil to the specified amount, then go to Step 23. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)
18	VISUALLY INSPECT REFRIGERANT LINE • Is a system hose crushed?	Yes	Replace the O-ring of the leaking area. Replace the crushed system hose. (See REFRIGERANT LINE REMOVAL/INSTALLATION.) After performing the following servicing, go to Step 23. • Adjust the compressor oil to the specified level. • After discharging, charge with new refrigerant to the specified level.
18		No	Replace the O-ring of the leaking area. After performing the following servicing, go to Step 23. • Adjust the compressor oil to the specified level. • After discharging, charge with new refrigerant to the specified level.
19	CHECK TO SEE WHETHER MALFUNCTION IS WATER IN REFRIGERANT SYSTEM OR ELSEWHERE • Does the refrigerant pressure on the low pressure side vary between the vacuum and normal range?	Yes	Replace the condenser. (Water in refrigerant system) (See CONDENSER REMOVAL/INSTALLATION.) Then go to Step 23.
19		No	Go to the next step.
20	CHECK TO SEE WHETHER MALFUNCTION IS IN RECEIVER DRYER FILTER OR EXPANSION VALVE • Remove the expansion valve and verify its condition. • 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. Perform discharge, charge with new refrigerant, and then go to Step 23.
20		No	Replace the condenser (Receiver/Dryer filter is clogged.). (See CONDENSER REMOVAL/INSTALLATION.) Then go to Step 23.
21	INSPECT EVAPORATIVE TEMPERATURE SENSOR • Inspect the evaporator temperature sensor. (See EVAPORATOR TEMPERATURE SENSOR INSPECTION [FULL-AUTO AIR CONDITIONER].) • Is it normal?	Yes	Verify the evaporator temperature sensor position. (See A/C UNIT DISASSEMBLY/ASSEMBLY.) Then go to Step 23.
21		No	Replace the evaporator temperature sensor, then go to Step 23. (See A/C UNIT DISASSEMBLY/ASSEMBLY.)
22	INSPECT AIR MIX DOOR RELATED PART INSTALLATION • Measure the climate control unit terminal 1M voltage when the temperature control dials are set to MAX COLD and MAX HOT by control panel. • Are voltages normal?	Yes	Go to the next step.
22		No	• Inspect the air mix link, air mix crank, air mix wire and air mix rod of the A/C unit correctly and securely installed to their positions. (See A/C UNIT DISASSEMBLY/ASSEMBLY.) • Repair or install correctly for suspect part according to inspection result. Then go to next Step.
23	VERIFY THAT MALFUNCTION SYMPTOM DOES NOT OCCURS AFTER REPAIR • If the refrigerant discharged during inspection has not been recharged, discharge and charge with new refrigerant to the specified level. • Does cool air blow out? (Are results of refrigerant system performance test normal?)	Yes	Troubleshooting completed. Explain repairs to customer.
23		No	Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.

6	Air from vents not cold enough
DESCRIPTION	• Magnetic clutch operates but A/C system malfunctions.
POSSIBLE CAUSE	Note • If the engine coolant temperature increases due to a cooling system malfunction, the fail-safe function disables the A/C operation. • Drive belt malfunction (Step 4) • Refrigerant pressure switch malfunction (ZJ, ZY) (Step 6) • Refrigerant pressure sensor malfunction (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)) (Step 5) • Cooling fan system malfunction (Step 8) • Condenser or related part malfunction (Step 9) • A/C unit or condenser malfunction (Steps 12, 13, 20) • Receiver/drier or expansion valve malfunction (valve closes too much) (Steps 11, 20) • Malfunction in refrigerant lines (Steps 14—19) • Over filling of compressor oil, malfunction in expansion valve or A/C unit air mix link system (Step 22) • Evaporative temperature sensor malfunction (Step 21)