NO.6 AIR FROM VENTS NOT COLD ENOUGH [MANUAL AIR CONDITIONER]

STEP	INSPECTION	ACTION
1	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.)
No	Go to the next step.
2	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.
No	Adjust or replace the drive belt, then the next step. (See DRIVE BELT REMOVAL/INSTALLATION [ZJ, ZY].) (See DRIVE BELT REPLACEMENT [MZ-CD 1.4 DI Turbo].) (See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)
3	INSPECT REFRIGERANT PRESSURE SWITCH/REFRIGERANT PRESSURE SENSOR • Inspect the refrigerant pressure switch. (ZJ, ZY) (See REFRIGERANT PRESSURE SWITCH INSPECTION [MANUAL AIR CONDITIONER].) • Inspect the refrigerant pressure sensor. (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)) (See REFRIGERANT PRESSURE SENSOR INSPECTION [MANUAL AIR CONDITIONER].) • Is it normal?	Yes	Go to the next step.
No	Replace the refrigerant pressure switch/refrigerant pressure sensor, then go to Step 23. (See REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) (See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
4	CHECK TO SEE WHETHER MALFUNCTION IS IN A/C UNIT INTAKE AND CONDENSER OR ELSEWHERE • Perform refrigerant pressure check. (See REFRIGERANT PRESSURE CHECK.) • Are the refrigerant high-pressure and low-pressure values both high?	Yes	Go to the next step.
No	After recording the inspection results, go to Step 9.
5	INSPECT COOLING FAN OPERATION • Verify the cooling fan operation. (See 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.
No	Repair or replace the malfunctioning location according to the inspection results. Then go to Step 23.
6	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.
No	Go to the next step.
7	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR ELSEWHERE • Verify the condition of the low pressure hose while the A/C is operating. • Is there frost or condensation adhering?	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.
No	Go to the next step.
8	INSPECT AIR MIX DOOR RELATED PART INSTALLATION • Remove the A/C unit. (See A/C UNIT REMOVAL/INSTALLATION.) • Are the air mix link, air mix crank, and air mix rod of the A/C unit correctly and securely installed to their positions?	Yes	Adjust the compressor oil to the specified amount, then go to Step 23. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)
No	Repair or install the links, cranks and rods securely in the proper position, then go to Step 23.
9	CHECK TO SEE WHETHER MALFUNCTION IS IN A/C UNIT AND REFRIGERANT PRESSURE LINE OR ELSEWHERE • Are the refrigerant high-pressure and low-pressure values low?	Yes	Go to the next step.
No	Go to Step 16.
10	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.
No	Go to the next step.
11	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.
No	Go to the next step.
12	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.
No	Go to Step 22.
13	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.
No	Go to Step 15.
14	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.
No	Adjust the compressor oil to the specified amount, then go to Step 23. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)
15	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.
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.
16	CHECK TO SEE WHETHER MALFUNCTION IS IN CONDENSER AND EXPANSION VALVE OR ELSEWHERE • Do the results of the refrigerant pressure inspection in Step 4 indicate vacuum on the low pressure side and extremely low pressure on the high pressure side?	Yes	Go to the next step.
No	Go to Step 20.
17	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE AND RECEIVER/DRIER OR ELSEWHERE • Does the refrigerant pressure on the low pressure side vary between the vacuum and normal range?	Yes	Replace the condenser. (See CONDENSER 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.
No	Go to the next step.
18	CHECK TO SEE WHETHER MALFUNCTION IS IN CONDENSER OR EXPANSION VALVE • Verify the condition of the outlet hose on the condenser high pressure side. • Is there condensation in the hose?	Yes	Replace the condenser. (See CONDENSER 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.
No	Go to the next step.
19	INSPECT 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.
No	Install the expansion valve, then go to Step 22.
20	CHECK TO SEE WHETHER MALFUNCTION IS IN A/C COMPRESSOR OR ELSEWTHERE • Do the results of the refrigerant pressure inspection in Step 4 indicate low pressure on the high pressure side and high pressure on the low pressure side?	Yes	Replace the A/C compressor, then go to Step 23. (See A/C COMPRESSOR REMOVAL/INSTALLATION.)
No	Go to the next step.
21	INSPECT EVAPORATIVE TEMPERATURE SENSOR • Inspect the evaporator temperature sensor. (See A/C UNIT DISASSEMBLY/ASSEMBLY.) • Is it normal?	Yes	Verify the evaporator temperature sensor position. (See A/C UNIT DISASSEMBLY/ASSEMBLY.) Then go to Step 23.
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 • Remove the A/C unit. (See A/C UNIT REMOVAL/INSTALLATION.) • Are the air mix link, air mix crank, and air mix rod of the A/C unit correctly and securely installed to their positions?	Yes	Go to the next step.
No	Repair or install the links, cranks and rods securely in the proper position, then go to the next step. (See A/C UNIT DISASSEMBLY/ASSEMBLY.)
23	VERIFY THAT MALFUNCTION SYMPTOM 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.
No	Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.

STEP

INSPECTION

ACTION

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.)

Go to the next step.

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.

Adjust or replace the drive belt, then the next step.

(See DRIVE BELT REMOVAL/INSTALLATION [ZJ, ZY].)

(See DRIVE BELT REPLACEMENT [MZ-CD 1.4 DI Turbo].)

(See DRIVE BELT REMOVAL/INSTALLATION [MZ-CD 1.6 (Y6)].)

INSPECT REFRIGERANT PRESSURE SWITCH/REFRIGERANT PRESSURE SENSOR

• Inspect the refrigerant pressure switch. (ZJ, ZY)

(See REFRIGERANT PRESSURE SWITCH INSPECTION [MANUAL AIR CONDITIONER].)

• Inspect the refrigerant pressure sensor. (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6))

(See REFRIGERANT PRESSURE SENSOR INSPECTION [MANUAL AIR CONDITIONER].)

• Is it normal?

Yes

Go to the next step.

Replace the refrigerant pressure switch/refrigerant pressure sensor, then go to Step 23.

(See REFRIGERANT PRESSURE SWITCH REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

(See REFRIGERANT PRESSURE SENSOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

CHECK TO SEE WHETHER MALFUNCTION IS IN A/C UNIT INTAKE AND CONDENSER OR ELSEWHERE

• Perform refrigerant pressure check.

(See REFRIGERANT PRESSURE CHECK.)

• Are the refrigerant high-pressure and low-pressure values both high?

Yes

Go to the next step.

After recording the inspection results, go to Step 9.

INSPECT COOLING FAN OPERATION

• Verify the cooling fan operation.

(See 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.

Repair or replace the malfunctioning location according to the inspection results.

Then go to Step 23.

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.

Go to the next step.

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR ELSEWHERE

• Verify the condition of the low pressure hose while the A/C is operating.

• Is there frost or condensation adhering?

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.

Go to the next step.

INSPECT AIR MIX DOOR RELATED PART INSTALLATION

• Remove the A/C unit.

(See A/C UNIT REMOVAL/INSTALLATION.)

• Are the air mix link, air mix crank, and air mix rod of the A/C unit correctly and securely installed to their positions?

Yes

Adjust the compressor oil to the specified amount, then go to Step 23.

(See A/C COMPRESSOR REMOVAL/INSTALLATION.)

Repair or install the links, cranks and rods securely in the proper position, then go to Step 23.

CHECK TO SEE WHETHER MALFUNCTION IS IN A/C UNIT AND REFRIGERANT PRESSURE LINE OR ELSEWHERE

• Are the refrigerant high-pressure and low-pressure values low?

Yes

Go to the next step.

Go to Step 16.

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.

Go to the next step.

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.

Go to the next step.

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.

Go to Step 22.

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.

Go to 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.

Adjust the compressor oil to the specified amount, then go to Step 23.

(See A/C COMPRESSOR REMOVAL/INSTALLATION.)

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.

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.

CHECK TO SEE WHETHER MALFUNCTION IS IN CONDENSER AND EXPANSION VALVE OR ELSEWHERE

• Do the results of the refrigerant pressure inspection in Step 4 indicate vacuum on the low pressure side and extremely low pressure on the high pressure side?

Yes

Go to the next step.

Go to Step 20.

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE AND RECEIVER/DRIER OR ELSEWHERE

• Does the refrigerant pressure on the low pressure side vary between the vacuum and normal range?

Yes

Replace the condenser.

(See CONDENSER 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.

Go to the next step.

CHECK TO SEE WHETHER MALFUNCTION IS IN CONDENSER OR EXPANSION VALVE

• Verify the condition of the outlet hose on the condenser high pressure side.

• Is there condensation in the hose?

Yes

Replace the condenser.

(See CONDENSER 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.

Go to the next step.

INSPECT 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.

Install the expansion valve, then go to Step 22.

CHECK TO SEE WHETHER MALFUNCTION IS IN A/C COMPRESSOR OR ELSEWTHERE

• Do the results of the refrigerant pressure inspection in Step 4 indicate low pressure on the high pressure side and high pressure on the low pressure side?

Yes

Replace the A/C compressor, then go to Step 23.

(See A/C COMPRESSOR REMOVAL/INSTALLATION.)

Go to the next step.

INSPECT EVAPORATIVE TEMPERATURE SENSOR

• Inspect the evaporator temperature sensor.

(See A/C UNIT DISASSEMBLY/ASSEMBLY.)

• Is it normal?

Yes

Verify the evaporator temperature sensor position.

(See A/C UNIT DISASSEMBLY/ASSEMBLY.)

Then go to Step 23.

Replace the evaporator temperature sensor, then go to Step 23.

(See A/C UNIT DISASSEMBLY/ASSEMBLY.)

INSPECT AIR MIX DOOR RELATED PART INSTALLATION

• Remove the A/C unit.

(See A/C UNIT REMOVAL/INSTALLATION.)

• Are the air mix link, air mix crank, and air mix rod of the A/C unit correctly and securely installed to their positions?

Yes

Go to the next step.

Repair or install the links, cranks and rods securely in the proper position, then go to the next step.

(See A/C UNIT DISASSEMBLY/ASSEMBLY.)

VERIFY THAT MALFUNCTION SYMPTOM 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.

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	• Drive belt malfunction (Step 2) • Refrigerant pressure switch malfunction (ZJ, ZY) (Step 3) • Refrigerant pressure sensor malfunction (MZ-CD 1.4 DI Turbo, MZ-CD 1.6 (Y6)) (Step 3) • Malfunction in A/C unit or condenser (Step 4) • Cooling fan system malfunction (Step 5) • Condenser or related part malfunction (Step 6) • Receiver/drier or expansion valve malfunction (valve closes too mach) (Steps 7, 18, 19) • A/C unit or condenser malfunction (Steps 8—10, 18) • Malfunction in refrigerant lines (Steps 11—17) • A/C compressor system malfunction, insufficient compressor oil (Step 20) • Evaporative temperature sensor malfunction (Step 21) • Over filling of compressor oil, malfunction in expansion valve or A/C unit air mix link system (Step 22)