WINDSHIELD FOGGED [MANUAL AIR CONDITIONER]

DESCRIPTION

• A/C compressor does not operate while airflow mode is in DEFROSTER or HEAT/DEF modes

• Air intake mode does not change to FRESH while airflow mode is in DEFROSTER or HEAT/DEF modes

POSSIBLE CAUSE

• A/C compressor malfunction

• Air intake link malfunction

• Open or short circuit in wiring harness between climate control unit and air intake actuator

• Climate control unit connector malfunction or poor connection

• Air intake actuator connector malfunction or poor connection

• Air intake actuator malfunction

• Climate control unit malfunction

• Blower unit malfunction

• Air intake door malfunction

• When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, inspect to make sure connectors, terminals and wiring harness are connected correctly and undamaged.

Step	Inspection		Action
1	COOL AIR BLOW OUT INSPECTION • When both the A/C switch and airflow volume control dial in the climate control unit are on, does cool air blow out from the vent?	Yes	Go to the next step.
1		No	Go to Step 1 of the following troubleshooting. (See NO COOL AIR [MANUAL AIR CONDITIONER].)
2*	INSPECT TO SEE WHETHER MALFUNCTION IS IN BLOWER UNIT OR AIR INTAKE ACTUATOR • Switch the ignition ON (engine off or on). • Measure voltage at the following terminal (wiring harness-side) when air intake mode at RECIRCULATE and FRESH. ― Climate control unit terminal J • Is voltage normal?	Yes	Go to Step 11.
2*		No	Go to the next step.
3	INSPECT AIR INTAKE ACTUATOR CONNECTOR CONNECTION CONDITION • Switch the ignition off. • Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Inspect the air intake actuator connector engagement and connection condition. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Is the connector normal?	Yes	Go to the next step.
3		No	Reconnect the air intake actuator connector properly. Go to Step 13.
4	INSPECT AIR INTAKE ACTUATOR CONNECTOR TERMINAL CONDITION • Disconnect the air intake actuator connector. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Inspect the connector and terminals (corrosion, damage, pin disconnection). • Are the connector and terminals normal?	Yes	Go to the next step.
4		No	Repair/replace the connector or terminal. Go to Step 13.
5	INSPECT AIR INTAKE ACTUATOR • Inspect air intake actuator. (See AIR INTAKE ACTUATOR INSPECTION [MANUAL AIR CONDITIONER].) • Is it normal?	Yes	Go to the next step.
5		No	Replace the air intake actuator, then go to Step 13. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
6	INSPECT CLIMATE CONTROL UNIT CONNECTOR CONNECTION CONDITION • Inspect the climate control unit connector engagement and connection condition. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Is the connector normal?	Yes	Go to the next step.
6		No	Reconnect the climate control unit connector properly. Go to Step 13.
7	INSPECT CLIMATE CONTROL UNIT CONNECTOR TERMINAL CONDITION • Disconnect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Inspect the connector and terminals (corrosion, damage, pin disconnection). • Are the connector and terminals normal?	Yes	Go to the next step.
7		No	Repair/replace the connector or terminal. Go to Step 13.
8*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO POWER SUPPLY BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Climate control unit and air intake actuator connectors disconnected. • Connect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Switch the ignition ON (engine off or on). • Measure voltage at the following terminal (wiring harness-side). ― Climate control unit terminal H ― Climate control unit terminal J ― Climate control unit terminal D ― Climate control unit terminal K ― Climate control unit terminal I • Are voltages approx. 0 V?	Yes	Go to the next step.
8*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal / evaporator temperature sensor terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to power supply. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to power supply. Go to Step 13.
9*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO GROUND BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Switch the ignition off. • Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 1.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Climate control unit and air intake actuator connectors disconnected. • Inspect for continuity between the following terminals (wiring harness-side) and body ground: ― Climate control unit terminal H ― Climate control unit terminal J ― Climate control unit terminal K ― Climate control unit terminal I • Is there continuity?	Yes	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to ground. Go to Step 13.
9*		No	Go to the next step.
10*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY OR OPEN BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Climate control unit and air intake actuator connectors disconnected. • Inspect for continuity between the following terminals (wiring harness-side): L.H.D. ― Climate control unit terminal H — air intake actuator terminal E ― Climate control unit terminal J — air intake actuator terminal F ― Climate control unit terminal D — air intake actuator terminal G ― Climate control unit terminal K — air intake actuator terminal B ― Climate control unit terminal I — air intake actuator terminal C R.H.D. ― Climate control unit terminal H — air intake actuator terminal G ― Climate control unit terminal J — air intake actuator terminal F ― Climate control unit terminal D — air intake actuator terminal E ― Climate control unit terminal K — air intake actuator terminal C ― Climate control unit terminal I — air intake actuator terminal B • Is there continuity?	Yes	Replace the climate control unit, then go to Step 13. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
10*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 13.
11	INSPECT AIR INTAKE LINK • Inspect the air intake link. (See BLOWER UNIT REMOVAL/INSTALLATION.) ― Is there grease on link? ― Are the links securely and properly installed? ― Are the links free of obstructions and hindrances? • Are the above items normal?	Yes	Go to the next step.
11		No	Apply grease to the links. If any the links are damaged, replace the air intake actuator, then go to Step 13. (See BLOWER UNIT DISASSEMBLY/ASSEMBLY.)
12	INSPECT TO SEE WHETHER MALFUNCTION IS IN CLIMATE CONTROL UNIT OR AIR INTAKE DOOR • Inspect the blower unit air intake door. (See BLOWER UNIT REMOVAL/INSTALLATION.) ― Is the door free of obstructions, cracks, and damage? ― Are the doors securely and properly installed? • Are the above items normal?	Yes	Go to the next step.
12		No	Remove obstruction, or install the doors in the proper position. If any doors are cracked or damaged, replace them, then go to the next step.
13	CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Does the air intake mode change smoothly?	Yes	Troubleshooting completed. Explain repairs to customer.
13		No	Recheck malfunction symptoms, then repeat from Step 1 if the malfunction recurs.

Step	Inspection		Action
1	COOL AIR BLOW OUT INSPECTION • When both the A/C switch and airflow volume control dial in the climate control unit are on, does cool air blow out from the vent?	Yes	Go to the next step.
1		No	Go to Step 1 of the following troubleshooting. (See NO COOL AIR [MANUAL AIR CONDITIONER].)
2	INSPECT AIR INTAKE ACTUATOR CONNECTOR CONNECTION CONDITION • Switch the ignition off. • Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Inspect the air intake actuator connector engagement and connection condition. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Is the connector normal?	Yes	Go to the next step.
2		No	Reconnect the air intake actuator connector properly. Go to Step 13.
3	INSPECT AIR INTAKE ACTUATOR CONNECTOR TERMINAL CONDITION • Disconnect the air intake actuator connector. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Inspect the connector and terminals (corrosion, damage, pin disconnection). • Are the connector and terminals normal?	Yes	Go to the next step.
3		No	Repair/replace the connector or terminal. Go to Step 13.
4*	INSPECT TO SEE WHETHER MALFUNCTION IS IN AIR INTAKE ACTUATOR OR ELSEWHERE • Air intake actuator connector disconnected. • Switch the ignition ON (engine off or on). • Measure voltage at the following terminal (wiring harness-side). 7-speed type airflow volume control dial ― Climate control unit terminal K (RECIRCULATE motor drive signal) ― Climate control unit terminal I (FRESH motor drive signal) 4-speed type airflow volume control dial ― Climate control unit terminal C (RECIRCULATE motor drive signal) ― Climate control unit terminal E (FRESH motor drive signal) • Are voltages normal?	Yes	Go to the next step.
4*		No	Go to Step 6.
5	INSPECT AIR INTAKE ACTUATOR • Inspect air intake actuator. (See AIR INTAKE ACTUATOR INSPECTION [MANUAL AIR CONDITIONER].) • Is it normal?	Yes	Go to the Step 11.
5		No	Replace the air intake actuator, then go to Step 13. (See AIR INTAKE ACTUATOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
6	INSPECT CLIMATE CONTROL UNIT CONNECTOR CONNECTION CONDITION • Inspect the climate control unit connector engagement and connection condition. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Is the connector normal?	Yes	Go to the next step.
6		No	Reconnect the climate control unit connector properly. Go to Step 13.
7	INSPECT CLIMATE CONTROL UNIT CONNECTOR TERMINAL CONDITION • Disconnect the climate control unit connector. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].) • Inspect the connector and terminals (corrosion, damage, pin disconnection). • Are the connector and terminals normal?	Yes	Go to the next step.
7		No	Repair/replace the connector or terminal. Go to Step 13.
8*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO POWER SUPPLY BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Climate control unit and air intake actuator connectors disconnected. • Connect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Switch the ignition ON (engine off or on). • Measure voltage at the following terminal (wiring harness-side). 7-speed type airflow volume control dial ― Climate control unit terminal K ― Climate control unit terminal I 4-speed type airflow volume control dial ― Climate control unit terminal C ― Climate control unit terminal E • Are voltages approx. 0 V?	Yes	Go to the next step.
8*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to power supply. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to power supply. Go to Step 13.
9*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (SHORT TO GROUND BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Switch the ignition off. • Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-D 2.2].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [SKYACTIV-G 1.5, SKYACTIV-G 2.0, SKYACTIV-G 2.5].) (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION [MZR 1.6].) • Climate control unit and air intake actuator connectors disconnected. • Inspect for continuity between the following terminals (wiring harness-side) and body ground: 7-speed type airflow volume control dial ― Climate control unit terminal K ― Climate control unit terminal I 4-speed type airflow volume control dial ― Climate control unit terminal C ― Climate control unit terminal E • Is there continuity?	Yes	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness for a short to ground. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness which has a short to ground. Go to Step 13.
9*		No	Go to the next step.
10*	INSPECT TO SEE WHETHER MALFUNCTION IS IN WIRING HARNESS (LACK OF CONTINUITY OR OPEN BETWEEN CLIMATE CONTROL UNIT AND AIR INTAKE ACTUATOR) OR ELSEWHERE • Climate control unit and air intake actuator connectors disconnected. • Inspect for continuity between the following terminals (wiring harness-side): L.H.D. (7-speed type airflow volume control dial) ― Climate control unit terminal K — air intake actuator terminal B ― Climate control unit terminal I — air intake actuator terminal C L.H.D. (4-speed type airflow volume control dial) ― Climate control unit terminal C — air intake actuator terminal B ― Climate control unit terminal E — air intake actuator terminal C R.H.D. ― Climate control unit terminal K — air intake actuator terminal C ― Climate control unit terminal I — air intake actuator terminal B • Is there continuity?	Yes	Replace the climate control unit, then go to Step 13. (See CLIMATE CONTROL UNIT REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)
10*		No	Refer to the wiring diagram and verify whether or not there is a common connector between climate control unit terminal and air intake actuator terminal. If there is a common connector: • Determine the malfunctioning part by inspecting the common connector and the terminal for corrosion, damage, or pin disconnection, and the common wiring harness. • Repair or replace the malfunctioning part. If there is no common connector: • Repair or replace the wiring harness. Go to Step 13.
11	INSPECT AIR INTAKE LINK • Inspect the air intake link. (See BLOWER UNIT REMOVAL/INSTALLATION.) ― Is there grease on link? ― Are the links securely and properly installed? ― Are the links free of obstructions and hindrances? • Are the above items normal?	Yes	Go to the next step.
11		No	Apply grease to the links. If any the links are damaged, replace the air intake actuator, then go to Step 13. (See BLOWER UNIT DISASSEMBLY/ASSEMBLY.)
12	INSPECT TO SEE WHETHER MALFUNCTION IS IN CLIMATE CONTROL UNIT OR AIR INTAKE DOOR • Inspect the blower unit air intake door. (See BLOWER UNIT REMOVAL/INSTALLATION.) ― Is the door free of obstructions, cracks, and damage? ― Are the doors securely and properly installed? • Are the above items normal?	Yes	Go to the next step.
12		No	Remove obstruction, or install the doors in the proper position. If any doors are cracked or damaged, replace them, then go to the next step.
13	CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Does the air intake mode change smoothly?	Yes	Troubleshooting completed. Explain repairs to customer.
13		No	Recheck malfunction symptoms, then repeat from Step 1 if the malfunction recurs.