JAC S2. Elctrical Wiring diagrams — part 3

Air-conditioning Device

Air-conditioning Device

24

No.

Tool No.

Tool name

Outside drawing

Use

10

Seal protector device

11

50 pounds recycling tanks

12

Pressure test adapter

Connecting A/C

pressure tester and

A/C pipes

13

A/C system lip seal removal tool

Removal A/C

system lip seal

14

O-type seal removal tool

Remove O-type

seal ring

15

Valve core removal and installation tool

Remove and

install valve core

16

O-type seal ring installation tool

Install O-type seal

ring

17

Spring clip pliers

Remove and

install spring clip

Air-conditioning Device

Air-conditioning Device

25

No.

Tool No.

Tool name

Outside drawing

Use

18

Spring clip pliers

Remove and

install spring clip

19

Refrigerant recycle\ regeneration and

refilling system

Recycle and fill

refrigerant

20

Passive test lamp

A/C system

leakage inspection

Air-conditioning Device

Air-conditioning Device

26

II、Troubleshooting

Troubleshooting List

No.

Fault Phenomenon

Fault reason analysis

Solution

Remark

1

A/C system has no
refrigerant

System exists leakage

Check with eyes：

1. Observe whether there is oil stain in connection parts of all

components; if any, it indicates there is leakage here. Spread
suds to suspected part and observe whether there is bubble.

2. Observe whether there is abnormal failure, whether there is

scraping, flattening and bruise on surface of condenser and
evaporator core.

With vacuumizing mode, listen to the part position if there is
“zizi” sound, which indicates the leakage.

Check with instrument：

1. Electronic leak detector with high sensitivity;
2. Dye-guided detection method

2

System
refrigeration oil
not right amount

Replace

system

component, fill or
reduce according to
rules

1. Firstly ensure specification of refrigeration oil, can’t
be mixed; generally using specification: PAG
2. After recycling refrigerant, replenish about 30g
refrigeration oil
3. Replace compressor, pour out all refrigeration oil in
compressor and fill the same refrigeration oil with
replaced compressor
4. Replace pipe: replenish about 30g refrigeration oil
5. Replace condenser: replenish about 60g refrigeration
oil
6. Replace evaporator: replenish about50g refrigeration
oil
7. Replace dryer: replenish about 10g refrigeration oil

3

Blowing

rate

abnormal

A/C has no wind

Circuit fault

Refer to “Blower not work”

Machinery fault
1. Blower motor damaged, replace motor
2. Temperature air door mechanism damaged, and

cannot adjust air door to refrigeration state

3. A/C controller damaged, replace A/C control mo dule
4. Speed regulating resistance damaged, replace speed

control module

A/C blowing rate
small

1. Voltage not enough, check power supply
2. Whether air duct is blocked, whether grille is fully

opened

3. Check whether face air blow has leakage
4. Speed control module fault, replace speed control
module
5. Whether air filter has excessive windage, whether

there is dust and foreign matters blocked

6. Blower motor rotates in reverse direction, adjust

positive and negative electrode of connector

4

A/C

not

refrigerate

System

has

no

refrigerant

Refer to “A/C system has no refrigerant ”

Not blow

Refer to “Blowing rate abnormal ”

Compressor

not

work

Circuit fault

Refer to “Compressor not work”

Machinery fault
1. Drive belt broken, replace
2. Compressor internal fault, replace

5

A/C refrigeration
is not good

Refrigerant

not

enough

1. Check whether pressure is in normal value range; if

lack of refrigerant, refill it.

2. Check whether system has micro leakage

Refrigeration oil too

1. Discharge redundant refrigeration oil, and refill the

Air-conditioning Device

Air-conditioning Device

27

No.

Fault Phenomenon

Fault reason analysis

Solution

Remark

much

satisfactory amount of refrigeration oil

Compressor

is

abnormal

1. Compressor belt or clutch slips

Blowing

rate

is

small

Refer to “Abnormal blowing rate”

Abnormal pressure

High pressure is lower than normal value, low pressure
is lower than normal value
1. Expansion valve is blocked, clear obstructions
2. Opening degree of expansion valve is not enough,

adjust expansion valve or replace

3. Refrigerant is little, add refrigerant
High pressure is higher than normal value, low pressure

is higher than normal value

1. Condenser radiating is not good; Check condenser

fan and replace faulted

2. Refrigerant is too much, release some
High pressure is lower than normal value, low pressure

is higher than normal value

1. Compressor malfunctions, lack of capacity, needs to
be replaced
2. Refrigerant not enough, add refrigerant
High pressure is higher than normal value, low pressure

is lower than normal value

1. There is impurity blocking in the system

6

A/C system no
heating

Heater core has no
hot water

Heating pipe gets blocked, clear obstacle

A/C

not

blowing

wind

Refer to “Blowing rate abnormal ”

Controller fault

Temperature regulation of controller damaged, and
can’t adjust temperature air door to maximum heating,
replace controller

7

A/C

system

heating is not
good

Heating

water

circulation

not

enough

Check whether engine coolant supply is insufficient,
engine failure

Poor

circulation

inside heater core

Clear obstacle in heater core, or replace heater

Blowing

rate

is

small

Refer to “Blowing rate abnormal ”

Mode air door is
wrong

Temperature air door’s rotation is not in place, and
there is a mix of cold and hot

8

A/C system has
abnormal sound

Compressor

has

abnormal sound

Open A/C, compressor works; check whether there is
fractive sound in clutch; if an y, please replace
compressor

Pipe

expansion

valve has abnormal
sound

Start the A/C, check if there is flowing “chirps” sound
in the expansion valve. Adjust the expansion valve and
replace it.

Air door mechanism
has abnormal sound

If there is resistance when adjusting the damper bodies;
whether there is "ticking" or "giggle" sound; if there is
such phenomenon, smear lubrication oil in the damper
body or replace body parts.

Motor damaged

Replace motor

Temperature

air

Replace temperature air door mechanism

Air-conditioning Device

Air-conditioning Device

28

No.

Fault Phenomenon

Fault reason analysis

Solution

Remark

door

mechanism

damaged, and can’t
adjust air door to
refrigeration state

Blower

has

abnormal sound

There is abnormal sound in blower
1. . A "humming" sound ; confirm if the motor rotates
reversely; adjust plug-line;
2. "Creak" or "Zizi" sound; the motor is damaged, and
replace the motor;
3. "Pop" sound; if there is a foreign body in the volute,
remove and check the volute.

Blower is not installed firmly, resulting in vibration and
abnormal sound.

There is water sound
in heater core

1. 1. Idling and stepping on the accelerator (compressor
does not start) to the degree that the condenser fan
rotates at high speed;
2. Continue to step on the accelerator to the degree that
the engine speed exceeds 5000 rpm with the duration of
one minute;
3. Stop accelerating, idle and drastic acceleration to
confirm whether there is still water flow sound; if so,

follow step ② until no sound of water.

9

A/C

system

has

peculiar smell

Filter mildew

Remove the filter to check if the surface has serious
pollution, and timely replace it when necessary.

Radiator surface has
been polluted

Whether the surface of evaporator and heater contains
oil in production; if it has, remove and clean it.

Poor

drainage

of

condenser water

Condensate water cannot be excluded entirely, and
there is water in the case, resulting in deteriorating;
replace the outlet location.

（I）Troubleshooting Flow Chart

Blower not work

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

1

Check

blower

relay fuse

Remove blower relay fuse IF37, and
measure whether blower relay fuse IF37
is fused by multimeter.

Whether fuse is
fused?

Maintain
fuse

short

circuit fault
and replace
fuse

Go to
step 3

2

Check

voltage

value of blower
relay

control

circuit

Measure voltage value between blower
relay ER2-86 terminal and reliable
ground.

Voltage standard
value: 11~14V

Next step

Replac
e relay

3

Check blower fuse

Remove blower relay fuse ESF04, and
measure whether blower relay fuse ESF04
is fused by multimeter.

Whether fuse is
fused?

Maintain
fuse

short

circuit fault
and replace
fuse

Go to
step 3

4

Check

voltage

value of blower
relay

controlled

circuit

Measure voltage value between blower
relay ER2-30 terminal and reliable
ground.

Voltage standard
value: 11~14V

Next step

Mainta
in
failure
circuit

Air-conditioning Device

Air-conditioning Device

29

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

5

Check

connected

circuit

between

blower relay and
blower

wiring

harness

Measure resistance value between blower
wiring harness connector M44 -2 terminal
and ER2-87 terminal.

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

6

Check

connected

circuit

between

blower

wiring

harness and A/C
control

panel

wiring

harness

connector

Measure resistance value between blower
wiring harness connector M44 -1 terminal
and A/C control panel wiring harness
connector M30-4 terminal.

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

7

Replace blower

Remove blower, and install new blower.

Adjust blowing rate button to check
whether blower works normally.

Blower

works

normal

System

is

normal

Next
step

8

Ensure system is
normal

Compressor not work

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

1

Check

A/C

compressor

relay

fuse

Remove A/C compressor relay fuse EF02,
and check whether blower relay fuse
EF02 is fused.

Whether fuse is
fused?

Maintain
fuse circuit
short circuit
fault,

and

replace fuse

Go

to

step 3

2

Check

voltage

value

of

A/C

compressor

relay

control circuit

Check voltage value between blower
relay ER2-86 terminal and reliable
ground.

Voltage standard
value: 11~14V

Next step

Replac
e relay

3

Check

A/C

compressor fuse

Remove A/C compressor fuse EF04, and
check whether blower relay fuse EF04 is
fused.

Whether fuse is
fused?

Maintain
fuse circuit
short circuit
fault,

and

replace fuse

Go

to

step 3

4

Check

voltage

value

of

A/C

compressor

relay

controller circuit

Check voltage value between blower
relay ER05-30 terminal and reliable
ground.

Voltage standard
value: 11~14V

Next step

Mainta
in
failure
circuit

5

Check

circuit

between

A/C

compressor

relay

and

A/C

compressor wiring
harness connector

Measure resistance value between A/C
compressor connector B05 -1 terminal and
ER05-87 terminal by multimeter .

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

6

Check

circuit

between

A/C

compressor

relay

and ECU wiring
harness connector

Measure resistance value between A/C
compressor relay ER05 -86 terminal and
ECU wiring harness connector A22 -10
terminal by multimeter.

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

7

Replace ECU

Disconnect ECU wiring harness, remove
ECU, and replace new ECU. Check
whether A/C compressor works normally.

Whether
compressor
works normally?

System

is

normal

Next
step

Air-conditioning Device

Air-conditioning Device

30

Step

Check content

Solution

Judgement

specification

Next step

Yes

No

8

Replace

A/C

pressure switch

Disconnect

pressure

switch

wiring

harness connector, and replace A/C
pressure switch/

Whether
compressor
works normally?

System

is

normal

Next
step

9

Check

circuit

between

A/C

pressure

switch

wiring

harness

connector and ECU
wiring

harness

connector

Use multimeter to respectively measure
resistance value of A/C pressure switch
wiring harness connector E15 -2 terminal
and ECU wiring harness connector A22 -
79 terminal, A/C pressure switch wiring
harness connector E15 -4 terminal and
ECU wiring harness connector A22 -40
terminal.

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

10

Check

circuit

between

A/C

pressure

switch

wiring

harness

connector and A/C
control

panel

wiring

harness

connector

Use multimeter to respectively measure
resistance value of A/C pressure switch
wiring harness connector E15 -1/E15-3
terminal and A/C control panel wiring
harness connector M29 -23 terminal.

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

11

Check

circuit

between evaporator
temperature sensor
wiring

harness

connector and A/C
control

panel

wiring

harness

connector

Use multimeter to respectively measure
resistance

value

of

evaporator

temperature

sensor

wiring

harness

connector M40-1 terminal and A/C
control panel wiring harness connector
M29-8 terminal, evaporator temperature
sensor wiring harness connector M40 -2
terminal and A/C control panel wiring
harness connector M29 -9 terminal.

Standard
resistance value:
less than 1Ω

Next step

Mainta
in
failure
circuit

12

Check

evaporator

temperature sensor

Measure resistance value of evaporator
temperature sensor by multimeter.

Judge

whether

resistance value
corresponding to
evaporator
temperature
sensor
temperature-
resistance list?

Next step

Replace
evaporator
temperature
sensor

13

Replace

A/C

control panel

Remove fixed bolts of A/C control panel,
disconnect A/C control panel wiring
harness connector, and replace new A/C
control panel

Whether
compressor
works normally?

System

is

normal

Next step

14

Replace

A/C

compressor

Disconnect A/C pipe, remove fixed bol ts
of

compressor,

and

replace

A/C

compressor

Whether
compressor
works normally?

System

is

normal

Next step

15

Ensure system is
normal

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31

III、A/C Check and Filling Refrigerant

（I）Special Tool

No.

Tool No.

Tool name

Tool diagram

1

Refrigerant recycling/ regeneration, refilling

system

2

Passive test lamp

3

R-134A manifold gauge

4

50 pounds recycling tank

5

Pressure test adapter

6

Microthermometer

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32

（II）Refrigerant Filling and Discharging

1. Install refrigerant filling instrument

1). Close manual valves at both ends of refrigerant filling instrument.

2). The filling pipe of the refrigerant filling instrument is installed in joints. Low-pressure pipe to the low pressure nozzle and
high pressure pipe to the high-pressure nozzle. Tighten the nut by hands after connection.

Low

High

Close

Open

2. Operations of discharging refrigerant

1). Connect the refrigerant filling instrument to the system.

2). Put a clean rag in the open part of central hose.

3). Gradually open the high pressure manual valve to discharge refrigerant.

△ Caution Exhausting gas velocity too fast may result in the discharging of the refrigeration oil from the compressor.

4). Check if there is the trace of refrigeration oil on the rag. If there is the trace, slightly close the manual valve.

5). When the filling instrument ruler decreases to 3.5kg/c㎡, slowly open the low pressure manual valve.

6). To reduce the system pressure, slowly open the high pressure and low pressure manual valve until the ruler indicates 0kg/c

㎡.

3. Vacuum operation for refrigeration system

△ Caution System must be vacuumized after discharging refrigerant. This operation is supposed to exclude the air and

moisture in the system, and it should be started in 15 minutes after all the parts are installed.

1). Confirm if the engine stays in “shut down”.

2). Connect the filling instrument to the compressor contact joint, and
close the two ends.

3). Confirm if the refrigerant is excluded from the system.

4). Central pipe is connected to the intake port of the vacuum pump.

5). Open the high pressure/low pressure valve of the filling instrument
after operating the vacuum pump.

6). After 10 minutes, the low pressure detector scale should be higher

than 0.96kg/c㎡ vacuum. Otherwise, the system has leakage and

should be repaired as following steps.

-Use refrigerant container filling system.

-Use leakage detector to check the leakage. If the leakage if detected,
repair it.

-Exclude the refrigerant and vacuumize the system.

- If the leakage does not occur, continue to vacuumize.

7). Operate the vacuum pump again.

8). Filling instrument scale for both ends should keep 0.96kg/c㎡ vacuum.

9). Continue to vacuumize until the ruler indicates 0.96kg/c㎡.

10). About 15 minutes after the implementation of vacuum operation, close the pressure valve of the filling instrument and stop
vacuumizing; separate pipes from the pump. In this way, refrigerant can be added.

Low

High

Close

Close

Air

Vacuum pump

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Air-conditioning Device

33

4. Use refrigerant control valve

1). Before the valve is connected to the refrigerant container, completely turn the handle counterclockwise.

2). Turn counterclockwise until the disc reaches the highest position.

3). After connecting of the central pipe to the valve device, rotate the disc clockwise by hand.

4). Turn the handle clockwise and dill hole in the upper portion of
the sealing part.

5). Loosen the nuts connecting the filling instrument center
connector and pipe.

6). After a few seconds of exhaust, tighten the nut.

5. Adding refrigerant (Gaseous state)

△ Caution This operation is by means of the device on low

pressure side to add the gaseous refrigerant into the system. At this time the refrigerant
container should be put vertical so that the gaseous refrigerant would flow into the system.

1). Install the refrigerant container on the adjusting valve.

2). Open the low pressure valve; adjust the valve until the low pressure scale stays below 4.2kg/m

2

.

3). Start the engine and start the air condition.

△ Caution To prevent the liquid refrigerant flows into compressor through the intake port, put the

container vertical.

4). When add the regulated amount of refrigerant, close the low
pressure valve.

Regulated amount of filling refrigerant: 460±20g

5). If the refrigerant filling speed is too slow, you can put the

container into a container of water of about 40 ℃.

△ Caution Under any circumstances, do not keep the water

heated to above 52 ℃, and hot light should not

touch the container.

Low

Close

Open

Refr
iger
ant

Refrig
erant

Refri
gera
nt

Soak into water to
about 40℃

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34

6. Adding refrigerant (liquid state)

△ Caution This operation is by means of high pressure side filling. Upend the refrigerant container so that

the refrigerant would flow into the system.

1). After the system is vacuumized, completely close both ends of high/low pressure valve.

2). Install the adjusting valve of refrigerant container.

3). Upend the container after the high pressure valve is fully opened.

4). The exclude pressure will increase when the system is over filled. Therefore, when measure the refrigerant weight, fill with
correct amount and close the high pressure valve.

Regulated amount of filling refrigerant: 460±20g

5). After adding regulated amount of refrigerant, close the filling instrument valve.

6). Use leakage detector to check if there is leakage.

△ Caution When use high pressure side filling, the engine will not be started. By use of liquid refrigerant

filling, low pressure valve cannot be opened. Performance test should be conducted before
separating the filling instrument.

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Air-conditioning Device

35

IV、A/C Controller Assembly

（I）Removal

1. Open the engine compartment hood.

2. Disconnect the negative cable of the battery. Refer to “Disconnection and connection of battery electrode”

3. Disassemble the air condition control module assembly.

1). Pry out the air condition control module;

2). Disconnect the wiring harness connector of the air condition control module assembly;

3). Remove the air condition control module;

（II）Installation

1.

Install air condition control module assembly

1). Connect the wiring harness connector of the air condition control module assembly;

2). Press the air condition control module with the installation panel assembly into the installation hole and make sure it is in
place;

2. Connect the cable to the negative pole of the battery;

3. Close the engine compartment hood;

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Air-conditioning Device

36

V、Speed Regulating Resistance

（I）Removal

1. Open engine cabin cover;

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery electrode”

3. Remove glove box assembly; refer to “Glove box assembly”;

4. Remove speed regulating resistance;

1). Disconnect wiring harness connector ① of speed regulating

resistance;

2). Remove 2 fixed bolts ②;

3). Take down speed regulating resistance;

（II）Installation

1. Install speed regulating resistance

1). Place speed regulating resistance to installation position, and tighten

2 fixed bolts ②;

2). Connect wiring harness connector ① of speed regulating

resistance;

2. Install glove box assembly;

3. Connect battery negative electrode;

4. Close engine cabin cover;

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37

VI、Exhausting Pipe Assembly

（I）Removal

1. Open engine cabin cover

2. Remove intake hose; refer to “intake hose assembly”

3. Recycle refrigerant, refrigeration oil; refer to “Refrigerant, refrigeration oil”

4. Remove exhausting pipe assembly

1). Remove 1 fixed nut of exhausting pipe assembly and condenser assembly;

2). Remove 1 fixed bolt of exhausting pipe assembly and

compressor assembly;

3). Take down exhausting pipe assembly;

（II）Installation

1. Install exhausting pipe assembly

1). Place exhausting pipe assembly to installation place, and

tighten 1 fixed bolt of exhausting pipe assembly and

compressor assembly;

2). Tighten fixed nut of exhausting pipe assembly and condenser assembly;

2. Fill refrigerant and refrigeration oil

3. Install intake hose

4. Close engine cabin cover

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38

VII、Pipe and Expansion Valve Assembly

（I）Removal

1. Open engine cabin cover

2. Disconnect battery negative electrode; refer to “Disconnection and connection of battery electrode”

3. Remove intake hose; Refer to “Intake hose assembly”

4. Recycle refrigerant, refrigeration oil; Refer to “Refrigerant and refrigeration oil”

5. Remove pipe and expansion valve assembly

1). Disconnect wiring harness connector of ternary pressure switch;

2). Remove 2 fixed bolts of expansion valve assembly and A/C
host;

3). Remove fixed bolt of pipe and expansion valve assembly and
vehicle body;

4). Remove fixed bolt of pipe and expansion valve assembly and
right front suspension;

5). Remove fixed bolt of pipe and expansion valve assembly

and condenser assembly;

6). Remove fixed bolt of pipe and expansion valve assembly and compressor assembly;

7). Take down pipe and expansion valve assembly;

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39

（II）Installation

1. Install pipe and expansion valve assembly

1). Place pipe and expansion valve assembly to installation position, and tighten fixed bolt of compressor

assembly;

2). Tighten fixed nut of pipe and expansion valve assembly and condenser assembly;

3). Tighten fixed bolt of pipe and expansion valve assembly and right
front suspension.

4). Tighten fixed bolt of pipe and expansion valve assembly and
vehicle body suspension.

5). Tighten 2 fixed bolts of expansion valve assembly and A/C host.

6). Connect wiring harness of ternary pressure switch.

2. Fill refrigerant, refrigeration oil

3. Install intake hose

4. Connect battery negative electrode

5. Close engine cabin cover