Juke F15 (2012 year). Service Repair Manual — part 228
REFRIGERANT
HA-21
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• Temperature setting: Full cold
• Fan speed: Maximum speed set
7.
Run the engine at approximately 1,500 rpm for 2 minutes or more.
8.
Stop the engine. Check again for refrigerant leakage. GO TO 4.
WARNING:
Be careful not to get burned when the engine is hot.
NOTE:
• Start refrigerant leakage check immediately after the engine is
stopped.
• When refrigerant circulation is stopped, pressure on the low-
pressure side rises gradually, and after this, pressure on the
high-pressure side falls gradually.
• The higher the pressure is, the easier it is to find the refriger-
ant leakage.
Recycle Refrigerant
INFOID:0000000006485594
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, or
throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1.
Perform lubricant return operation. Refer to
HA-23, "Perform Lubricant Return Operation"
. (If refrigerant or
lubricant leakage is detected in a large amount, omit this step, and then GO TO 2.)
CAUTION:
Never perform lubricant return operation if a large amount of refrigerant or lubricant leakage is
detected.
2.
Check gauge pressure readings of recovery/recycling/recharging equipment. When remaining pressure
exists, recycle refrigerant from high-pressure hose and low-pressure hose.
NOTE:
Follow manufacturer instructions for the handling or maintenance of the equipment. Never fill the equip-
ment with non-specified refrigerant.
3.
Remove A/C service valve cap from the vehicle.
4.
Connect recovery/recycling/recharging equipment to A/C service valve.
5.
Operate recovery/recycling/recharging equipment, and recycle refrigerant from the vehicle.
6.
Evacuate air for 10 minutes or more to remove any remaining refrigerant integrated to compressor lubri-
cant, etc.
7.
Refrigerant recycle operation is complete.
Charge Refrigerant
INFOID:0000000006485595
WARNING:
• Always use HFC-134a for A/C refrigerant. If CFC-12 is accidentally charged, compressor is damaged
due to insufficient lubrication.
• Always observe and follow precautions described on refrigerant container. Incorrect handling may
result in an explosion of refrigerant container, frostbite, or the loss of eyesight.
• Never breathe A/C refrigerant and lubricant vapor or mist. Exposure my irritate eyes, nose, or throat.
• Never allow HFC-134a to be exposed to an open flame or others because it generates poisonous gas
when in contact with high temperature objects. Keep workshop well ventilated.
1.
Connect recovery/recycling/recharging equipment to the A/C service valve.
SHA839E
HA-22
< BASIC INSPECTION >
[HR16DE]
REFRIGERANT
2.
Operate recovery/recycling/recharging equipment, and evacuate air from A/C system for 25 minutes or
more.
CAUTION:
Evacuate air for 15 minutes or more if the parts are replaced.
3.
Check the airtightness of A/C system for 25 minutes or more. If pressure rises more than the specified
level, charge A/C system with approximately 200 g (0.4 lb) refrigerant and check that there is no refriger-
ant leakage. Refer to
CAUTION:
Check the airtightness for 15 minutes or more if the parts are replaced.
4.
If parts other than compressor are replaced, fill compressor lubricant according to parts that are replaced.
5.
Charge the specified amount of refrigerant to A/C system.
6.
Check that A/C system operates normally.
7.
Disconnect recovery/recycling/recharging equipment. (Collect the refrigerant from the high-pressure hose
and low-pressure hose of recovery/recycling/recharging equipment.)
8.
Install A/C service valve cap.
9.
Refrigerant charge is complete.
LUBRICANT
HA-23
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LUBRICANT
Description
INFOID:0000000006485596
MAINTENANCE OF LUBRICANT LEVEL
The compressor lubricant is circulating in the system together with the refrigerant. It is necessary to fill com-
pressor with lubricant when replacing A/C system parts or when a large amount of refrigerant leakage is
detected. It is important to always maintain lubricant level within the specified level. Otherwise, the following
conditions may occur.
• Insufficient lubricant amount: Stuck compressor
• Excessive lubricant amount: Insufficient cooling (caused by insufficient heat exchange)
Inspection
INFOID:0000000006485597
If a compressor is malfunctioning (internal noise, insufficient cooling), check the compressor oil.
1.
COMPRESSOR OIL JUDGMENT
1.
Remove the compressor. Refer to
HA-32, "COMPRESSOR : Removal and Installation"
2.
Sample a compressor oil and judge on the figure.
Judgement result 1>>Replace compressor only.
Judgement result 2>>Replace compressor and liquid tank.
Perform Lubricant Return Operation
INFOID:0000000006485598
CAUTION:
If a large amount of refrigerant or lubricant leakage is detected, never perform lubricant return opera-
tion.
1.
Start the engine and set to the following conditions.
• Engine speed: Idling to 1,200 rpm
• A/C switch: ON
• Fan speed: Maximum speed set
• Intake door position: Recirculation
• Temperature setting: Full cold
2.
Perform lubricant return operation for approximately 10 minutes.
3.
Stop the engine.
4.
Lubricant return operation is complete.
Lubricant Adjusting Procedure for Components Replacement Except Compressor
INFOID:0000000006485599
Fill with lubricant for the amount that is calculated according to the following conditions.
Example: Lubricant amount to be added when replacing evaporator and liquid tank [m (Imp fl oz.)] = 35 (1.2)
+ 5 (0.2) +
α
Name
: A/C System Oil Type R
JSIIA0927GB
HA-24
< BASIC INSPECTION >
[HR16DE]
LUBRICANT
Lubricant Adjusting Procedure for Compressor Replacement
INFOID:0000000006485600
1.
Drain lubricant from removed compressor and measure lubricant amount.
1.
Drain lubricant from high-pressure port (A) and low-pres-
sure port (B) while rotating magnet clutch.
2.
Measure total amount of lubricant that is drained from
removed compressor.
2.
Drain lubricant from a new compressor that is calculated accord-
ing to the following conditions.
CAUTION:
If lubricant amount that is drained from removed compressor is less than 60 m (2.1 Imp fl oz.),
perform calculation by setting “D” as 40 m (1.4 Imp fl oz.).
Example: Lubricant amount to be drained from a new compressor when replacing compressor and liquid
tank [m (Imp fl oz.)] [D = 60 (2.1),
α
= 5 (0.2)]
120 (4.2)
−
[60 (1.6) + 20 (0.7) + 5 (0.2) + 5 (0.2)] = 30 (1.0)
Conditions
Lubricant amount to be added to A/C system
m
(Imp fl oz.)
Replace evaporator
35 (1.2)
Replace condenser
15 (0.5)
Replace liquid tank
5 (0.2)
Refrigerant leakage is detected
Large amount leakage
30 (1.1)
Small amount leakage
—
Lubricant amount that is recycled together with refrigerant during recycle operation
α
JMIIA0940ZZ
Amount to be drained (A) [m (Imp fl oz.)] = F
−
(D
+ S + R +
α
)
F
: Lubricant amount that a new compressor
contains [120 (4.2)]
D
: Lubricant amount that is drained from re-
moved compressor
S
: Lubricant amount that remains inside of re-
moved compressor [20 (0.7)]
R
: Lubricant amount to be added according to
components that are removed except com-
pressor
α
: Lubricant amount that is recycled together
with refrigerant during recycle operation
Conditions
Lubricant amount to be added to A/C system
m
(Imp fl oz.)
Replace evaporator
35 (1.2)
Replace condenser
15 (0.5)
Replace liquid tank
5 (0.2)
JPIIA1455GB
LUBRICANT
HA-25
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3.
Install compressor and check the operation.
HA-26
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PERFORMANCE TEST
PERFORMANCE TEST
Inspection
INFOID:0000000006485601
INSPECTION PROCEDURE
1.
Connect recovery/recycling/recharging equipment (for HFC-134a) or manifold gauge.
2.
Start the engine, and set to the following condition.
Test condition
3.
Maintain test condition until A/C system becomes stable. (Approximately 10 minutes)
4.
Check that test results of “recirculating-to-discharge air temperature” and “ambient air temperature-to-
operating pressure” are within the specified value.
5.
When test results are within the specified value, inspection is complete.
If any of test result is out of the specified value, perform diagnosis by gauge pressure. Refer to
.
RECIRCULATING-TO-DISCHARGE AIR TEMPERATURE TABLE
AMBIENT AIR TEMPERATURE-TO-OPERATING PRESSURE TABLE
Surrounding condition
Indoors or in the shade (in a well-ventilated place)
Vehicle condition
Door
Closed
Door glass
Full open
Hood
Open
Engine speed
Idle speed
A/C condition
Temperature control switch or dial
Full cold
A/C switch
ON
Air outlet
VENT (ventilation)
Intake door position
Recirculation
Fan speed
Maximum speed set
Inside air (Recirculating air) at blower assembly inlet
Discharge air temperature from center ventilator
°
C (
°
F)
Relative humidity
%
Air temperature
°
C (
°
F)
50 – 60
20 (68)
3.6 – 5.6 (38 – 42)
25 (77)
9.3 – 11.8 (49 – 53)
30 (86)
12.9 – 15.9 (55 – 61)
35 (95)
19.4 – 22.9 (67 – 73)
60 – 70
20 (68)
5.6 – 7.6 (42 – 46)
25 (77)
11.8 – 14.3 (53 – 58)
30 (86)
15.9 – 18.9 (61 – 66)
35 (95)
22.9 – 26.4 (73 – 80)
PERFORMANCE TEST
HA-27
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Fresh air
High-pressure (Discharge side)
kPa (bar, kg/cm
2
, psi)
Low-pressure (Suction side)
kPa (bar, kg/cm
2
, psi)
Relative humidity
%
Air temperature
°
C (
°
F)
50 – 70
25 (77)
1,085 – 1,112
(10.9 – 11.1, 11.1 – 11.3, 157.3 –
161.2)
198 – 243
(1.9 – 2.4, 2.0 – 2.5, 28.7 – 35.2)
30 (86)
1,326 -– 1,620
(13.3 – 16.2, 13.5 – 16.5, 192.2 –
234.9)
260 – 318
(2.6 – 3.2, 2.7 – 3.2, 37.7 – 46.1)
35 (95)
1,482 – 1,811
(14.8 – 18.1, 15.1 – 18.5, 214.9 –
262.6)
314 – 384
(3.1 – 3.8, 3.2 – 3.9, 45.5 – 55.7)
40 (104)
1,812 – 2,214
(18.1 – 22.1, 18.5 – 22.6, 262.7 –
321.0)
419 – 512
(4.2 – 5.1, 4.3 – 5.2, 60.8 – 74.2)
HA-28
< SYMPTOM DIAGNOSIS >
[HR16DE]
REFRIGERATION SYSTEM SYMPTOMS
SYMPTOM DIAGNOSIS
REFRIGERATION SYSTEM SYMPTOMS
Trouble Diagnosis For Unusual Pressure
INFOID:0000000006485602
Diagnose using a manifold gauge whenever system’s high and/or low side pressure(s) is/are unusual. The
marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Refer to
above table (Ambient air temperature-to-operating pressure table) since the standard (usual) pressure, how-
ever, differs from vehicle to vehicle.
Symptom Table
INFOID:0000000006485603
Gauge indication
Refrigerant cycle
Probable cause
Corrective action
Both high- and low-pressure sides
are too high.
The pressure returns to nor-
mal soon after sprinkling wa-
ter on condenser.
Overfilled refrigerant.
Collect all refrigerant, evacuate
refrigerant cycle again, and
then refill it with the specified
amount of refrigerant.
Air flow to condenser is insuf-
ficient.
Insufficient condenser cooling
performance.
• Poor fan rotation of radiator
and condenser.
• Improper installation of air
guide.
• Clogged or dirty condenser
fins.
• Repair or replace malfunc-
tioning parts.
• Clean and repair condenser
fins.
When compressor is stopped,
a high-pressure reading
quickly drops by approximate-
ly 196 kPa (2 kg/cm
2
, 28 psi).
It then gradually decreases.
Air mixed in refrigerant cycle.
Collect all refrigerant, evacuate
refrigerant cycle again, and
then refill it with the specified
amount of refrigerant.
• Low-pressure pipe is cooler
than the outlet of evapora-
tor.
• Low-pressure pipe is frost-
ed.
Expansion valve opened too
much (excessive flow of refrig-
erant).
Replace expansion valve.
High-pressure side is excessively
high and low-pressure side is too
low.
High-pressure pipe and upper
side of condenser become
hot, however, liquid tank does
not become so hot.
Clogged or crushed high-pres-
sure pipe located between
compressor and condenser.
Repair or replace the malfunc-
tioning parts.
High-pressure side is too low and
low-pressure side is too high.
• The readings of both sides
become equal soon after
compressor operation
stops.
• There is no temperature dif-
ference between high- and
low-pressure sides.
Malfunction in compressor sys-
tem (insufficient compressor
pressure operation).
• Damage or breakage of
valve.
• Malfunctioning gaskets.
Replace compressor.
AC359A
AC360A
AC356A
REFRIGERATION SYSTEM SYMPTOMS
HA-29
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Both high- and low-pressure sides
are too low.
• The area around evapora-
tor outlet does not become
cold.
• The area around evapora-
tor inlet becomes frosted.
Clogged expansion valve.
• Breakage of temperature
sensor.
• Clogging by foreign material.
Eliminate foreign material from
expansion valve, or replace it.
• There is a temperature dif-
ference between the areas
around outlet and inlet
pipes of liquid tank.
• Liquid tank becomes frost-
ed.
Malfunction in inner liquid tank
(clogged strainer).
Replace liquid tank.
Evaporator becomes frosted.
Clogged or crushed low-pres-
sure pipe.
Repair or replace malfunction-
ing parts.
Malfunction in intake sensor
(AUTOMATIC AIR CONDI-
TIONING) or thermo control
amp. (MANUAL AIR CONDI-
TIONING).
• Check intake sensor system.
Refer to
(AUTOMATIC
AIR CONDITIONING).
• Check thermo control amp.
(MANUAL AIR CONDITION-
ING).
There is a small temperature
difference between the high
and low pressure pipes for re-
frigerant cycle.
• Shortage of refrigerant.
• Leakage of refrigerant.
• Check for leakage.
• Collect all refrigerant, evacu-
ate refrigerant cycle again,
and then refill it with the spec-
ified amount of refrigerant.
Low-pressure side sometimes be-
comes negative.
• Sometimes the area
around evaporator outlet
does not become cold.
• Sometimes the area
around evaporator inlet is
frosted.
• Icing caused by the mixing of
water in cooler cycle.
• Deteriorated dryer in liquid
tank.
• Collect all refrigerant.
• Evacuate refrigerant cycle
completely, and then refill it
with the specified amount of
refrigerant. At this time, al-
ways replace liquid tank.
Gauge indication
Refrigerant cycle
Probable cause
Corrective action
AC353A
AC354A
HA-30
< SYMPTOM DIAGNOSIS >
[HR16DE]
NOISE
NOISE
Symptom Table
INFOID:0000000006485604
Symptom
Noise source
Probable cause
Corrective action
Unusual noise from compressor
when A/C is ON.
Inside of compressor
Wear, breakage, or clogging of foreign
material in inner parts.
Check compressor oil. Re-
fer to
.
Magnet clutch
Contact of clutch disc with pulley.
Check clearance between
clutch disc and pulley. Refer
to
.
Compressor body
Loosened compressor mounting bolts.
Check bolts for tightness.
Refer to
Unusual noise from cooler piping.
Cooler piping (pipe and
flexible hose)
Improper installation of clip and brack-
et.
Check the installation condi-
tion of the cooler piping. Re-
fer to
Unusual noise from expansion
valve when A/C is ON.
Expansion valve
Shortage of refrigerant.
• Check for leakage.
• Collect all refrigerant,
evacuate refrigerant cycle
again, and then refill it
with the specified amount
of refrigerant.
Wear, breakage, or clogging of foreign
material in inner parts.
Eliminate foreign material
from expansion valve, or re-
place it.
Unusual noise from belt.
—
Loosened belt
Check belt tension. Refer to
.
Internal compressor parts get locked
Replace compressor.
COMPRESSOR
HA-31
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REMOVAL AND INSTALLATION
COMPRESSOR
Exploded View
INFOID:0000000006485605
REMOVAL
DISASSEMBLY
1.
High-pressure flexible hose
2.
O-ring
3.
Compressor
4.
O-ring
5.
Low-pressure flexible hose
A.
To condenser
B.
To evaporator
: N·m (kg-m, ft-lb)
JMIIA0939GB
1.
Compressor unit
2.
Field coil
3.
Snap ring
4.
Pulley assembly
5.
Snap ring
6.
Shim
7.
Clutch disc
: N·m (kg-m, ft-lb)
JMIIA0802GB
HA-32
< REMOVAL AND INSTALLATION >
[HR16DE]
COMPRESSOR
COMPRESSOR
COMPRESSOR : Removal and Installation
INFOID:0000000006485606
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to
23, "Perform Lubricant Return Operation"
REMOVAL
1.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to
2.
Remove mounting bolts, and then disconnect low-pressure flexible hose and high-pressure flexible hose
from the compressor.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with suitable material such as vinyl tape to
avoid the entry of air.
3.
Remove drive belt. Refer to
EM-155, "Removal and Installation"
4.
Disconnect compressor (magnet clutch) connector.
5.
Remove mounting bolts, and then remove compressor form the vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Perform lubricant adjusting procedure before installing new compressor. Refer to
.
• Check for leakages when recharging refrigerant. Refer to
• Check tension of the drive belt after installing compressor. Refer to
.
MAGNET CLUTCH
MAGNET CLUTCH : Removal and Installation of Compressor Clutch
INFOID:0000000006485607
REMOVAL
Overhaul
1.
When removing center bolt, hold clutch disc with clutch disc
wrench (SST:KV99232340) (A).
2.
Remove clutch disc.
3.
Remove snap ring using external snap ring pliers.
4.
Position center pulley puller on the end of the drive shaft, and remove pulley assembly using any commer-
cially available pulley puller.
To prevent pulley groove from being deformed, puller claws should be positioned into the edge of the pul-
ley assembly.
5.
Disconnect harness connector from compressor unit.
6.
Remove snap ring using external snap ring pliers, and then remove field coil.
INSTALLATION
JMIIA0574ZZ
COMPRESSOR
HA-33
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1.
Install field coil (1).
Be sure to align the coil’s pin (2) with the hole in the compres-
sor’s front head.
2.
Install field coil harness clip.
3.
Install pulley assembly (1) using pulley installer
(SST:KV99106200) (A) and a hand press, and then install snap
ring (2) using snap ring pliers.
4.
Install clutch disc on drive shaft, together with original shim(s). Press clutch disc down by hand.
5.
Tighten center bolt to the specified torque while fixing clutch disc
not to rotate using a clutch disc wrench (SST:KV99232340).
After tightening the bolt, check that the pulley rotates smoothly.
Break-in Operation
When replacing compressor clutch assembly, always perform the break-in operation, by engaging and disen-
gaging the clutch approximately 30-times. Break-in operation increases the level of transmitted torque.
Inspection
INFOID:0000000006485608
CHECK DISC TO PULLEY CLEARANCE
Check the clearance (B) between pulley assembly (1) and clutch
disc (2) along the entire periphery with a feeler gauge (A).
Replace compressor if specified clearance is not obtained.
JMIIA0575ZZ
JMIIA0576ZZ
JMIIA0577ZZ
Clearance
: Refer to
JPIIA1566ZZ
HA-34
< REMOVAL AND INSTALLATION >
[HR16DE]
COOLER PIPE AND HOSE
COOLER PIPE AND HOSE
Exploded View
INFOID:0000000006485609
HIGH-PRESSURE FLEXIBLE HOSE
HIGH-PRESSURE FLEXIBLE HOSE : Removal and Installation
INFOID:0000000006485610
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to
23, "Perform Lubricant Return Operation"
REMOVAL
1.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to
1.
A/C unit assembly
2.
O-ring
3.
High-pressure pipe
4.
Condenser
5.
Low-pressure flexible hose
6.
O-ring
7.
Compressor
8.
O-ring
9.
High-pressure flexible hose
: Do not reuse
: N·m (kg-m, in-lb)
: N·m (kg-m, ft-lb)
JMIIA0870GB
COOLER PIPE AND HOSE
HA-35
< REMOVAL AND INSTALLATION >
[HR16DE]
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2.
Remove mounting bolt (A), and then disconnect high-pressure
flexible hose from condenser.
CAUTION:
Cap or wrap the joint of the A/C piping and condenser with
suitable material such as vinyl tape to avoid the entry of air.
3.
Remove mounting bolt (A), and then disconnect high-pressure
flexible hose from compressor.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.
4.
Remove high-pressure flexible hose from vehicle.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to
LOW-PRESSURE FLEXIBLE HOSE
LOW-PRESSURE FLEXIBLE HOSE : Removal and Installation
INFOID:0000000006485611
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to
23, "Perform Lubricant Return Operation"
REMOVAL
1.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to
2.
Remove air duct. Refer to
EM-161, "Removal and Installation"
3.
Remove low-pressure flexible hose (1) mounting bolt (A), and nut (B).
JMIIA0877ZZ
JMIIA0878ZZ
JMIIA0876ZZ
HA-36
< REMOVAL AND INSTALLATION >
[HR16DE]
COOLER PIPE AND HOSE
4.
Remove plastic nut, and then move lower dash insulator aside.
5.
Remove mounting bolt (A), and then disconnect low-pressure
flexible hose (1) and high-pressure pipe (2) from expansion
valve. Refer to
HA-56, "EXPANSION VALVE : Removal and
.
CAUTION:
Cap or wrap the joint of the A/C piping and expansion valve
with suitable material such as vinyl tape to avoid the entry
of air.
6.
Remove mounting bolt (A), and then remove low-pressure flexi-
ble hose (1) from compressor.
CAUTION:
Cap or wrap the joint of the A/C piping and compressor with
suitable material such as vinyl tape to avoid the entry of air.
INSTALLATION
Note the following items, and then install in the reverse order of removal.
CAUTION:
• Replace O-rings with new ones. Then apply compressor oil to them when installing.
• Check for leakages when recharging refrigerant. Refer to
HIGH-PRESSURE PIPE
HIGH-PRESSURE PIPE : Removal and Installation
INFOID:0000000006485612
CAUTION:
Perform lubricant return operation before each refrigeration system disassembly. However, if a large
amount of refrigerant or lubricant is detected, never perform lubricant return operation. Refer to
23, "Perform Lubricant Return Operation"
REMOVAL
1.
Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Refer to
2.
Remove air duct. Refer to
EM-161, "Removal and Installation"
: Plastic nut
JMIIA0881ZZ
JMIIA0882ZZ
JMIIA0875ZZ
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