Mazda Protege 5. Manual - part 273

SYMPTOM TROUBLESHOOTING

07–03–11

07–03

End Of Sie

CHECK TO SEE WHETHER MALFUNCTION
IS IN REFRIGERANT PRESSURE SWITCH OR
ELSEWHERE

•

When refrigerant pressure switch connector
terminals A and B (on wiring harness side)
are shorted, does cool air blow out?

Yes

Go to next step.

Undo short, reconnect refrigerant pressure switch
connector, then go to Step 15.

INSPECT REFRIGERANT PRESSURE
SWITCH

•

Inspect refrigerant pressure switch.
(See 07–40–9 REFRIGERANT PRESSURE
SWITCH INSPECTION)

•

Is it okay?

Yes

If refrigerant amount empty, replace receiver/drier, vacuum
refrigerant line more than 30 minutes by vaccum pump,
and add refrigerant to specified level, then go to Step 21.

Replace refrigerant pressure switch, then go to Step 22.

*15

CHECK TO SEE WHETHER MALFUNCTION
IS IN MAGNETIC CLUTCH SYSTEM OR
ELSEWHERE

•

Does magnetic clutch operate when terminal
E of A/C relay connector is grounded?

Yes

Undo short, then go to next step.

Go to Step 18.

*16

INSPECT WIRING HARNESS BETWEEN A/C
RELAY AND PCM FOR CONTINUITY

•

Turn A/C switch off.

•

Test voltage at PCM connector (96-pin)
terminal.

•

Is voltage approximately 12 V?

Yes

Go to next step.

Repair wiring harness between A/C relay and PCM, then go
to Step 22.

*17

INSPECT INPUT SIGNAL FOR PCM A/C CUT-
OFF CONTROL

•

Inspect the following input signal
components:
— Transaxle range switch and power

steering pressure switch including PCM
wiring harness (A/C cut-off control)

•

Are they okay?

Yes

Inspect coolant system operation.
(See 01–03B–4 FOREWORD [FS])
(See 01–03A–4 FOREWORD [ZM])

Inspect PCM.

*18

CHECK TO SEE WHETHER MALFUNCTION
IS IN MAGNETIC CLUTCH AND THERMAL
PROTECTOR OR ELSEWHERE

•

Test voltage at magnetic clutch stator and
thermal protector terminal A (A/C control
signal).

•

Is voltage approximately 12 V?

Yes

Inspect magnetic clutch, then go to Step 22.

Go to next step.

INSPECT A/C RELAY POWER SUPPLY
FUSES

•

Are A/C relay power supply fuses okay?

Yes

Go to next step.

Inspect for a short to ground on blown fuse circuit. Repair or
replace as necessary.
Install appropriate amperage fuse.

*20

INSPECT WIRING HARNESS BETWEEN
FUSE BLOCK AND A/C RELAY FOR
CONTINUITY

•

Turn ignition switch to ON position.

•

Test voltage at the following A/C relay
connector terminals:
— Terminal A (IG2 signal)
— Terminal C (A/C control signal)

•

Is voltage approximately 12 V?

Yes

Go to next step.

Repair wiring harness between fuse block and A/C relay,
then go to Step 22.

*21

CHECK TO SEE WHETHER MALFUNCTION
(LACK OF CONTINUITY) IS IN A/C RELAY OR
WIRING HARNESS (BETWEEN A/C RELAY
AND MAGNETIC CLUTCH)

•

Test voltage at A/C relay terminal D (A/C
control signal).

•

Is voltage approximately 12 V?

Yes

Repair wiring harness between A/C relay and stator and
thermal protector, then go to next step.

Inspect A/C relay, then go to next step.

VERIFY THAT MALFUNCTION SYMPTOM
OCCURS AFTER REPAIR

•

Does cool air blow out? (Is refrigerant
system performance test result correct?)

Yes

Troubleshooting completed.
Explain repairs to customer.

Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.

STEP

INSPECTION

ACTION

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SYMPTOM TROUBLESHOOTING

07–03–12

NO.8 NOISE WHILE OPERATING A/C SYSTEM

A3U070301038W10

Diagnostic procedure

Noise while operating A/C system.

DESCRIPTION

•

Noise from magnetic clutch, A/C compressor, hose or refrigerant line.

POSSIBLE

CAUSE

•

Magnetic clutch operation noise (Step 4)

•

A/C compressor vane noise (Steps 5—13)

•

A/C compressor slippage noise (Steps 14—17)

•

Hose or refrigerant line interference noise (Step 18)

STEP

INSPECTION

ACTION

CHECK A/C COMPRESSOR VANE NOISE

•

Is there a jingling, popping, beeping, or
buzzing sound (A/C compressor vane
noise)?

Yes

Go to Step 5.

Go to next step.

INSPECT A/C COMPRESSOR SLIPPAGE
NOISE

•

Is there a squeaking or whirling sound (A/C
compressor slippage noise)?

Yes

Go to Step 14.

Go to next step.

INSPECT A/C COMPRESSOR
INTERFERENCE NOISE

•

Is there a rattling or vibrating sound
(interference noise)?

Yes

Go to Step 18.

Go to next step.

INSPECT MAGNETIC CLUTCH OPERATION
NOISE

•

Is there a clicking sound (magnetic clutch
operation noise)?

Yes

Adjust clearance between pressure plate of magnetic clutch
and A/C compressor pulley, then go to Step 19.
(See 07–40–7 MAGNETIC CLUTCH ADJUSTMENT)

Condition is normal. (Recheck malfunction symptoms.)

INSPECT A/C COMPRESSOR NOISE TIME

•

Is noise heard continuously for more than 3
seconds after A/C compressor comes on?

Yes

Go to next step.

Condition is normal. (Noise occurs for 2—3 seconds
immediately after A/C compressor turns on.)

INSPECT IDLE SPEED

•

Inspect idle speed.
(See 01–10B–26 Idle Speed Adjustment)

•

Is it okay?

Yes

Go to next step.

Adjust idle speed, then go to Step 19.

INSPECT REFRIGERANT AMOUNT

•

Inspect refrigerant amount.

•

Is it okay?

Yes

Go to Step 10.

Go to next step.

INSPECT REFRIGERANT LINES

•

Inspect refrigerant lines.
— Is piping free of damage and cracks?
— Are piping connections free of oil grime?

(Visual inspection)

— Are piping connections free of gas

leakage?

— Are piping installation points on

condenser free of gas leakage?

— Are piping installation points on receiver/

drier free of gas leakage?

— Are piping installation points on A/C

compressor free of gas leakage?

— Are piping installation points on cooling

unit free of gas leakage

— Perform gas leak inspection using gas

leak tester.

•

Are above items okay?

Yes

Go to next step.

If piping or A/C component(s) is damaged or cracked,
replace then go to Step 19.
If there is gas leakage, repair or replace connection and
replace receiver/drier*, then go to Step 19.

INSPECT EVAPORATOR PIPING
CONNECTIONS IN COOLING UNIT FOR GAS
LEAKAGE

•

Are piping connections for evaporator in
cooling unit free of gas leakage?

Yes

Adjust refrigerant amount to specified level, then go to Step
19.

If piping is damaged or cracked, replace then go to Step 19.
If there is gas leakage, repair or replace connection and
replace receiver/drier*, then go to Step 19.

CHECK TO SEE WHETHER MALFUNCTION
IS IN COMPRESSOR OIL OR ELSEWHERE

•

Add 20 ml {20 cc, 0.8 fl oz} of compressor
oil.

•

Is noise heard when racing engine?

Yes

Go to next step.

Troubleshooting completed.
Explain repair to customer.

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SYMPTOM TROUBLESHOOTING

07–03–13

07–03

: If there is gas leakage, air enters into the A/C system. The desiccant within the receiver/drier absorbs the

moisture from the air and becomes saturated. If the A/C system is used in this condition, the inside of the A/C
compressor will begin to rust due to this moisture, which may cause lock up or noise to occur. Therefore,
replacement of the receiver/drier is necessary.

End Of Sie

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

•

Drain compressor oil.

•

Is it contaminated with metal particles?

Yes

Go to next step.

Replace A/C compressor, then go to Step 19.

CHECK TO SEE WHETHER MALFUNCTION
IS SOMEWHERE IN A/C SYSTEM OR
ELSEWHERE

•

Is compressor oil whitish and mixed with
water?

Yes

Replace entire A/C system (excluding heater), then go to
Step 19.

Go to next step.

INSPECT A/C COMPRESSOR OIL

•

Is compressor oil darker than normal and
contaminated with aluminum chips?

Yes

Replace A/C compressor and receiver/drier, then go to Step
19. (Since A/C compressor may be worn and receiver/drier
may be clogged, replacement of receiver/drier is
necessary.)

Condition is normal. Recheck malfunction symptoms.

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

•

Is noise heard immediately after A/C
compressor is stopped?

Yes

Replace A/C compressor, then go to Step 19. (A/C
compressor discharge valve left open)

Go to next step.

INSPECT DRIVE BELT

•

Inspect drive belt.
(See 01–10B–3 DRIVE BELT INSPECTION
[FS])

•

Is it okay?

Yes

Go to next step.

Adjust or replace drive belt, then go to Step 19.
(See 01–03B–4 FOREWORD [FS])
(See 01–03A–4 FOREWORD [ZM])

INSPECT DRIVE BELT CONDITION

•

Is drive belt worn?

•

Does it have foreign material imbedded in it,
or have oil on it?

Yes

Remove obstruction, remove oil, or replace drive belt, then
go to Step 19.

Go to next step.

INSPECT MAGNETIC CLUTCH

•

Inspect magnetic clutch.
(See 07–40–8 MAGNETIC CLUTCH
INSPECTION)

•

Is it okay?

Yes

Replace A/C compressor (excluding pressure plate, A/C
compressor pulley, and stator), then go to Step 19.

Replace magnetic clutch, then go to Step 19.

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

•

Is noise emitted from A/C compressor?

Yes

Visually inspect A/C compressor, replace appropriate parts
if necessary, then go to next step.

If noise is due to refrigerant lines, repair detached or
missing clips, tighten loose bolts, then go to next step.

VERIFY THAT MALFUNCTION SYMPTOM
OCCURS AFTER REPAIR

•

Has A/C compressor noise stopped?

Yes

Troubleshooting completed.
Explain repairs to customer.

Recheck malfunction symptoms, then repeat from Step 1 if
malfunction recurs.

STEP

INSPECTION

ACTION

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REFRIGERANT SYSTEM

07–10–1

07–10

REFRIGERANT SYSTEM

REFRIGERANT SYSTEM SERVICE

WARNINGS . . . . . . . . . . . . . . . . . . . . . . 07–10–1

Using/Handling Unapproved

Refrigerant . . . . . . . . . . . . . . . . . . . . . 07–10–1

Handling Refrigerant . . . . . . . . . . . . . . 07–10–1
Storing Refrigerant . . . . . . . . . . . . . . . . 07–10–1

REFRIGERANT SYSTEM SERVICE

CAUTIONS . . . . . . . . . . . . . . . . . . . . . . 07–10–1

Handling Compressor Oil . . . . . . . . . . . 07–10–1

REFRIGERANT SYSTEM GENERAL

PROCEDURES . . . . . . . . . . . . . . . . . . . . 07–10–2

Manifold Gauge Set Installation . . . . . . 07–10–2

REFRIGERANT SYSTEM

PERFORMANCE TEST . . . . . . . . . . . . . 07–10–2

REFRIGERANT PRESSURE CHECK . . . 07–10–3
REFRIGERANT RECOVERY . . . . . . . . . . 07–10–3
REFRIGERANT CHARGING . . . . . . . . . . 07–10–3

Charging Recycled R-134a

Refrigerant . . . . . . . . . . . . . . . . . . . . . 07–10–3

Charging New R-134a Refrigerant . . . . 07–10–4

End of Toc

REFRIGERANT SYSTEM SERVICE WARNINGS

A3U071001039W01

Using/Handling Unapproved Refrigerant

•

Using a flammable refrigerant, such as OZ-12, in this vehicle is dangerous. In an accident, the
refrigerant may catch fire, resulting in serious injury or death. When servicing this vehicle, use only
R-134a.

•

Checking for system leakage on a vehicle that has been serviced with flammable refrigerant, such as
OZ-12, is dangerous. Conventional leak detectors use an electronically generated arc which can ignite
the refrigerant, causing serious injury or death. If a flammable refrigerant may have been used to
service the system, or if you suspect a flammable refrigerant has been used, contact the local fire
marshal or EPA office for information on handling the refrigerant.

Handling Refrigerant

•

Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and
throat. Also, due to environmental concerns, use service equipment certified to meet the requirements
of SAE J2210 (R-134a recycling equipment) when draining R-134a from the air conditioning system. If
accidental system discharge occurs, ventilate work area before resuming service.

•

Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with
compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated
pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and
safety information may be obtained from refrigerant manufacturers.

•

Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if
the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any
operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources
and maintain adequate ventilation.

•

Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When
handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes,
immediately wash them with clean water and consult a doctor.

Storing Refrigerant

•

The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode,
scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at
temperatures below 40

°°°°

C {104

°°°°

F}.

End Of Sie

REFRIGERANT SYSTEM SERVICE CAUTIONS

A3U071001039W02

Handling Compressor Oil

•

Use only ATMOS GU10 compressor oil for this vehicle. Using a PAG oil other than ATMOS GU10
compressor oil can damage the A/C compressor.

•

Do not spill ATMOS GU10 compressor oil on the vehicle. A drop of compressor oil on the vehicle
surface can eat away at the paint.
— If oil gets on the vehicle, wipe it off immediately.

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