air condition MAZDA PROTEGE 1992 Repair Manual

INDEX U
AIR CONDITIONER
-1 c.Juuux-002
1 . Compressor 6. Refrigerant pressure switch No.2
Removal / Installation.. ................ page U-41 Inspection..
................................. page U-55
Disassembly I Assembly .............
page U-43 7. Condenser fan
Adjustment ................................. page U-46 Removal / Installation
.................. page U-57
2. Magnetic clutch Inspection ...................................
page U-57
Disassembly I Assembly .............
page U-51 8. Cooling unit
Inspection.. .................................
page U-51 Removal I Installation ..................
page U-38
Adjustment .................................
page U-51 Disassembly / Assembly..
........... page U-39
3. Condenser Replacement .............................. page U-39
Removal I Installation.. ................
page U-53 On-vehicle inspection..
............... page U-40
Inspection ...................................
page U-53 Inspection..
................................. page U-40
4 . Receiver/Drier
9. A/C relay
Removal I Installation.. ................
page U-52 Inspection ................................... page U-56
5. Refrigerant pressure switch No. 1
10. Condenser fan relay
Inspection.. .................................
page U-55 Inspection ................................... page U-56
u-3

C
b l HEATER 6 AIR CONDITIONER 1 G
MAIN
I3 Fl
AD FAN
JB-06
4
B/R (F)
1,
1 I
t
G-07
REAR WIPER
IOA
-L/G (F) _fcoJI)
a-07
63
ENGINE
CONTROL UNIT
(SECTION 6-1~. 2bl A/C SWITCH 6 BLOWER SWITCH ILLUMINATION
LAMPS’REFER TO SECTION I-4
RESISTOR ASSEMBLY L/B
-1
r
BjG L)B
(AC9 (AC)
4NT
A/C SWITCH -L/B
4)
6 33
;~~l-bJG FAN
(SECTION B-3.
i-01 CONDENSER FAN (AC) -03 DIODE (AC) G-04 REFRIGERANT G-05 REFRIGERANT G-06 MAGNETIC CLUTCH (AC) G-07 IE) - (AC) CONNECTOR
PRESSURE SWITCH NO.2 (AC) PRESSURE SWITCH NO. 1 (AC)
I I I I
s-10 A/C SWITCH(ACl G-12 BLOWER MOTOR (F) G-13 RESISTOR ASSEMBLY (II
I
I j-14 BLOWER SWITCH (I)

TROUBLESHOOTING GUIDE U
‘)
IO
1
Step 4 Measure voltage at refrigerant pressure switch
No.2
Measure the voltage at the following terminal wires of the
refrigerant pressure switch No.2 connector. VB: Battery voltage
Wire
WO)
(‘3 Voltage Action
VB Next check wire (B)
ov Repair wire (B/O)
V0 Repair wire (B)
ov Go to Step 5
Step 5 Measure refrigerant pressure
1. Connect the A/C manifold gauge set.
2. Operate the engine at 2,000 rpm and set the air condition-
er to maximum cooling.
3. Measure the high-pressure side refrigerant pressure.
Refrigerant pressure
Below: 1 ,177 kPa
(12 kg/cm*, 171 psi)
Above: 1 ,177 kPa
(12 kg/cm’. 171 psi) Action
Normal operation
Replace refrigerant pressure switch No.2
u-9

U TROUBLESHOOTING GUIDE
Symptom: Magnetic clutch does not operate. (Condenser fan operates normally.)
03uoux-015
_-I
I 23UOUX-011
Step 1 Measure voltage at compressor connector
1. Run the engine at idle.
2. Turn A/C and the blower switches ON.
3. Measure the voltage at the following terminal wire of the
compressor connector.
VB: Battery voltage
Wire
P/W Voltage
V0
ov Action
Go to Step 2
Go to Step 5
Step 2 Measure voltage at magnetic clutch connector
Measure the voltage at the following terminal wire of the mag-
netic clutch connector. Ve: Battery voltage
--
Wire Voltage Action
(B)
VB Go to Step 3
ov
t Go to Step 4
Step 3 Check magnetic clutch
1, Disconnect the magnetic clutch connector.
2. Check for continuity between the magnetic clutch and a
body ground.
Continuity
Yes
No Action
Adjust magnetic clutch clearance or
check for compressor internal trouble
Check ground wire
If ground wire OK, replace magnetic
clutch
Step 4 Check thermal protector
1. Turn the air conditioner OFF for about 10 minutes.
2. After 10 minutes, check for continuity of the thermal pro-
tector.
Continuity Action
Yes Normal operation
No Replace thermal protector .._

TROUBLESHOOTING GUIDE
I I
Symptom: Insufficient cooling.
No cooling.
Intermittent cooling.
I I
03uoux-110
SIGHT GLASS
o5uoux-020
Step 1 Checking refrigerant charge
1. Run the engine at a fast idle.
2. Operate the air conditioner at maximum cooling for a few
minutes.
3. Observe the sight glass to determine the amount of refriger-
ant and the related action as shown below.
Item Symptom Amount of refrigerant Action
1 Bubbles present in sight glass Insufficient refrigerant Check refrigerant pressure;
go to Step 2
2 No bubbles present in sight glass Too much or proper amount of Turn air conditioner OFF, and
refrigerant watch bubbles (Refer to Items 3
and 4)
__
3 Immediately after air conditioner turned Too much refrigerant Check refrigerant pressure;
OFF, refrigerant in sight glass stays clear go to Step 2
4 When air conditioner turned OFF, refrigerant
Proper amount of refrigerant Refrigerant amount normal
foams, and then sight glass becomes clear
9MUOUX-073
23UOUX-05i
Step 2 Checking refrigerant pressure
1. Connect the A/C manifold gauge set.
2. Operate the engine at 2,000 rpm and set the air condition-
er to maximum cooling.
3. Measure the low- and high-pressure sides.
(Refer to page U-37.)
Normal pressure
Low-pressure side:
147-294 kPa (1 J-3.0 kg/cm*, 21-43 psi)
High-pressure side:
1,177-1,619 kPa (12.0-16.5 kg/cm2, 171-235 psi)
4. If the pressures are not as specified, refer to the chart on
the next page and check the system.
u-14

U TROUBLESHOOTING GUIDE
Case 1: Insufficient refrigerant
Measured pressure
Low-pressure side: Less than 78.5 kPa (0.8 kg/cm2, 11.4 psi)
High-pressure side: 785-883 kPa (8-9 kg/cm2, 114-128 psi)
Condition
l Outlet air from vents not cold.
l Bubbles seen in sight glass.
Step 1
1. Check for oil stains on the pipes, hoses and other parts, (Refer to illustration below.)
2. If oil staining is found at the connection of pipes or hoses, replace the O-ring; then, evacuate, charge,
and test the system.
3. If oil staining is not found, go to Step 2.
05UOUX-02
Step 2
1. Check for leakage from the following connections with a gas leak tester.
l Inlet and outlet of condenser.
l Inlet and outlet of receiver/drier.
l Inlet and outlet of compressor.
l Sight glass.
l Inlet and outlet of cooling unit.
2. If leakage is evident, go to Step 3.
3. If leakage cannot be found, evacuate, charge, and test the system. (System OK, but refrigerant leaked
gradually over time.)
Step 3
1. Check tightening torque of the connection where leak was detected.
2. If the connection is loose, tighten the connection to the specified torque; then evacuate, charge, and test
the system. --
3. If the connection is properly tightened, replace the O-ring; then evacuate, charge, and test the system.
U-16

TROUBLESHOOTING GUIDE U
Case 2: Excessive refrigerant or insufficient condenser cooling
Measured pressure
Low-pressure side: Above 245 kPa (2.5 kg/cm2, 35.6 psi)
High-pressure side: Above 1,962 kPa (20 kg/cm2, 284 psi)
Condition
Insufficient cooling
Note
l If the condenser fan does not operate when the air conditioner is operating, see “Condenser
fan does not operate”; page U-8, before proceeding.
TO LOW
GAUGE
H-PRESSURE
GAUGE FITTING
13uoux-00 5 03uoux-031
Step 1
1. Check the condenser for bent fins or damage.
Repair or replace as necessary.
2. If the condenser is OK, go to Step 2.
Step 2
1. Discharge the excess refrigerant. (Refer to page U-32.)
Warning
l Always wear gloves and eye protection when dis-
charging the refrigerant.
2. Verify that the refrigerant pressure is normal.
Case 3: Air in system
Measured pressure
Low-pressure: Above 245 kPa (2.5 kg/cm2, 35.6 psi)
High-pressure: Above 2,256 kPa (23 kg/cm2, 327 psi)
Condition
Insufficient cooling
. . CAUSE ACTION
AIR IN SYSTEM EVACUATE
SYSTEM
9MUOUX-086
Step 1
Discharge the refrigeration system. (Refer to page U-32.)
Step 2
Evacuate the system to remove all air from it.
gFI;;r; page U-33.)
Charge the system with refrigerant. (Refer to page U-33.)
Step 4
After charging, measure the refrigerant pressure.
(Refer to page U-37.)
Step 5
If the low- and high-pressure sides are still too high, replace
I
23UOUX-057 the receiver/drier.

U TROU6LESHOOTlNG GUIDE
Case 4 Moisture in system
Measured pressure
Low-pressure: 50 cmHg (2.0 inHg): [Vacuum1
High-pressure: 667-l ,472 kPa (7-15 kg/cm , loo-213 psi)
Condition
Intermittent cooling
(Moisture in refrigeration system freezes in expansion valve and causes temporary blocking.
After time, ice melts and condition returns to normal.)
SMUOUX-088
CAUSE ACTION
7 r
MOISTURE
IN SYSTEM WW;MTE
-
23uoux-O!
Case 5 No refrigerant circulation
Measurement pressure
Low-pressure: 76 cmHg (3.0 inHg) [Vacuum]
High-pressure: Below 589 kPa (6 kg/cm’, 85 psi)
Condition
Refrigerant flow obstructed by moisture or dirt, causing freezing or blockage of expansion valve
9MUOUX.090
Step 1
Discharge the refrigeration system, (Refer to page U-32.)
Step 2
Evacuate the system to remove all air and moisture from it.
$?&$r:o page U-32.)
Charge the system with refrigerant. (Refer to page U-33.)
Step 4
After charging, measure the refrigerant pressure.
(Refer to page U-37.)
Step 5
If the low- and high-pressure sides are still too high, replace
the receiver/drier.
CAUSE ACTION
f r^‘---7
MOISTURE
Id EVACUATE
IN SYSTEM SYSTEM
I I
05UOUX-02
CAUSE ACTION
23UOUX-OE
Step 1
Turn the air conditioner OFF for about 10 minutes. Turn the
air conditioner ON to determine whether the blockage is due
to moisture or dirt.
a) If caused by moisture
System will operate normally after being OFF for 10 minutes.
(Ice melts and relieves blockage.)
Refer to “Moisture in system”.
b) If caused by dirt
System remains abnormal after being OFF 10 minutes.
Go to Step 2.
Step 2
1. Remove the expansion valve. (Refer to page U-39.)
2. Blow out the dirt with compressed air.
3. If unable to remove the dirt, replace the expansion valve.
4. Evacuate, charge, and test the system.
U-18

U AIR CONDITIONER
AIR CONDITIONER
STRUCTURAL VIEW
/
23UOUX-02
6. Refrigerant pressure switch No.2
Inspection.. ................................. page U-55
7. Condenser fan
Removal / Installation.. ................ page U-57
Inspection.. ................................. page U-57
8. Cooling unit
Removal / Installation .................. page U-38
Disassembly / Assembly.. ........... page U-39
Replacement.. ............................ page U-39
On-vehicle inspection ................. page U-40
Inspection ................................... page U-40
9. A/C relay
Inspection ................................... page U-56 --’
10. Condenser fan relay
Inspection ................................... page U-56 1. Compressor
Removal / Installation . . . . . . . . . . . . . . . . . . page U-41
Disassembly / Assembly... . . . . . . . . . . page U-43
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-50
2. Magnetic clutch
Disassembly / Assembly . . . . . . . . . . . . . page U-51
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-51
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-51
3. Condenser
Removal / Installation . . . . . . . . . . . . . . . . . . page U-53
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-53
4. Receiver/Drier
Removal / installation . . . . . . . . . . . . . . . . . . page U-52
5. Refrigerant pressure switch No.1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page U-55
u-30

AIR CONDITIONER U
REFRIGERANT SYSTEM
Safety Precaution
1. R-12 liquid refrigerant is highly volatile. A drop of it on the
skin could result in localized frostbite. When handling the
refrigerant, be sure to wear gloves.
2. If the refrigerant splashes into the eyes, wash them with clean
water immediately. Always wear goggles or glasses to pro-
tect the eyes.
9MUOUX-125 3. The R-12 container is a highly pressurized vessel.
Never subject it to high heat, and be sure that the temper-
ature where it is stored is below 52OC
(125.6OF).
4. A halide leak detector is often used to check the system
for refrigerant leakage. R-l 2, upon coming into contact with
the flame, produces phosgene, a toxic gas. Always provide
adequate ventilation.
o3uoux-11 4
9MUOUX-12
Refrigerant System Service Basics
Refrigerant container service valve
1. Turn the handle fully counterclockwise before connecting
the valve to the refrigerant container.
2. Turn the outlet valve counterclockwise until it reaches its
highest position.
3. Turn the outlet valve fully clockwise by hand. Connect the
center hose to the valve fitting.
4. Turn the handle clockwise to puncture the sealed can.
5. Turn the handle fully counterclockwise to fill the center hose.
Do not open the high- or low-pressure manual valves.
6. Loosen the hose nut connected to the center fitting of the
manifold gauge. Allow air to escape. Then retighten the nut.
13uoux-012
u-31