Mazda CT-L1005 Training Manual
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Mazda CT-L1005 Training Manual

Mazda CT-L1005 Training Manual

Basic climate control
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Basic Climate Control
CT-L1005

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Summary of Contents for Mazda CT-L1005

  • Page 1 Training Manual Basic Climate Control CT-L1005...
  • Page 2 No part of this hardcopy may be reproduced in any form without prior permission of Mazda Motor Europe GmbH. The illustrations, technical information, data and descriptive text in this issue, to the best of our knowledge, were correct at the time of going to print.

  • Page 3: Table Of Contents

    Basic Climate Control Table of Contents Introduction ..................01-1 Fundamentals ..................02-1 Physical Comfort..................02-1 Getting Comfortable................02-2 Changing the Air Temperature ............02-2 Warming the Air in the Vehicle ............02-4 Cooling the Air in the Vehicle.............. 02-5 Latent Heat ..................02-6 Dehumidifying the Air................
  • Page 4 Table of Contents Basic Climate Control A/C System with Fixed Orifice................03-23 Parts Location ..................03-23 Compressors................... 02-24 Variable Displacement Swash Plate Compressor ......03-24 Variable Displacement Scroll Compressor ........03-25 Fixed Orifice ..................03-25 Accumulator / Drier ................03-27 Control ....................

  • Page 5: Introduction

    • Anyone associated with the diagnosis and repair of climate control systems must have the knowledge to deliver a “Fix it right first time” repair. Therefore, the Mazda Masters development and qualification path provides the following training courses required for servicing and diagnosing climate control systems: –...
  • Page 6 Introduction Basic Climate Control • The training manual “Basic Climate Control” is divided into the following main chapters: – Fundamentals – A/C System – Heating System – Diagnosis and Repair NOTE: The data, tables, and procedures presented in this training manual serve only as examples.

  • Page 7: Fundamentals

    Basic Climate Control Fundamentals Fundamentals Physical Comfort • When do we feel comfortable? What is comfort? When we aren’t comfortable, how can we become comfortable? • There is a norm that shows where most people find it comfortable based on the air temperature, and relative humidity.

  • Page 8: Getting Comfortable

    Fundamentals Basic Climate Control Getting Comfortable • To change the level of comfort in a building there are several possibilities: open a window, turn on a fan, adjust the thermostat, take some clothes off, or put some clothes on. While it’s possible to do all of these things in a vehicle, there are of course practical limitations.
  • Page 9 Basic Climate Control Fundamentals • In the first example a cold glass of water is brought into a warm room. The water will absorb some of the heat from the air in the room, and settle to the ambient temperature of the room.

  • Page 10: Warming The Air In The Vehicle

    Fundamentals Basic Climate Control Warming the Air in the Vehicle • To carry the second example across to the vehicle, think of the heater core as the cup of coffee being brought into a relatively colder room. The heater core gives its heat up to the outside air that comes in contact with the fins.

  • Page 11: Cooling The Air In The Vehicle

    Basic Climate Control Fundamentals Cooling the Air in the Vehicle • The example of the cold glass of water can be partially compared to the evaporator. The evaporator is filled with a cold liquid, and this liquid absorbs the heat from the air as it comes in contact with the fins of the evaporator.

  • Page 12: Latent Heat

    Fundamentals Basic Climate Control Latent Heat • The following graph shows the amount of heat added to 1 kg of water on the horizontal axis, and on the vertical axis shows the temperature of the water. In the first stage the water is frozen, and as heat is added to it, the temperature rises.
  • Page 13 Basic Climate Control Fundamentals L1005_022 Heat energy Temperature Ice being warmed Steam being warmed Ice changing to water Latent heat of fusion Water being warmed Latent heat of vaporization Water changing to steam Curriculum Training 02-7...

  • Page 14: Dehumidifying The Air

    Fundamentals Basic Climate Control Dehumidifying the Air • The air entering the vehicle normally has a relatively high humidity. When this humid air comes in contact with the cool surface of the evaporator the moisture in the air will condense as tiny droplets of water. These water drops will accumulate and run down the evaporator, and leave the vehicle through the drain tube.

  • Page 15: Filtering The Air

    NOTE: The cabin filters used in Mazda vehicles cannot be cleaned and must therefore be replaced at certain intervals (see the workshop manual). But if a customer drives in dusty areas, or often drives in heavy stop and go traffic, a more frequent change interval might be required.

  • Page 16: Refrigerant

    Refrigerant • The refrigerant used in current Mazda vehicles is called R134a. It is a hydrofluorocarbon ) that at normal atmospheric pressure boils at –26°C. This property, combined with the fact that it does not harm the ozone layer, makes it an almost perfect substance for A/C.

  • Page 17: Refrigerant In A Closed Container

    Basic Climate Control Fundamentals Refrigerant in a Closed Container • When R134a is in a closed container, and the container is in a surrounding with an ambient temperature above –26°C, some of the liquid will boil off until pressure is developed.

  • Page 18: Handling Refrigerant

    Fundamentals Basic Climate Control Handling Refrigerant • Because R134a boils at –26°C, if a line is opened while there is refrigerant still in the system, the refrigerant will boil by absorbing heat from the surrounding area. This means that if your hand comes in contact with the refrigerant as it escapes, you will experience acute frostbite (a strong burning sensation).

  • Page 19: Compressor Oil

    In addition, mineral oil and PAG oil must not be mixed. • The current range of Mazda vehicles all use PAG oils, but there are several different types available. They can have differing characteristics such as different viscosity. For this reason, the different compressor oils are not interchangeable.
  • Page 20 Fundamentals Basic Climate Control Notes: 02-14 Curriculum Training...

  • Page 21: A/C System

    A/C System • There are two different types of A/C systems used on Mazda vehicles. The most common system uses an expansion valve. The expansion valve separates the high pressure side of the system from the low pressure side, and throttles the refrigerant bringing it to its coldest temperature.
  • Page 22 A/C System Basic Climate Control • In the A/C system the refrigerant is found in two different states, and two different temperatures. As the refrigerant leaves the compressor it is a warm and high-pressure gas. It then travels through the condenser where the outside air coming in contact with the fins of the condenser absorbs the heat from the refrigerant, cooling it and liquifying it.

  • Page 23: A/C System With Expansion Valve

    Basic Climate Control A/C System • The now low pressure, and even colder refrigerant travels to the evaporator where the heat from the air passing by the fins of the evaporator boils the refrigerant, changing it to a cool low-pressure gas. This gas then moves into the compressor where the pressure and temperature are increased.

  • Page 24: Compressor

    The compressor is mounted on the engine. To allow for the motion of the engine, the refrigerant lines to and from the compressor are flexible. • The different types of compressors used in Mazda vehicles are explained on the following pages. 03-4...

  • Page 25: Vane Rotary Compressor

    Basic Climate Control A/C System Vane Rotary Compressor • A vane-rotary compressor has an eccentrically mounted rotor with vanes that are ‘thrown’ out by centrifugal force to create a seal against the housing. As the rotor moves through its eccentric path, the chamber becomes smaller, compressing the refrigerant. L1005_035 Rotor Vane...

  • Page 26: Scroll Compressor

    A/C System Basic Climate Control Scroll Compressor • A scroll compressor uses a fixed helix, and a moving helix mounted so that the moving helix creates a chamber that draws the refrigerant in, seals the chamber off, and compresses the refrigerant. L1005_036 Thrust plate Moving helix...

  • Page 27: Swash Plate Compressor

    Basic Climate Control A/C System Swash Plate Compressor • This compressor uses a swash plate, which is mounted at an angle on a shaft. The swash plate moves a number of double acting pistons to draw in and compress the refrigerant.

  • Page 28: Condenser

    A/C System Basic Climate Control Condenser • The condenser receives heated refrigerant from the compressor and reduces the temperature, thereby liquifying it. Refrigerant normally boils at –26°C, but under pressure the boiling point is increased, so accordingly the condensation point is increased. This means that as the relatively cool outside air passes the condenser, it absorbs the heat from the refrigerant, allowing it to change state.

  • Page 29: Fin And Tube Condenser

    Basic Climate Control A/C System Fin and Tube Condenser • The refrigerant flows through tubes laid out in a serpentine path. The fins brazed to the tubes increase the transfer of heat from the refrigerant to the ambient air. L1005_042 Fins Refrigerant tubes Curriculum Training...

  • Page 30: Multiflow Condenser

    A/C System Basic Climate Control Multiflow Condenser • The multiflow condenser sends the refrigerant through smaller channels, resulting in more heat transfer than in a fin and tube condenser. In addition, the refrigerant is sent through the condenser in a parallel flow, increasing the cooling performance even more. L1005_045 Manifold Condenser...

  • Page 31: Multiflow Condenser With Sub-Cooler

    Basic Climate Control A/C System Multiflow Condenser with Sub-cooler • The multiflow condenser with a sub-cooler sends the refrigerant to the receiver / drier and then back into the lower sub-cooling portion of the condenser. Incorporating the receiver / drier into the condenser ensures that at this last sub-cooling stage (no.4 in the illustration) only liquid refrigerant is being cooled.

  • Page 32: Receiver / Drier

    A/C System Basic Climate Control Receiver / Drier • The receiver / drier has three main roles in the system. It acts as a reservoir for liquid refrigerant, it makes sure that no gaseous refrigerant travels to the expansion valve, and it removes moisture from the system.
  • Page 33 Basic Climate Control A/C System • To remove the moisture from the system a desiccant is incorporated into the receiver / drier. The desiccant is a chemical substance that absorbs moisture, but cannot release it. The amount of water that the desiccant can absorb is relatively tiny, since it is primarily there to absorb the unavoidable moisture that enters the system during manufacturing.

  • Page 34: Expansion Valve

    A/C System Basic Climate Control Expansion Valve • The expansion valve is the second barrier between the high-pressure and the low- pressure side of the A/C system (the compressor is the first). The expansion valve throttles the high-pressure liquid refrigerant, reducing the pressure and the temperature of the refrigerant.
  • Page 35 Basic Climate Control A/C System • This warmer refrigerant will transmit its heat through the heat-conducting element on to the refrigerant in turn causing the reference pressure to increase. This pressure will push on the ball valve, making the opening larger, and allowing more refrigerant to travel to the evaporator.

  • Page 36: Evaporator

    A/C System Basic Climate Control Evaporator • The hot air entering the vehicle passes though the fins of the evaporator, and gives its heat up to the refrigerant travelling through the inside of the evaporator. The heat is absorbed by the refrigerant as it changes its state from a liquid to a gas. Vaporisation Plotted on the Refrigerant Curve L1005_023d Pressure...
  • Page 37 Basic Climate Control A/C System • The construction of the evaporator is similar to that of a radiator. The refrigerant flows through tubes that have fins attached to them to allow for heat dissipation. Internal flow of refrigerant through the evaporator L1005_010 Liquid refrigerant from expansion valve Rejoining point...
  • Page 38 A/C System Basic Climate Control • The condensed water that forms on the surface of the evaporator comes from the moisture in the air passing through the fins of the evaporator. The moisture being removed from the air also has the added benefit of reducing the relative humidity of the air entering the vehicle.

  • Page 39: Refrigerant Lines

    Basic Climate Control A/C System Refrigerant Lines • The refrigerant lines to and from the compressor are flexible lines; the other lines in the A/C circuit are rigid. Depending on the type of connection, there may be a special procedure or a special tool required. L1005_026 Male side block Pliers to hold the female side...

  • Page 40: Control

    A/C System Basic Climate Control Control Refrigerant Pressure Switch • The triple-type refrigerant pressure switch is located on the high-pressure side of the A/C system, and consists of the low and high pressure switch and the medium pressure switch. L1005_060 Low / High Pressure Switch •...

  • Page 41: Medium Pressure Switch

    Basic Climate Control A/C System Medium Pressure Switch • The medium-pressure switch outputs a cooling fan control signal to the PCM depending on the condenser load. The PCM then controls the cooling fan(s) to draw extra air through the condenser in case a higher cooling performance is needed. Magnetic Clutch •...

  • Page 42: Wiring Diagram

    A/C System Basic Climate Control • Once the driver activates the A/C, the climate control unit sends a signal to the PCM. If the pressure in the system is neither too low nor too high, the PCM in turn energizes the A/C relay that supplies power to the magnetic clutch.

  • Page 43: A/C System With Fixed Orifice

    Basic Climate Control A/C System A/C System with Fixed Orifice • This section only describes the components that differ from those found in the A/C system with expansion valve. Parts Location L1005_030 Compressor High-pressure service valve Condenser Rigid refrigerant lines Fixed orifice A/C cycling switch Evaporator...

  • Page 44: Compressors

    A/C System Basic Climate Control Compressors • The Tribute is equipped with a swash-plate compressor with fixed displacement, while the Mazda3 Diesel and the Mazda2 use variable displacement compressors. The main difference between both compressor types is that the variable displacement compressor does not cycle on and off during normal operation.

  • Page 45: Variable Displacement Scroll Compressor

    Basic Climate Control A/C System Variable Displacement Scroll Compressor • The variable displacement scroll compressor functions similar to the standard scroll compressor described earlier. The only difference is an additional control valve that enables the compressor to reduce the delivery to as little as 30% of maximum output. The control valve varies the delivery by passing refrigerant from a chamber between the two helices back to the low-pressure side.
  • Page 46 A/C System Basic Climate Control • The tools shown below are required to service the fixed orifice. L1005_047 Removal and installation tool Damaged orifice removal tool 03-26 Curriculum Training...

  • Page 47: Accumulator / Drier

    Basic Climate Control A/C System Accumulator / Drier • The accumulator / drier serves a similar function to that of the receiver / drier. One difference is the location in the A/C circuit. The accumulator / drier is located between the evaporator and the compressor.

  • Page 48: Control

    A/C System Basic Climate Control • To move the compressor oil accumulating in the accumulator / drier further along in the system it uses a small orifice in the bottom of the pick up tube. As the gaseous refrigerant moves past this opening, the oil is drawn through the small oil pick up orifice. At the same time the oil is atomised ensuring that it enters the stream of the refrigerant, and is carried along to the rest of the system.

  • Page 49: Refrigerant Pressure Switch

    Basic Climate Control A/C System Refrigerant Pressure Switch • The dual-type refrigerant pressure switch is located on the high-pressure side of the A/C system and consists of a medium- and a high-pressure switch. The medium-pressure switch outputs a cooling fan control signal to the PCM depending on the condenser load. •...

  • Page 50: Wiring Diagram

    A/C System Basic Climate Control Wiring Diagram L1005_048 A/C cycling switch A/C relay High pressure switch Magnetic clutch Medium pressure switch 03-30 Curriculum Training...

  • Page 51: Component Overview

    Basic Climate Control A/C System Component Overview Expansion Fixed Integrated Model Compressor Type Condenser Type Valve Orifice Drier* Variable displacement Mazda2 Petrol Multiflow Swash Plate Variable displacement Mazda2 Diesel Multiflow Scroll Multiflow Mazda3 Petrol Vane-rotary (sub-cooling type) Variable displacement Mazda3 Diesel Multiflow Swash Plate Multiflow...
  • Page 52 A/C System Basic Climate Control Notes: 03-32 Curriculum Training...

  • Page 53: Heating System

    Basic Climate Control Heating System Heating System • To warm the passenger compartment during cold weather the heat from the engine is indirectly used. The heat is transferred to the engine coolant, and the engine coolant passes through the heater core in the passenger compartment, which gives the heat up to the incoming air.

  • Page 54: Thermostat

    Heating System Basic Climate Control Thermostat • When starting a cold engine, the thermostat stays closed to ensure that the coolant flows only through the ‘small circuit’. This ensures that the engine reaches its operating temperature as quickly as possible, and that heat is available for the heater core to heat up the air as quickly as possible.
  • Page 55 Pressure Gauges • Mazda special tool 49 C061 001A consists of a low- and high-pressure gauge for the A/C system that allows the refrigerant pressures to be monitored during operation. After attaching the pressure gauges the first thing that should be seen is that the pressures on the high- and low-pressure side are equal.

  • Page 56: Diagnosis And Repair

    Refrigerant Pressure Check • Mazda service literature provides a procedure for checking the refrigerant pressure in the A/C system. The procedure involves making sure the engine is at operating temperature, and taking pressure and temperature readings while the A/C is operating (see the workshop manual for the vehicle specific procedure).
  • Page 57 Basic Climate Control Diagnosis and Repair Measured Pressure Possible Cause Low-pressure side: Insufficient refrigerant Below 0.08 MPa (0.8 bar) High-pressure side: 0.8 MPa (8 bar) Low-pressure side: Excessive refrigerant or 0.25 MPa (2.5 bar) insufficent condenser cooling High-pressure side: 2.0 MPa (20 bar) Low-pressure side: Air in system 0.25 MPa (2.5 bar)

  • Page 58: Leak Testing

    Diagnosis and Repair Basic Climate Control Leak Testing • The amount of refrigerant in automotive A/C systems has been steadily decreasing. The lower fill volumes mean that leaks present in the system are going to be noticeable earlier, as a reduction in cooling performance, compared to previous systems filled with more refrigerant.

  • Page 59: Control System Check

    Basic Climate Control Diagnosis and Repair Control System Check • Using the Datalogger of the WDS, the PCM control strategy for the A/C system can be checked: – The input signal from the low- / high-pressure switch to the PCM can be checked using the PID AC_REQ.

  • Page 60: Draining The A/C System

    Diagnosis and Repair Basic Climate Control Draining the A/C System • Before a component of the A/C system can be removed, the refrigerant needs to be drained from the system. NOTE: Failure to drain the refrigerant from the system before removing a component could cause injury, and also lead to unnecessary environmental pollution.

  • Page 61: Summary Of Refrigerant Draining And Filling Procedures

    Basic Climate Control Diagnosis and Repair Summary of Refrigerant Draining and Filling Procedures Connect the A/C service machine. Empty the oil container. Drain the refrigerant from the system. Follow the Workshop manual Was approximately the correct procedures to find and repair the amount of refrigerant drained? leak.

  • Page 62: Component Replacement

    Diagnosis and Repair Basic Climate Control Component Replacement • Once the refrigerant has been drained from the A/C system, the component in question can be removed. When a component is removed, the refrigerant lines to the rest of the system should be plugged to ensure that moisture does not enter the system. NOTE: If there is no refrigerant left in the system this means that air has entered the system, and the drier is exposed to moisture.

  • Page 63: Compressor Damage

    Basic Climate Control Diagnosis and Repair Compressor Damage • The most serious compressor damage arises from lack of lubrication. In this case, there is a possibility that metal particles will be carried throughout the system. NOTE: Burnt compressor oil and metal particles in the oil are reliable indicators of a seized compressor.

  • Page 64: Diagnosis On The Heating System

    Diagnosis and Repair Basic Climate Control Diagnosis on the Heating System • The key element in diagnosing the heating system is determining the integrity of the cooling system. The primary tool to do this is the radiator cap tester in conjunction with the correct adapter.
  • Page 65 Basic Climate Control List of Abbreviations Air Conditioning HVAC Heating Ventilation & Air Conditioning Output State Control Poly-Alkaline Glycol Powertrain Control Module Parameter Identification Worldwide Diagnostic System Curriculum Training 06-1...
  • Page 66 List of Abbreviations Basic Climate Control Notes 06-2 Curriculum Training...

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