Mazda TTCC007700--1155--0011H Student Manual
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Mazda TTCC007700--1155--0011H Student Manual

Mazda TTCC007700--1155--0011H Student Manual

Air conditioning
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Air Conditioning

Operation & Diagnosis
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Student Guide
Mazda Motor Corporation
Technical Service Training

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Summary of Contents for Mazda TTCC007700--1155--0011H

  • Page 1: Air Conditioning

    Air Conditioning Operation & Diagnosis Student Guide Mazda Motor Corporation Technical Service Training...
  • Page 2 NOTE This course is developed based on the service materials of Mazda 3 included in the CD-ESI (Electronic Service Information) 2/2004 Ver. 3.0 CD08-XX-04BE. OBJECTIVES...
  • Page 3 AIR CONDITIONING SG00 - General TC070-15-01H CONTENTS SG00 – General SG01 – Basic System Activity01 - Identifying A/C Components Activity02 - Locating A/C Protection Devices Activity03 - A/C performance Check Activity04 - Refrigerant Charging SG02 – Control System [Manual Air-conditioning] Activity05 - Units and parts checks* Activity06 - Symptom troubleshooting SG00-2...
  • Page 4 AIR CONDITIONING SG00 - General TC070-15-01H TIMETABLE Day 1 Time Session Remark 8:30 – 9:00 Introductions 9:00 – 10:20 Review A/C Fundamentals A/C Fundamentals textbook 10:20 – 10:30 Break 10:30 – 11:50 Basic System SG (Classroom) 12:00 – 13:00 Lunch Identifying AC Components 13:00 –...
  • Page 5 AIR CONDITIONING SG00b - Pre-Test TC070-15-01H 1. Technician A says the refrigerant used in the A/C system absorbs and releases large amounts of heat as it changes from a liquid to a gas. Technician B says as the refrigerant circulates through the tubes and hoses of an operating A/C system, it constantly changes from a liquid to a gas and back to a liquid again.
  • Page 6 SG00b - Pre-Test TC070-15-01H 5. Technician A says in a Mazda A/C system the refrigerant changes state from a liquid to a vapor in the compressor while losing heat. Technician B says the compressor acts as a pump for the refrigerant in an A/C system.
  • Page 7 AIR CONDITIONING SG00b - Pre-Test TC070-15-01H 9. Which component in this illustration removes heat from the passenger compartment and transfers it to the refrigerant? a. 2 b. 3 c. 4 d. 5 10. At point A the refrigerant is; a. High pressure liquid b.
  • Page 8 AIR CONDITIONING SG00b - Pre-Test TC070-15-01H 12. Technician A says do not expose refrigerant to open flame. R-12 may produce poisonous phosgene gas, and R-134a may support combustion. Technician B says a propane torch style leak detector is the best type of detector for R-12 and R134a systems.
  • Page 9 AIR CONDITIONING SG00b - Pre-Test TC070-15-01H 16. Technician A says the accumulator traps liquid refrigerant allowing it time to completely vaporize. Technician B says if liquid refrigerant reaches the compressor it could be damaged. Who is correct? a. Technician A b.
  • Page 10 AIR CONDITIONING SG00b - Pre-Test TC070-15-01H 20. Which statement is true about this climate control plenum assembly? a. All air passes through the evaporator b. The air is being re-circulated c. The temperature blend door is set for max heat d.

  • Page 11: Table Of Contents

    Gauge manifold reading ................9 Refrigerant System Service Warnings (Reference) ........10 Refrigerant System Service Cautions ............10 AC abbreviation ..................... 12 Item Specification ..................12 Review Exercise .................... 13 NOTE This SG: Student Guide is developed based on Mazda 3. SG01-1...

  • Page 12: Sg00

    AIR CONDITIONING SG01 - Basic System TC070-15-01H A/C Components Name the components. SG01-2...

  • Page 13: A/C Unit Construction/Operation

    AIR CONDITIONING SG01 - Basic System TC070-15-01H A/C unit construction/operation • The figure below shows A/C unit which integrates the blower, cooling and heater units. 1. Evaporator* 2. Heater core* 3. Expansion valve 4. Air intake door* 5. Air mix door* 6.

  • Page 14: Evaporator

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Evaporator • The figure below shows a double-tank drawn cup. 1. Separation part 2. Rejoining point 3. Separation part 4. Rejoining point Expansion valve • The liquid refrigerant of about 1.5 MPa is sprayed at the expansion valve. The splayed refrigerant is, then, expanded its volume that causes its pressure decreased to about 0.2 MPa.

  • Page 15: Air Mix Door Operation

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Air Mix Door Operation • The air mix door, installed in the A/C unit, controls HOT or COLD position, depending on the position of the temperature control dial. As a result, airflow distribution changes, and the airflow temperature is controlled. Airflow Mode Door Operation •...

  • Page 16: Air Filter Function

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Air filter function • The figure below shows air filter that can remove pollen and dust has been added. • The air filter cannot be reused and must be replaced periodically. NOTE Even new air filters are gray; be careful not to mistake the gray color as dirt. A/C compressor •...

  • Page 17: Condenser

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Condenser • The figure below shows a sub cool condenser. It is a multi-flow condenser which is equipped with a sub cooling part and integrated with a receiver/drier. • The sub cool condenser separates liquid-gas refrigerant initially cooled at the condenser via the receiver/drier, where it returns again to the condenser sub cooling part and is cooled, accelerating liquefaction and improving cooling capacity.

  • Page 18: Spring-Lock Coupling

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Spring-lock Coupling • Spring-lock coupling is used for pipe-to-pipe connections. As a result, pipes can be connected easily, maintenance of torque is unnecessary, and serviceability is improved. • There is a garter spring in the cage on the male side (cooler pipe or cooler hose (LO)) of spring-lock coupling type and the end of the pipe on the female side (A/C unit) is flared.

  • Page 19: Gauge Manifold Reading

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Gauge manifold reading Normal LO: 0.15 – 0.25 MPa HI: 1.37 – 1.57 MPa It may vary under the different condition. A: Insufficient refrigerant B: Excessive refrigerant or insufficient cooling C: Compressor failure SG01-9...

  • Page 20: Refrigerant System Service Warnings (Reference)

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Refrigerant System Service Warnings (Reference) Handling Refrigerant • Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. Also, due to environmental concerns, we urge use of recovery/recycling/recharging equipment when draining R-134a from the air conditioning system.
  • Page 21 AIR CONDITIONING SG01 - Basic System TC070-15-01H 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.

  • Page 22: Ac Abbreviation

    OFF: Switch Off ON: Switch On PCM: Powertrain Control Module REC: Recirculate SW: Switch Item Specification (Mazda 3) Heating capacity (kW {kcal/h}): 4.550 {3,913} Cooling capacity (kW {kcal/h}): 3.960 {3,406} Refrigerant Type: R-134a Regular amount: (approx. quantity) (g {oz}) 525 {18.5}...

  • Page 23: Review Exercise

    AIR CONDITIONING SG01 - Basic System TC070-15-01H Review Exercise 1. Name the components. SG01-13...
  • Page 24 AIR CONDITIONING SG01 - Basic System TC070-15-01H 2. Explain the function of the “Airflow Mode Door”. 3. Explain the function of the “Air Mix Door”. 4. Explain the function of the “Air Filter”. 5. Explain the purpose of the “Thermal Protector” and where it is located. SG01-14...
  • Page 25 AIR CONDITIONING SG01 - Basic System TC070-15-01H 6. In this example match the gauge reading with the possible condition. Compressor Failure Insufficient refrigerant Excessive refrigerant Normal SG01-15...
  • Page 26 AIR CONDITIONING 01 - Identifying A/C Components TC070-15-01H Technician Name IDENTIFYTING A/C COMPONENTS Purpose: In this activity, you will identify major A/C components. What you will need to complete this activity: Current model vehicle Workshop Manual or Body Electrical Trouble Shooting Manual Component Identification Identify the numbered A/C components on the vehicle and record in the spaces below.
  • Page 27 AIR CONDITIONING 01 - Identifying A/C Components TC070-15-01H NOTE If the answer of any of the questions was no, fix the problem before continuing the inspection. Visual and component inspection help isolate the concern to a specific system. Instructor Sign-Off: Now that you have completed this activity, you should be able to: Identify A/C components This skill will help you service an A/C system.
  • Page 28 AIR CONDITIONING 02 - Locating A/C Protection Devices TC070-15-01H Technician Name LOCATING A/C PROTECTION DEVICES Purpose: In this activity, you will locate A/C protection devices and explain how they operate. What you will need to complete this activity: Current model vehicle Workshop Manual or Body Electrical Trouble Shooting Manual Protection Devices react to abnormally high or low pressure and excessively high temperature which would damage the system.
  • Page 29 AIR CONDITIONING 02 - Locating A/C Protection Devices TC070-15-01H Pressure Relief Valve 1. Where is this device located? 2. At what pressure will you expect the pressure relief valve to discharge refrigerant to the atmosphere? Instructor Sign-Off: Now that you have completed this activity, you should be able to: locate A/C system protection devices explain the function of protection devices This skill will help you evaluate protection devices for correct operation.
  • Page 30 AIR CONDITIONING 03 - Conducting a Performance Check TC070-15-01H Technician Name CONDUCTING A PERFORMANCE CHECK Purpose: In this activity, you will diagnose a vehicle’s air conditioning system. A performance check is the basis of air conditioning diagnosis. All diagnostic routines should begin and end with this test to determine if the system is performing to specifications.
  • Page 31 AIR CONDITIONING 03 - Conducting a Performance Check TC070-15-01H 5. Operate temperature select control throughout its range and confirm that the airflow temperature matches the setting. Start with the control in the coolest setting and slowly increase temperature to highest setting, then back to original setting.
  • Page 32 AIR CONDITIONING 03 - Conducting a Performance Check TC070-15-01H 6. Measure the ambient temperature and high- and low- pressure side reading of the pressure gauge. Ambient temperature °C High pressure psi / Low pressure Ambient temperature 7. Verify that the intersection of the pressure reading of the pressure gauge and ambient temperature is in the shaded zone.
  • Page 33 AIR CONDITIONING 03 - Conducting a Performance Check TC070-15-01H 4. Start engine and hold at 1,500 rpm. 5. After the blower air is stabilized, read the dry-bulb thermometer. Dry-bulb temperature °C 6. Verify that the temperature reading is in the shaded zone. INFORMATION POINT Stabilized refrigerant pressures occur when maximum high side pressure remains the same each time the compressor cycle off.
  • Page 34 AIR CONDITIONING 03 - Conducting a Performance Check TC070-15-01H Instructor Sign-Off: Now that you have completed this activity, you should be able to: conduct A/C performance checks This skill will help you accurately diagnose an A/C system. Instructor’s initials: SG03-5...
  • Page 35 AIR CONDITIONING 04 - Refrigerant Charging TC070-15-01H Technician Name REFRIGERANT CHARGING Purpose: After completing this activity, you will be able to recharge refrigerant to the A/C system and confirm proper cooling. What you will need to complete this activity: Current model vehicle Workshop Manual or Body Electrical Trouble Shooting Manual R-134a Refrigerant Pressure Gauge Set (49 C061 0A0B Gas Charge Set) Vacuum Pump...
  • Page 36 AIR CONDITIONING 04 - Refrigerant Charging TC070-15-01H 4. Place the refrigerant tank on the scale. Regular amount of refrigerant (approx. quantity) 500 g {17.65 oz} Evacuation 1. Open all the valves of the pressure gauge. NOTE Close the SST (49 C061 001A) valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.
  • Page 37 AIR CONDITIONING 04 - Refrigerant Charging TC070-15-01H NOTE When using service can, do not open the high-pressure side valve while the engine is running. If you open, the compressed refrigerant will enter into the can causing a burst and it may damages surroundings and you may get injured. 3.
  • Page 38 AIR CONDITIONING 04 - Refrigerant Charging TC070-15-01H Instructor Sign-Off: Now that you have completed this activity, you should be able to: perform A/C refrigerant charging This skill will help you properly charge the refrigerant. Instructor’s initials: SG04-4...
  • Page 39 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H OBJECTIVES After completing this section, you will be able to: Identify the components of Manual Air Conditioner and distinguish the components from those of Full-auto Air Conditioner. Describe a control system and how the system controls the Manual Air Conditioner.

  • Page 40: Control System [Manual Air Conditioner]

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Control System [Manual Air Conditioner] Structural View (Mazda 3) 1. Air intake actuator 2. Blower motor 3. Resistor 4. Magnetic clutch (Z6) 5. Magnetic clutch (LF) 6. Evaporator temperature sensor 7.

  • Page 41: Control System [Full-Auto Air Conditioner]

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Control System [Full-auto Air Conditioner] Tick the components that are equipped with only Full-auto Air Conditioner. 1. Air intake actuator 2. Air mix actuator 3. Airflow mode actuator 4. Blower motor 5.

  • Page 42: Control System Wiring Diagram [Manual Air Conditioner]

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Control System Wiring Diagram [Manual Air Conditioner] 1. Blower relay 2. Blower motor 3. Resistor 4. Air intake actuator 5. Evaporator temperature sensor 6. A/C relay 7. Magnetic clutch 8. Refrigerant pressure switch 9.

  • Page 43: Blower Relay

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Blower relay Blower relay is classified as Type B as shown in the table below. Its function is to be checked by measuring the continuities. Type B relay * It requires supplying battery voltage. Service Tip Although your multi-meter might have a function to check continuity by giving beep sounds, use the range of your multi-meter to check resistance (ohm) when you check...

  • Page 44: Resistor

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Resistor According to the fan switch position, the number of resister connected in series with the blower motor varies. The voltage applied to the blower motor changes due to the variation.

  • Page 45: Evaporator Temperature Sensor

    Look at the chart below, Control Reference Value. The predetermined value “t1” must be above freezing point. The difference between “t1” and “t2” are usually 2 – 3 ºC. t1 =4.5, t2=5.5 (Mazda 3) The difference value in temperature between “t1” and “t2” is referred as hysteresis that prevents continuing repetition of changes ON and OFF at a specified temperature.
  • Page 46 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Look at both graphs, “Temperature – Resistance” and “Temperature – Voltage (PCM input)” and read the resistance and voltage at each given temperature as below. Resistance kilo-ohm, Voltage V at -10 ºC Resistance kilo-ohm, Voltage V at 0 ºC...

  • Page 47: A/C Relay

    A/C relay is classified as Type A as shown in the table below. Its function is to be checked by measuring the continuities. * It requires supplying battery voltage. Magnetic clutch Mazda 3 [Z6, ZY] Mazda 3 [LF, L3] 1. Bolt 1. Bolt 2.
  • Page 48 SG02 - Control System [Manual Air Conditioning] TC070-15-01H A bimetallic (Indirect sensing type) type thermal protector is shown in the figure below. 1. Thermal protector Mazda 3 Magnet clutch function can be checked by directly applying the battery voltage as shown in the figure below. SG02-10...

  • Page 49: Refrigerant Pressure Switch

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Refrigerant pressure switch The figure below shows a triple pressure type refrigerant pressure switch that consists of the low/high-pressure switch and the medium-pressure switch. The low/high-pressure switch protects the refrigerant cycle by cutting the A/C signal when pressure in the refrigerant cycle is either abnormally high or low.

  • Page 50: Fan Switch

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Fan switch The diagram of fan switch is shown in the figure below. Its function can be verified by checking the continuity between the terminals at a given status of switch position as shown in the table below.
  • Page 51 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H The airflow mode selector dial, temperature control dial, airflow volume control dial have been enlarged to improve ease of operation. 1. Climate control unit 2. Airflow mode selector dial 3. Airflow volume control dial 4.
  • Page 52 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Outline of Control System Manual air conditioner defroster control and A/C compressor control. Defroster Control 1. When the airflow mode selector dial is turned to DEFROSTER position, a wire moves the airflow mode main link, turning the airflow mode to DEFROSTER. 2.
  • Page 53 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H A/C Compressor Control The climate control unit sends an A/C signal to the PCM via the main fuse block and instrument cluster (PJB and instrument cluster) based on signals sent from the A/C switch, fan switch and evaporator temperature sensor.
  • Page 54 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Climate control unit inspection (Reference) 1. Turn the ignition switch to the ON position. 2. Connect the negative (-) lead of the tester to body ground. 3. By inserting the positive (+) lead of the tester into each climate control unit terminal, measure the voltage according to the terminal voltage table.
  • Page 55 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H (Cont’d) SG02-17...

  • Page 56: Technical Data

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Technical Data SG02-18...

  • Page 57: Review Exercise

    AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H Review Exercises 1. Refer to the illustration and place the number of each component by the correct description. Air Intake actuator Resistor Evaporator temperature sensor Main fuse block Blower relay Climate control unit Refrigerant pressure switch A/C Relay...
  • Page 58 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H 2. In the above manual wiring diagram identify the components and place the number beside the correct description. Blower Relay Air Intake Actuator Blower Motor Magnetic Clutch A/C Relay Fan Switch SG02-20...
  • Page 59 AIR CONDITIONING SG02 - Control System [Manual Air Conditioning] TC070-15-01H 3. Describe the operation of the blower motor resistor. 4. Describe the function of the “Air Intake Actuator”. 5. Describe the function of the “Evaporator Temperature Sensor”. 6. Describe the function of the “Medium Pressure Switch”. SG02-21...
  • Page 60 NOTE: This activity sheets are designed based on Mazda 3 technical information. It’s recommended to provide Mazda 3 and/or units and parts for Mazda 3. AC – 05 is an optional activity. If units and parts are not available, this activity is to be cancelled.
  • Page 61 AIR CONDITIONING 05 - Units and Parts Checks TC070-15-01H Blower relay Check continuities Step 1 and 2. Continuity Step 1: OK / NG Continuity Step 2: OK / NG Blower motor Inspect by directly applying battery voltage. Operation: OK / NG Resistor Measure the resistances.
  • Page 62 AIR CONDITIONING 05 - Units and Parts Checks TC070-15-01H Magnetic clutch Connect battery positive voltage to magnetic clutch terminal A and the A/C compressor body to ground. Operation: OK / NG Refrigerant pressure switch 1. Install the manifold gauge. 2. Disconnect the refrigerant pressure switch connector. 3.
  • Page 63 AIR CONDITIONING 05 - Units and Parts Checks TC070-15-01H Climate control unit inspection Connected Measurement Voltage Terminal Signal name Remark condition ROOM 15 A Under any condition fuse A/C 10 A fuse IG SW ON IG SW LOCK Body ground Under any condition Sensor GND Evaporator...
  • Page 64 AIR CONDITIONING 05 - Units and Parts Checks TC070-15-01H Instructor Sign-Off: Now that you have completed this activity, you should be able to: Perform checks for A/C components This skill will help you evaluate protection devices for correct operation. Instructor’s initials: SG05-5...
  • Page 65 The purpose of this activity is to experience symptom troubleshooting to diagnose logically. Try not to find the defect setting by just guesswork. NOTE This activity sheets are designed based on Mazda 3 technical information. It’s recommended to provide Mazda 3. SG06-1...
  • Page 66 AIR CONDITIONING 06 - Symptom Troubleshooting TC070-15-01H Troubleshooting Index TROUBLESHOOTING ITEM TROUBLESHOOTING ITEM Insufficient air (or no air) blown from • Problem with each vent and/or duct vents Amount of air blown from vents does • Malfunction in blower system not change.
  • Page 67 AIR CONDITIONING 06 - Symptom Troubleshooting TC070-15-01H 8 No cool air (DESCRIPTION: Magnetic clutch does not operate.) Among the nine troubleshooting items indicated on the previous page, we see the item No. 8 to learn how to diagnose Air Conditioner. Preparatory study As it’s given the description “Magnetic clutch does not operate”, the trouble is with an electrical/electronic device.
  • Page 68 AIR CONDITIONING 06 - Symptom Troubleshooting TC070-15-01H The figure below describes the A/C Compressor Control. The climate control unit sends an A/C signal to the PCM via the main fuse block and instrument cluster (PJB and instrument cluster) based on signals sent from the A/C switch, fan switch and evaporator temperature sensor.
  • Page 69 AIR CONDITIONING 06 - Symptom Troubleshooting TC070-15-01H POSSIBLE CAUSE • A/C relay malfunction (Step 2) • A/C compressor malfunction (Step 3) • Evaporator temperature sensor malfunction (Step 4) STEP INSPECTION ACTION 1 INSPECT AIR BLOW OUT • Does air blow out? Yes Go to the next step.
  • Page 70 AIR CONDITIONING 06 - Symptom Troubleshooting TC070-15-01H Repair Order Name of student: Total score: Description/Procedure/Remarks/Results Score Instructor Sign-Off: Now that you have completed this activity, you should be able to: Isolate trouble cause based on Symptom based approach This skill will help you evaluate protection devices for correct operation. Instructor’s initials: SG06-6...
  • Page 71 All materials (texts, images, graphics, animation and other materials) in the training materials are subject to the copyrights and other intellectual property rights of Mazda Motor Corporation, its affiliated companies, and its licensors. These materials may not be copied, processed, sold, inspected, published not only for commercial use but also for third party, and these materials may not be modified or reposted to other sites/CDs/DVDs.

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