Mazda TC070-15-01H Student Manual Download Page 35

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AIR CONDITIONING
04 - Refrigerant Charging

SG04-1

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

Electronic Leak Detector

Safety Glasses

NOTE

Do not exceed the specification when charging the system with refrigerant. Doing
so will decrease the efficiency of the air conditioner or damage the refrigeration
cycle parts.

Recover/Recycle R-134a Refrigerant

NOTE

Follow the device manufacturer's instructions.

1.  Connect an R-134a recovery/recycling/recharging device to the vehicle.

2.  Recover and recycle the refrigerant

Charging Preparation

1. Install the R-134a Refrigerant

Pressure Gauge Set.

2. Connect the vacuum pump.

3. Connect the

SST

(49 C061 004)

to the refrigerant tank

Summary of Contents for TC070-15-01H

Page 1: ...L LE EV VE EL L 1 1 Air Conditioning Operation Diagnosis T TC C0 07 70 0 1 15 5 0 01 1H H Student Guide Mazda Motor Corporation Technical Service Training...

Page 2: ...you have learnt so far and get information from relevant service materials such workshop manual and wiring diagram NOTE This course is developed based on the service materials of Mazda 3 included in t...

Page 3: ...01 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 conditi...

Page 4: ...ices Refrigerant Pressure Check SG Activity Workshop 14 50 15 00 Break 15 00 17 00 Performance Check SG Activity Workshop Day 2 Time Session Remark 8 30 9 50 Control System SG Classroom 9 50 10 00 Bre...

Page 5: ...high pressure vapor Technician B says at point E in this illustration the refrigerant is a low pressure vapor Who is correct a Technician A b Technician B c Both Technicians d Neither technician 3 On...

Page 6: ...dding heat Technician B says the compressor raises the pressure of the vaporized refrigerant and not the temperature Who is correct a Technician A b Technician B c Both Technicians d Neither technicia...

Page 7: ...frigerant is a High pressure liquid b High pressure vapor c Low pressure liquid d Low pressure vapor 11 Technician A says R 12 and R 134a system have different sized service valves to prevent accident...

Page 8: ...erating A C system Who is correct a Technician A b Technician B c Both Technicians a Neither technician 14 Technician A says after repairs have been performed or if a system has been open for a long p...

Page 9: ...tem Technician B says if the refrigerant has leaked out of an A C system the technician should charge the system with a small amount of refrigerant for leak testing purposes Who is correct a Technicia...

Page 10: ...t SG00b 6 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 se...

Page 11: ...Shop AC02 Locating A C Protection Devices Shop AC03 A C performance Check Shop AC04 Refrigerant Charging Shop In this section Basic System A C Components 2 A C Unit construction operation 3 Evaporator...

Page 12: ...AIR CONDITIONING SG01 Basic System SG01 2 TC070 15 01H A C Components Name the components...

Page 13: ...ansion valve 4 Air intake door 5 Air mix door 6 Airflow mode door 7 Evaporator temperature sensor 8 Resistor manual air conditioner 9 Power MOS FET full auto air conditioner 10 Air intake actuator 11...

Page 14: ...ing angle of the ball valve in the expansion valve Opening angle is adjusted by a balance of the R 134a pressure Pd in the diaphragm and a composite force of evaporator discharge pressure PI against t...

Page 15: ...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 The airflo...

Page 16: ...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 A rotary vane type H12A...

Page 17: ...s 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 R...

Page 18: ...e 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 When the pipes are being connected the flared end of the female side forces t...

Page 19: ...tem SG01 9 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 B C A Insufficient refrigerant B Excessive refrigerant or insufficie...

Page 20: ...nguish 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 th...

Page 21: ...If moisture mixes with the compressor oil the refrigerant system could be damaged Therefore install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moi...

Page 22: ...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 A C compressor Type Vane rotary Discharge capacity ml cc fl oz 120 120 4 06 Ma...

Page 23: ...AIR CONDITIONING SG01 Basic System SG01 13 TC070 15 01H Review Exercise 1 Name the components...

Page 24: ...ystem SG01 14 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 Prot...

Page 25: ...CONDITIONING SG01 Basic System SG01 15 TC070 15 01H 6 In this example match the gauge reading with the possible condition Compressor Failure Insufficient refrigerant Excessive refrigerant Normal A B...

Page 26: ...refer to the Workshop Manual 1 6 2 7 3 8 4 9 5 10 Visual Inspection 1 Do the condenser and radiator have any obstructions to airflow Yes No NOTE Perform the following checks with engine off and key o...

Page 27: ...ns 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 y...

Page 28: ...erant Pressure Switch 1 Where is the pressure switch located 2 How does it protect a system that has a leak in the condenser 3 How does it protect a system that has inoperative condenser fans 4 Is the...

Page 29: ...e 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...

Page 30: ...rge Set Safety Glasses NOTE Humidity and temperature have an effect on the outcome of this test Function Check NOTE During the following tests monitor instrument panel gauges and warning lights for ou...

Page 31: ...re This is because the evaporator is concentrated in the small area of the duct very close to the evaporator Gauge Installation Install R 134a Refrigerant Pressure Gauge Set according to the workshop...

Page 32: ...ture 7 Verify that the intersection of the pressure reading of the pressure gauge and ambient temperature is in the shaded zone Performance Check 1 Place a dry bulb thermometer in the driver side cent...

Page 33: ...on inspect the refrigerant system according to the troubleshooting chart in the Workshop Manual NOTE It is acceptable for outlet temperatures to be cooler than the specification If you perform the tes...

Page 34: ...Performance Check SG03 5 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...

Page 35: ...B Gas Charge Set Vacuum Pump Electronic Leak Detector Safety Glasses NOTE Do not exceed the specification when charging the system with refrigerant Doing so will decrease the efficiency of the air con...

Page 36: ...760 mmHg 29 9 inHg Close each valve Air tightness Check 1 Stop the vacuum pump and wait for 5 min 2 Check the high and low pressure side readings of the gauge If the reading has changed inspect for le...

Page 37: ...om the cooler pipe hose connections If leakage is found at a loose joint tighten the joint then inspect for leakage again 6 Open the high pressure side valve and charge with refrigerant until the weig...

Page 38: ...ant Charging SG04 4 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 refri...

Page 39: ...ctivities Activity Title Description Location AC 05 Units and parts checks Shop AC 06 Symptom troubleshooting Shop What s in this section Control System Manual Air Conditioner 2 Control System Full au...

Page 40: ...ontrol 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 Refrigerant pre...

Page 41: ...nditioner 1 Air intake actuator 2 Air mix actuator 3 Airflow mode actuator 4 Blower motor 5 Power MOS FET 6 Magnetic clutch Z6 7 Magnetic clutch LF 8 Solar radiation sensor 9 Ambient temperature senso...

Page 42: ...0 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...

Page 43: ...beep sounds use the range of your multi meter to check resistance ohm when you check continuity between the terminals B and D This is because your multi meter may determine there is a malfunction due...

Page 44: ...o the blower motor therefore the lower the revolution of the blower motor Provided the measurements are as shown in the table 1 what do you assume resistance of each register Complete the table 2 Tabl...

Page 45: ...e evaporator surface temperature within the specified range to prevent the evaporator from being frosted Look at the chart below Control Reference Value The predetermined value t1 must be above freezi...

Page 46: ...ted from the control system wiring diagram And the right one is a rearranged diagram of the circuit The evaporator temperature sensor is grounded through the climate control unit The circuit operates...

Page 47: ...g the continuities It requires supplying battery voltage Magnetic clutch Mazda 3 Z6 ZY Mazda 3 LF L3 1 Bolt 2 Pressure plate 3 Shim 4 Snap ring 5 A C compressor pulley 6 Screw 7 Clamp 8 Screw 9 Stator...

Page 48: ...itioning SG02 10 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 apply...

Page 49: ...r abnormally high or low The medium pressure switch outputs an idling increase signal according to the A C compressor operation load Why do you think the system needs to cut the A C signal when pressu...

Page 50: ...w 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 Climate control unit A wire type climate control unit i...

Page 51: ...ctor dial 3 Airflow volume control dial 4 Temperature control dial 5 A C switch 6 REC FRESH switch 7 Rear window defroster switch Block Diagram The climate control unit sends an A C signal to the PCM...

Page 52: ...osition a wire moves the airflow mode main link turning the airflow mode to DEFROSTER 2 The defroster switch turns on at the same time and the CPU sends a signal to turn the air intake mode to FRESH 3...

Page 53: ...it 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 The P...

Page 54: ...te 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 cli...

Page 55: ...AIR CONDITIONING SG02 Control System Manual Air Conditioning SG02 17 TC070 15 01H Cont d...

Page 56: ...AIR CONDITIONING SG02 Control System Manual Air Conditioning SG02 18 TC070 15 01H Technical Data...

Page 57: ...ses 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 contro...

Page 58: ...nual Air Conditioning SG02 20 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 Moto...

Page 59: ...ditioning SG02 21 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 D...

Page 60: ...model vehicle Workshop Manual or Body Electrical Trouble Shooting Manual DVOM Digital Volts Ohm Meter NOTE Most of units and parts can be checked individually To avoid any damage on vehicle it is reco...

Page 61: ...hm Condition OK NG A B ohm Condition OK NG A C ohm Condition OK NG Air intake actuator Check the air intake actuator for its function by directly applying the battery voltage C B G Ground Operation OK...

Page 62: ...ify the high pressure side reading of the manifold gauge and continuity between the refrigerant pressure switch terminals Continuity OK NG at psi Fan switch Remove the climate control unit Verify that...

Page 63: ...at 1st M A C PJB A C switch OFF N Evaporator temperature sensor input Evaporator temperature sensor Compared with temperature detected by evaporator temperature sensor Rear window defroster switch ON...

Page 64: ...cks SG05 5 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 c...

Page 65: ...d approach What you will need to complete this activity Current model vehicle Workshop Manual or Body Electrical Trouble Shooting Manual DVOM Digital Volts Ohm Meter NOTE The purpose of this activity...

Page 66: ...er Malfunction in blower system 4 Air intake mode does not change Air intake mode does not change when switching REC FRESH mode 5 No temperature control with climate control unit Malfunction in A C un...

Page 67: ...coil inside the A C relay to close the contact of the relay Magnetic clutch is grounded through its body an open circuit between Magnetic clutch and ground is unlikely occurred If the magnetic clutch...

Page 68: ...the circuit of the A C relay to supply power activating the magnetic clutch 1 A C switch ON OFF 2 Fan switch OFF position Other than OFF position 1 2 3 or 4 3 Evaporator temperature sensor V or more...

Page 69: ...to the next step 3 INSPECT A C COMPRESSOR OPERATION Start the engine Turn the A C switch and fan switch on Does the A C compressor operate Yes Go to Step 1 of troubleshooting index No 7 No Go to the...

Page 70: ...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...

Page 71: ...terials 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 insp...

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