ON-VEHICLE INSPECTION
PROCEDURE
1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET
HINT:
The following examples show the readings of a manifold gauge set and the corresponding air conditioning system problems.
(a) Read the manifold gauge pressure when the following conditions are met:
| (1) Normal functioning air conditioning system Gauge Reading
|
|
(2) Abnormally functioning air conditioning system
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system periodically cools and then fails to cool |
| Probable Cause | Moisture in air conditioning system freezes at expansion valve orifice, causing refrigerant to temporarily stop circulating |
| After system stops and warms up again, ice melts and normal operation is temporarily restored | |
| Diagnosis | Cooler dryer (integrated into condenser tank) saturated with moisture |
| Moisture in air conditioning system is freezing at expansion valve orifice and blocking circulation of refrigerant | |
| Corrective Actions | Replace cooler dryer |
| Remove moisture by repeatedly evacuating air from air conditioning system | |
| Recharge air conditioning system with proper amount of new or purified refrigerant |
HINT:
For the example above, moisture is present in the air conditioning system.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool effectively |
| Insufficient cooling performance | |
| Probable Cause | Refrigerant leaks from air conditioning system |
| Diagnosis | Insufficient refrigerant |
| Refrigerant leaking | |
| Corrective Actions | Check for refrigerant leaks and repair if necessary |
| Recharge air conditioning system with proper amount of new or purified refrigerant | |
| If gauges indicate pressure of close to 0, then it is necessary to evacuate air conditioning system after repairing leaks |
HINT:
For the example above, there is insufficient refrigerant.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool effectively |
| Frost exists on pipe from condenser to evaporator unit | |
| Probable Cause | Refrigerant flow is obstructed by dirt inside pipes of condenser core |
| Diagnosis | Condenser is clogged |
| Corrective Actions | Replace condenser |
HINT:
For the example above, there is poor circulation of refrigerant.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool effectively (System may cool occasionally) |
| Frost or condensation is seen on piping on both sides of receiver/dryer or expansion valve | |
| Probable Cause | Refrigerant flow is obstructed by moisture or dirt in air conditioning system |
| Expansion valve is stuck closed | |
| Diagnosis | Refrigerant does not circulate |
| Corrective Actions | Replace expansion valve |
| Replace condenser | |
| Evacuate air conditioning system and recharge with proper amount of new or purified refrigerant |
HINT:
For the example above, the refrigerant does not circulate.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool effectively |
| Probable Cause | Unable to provide sufficient performance due to excessive amount of refrigerant |
| Cooling effectiveness of condenser is insufficient | |
| Diagnosis | Excessive amount of refrigerant in air conditioning system because excessive refrigerant was added during recharging |
| Cooling effectiveness of condenser is insufficient because condenser fins are clogged or cooling fan is faulty | |
| Corrective Actions | Clean condenser |
| Check operation of condenser cooling fan | |
| If condenser is clean and fan operation is normal, check amount of refrigerant and recharge air conditioning system with proper amount of new or purified refrigerant |
HINT:
For the example above, the air conditioning system is overcharged or cooling effectiveness of condenser is insufficient.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool |
| The low pressure piping is too hot to touch | |
| Probable Cause | Air in air conditioning system |
| Diagnosis | Air present in air conditioning system |
| Insufficient vacuum purging when evacuating air conditioning system | |
| Corrective Actions | Replace cooler dryer |
| Check compressor oil to see if it is dirty or insufficient | |
| Evacuate air conditioning system and recharge it with new or purified refrigerant |
NOTICE:
These gauge indications occur when the air conditioning system has been left open and then recharged without evacuating the system.
HINT:
For the example above, air is present in the air conditioning system.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool effectively |
| Frost or large amount of condensation on piping on low pressure side | |
| Probable Cause | Expansion valve may be stuck open or metering refrigerant incorrectly |
| Diagnosis | Excessive refrigerant in low pressure piping |
| Expansion valve open too wide | |
| Corrective Actions | Replace expansion valve |
HINT:
For the example above, there is an expansion valve malfunction.
| *a | LO |
| *b | HI |
| Symptom | Air conditioning system does not cool effectively |
| Probable Cause | Internal leak in compressor |
| Diagnosis | Low compression |
| Leak from damaged valve or other compressor component | |
| Corrective Actions | Replace compressor |
HINT:
For the example above, there is insufficient compressor compression.
(3) Gauge readings (Reference)
| *a | Pressure on Low Pressure Side kPa (kgf/cm2, psi) | *b | Pressure on High Pressure Side kPa (kgf/cm2, psi) |
| *c | Blower High Zone | *d | Blower Low Zone |
Precaution
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