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) Normally 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 |
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