RM3660EC _58 Vehicle Interior _080733 HEATING / AIR CONDITIONING _0393725 REFRIGERANT G

HEATING / AIR CONDITIONING  REFRIGERANT  ON-VEHICLE INSPECTION  


PROCEDURE

Hide 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:

·

The doors are fully open.

·

The engine is idling (for Gasoline Model) or power switch is on (READY) (for HV Model).

·

The A/C switch is on.

·

The temperature is set to max cold.

·

The blower speed is set to high.

·

The temperature at the air inlet with recirculate selected is 30 to 35°C (86 to 95°F).


i.
E268307

Normally functioning air conditioning system

Gauge Reading
Pressure Side Refrigerant Volume
Low 150 to 250 kPa (1.5 to 2.5 kgf/cm2, 22 to 36 psi)
High 1370 to 1570 kPa (14.0 to 16.0 kgf/cm2, 199 to 228 psi)


ii.

Abnormally functioning air conditioning system

1.
E225742C10
0.906,1.698 1.188,1.927 0.281,0.229 10 false *a 2.375,1.698 2.656,1.927 0.281,0.229 10 false *b
*a LO
*b HI


During operation, pressure on low pressure side cycles between normal and vacuum

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.


2.
E225743C10
0.958,1.708 1.146,1.896 0.188,0.188 10 *a 2.354,1.708 2.542,1.896 0.188,0.188 10 *b
*a LO
*b HI


Pressure is low on both low and high pressure sides

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.


3.
E225744C10
0.95,1.724 1.209,1.924 0.259,0.2 10 *a 2.342,1.724 2.601,1.924 0.259,0.2 10 *b
*a LO
*b HI


Pressure is low on both low and high pressure sides

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.


4.
E225745C10
0.965,1.747 1.159,1.933 0.195,0.186 10 *a 2.408,1.747 2.603,1.933 0.195,0.186 10 *b
*a LO
*b HI


Vacuum is indicated on low pressure side and very low pressure is indicated on high pressure side

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.


5.
E225746C10
0.948,1.75 1.146,1.958 0.198,0.208 10 *a 2.354,1.75 2.552,1.958 0.198,0.208 10 *b
*a LO
*b HI


Pressure is too high on both low and high pressure sides

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.


6.
E225747C09
0.938,1.771 1.208,1.99 0.271,0.219 10 *a 2.354,1.771 2.625,1.99 0.271,0.219 10 *b
*a LO
*b HI


Pressure is too high on both low and high pressure sides

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.


7.
E225748C10
0.948,1.76 1.146,1.99 0.198,0.229 10 *a 2.354,1.76 2.552,1.99 0.198,0.229 10 *b
*a LO
*b HI


Pressure is too high on both low and high pressure sides

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.


8.
E225749C09
0.927,1.76 1.167,1.99 0.24,0.229 10 *a 2.396,1.75 2.635,1.979 0.24,0.229 10 *b
*a LO
*b HI


Pressure is too high on both low and high pressure sides or pressure is too low on high pressure side

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.




iii.

Gauge readings (Reference)

E268295C04
2.99,2.417 3.156,2.417 3.156,2.417 3.156,2.729 false 3.333,2.896 3.5,2.896 3.5,2.896 3.5,3.063 false 3.469,3.396 3.635,3.396 3.635,3.396 3.635,3.229 false 3.729,3.802 3.896,3.802 3.896,3.802 3.896,3.635 false 3.583,1.667 4.167,2.063 false 4.75,2.521 5.333,2.917 false 0.229,3.135 2.219,3.333 1.99,0.198 10 false 200 (2.0, 29) 0.229,2.448 2.219,2.646 1.99,0.198 10 false 300 (3.1, 44) 0.229,1.75 2.219,1.948 1.99,0.198 10 false 400 (4.1, 58) 0.229,1.073 2.219,1.271 1.99,0.198 10 false 500 (5.1, 73) 1.375,4.24 3.365,4.438 1.99,0.198 10 false 500 (5.1, 73) 2.552,4.24 4.542,4.438 1.99,0.198 10 false 1000 (10.2, 145) 3.833,4.24 5.823,4.438 1.99,0.198 10 false 1500 (15.3, 218) 5.104,4.24 7.094,4.438 1.99,0.198 10 false 2000 (20.4, 290) 1.229,3.552 3.219,3.75 1.99,0.198 10 false 140 (1.4, 20) 1.302,3.146 3.292,3.344 1.99,0.198 10 false 200 (2.0, 29) 1.229,2.969 3.219,3.167 1.99,0.198 10 false 220 (2.2, 32) 1.24,2.635 3.229,2.833 1.99,0.198 10 false 270 (2.8, 39) 1.958,2.323 3.948,2.521 1.99,0.198 10 false 1060 (10.8, 154) 2.313,2.802 4.302,3 1.99,0.198 10 false 1200 (12.2, 174) 2.448,3.313 4.438,3.51 1.99,0.198 10 false 1250 (12.7, 181) 2.708,3.708 4.698,3.906 1.99,0.198 10 false 1320 (13.5, 191) 1.021,0.573 1.333,0.771 0.313,0.198 10 false *a 6.292,4.094 6.604,4.292 0.313,0.198 10 false *b 3.427,1.542 3.74,1.74 0.313,0.198 10 false *c 5.365,2.875 5.677,3.073 0.313,0.198 10 false *d
*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