REFRIGERANT ON-VEHICLE INSPECTION


  1. INSPECT REFRIGERANT VOLUME

    A01GNBRE01
    Text in Illustration
    *1 Sight Glass

    1. Check the sight glass on the cooler refrigerant liquid pipe A.

      Test conditions:


      • Temperature at the air inlet is 30 to 35°C (86 to 95°F).

      • Engine is running at 1500 rpm.

      • Blower speed control switch is at HI.

      • A/C switch is ON.

      • Temperature control switch is at the MAX. COOL position.


      • Doors are fully open.

      Item Symptom Amount of Refrigerant Corrective Procedures
      1 Bubbles visible Insufficient*

      (1) Check for gas leakage and repair if necessary

      (2) Add refrigerant until bubbles disappear
      2 No bubbles visible Empty, insufficient or too much Refer to items 3 and 4
      3 No temperature difference between compressor inlet and outlet Empty or nearly empty

      (1) Check for gas leakage with halogen gas leak detector and repair if necessary

      (2) Add refrigerant until bubbles disappear
      4 Considerable temperature difference between compressor inlet and outlet Correct or too much Refer to items 5 and 6
      5 Immediately after air conditioning is turned OFF, refrigerant becomes clear Too much

      (1) Drain or discharge refrigerant

      (2) Bleed air and supply proper amount of purified refrigerant
      6 Immediately after air conditioning is turned OFF, refrigerant foams and then becomes clear Correct -

      Tech Tips

      *: If the ambient temperature is higher than usual but cooling is sufficient, bubbles in the sight glass are permissible.

  2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET


    1. This method uses a manifold gauge set to locate problem areas. Read the manifold gauge pressure when these conditions are established.

      Test conditions:


      • Temperature at the air inlet is 30 to 35°C (86 to 95°F).

      • Engine is running at 1500 rpm.

      • All doors are fully open.

      • Blower speed control switch is at HI.

      • A/C switch is ON.

      Gauge readings (Reference).

      A01GJLNE48
      Text in Illustration
      *a Pressure on low-pressure side *b Blower HI zone
      *c

      Blower LO zone (MPa (kgf/cm2, psi))

      		 *d

      Pressure on high-pressure side (MPa (kgf/cm2, psi))

      1. A01GKJ8E01

        Normally functioning refrigeration system

        Gauge Reading
        Pressure side Refrigerant volume
        Low

        0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2)
        High

        1.37 to 1.57 MPa (14 to 16 kgf/cm2)

      2. The air conditioning system periodically changes between normal and improper function due to moisture in the refrigerant system.

        A01GMFFE16
        Symptom Probable Cause Diagnosis Corrective Actions
        During operation, pressure on low pressure side cycles between normal and vacuum Moisture in refrigeration system freezes at expansion valve orifice, causing temporary stop of cycle. However, when melted, normal state is restored.

        • Dryer is overly saturated

        • Moisture in refrigeration system freezes at expansion valve orifice and blocks refrigerant circulation

        1. Replace cooler dryer

        2. Remove moisture from cycle by repeatedly evacuating air

        3. Supply appropriate volume of new refrigerant

      3. The air conditioning system does not function effectively due to insufficient cooling.

        A01GM7VE09
        Symptom Probable Cause Diagnosis Corrective Actions

        • Pressure low on both low and high pressure sides

        • Cooling performance insufficient

        		 Gas leakage from refrigeration system

        • Insufficient refrigerant

        • Refrigerant leakage

        1. Check for gas leakage and repair if necessary

        2. Supply appropriate volume of new refrigerant

        3. If indicated pressure value is close to 0 when connected to gauge, create vacuum after inspecting and repairing the location of leakage

      4. The air conditioning system does not function effectively due to poor circulation of the refrigerant.

        A01GKHIE10
        Symptom Probable Cause Diagnosis Corrective Actions

        • Pressure low on both low and high pressure sides

        • Frost exists on piping from condenser to air conditioning unit

        		 Refrigerant flow obstructed by dirt in condenser Condenser clogged Replace condenser

      5. The air conditioning system does not function or functions intermittently because the refrigerant does not circulate.

        A01GL5VE09
        Symptom Probable Cause Diagnosis Corrective Actions

        • Vacuum indicated on low pressure side, and extremely low pressure indicated on high pressure side

        • Frost or condensation seen on piping on both sides of condenser or expansion valve

        • Refrigerant flow obstructed by moisture or dirt in refrigeration system

        • Refrigerant flow obstructed by gas leakage from expansion valve

        		 Refrigerant does not circulate

        1. Check expansion valve refrigerant

        2. Clean expansion valve by blowing air

        3. Replace condenser

        4. Evacuate air and charge appropriate volume of new refrigerant

        5. For gas leakage from expansion valve, replace expansion valve

      6. The air conditioning system does not function effectively due to overcharged refrigerant or insufficient cooling of the condenser.

        A01GJWHE10
        Symptom Probable Cause Diagnosis Corrective Actions
        Pressure extremely high on both low and high-pressure sides

        • Excessive refrigerant

        • Cooling performance of condenser insufficient

        • Condenser is dirty

        • Condenser fan motor is malfunctioning

        • Excessive refrigerant

        1. Clean condenser

        2. Check condenser fan motor operation

        3. If 1 and 2 normal, check the amount of refrigerant and supply appropriate volume of refrigerant

      7. The air conditioning system does not function due to air in the refrigeration system.

        CAUTION:

        The low-pressure piping may be very hot and cause serious burns.

        Note

        These gauge indications occur when the refrigeration system opens and the system is charged with refrigerant without vacuum purging.

        A01GKHCE20
        Symptom Probable Cause Diagnosis Corrective Actions

        • Pressure extremely high on both low and high-pressure sides

        • Low-pressure piping is too hot to touch

        		 Air in refrigeration system

        • Air in refrigeration system

        • Vacuum purging insufficient

        1. Check if compressor oil is dirty or insufficient

        2. Evacuate air and charge new refrigerant

      8. The air conditioning system does not function effectively due to an expansion valve malfunction.

        A01GN2GE11
        Symptom Probable Cause Diagnosis Corrective Actions

        • Pressure extremely high on both low and high-pressure sides

        • Frost or condensation on piping on low-pressure side

        		 Problem with expansion valve

        • Excessive refrigerant in low pressure piping

        • Expansion valve too wide open

        		 Replace expansion valve

      9. The air conditioning system does not function due to a defective compressor.

        A01GK7SE10
        Symptom Probable Cause Diagnosis Corrective Actions

        • Pressure extremely high on both low and high-pressure sides

        • Pressure extremely low on high pressure side

        		 Internal leakage in compressor

        • Compression failure

        • Leakage from damaged valve or broken sliding parts

        		 Repair or replace compressor