Step
| Action
| Value(s)
| Yes
| No
|
1
| Connect the J 39500-B
.
Are the pressures greater than the specified values?
| 350 kPa (50 psi)
| Go to
Step 2
| Go to
Step 6
|
2
| Inspect and
correct for a blown Air Conditioner (A/C) fuse.
Does the complaint persist?
| Go to
Step 3
| System OK
|
3
| Inspect and correct for the following conditions:
• | Disconnected A/C clutch wire |
• | Proper A/C clutch rotation |
Refer to
HVAC Compressor Clutch Does Not Engage
. Does the complaint persist?
| --
| Go to
Step 4
| System OK
|
4
| Inspect and correct for the following
conditions:
Refer to Engine Cooling.
Does the complaint persist?
| --
| Go to
Step 5
| System OK
|
5
|
- Read the DCS for Bulletins and Hints.
- Follow the procedures indicated.
Does the complaint persist?
| --
| Go to
Step 8
| System OK
|
6
|
- Add 0.453 kg (1 lb) of refrigerant.
- Perform a leak check. Refer to Leak Testing
.
Did you find a leak?
| --
| Go to
Step 7
| System OK
|
7
|
- Repair the leak.
- Inspect the system performance. Refer to System Performance Test
.
Does the complaint persist?
| --
| Go to
Step 1
| System OK
|
8
| Perform an A/C Performance Check using the following steps:
- Ensure that the ambient temperature is at least equal to the specified
value.
- Ensure that the engine is idling at normal operating temperature.
- Turn the A/C to the ON position.
- Select the coldest setting.
- Select the MAX blower speed.
- Record the A/C pressures.
- Record the A/C temperatures.
- Refer to System Performance Test
.
Does the A/C performance meet the requirement on the Performance Chart?
| 5°C
(41°F)
| Go to
Step 9
| Go to HVAC High Side vs. Low Side Pressure Chart
|
9
| Was the customer
complaint made due to high temperature and/or high humidity?
| --
| Go to
Step 10
| System OK
|
10
| Perform a leak test.
Refer to Leak Testing
.
Did you find a leak?
| --
| Go to
Step 11
| System OK
|
11
| Recharge the A/C system. Refer to Refrigerant Recovery and Recharging
.
Does the complaint persist?
| --
| Go to
Step 8
| System OK
|
Gray Area Diagnosis and Service
Problem
| Action
|
Important: The V5 clutch may cycle if the discharge pressure exceeds 2758 kPa
(400 psi).
|
Improper condenser operation
| Improper condenser operation may result from
one of the following causes:
• | Extremely high ambient humidity |
• | Insufficient air flow across condenser |
• | Damaged or dirty condenser fins |
|
High side refrigerant restriction
|
- Feel liquid line before expansion tube (orifice). A cold line
indicates restriction in the high side.
- Inspect for a frost spot in order to locate the restriction.
- Repair the line as necessary.
|
Refrigerant system overcharged (high discharge and high suction pressures)
| The clutch
may cycle ON/OFF and cause compressor noise. Refer to air in system.
|
Expansion
tube (orifice) blocked
| Low suction pressures.
|
Air in system (High discharge and high suction pressures).
|
- Recover the refrigerant. Refer to Refrigerant Recovery and Recharging
.
- Inspect the expansion (orifice) tube for blockage. Refer to Expansion (Orifice) Tube Replacement
.
Clean or replace the tube as required.
- Recharge the A/C system. Refer to Refrigerant Recovery and Recharging
.
- Leak test the system. Refer to Leak Testing
.
|
Striped Area Diagnosis and Service
Problem
| Action
|
The compressor is damaged internally.
|
• | If the suction pressure and the discharge pressure are equal and
if these pressures do not change when you turn the A/C mode ON and OFF, the
compressor may be internally damaged. |
• | Signs of internal compressor damage include the following: |
- | Excess heat at the clutch surfaces |
- | A free wheeling clutch driver |
• | When replacing the compressor, follow the component replacement
procedures in order to maintain correct oil charge in the system. |
|
The expansion tube (orifice) is missing.
| Feel the liquid line after the expansion tube. If the line
is warm, recover the refrigerant. Refer to Refrigerant Recovery and Recharging
. Inspect the system for proper
installation of the expansion tube. Refer to Expansion (Orifice) Tube Replacement
. If the expansion
tube or the O-ring is missing, replace the expansion tube.
|
The compressor
runs at minimum stroke.
|
• | If the compressor discharge pressures remain only 10-30 psi
above the suction pressure, the compressor may be at minimum stroke. |
• | Run the engine at approximately 3000 RPM for 3 minutes
until pressures become normal. During this period, cycle the mode lever from
vent to A/C every 20 seconds. If no change occurs, perform
the control valve low load test below. |
|
The compressor control valve is set improperly.
| The low load test creates a low cooling load
that causes the V5 compressor to go toward a minimum stroke. Minimum stroke
is necessary in order to evaluate the control valve set point. Perform
the low load test using the following procedure:
- Start the engine.
- Run the engine at a fast idle.
- Open the hood.
- Close the windows and the doors.
- Set the A/C controls to LOW blower and MAX cooling.
- Record the test results.
- Evaluate the test results as follows:
• | If suction pressure is 25-35 psi, the control valve
is functioning properly. |
• | If the suction pressure is outside the limits of 25-35 psi,
replace the control valve. |
|
The refrigerant system is undercharged.
|
- The refrigerant may be undercharged when the suction pressure
is below 35 psi during the high load test.
- The suction line before the accumulator will be warm if the charge
is low.
- Add 1 lb of refrigerant.
- Recheck the pressure. Verify that the pressure is in the white
area on the chart. Then find and correct the leak.
- Recover and recharge the A/C system. Refer to Refrigerant Recovery and Recharging
.
|
The expansion tube (orifice) is blocked.
|
- Recover the refrigerant. Refer to Refrigerant Recovery and Recharging
.
- Inspect the expansion (orifice) tube for blockage. Refer to Expansion (Orifice) Tube Replacement
.
Clean or replace as required.
- Evacuate the system to a vacuum. Improper evacuation of the system
prior to recharge will cause air to remain in the system.
- Recharge the A/C system. Refer to Refrigerant Recovery and Recharging
.
- Leak test the system. Refer to Leak Testing
.
|