Heating, Ventilation, and

Air Conditioning System

Service Manual for

Recreational Vehicles

This manual applies to vehicles

using HFC-134a refrigerant ONLY.
 FOREWORD

This manual was developed to assist certified technicians in servicing the air conditioning system on
class A motorhomes built on Ford, GM, Spartan, or Freightliner chassis, equipped with a DENSO air
conditioning system.
Since the dash A/C system utilizes chassis components (compressor, condenser, receiver/drier and
discharge hose), it is advised that the appropriate chassis repair manual for Ford, GM, or Freightliner be
consulted when required or necessary.

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ii
 TABLE OF CONTENTS

GENERAL INFORMATION .................................................................................................. 1

1. The Purpose of Air Conditioning ................................................................................ 1
2. Technical Terms .......................................................................................................... 1
3. Change of State ......................................................................................................... 5
4. The Relationship Between Pressure and Temperature .............................................. 6
5. Basic Theory of Cooling ............................................................................................. 7
6. Refrigerant .................................................................................................................. 7
7. Principles of Air Conditioning ................................................................................... 10
8. Automotive Refrigeration System ............................................................................ 11
SAFETY PRECAUTIONS ................................................................................................... 14
1. Safety Precautions ................................................................................................... 14
2. Ultraviolet Rays and Ozone Layer ............................................................................ 15
TOOLS AND EQUIPMENT ................................................................................................ 16
1. Service Tool Kit......................................................................................................... 16
2. Handling of Service Tools ......................................................................................... 16
3. Robinair Enviro Charge 34700 Series ...................................................................... 18
TORQUE AND BOLT SPECIFICATIONS ........................................................................... 19
1. Standard Torque: Coupling Nut Type Fittings ......................................................... 19
2. Torque Specification for Bolts/Nuts/Screws ............................................................ 19
COMPONENT LOCATIONS AND POSITIONS ................................................................. 20
1. Interior Component Locations (All Models) .............................................................. 20
2. Raised Floor Measurements and Cutouts................................................................ 23
TROUBLESHOOTING ........................................................................................................ 24
1. Troubleshooting Table .............................................................................................. 24
2. Troubleshooting by Manifold Gauge ........................................................................ 25
3. Visual and Audible Troubleshooting Questions ........................................................ 33
4. Troubleshooting Chart .............................................................................................. 34
5. Insufficient Cooling ................................................................................................... 35
6. Abnormal Noise ........................................................................................................ 38
COMPONENT TESTING .................................................................................................... 39
1. Blower/Cooling Unit ................................................................................................. 39
2. Compressor Fitting ................................................................................................... 42
3. Refrigerant Hoses/Tubes .......................................................................................... 42
4. Heater Hoses: On Vehicle Inspection ....................................................................... 42
5. Heater ....................................................................................................................... 43
6. Thermostat ............................................................................................................... 45
7. A/C Control System: On Vehicle Inspection............................................................. 46
8. Control Panel Removal............................................................................................. 46
9. Pressure Switch ....................................................................................................... 47
10. Blower ...................................................................................................................... 48
11. Relays ...................................................................................................................... 49
12. Air Intake Servo ....................................................................................................... 50
13. Vent Mode Servo ..................................................................................................... 51

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 TABLE OF CONTENTS

REFRIGERANT LINE REPLACEMENT ............................................................................. 52

1. On Vehicle Inspection............................................................................................... 52
2. Refrigerant Lines Replacement ................................................................................ 52
3. Torque Specifications ............................................................................................... 52
4. CHASSIS .................................................................................................................. 53
REFRIGERANT CHARGING .............................................................................................. 63
1. About Certification ................................................................................................... 63
2. Section 609 of the Clean Air Act Amendments of 1990 .......................................... 64
3. Evacuating and Charging Refrigerant ...................................................................... 65
4. Refrigerant Volume ................................................................................................... 67
5. Performance Test ..................................................................................................... 68
WIRING DIAGRAMS .......................................................................................................... 70

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 GENERAL INFORMATION

1. The Purpose of Air Conditioning

The purpose of an automotive air conditioner is to
maintain a cool, comfortable environment for
passengers.
Here are the four ways this is achieved:
• Temperature Control
• Air Circulation Control
• Humidity Control
• Air Purification Fig. 2: Heat Quantity

2) Specific Heat
Specific heat is the quantity of heat
required to CHANGE THE TEMPERA-
TURE of an object by one degree.
The unit of specific heat is Kcal/kg°C
or BTU/lb°F.

Fig. 1: The Four Factors of Air Conditioning

2. Technical Terms
A. Heat
1) Heat Quantity
Heat is a form of energy. There are two
units to measure heat quantity, Kcal or Fig. 3: Specific Heat
BTU (British Thermal Unit). 3) Heat Transfer
• One Kcal heat quantity changes As heat travels over a distance, it
the temperature of one Kg of liquid tends to lose energy. Heat can be
water by one degree centigrade. transmitted through CONDUCTION,
• One BTU of heat changes the CONVECTION or RADIATION. It can
temperature of one pound of liquid also be transmitted by a combination
water by one degree Fahrenheit. of any or all of these methods.

1 Kcal = 0.252 BTU a) Conduction is the transfer of heat by

direct contact. When you heat one
1 BTU = 3.968 Kcal side of a steel bar, the other side
becomes warmer by conduction.
b) Radiation is the transfer of heat by
rays. Heat from the sun is trans-
ferred to the earth in rays. But the
sun isn’t the only object that
radiates heat. Every object that
contains heat can radiate it.

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 GENERAL INFORMATION

c) Convection is the transfer of heat

by the movement of heated liquid
or gas. When heat is applied to the
bottom of a container of liquid or
gas, the warmed particles at the
bottom expand and rise. The
colder particles at the top, which
are denser than the heated par-
ticles, sink to the bottom.

Fig. 5: Temperature Scales

2) Wet Bulb and Dry Bulb Thermometers

The bulb (heat sensitizing part) of a
glass tube thermometer is wrapped
with a gauze or other rough mesh
cloth. One end of the cloth is im-
mersed in a water container to allow
the water to be drawn up by a capil-
lary action and to moisten the heat
Fig. 4: Three Ways Heat is Transferred sensitizing part. The water in the cloth
surface near the heat sensitizing part
B. Temperature evaporates and robs the latent heat of
evaporation from the surrounding air,
1) Temperature Scales causing the air temperature around the
Temperature is the degree to which an heat sensitizing parts to drop. The
object is hot or cold. The unit generally temperature registered by the ther-
used to express this is degrees mometer at this time is called the wet
Centigrade (°C) or degrees Fahrenheit bulb temperature.
(°F). In the Centigrade scale, the This is used to find out the humidity
freezing point (solid point) of pure in combination with the dry bulb
water is taken as 0°C, and the dis- temperature.
tance between the freezing point and
the boiling point are divided into 100
parts and each part is designated as
1°C.
In the Fahrenheit scale, the freezing
point of pure water is taken as 32°F,
and the distance between the freezing
point and the boiling point are divided
into 180 parts with each part desig-
nated as 1°F.
[°C] = 5/9([°F] - 32)
[°F] = 9/5([°C] + 32)
Fig. 6: Thermometer

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 GENERAL INFORMATION

3) Dew Point Temperature In other words, if the relative humidity

is 50 percent, the air could hold as
When the air surrounding us is cooled, much water again as it does at that
the air temperature drops, and when temperature.
the humidity becomes 100%, that is,
when the dry bulb and wet bulb Water capacity means the amount of
temperatures become the same, the water vapor which the air could hold
water vapor contained in the air will be at a given temperature. The water
in a saturated state. capacity changes according to the
temperature of the air. The water
On further cooling, the water vapor capacity of cooled air is lower. There-
reaches a condition where it cannot fore, the amount of vapor in the air at
remain in a vapor state so that a part 50°C, 50 percent, is different from that
condenses and becomes dew. The in the air at 10°C, 50 percent.
temperature at which the humidity
becomes 100% and dew is formed is
called the dew point temperature.

C. Humidity
1) Humidity
When you pour water and ice into a
glass, you notice that drops of water
are generated on the glass. Do you
sometimes wonder where these drops
of water come from?
Drops of water come from the sur-
rounding air, so humidity is water Fig. 8: Relative Humidity
vapor contained in the air. 3) Absolute Humidity
Absolute humidity is the amount of
water the air contains, compared with
the dry air.

D. Pressure
1) What Is Pressure?
Pressure is defined as the vertical
force exerted on a unit area by a solid,
liquid, or gas. The unit generally used
to indicate the pressure is “kg/cm”.

Fig. 7: Humidity When indicating blower performance,

mmAq (water column) is generally
2) Relative Humidity used, and when indicating pressure
below atmospheric (vacuum), cmHg
There are two ways to measure (mercury column) is commonly used.
humidity: relative humidity and abso-
lute humidity. When expressing boiler pressure, the
atmospheric pressure is taken as the
The most common way to measure basis, and the pressure is expressed in
humidity is using the relative method. number of atmospheres (atmos). The
Relative humidity is the amount of concept held toward pressure is entirely
water the air contains, compared with in accordance with Pascal’s law.
the amount the air could hold at a
given temperature.

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 GENERAL INFORMATION

Pascal’s Law: “Pressure exerted on a 3) Absolute Pressure

liquid confined in a container is
transmitted undiminished in all direc- Absolute pressure is that in which a
tions. Regardless of container shape, perfect vacuum is taken as 0 kg/cm2.
if the interior area is equal, the pres- Thus, the atmospheric pressure, when
sure subject there will be equal.” expressed in terms of absolute pres-
sure, will be 1.03 kg/cm2.
To differentiate, pressure measured
with a gauge is called gauge pressure.
For identification, absolute pressure is
indicated by [kg/cm2 abs.] and gauge
pressure by [kg/cm2G]. Absolute
pressure to gauge pressure relation-
ship is as follows:
Absolute press. [kg/cm2 abs.] + Gauge
press. [kg/cm2G] + 1.03 kg/cm2
4) Vacuum
Fig. 9: Pressure
Vacuum is the pressure below atmo-
2) Atmospheric Pressure spheric pressure and is expressed in
terms of a mercury column (cmHg,
This is the pressure that is subjected mmHg).
on all objects and matter on earth.
This pressure is the weight of the air When the vacuum is measured with a
surrounding everyone and is equal to mercury column, the difference
1 atmosphere. between this measurement and that
for atmospheric pressure becomes the
At this pressure the mercury column amount of vacuum.
will be 760 mmHg (76 cmHg).
1 atm=1.03 kg/cm2=760 mmHg=14.7 psi
Pressure gauges commonly indicate
atmospheric pressure in units of kg/
cm2 or psi.

Fig. 10: Pressure Scales

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 GENERAL INFORMATION

3. Change of State Kcal of latent heat to change to 1 kg of

water at 0°, and 1 kg of water at 100°C
A. State Change of Water must absorb 539 Kcal of latent heat to
change to 1 kg of steam.
Now, we will consider how ice changes its
state when we add heat to it, because
water is the most common example to
understand heat and states of object.
If we add heat to ice until the temperature
of ice reaches 0°C (32°F), ice melts into
water, and while the ice is melting, the
temperature of ice and water remains at
0°C. After the ice has melted, the tem-
perature of water begins to rise.
When the temperature of water reaches
100°C (212°F), water begins to become
steam. Until all the water becomes steam, Fig. 12: Sensible Heat and Latent Heat
the temperature of water remains 100°C
(212°F). C. The Three States of Matter
As you know, matter exists in three states:
solid, liquid and gas. In the case of water,
the solid state is ice, the liquid state is
water, and the gas state is steam.

Fig. 11: State Change Of Water

B. Sensible Heat and Latent Heat

The chart below shows the relation
between heat and temperature. There are Fig. 13: Three states of Matter
two kinds of heat called sensible heat and
latent heat. 1) Fusion

Sensible Heat can change the temperature When a solid melts into a liquid, heat
of water but cannot change the state of is absorbed from its surroundings.
water. Therefore, the sensible heat raises 2) Solidification
or lowers the temperature of water. In the
case of water, 1 kg of water at 0°C must In the opposite situation, when liquid
absorb 100 Kcal of sensible heat to changes into a solid, heat is released
change to 1 kg of water at 100°C. to its surroundings.
Latent Heat can change the state of water, 3) Evaporation
but cannot change the temperature of
water. Ice melts into water by adding When liquid evaporates into gas, heat
latent heat and water evaporates into is absorbed from its surroundings.
steam by adding latent heat. In the case of
water, 1 kg of ice at 0°C must absorb 80

5
 GENERAL INFORMATION

4) Condensation
In the opposite situation, heat is
released to the surrounding matter.
In the case of water, when 1 kg of
water evaporated into 1 kg of steam,
539 Kcal of heat is absorbed from its
surroundings.
In the opposite situation, 539 Kcal of
heat is released to the surrounding
matter.
5) Sublimation
In a rare case such as dry ice (solid
carbon dioxide) and napthaline,
heating causes the solid to directly
turn into gas.
6) Adhesion
The reverse of the sublimation process
is called adhesion.

4. The Relationship Between Pressure A. Under normal atmospheric pressure (0 kg/

and Temperature cm2G) water boils at 100°C.

So far we have been discussing the state of B. If the pressure exerted on water increases
change that occurs in water under atmo- by 0.09 kg/cm2 from atmospheric pres-
spheric pressure. The boiling point of water or sure, the water does not boil until water
any liquid changes depending on the pressure temperature reaches 118°C.
working on the liquid.
C. The water under pressure which is lower
Rule 1. When the pressure is high, the boiling than normal atmosphere by 0.4 kg/cm2
point of liquid also becomes high. begins to boil as soon as the water
temperature passes 84°C.
Rule 2. Conversely, under a low pressure,
liquid begins to boil at a lower temperature. The above rules between pressure and boiling
point can be applied to all liquids. HFC-134a,
The illustration below shows how the boiling the refrigerant used in automobile air condi-
point is influenced by pressure change. tioner is no exception.

Fig. 14: Pressure and Boiling Point Relation

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 GENERAL INFORMATION

5. Basic Theory of Cooling 6. Refrigerant

We feel a little cold even on a hot day after Any substance used to create refrigeration is
swimming. This is because water on your called a refrigerant. It may be in the form of a
body takes away the heat through evapora- liquid, gas or solid. In general, a refrigerant is a
tion. The same principle is at work when we substance that serves as a moving fluid in the
apply alcohol to our arms. Evaporation of the refrigerator and circulates through the func-
alcohol removes the heat. tional parts to attain the refrigerating effect by
absorbing heat through expansion and evapo-
This natural phenomenon can be used to ration. The resulting low temperature matters
create coolness. That is, liquid takes the heat such as cold water and ice are called second-
from substances when it evaporates. ary refrigerants.

A. Properties of Refrigerants
Among the refrigerants there are toxic
gases, inflammable gases, those that have
strong properties of oxidizing or corroding
metals, as well as those that are expen-
sive. The important properties demanded
in the refrigerant are as follows:
1) Since refrigeration is attained by
evaporation of liquid, the refrigerant
must evaporate or vaporize easily.
Fig. 15: Evaporating Heat 2) The larger the latent heat at vaporiza-
tion, the smaller the amount of the
Next, we conduct an experiment in latent heat. refrigerant will be required for circula-
As the liquid placed in a heat insulating box tion, and the smaller will be the
begins to evaporate, it takes heat out of the air refrigerator.
from around the receptacle in the box and
becomes gas when the valve is turned. The 3) The equipment must be safe to
temperature of the air goes down before operate so that refrigerant will not be
opening the valve. flammable or explosive.
This is the way we will create coolness. 4) The refrigerant must not be hazardous
However, since we are forced to constantly and preferably a substance in which
add liquid to this receptacle, this is an ineffi- leakage can be detected easily.
cient method. The best way to achieve this
coolness is to change the gas to liquid and 5) The stability must be high to allow
then evaporate it again. repeated use without decomposing or
changing in property.
6) There should be no injurious effect on
parts or packings used in the com-
pressor and other units.
7) The critical temperature should be far
higher than the condensation
temperature.
8) If the evaporation pressure is lower
than atmospheric, there will be a
chance of air entering in the refrigera-
tion cycle so that evaporation pressure
should be higher than atmospheric
Fig. 16: Cooling Experiment
pressure.

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GENERAL INFORMATION

9) The higher the condensation pressure, f) Halogenated Carbide

the greater will be the requirement to
make functional parts such as the This is the general term for hydro-
compressor, condenser, and pipe of carbons containing one or more
higher resistant construction. As a halogens (Cl, F, Br). Out of these,
result, a refrigerant with a too high types containing chlorofluorocar-
condensation pressure will be bons are made in numerous
unsuitable. varieties. Its greatest advantage is
the fact that it is very safe and
B. Types of Refrigerants chemically stable.

Refrigerants can be classified into inor- g) Azeotropic Mixture

ganic compounds, carbide halogenated This is a mixture of two different
hydrocarbons, and azeotropic mixtures. refrigerants although it acts as if it
1) Inorganic Compounds were a single refrigerant.

In inorganic compound refrigerants, C. Properties of Refrigerant HFC-134a

there are ammonia, sulfurous acid gas,
and water. Refrigerant is a substance that serves as a
moving fluid in a refrigerator and circulates
a) Ammonia through functional parts to produce the
cooling effect by absorbing heat through
Although highly toxic, the other the expansion valve and vaporizing. The
properties are excellent for use as refrigerant used in new vehicle today is
refrigerant. Ammonia is used in now HFC-134a, which has no ozone
large size refrigerators. destroying properties (does not contain
b) Sulfurous Acid Gas chlorine).

This refrigerant is not commonly

used because of its strong odor
and high toxicity.
c) Carbon Dioxide
Carbon dioxide is a safe gas that
allows refrigerators to be made
smaller. However, the critical
temperature is a very low 31°C
(89°F). At present, dry ice (solid
carbon dioxide) has found wide
use as secondary refrigerant.
Fig. 17: Boiling Point of HFC-134a
d) Water
Water is used as a refrigerant for Characteristics of HFC-134a
refrigerators such as the injection
type and absorption type. Water boils at 100°C (212°F) under atmo-
spheric pressure, but HFC-134a boils at -
e) Hydrocarbons 26.9°C (-16.4°F) under atmospheric
These refrigerants include meth- pressure.
ane, ethane, and propane. They Water boils at 121°C (250°F) under 1 kg/
are used mainly in the petrochemi- cm2G (98 kPa) of pressure, but HFC-134a
cal industry. In addition, hydrocar- boils at -10.6°C (12.8°F) under 1 kg/cm2G
bons are considered inferior in (98 kPa) of pressure
safety.

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 GENERAL INFORMATION

If HFC-134a were released to the air under Example-4

normal room temperature and atmo-
spheric pressure, it will absorb the heat The liquid refrigerant can be converted
from the surrounding air and boil immedi- into a gas by increasing the tempera-
ately, changing into a gas. HFC-134a is ture without changing the pressure.
also easily condensed back into liquid
under pressurized conditions by removing
the heat.
The graph shows the characteristic
relationship between the temperature and
pressure of HFC-134a.
The curve in the graph indicates the
boiling point of HFC-134a under different
temperatures and pressures. The upper
portion above the curve is gaseous
HFC-134a and the lower portion is liquid
HFC-134a.
Example-1
D. Precautions on Handling HFC-
The gaseous refrigerant can be
converted into the liquid refrigerant by
134a
increasing the pressure without The following precautions should be fully
changing the temperature. exercised when handling HFC-134a.
Example-2 1) Avoid Heat
The gaseous refrigerant can also be Do not allow the refrigerant to stand,
converted into a liquid by decreasing be stored in direct sunlight or near a
the temperature without changing the heat source. HFC-134a should never
pressure. be exposed to temperatures above
52°C (126°F). If heat must be applied
to the container (service can), it should
be heated with warm water under
40°C (104°F). Never heat the container
or the bath filled with warm water
directly over a flame.

Conversely
Example-3
The liquid refrigerant can be converted
into gas by decreasing the pressure
without changing the temperature . Fig. 18: Heat Precautions

9
 GENERAL INFORMATION

2) Avoid Contact With Skin

At atmospheric pressure, HFC-134a
vaporizes so rapidly that if it touches
the skin, there is a real danger of that
area becoming frostbitten. It is espe-
cially dangerous if HFC-134a gets in
the eye. There is a great risk that the
moisture in the eye will be frozen,
which can lead to blindness.
Always wear safety goggles when
handling HFC-134a and take extra
care that it does not touch exposed Fig. 20: Expansion and Evaporation
skin.
B. How to Condense Gaseous HFC-
134a Into Liquid
The air conditioning system cannot cool the
air when the liquid refrigerant is used up
(i.e. changed to the gaseous refrigerant.)
To change the gaseous refrigerant into a
liquid refrigerant, a compressor is used in
the car air conditioning.
As you know, when the gas is compressed
in the compressor, both the temperature
and pressure increase.
Fig. 19: Contact Precautions For example, when the gaseous refrigerant
is compressed from 2.1 kg/cm2 (0.21 MPa)
7. Principles of Air Conditioning to 15 kg/cm2 (1.47 MPa), the temperature
also increases from 0°C to 80°C. (32°F to
A. Expansion and Evaporation 176°F)
In the mechanical refrigeration system, The boiling point of refrigerant at 15 kg/
cooled air is created by the following cm2G (1.47 MPa) is 57°C (135°F). The
method: temperature 80°C (176°F) of compressed
gaseous refrigerant is higher than its
1) The high temperature and high pres-
boiling point (57°C) and also higher than
sure liquid refrigerant is stored in the
the surrounding air. The refrigerant stays in
container called a receiver.
gaseous state.
2) Next, the liquid refrigerant is released
to the evaporator through a small hole
called the expansion valve. At this
time, the temperature and pressure of
the liquid refrigerant are both lowered,
and some of the liquid refrigerant is
now changed to vapor.
3) The low temperature and low pressure
refrigerant flows into the container
called the evaporator. In the evapora-
tor, the liquid refrigerant evaporates
and removes heat from the surround-
ing air. Fig. 21: How to Condense HFC-134a

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 GENERAL INFORMATION

C. Condensing the Gaseous HFC-134a 5) This cold and foggy refrigerant flows
into the evaporator. Vaporizing the
In the car air conditioning, the high pres- liquid in the evaporator, the heat from
sure, high temperature gaseous refrigerant the warm air stream passing through
is transformed into a liquid by cooling it the evaporator core is transferred to
down at the condenser. the refrigerant.
By flowing through the condenser, the All the liquid will change into the
compressed gaseous refrigerant releases gaseous refrigerant in the evaporator
heat to the surrounding air and is con- and only the heat-laden gaseous
densed back into a liquid. At this time, the refrigerant is in the compressor. Then,
refrigerant temperature becomes lower the cycle begins once again.
than the boiling point (around 57°C). The
liquid refrigerant then returns to the
receiver.

Fig. 23: Refrigeration Cycle

8. Automotive Refrigeration System

Fig. 22: Condensation of HFC-134a A. Basic Components
Compressor: It is critical that only gas be
D. Refrigeration Cycle drawn into the compressor. If liquid enters,
1) The compressor discharges high it will cause a hydrostatic lock in the
temperature and high pressure refrig- compressor and stall. The gas drawn in is
erant that contains the heat absorbed compressed to over 14.1 kg/cm2 (201 psi,
from the evaporator plus the heat 1.383 kPa), which becomes extremely hot.
created by the compressor in a
discharge stroke.
2) This gaseous refrigerant flows into the
condenser. In the condenser, the
gaseous refrigerant condenses into
liquid refrigerant.
3) This liquid refrigerant flows into the
receiver which stores and filters the
liquid refrigerant until the evaporator
requires the refrigerant.
4) After going through the expansion
valve, the liquid refrigerant changes Fig. 24: Compressor
into low temperature, low pressure
liquid and gaseous mixture.

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 GENERAL INFORMATION

Condenser: The condenser mounted at 3) The sight glass is installed on the top
the front of the coach acts as a radiator, of the receiver. The refrigerant charge
drawing off some of the heat of compres- amount is very important for the
sion, and changes the high temperature efficiency of the air conditioner. The
gas into a liquid under high pressure. sight glass is used to check the
When operating normally, the inlet of the amount of refrigerant. Also the sight
condenser is full of hot gas and the outlet glass is installed on the high pressure
is full of hot liquid. There are some models pipe between the receiver and the
which are equipped with a fan exclusively expansion valve.
for the condenser
Expansion Valve: This small valve controls
the flow of refrigerant into the evaporator.
It is controlled by a temperature sensor at
the evaporator outlet. If the outlet tem-
perature is too high, it means not enough
refrigerant is flowing into the evaporator
and the result will be poor cooling.

Fig. 25: Condenser

Receiver/Drier: The receiver is a part of the

system that is used to store the liquid
refrigerant.

Fig. 27: Expansion Valve

If the outlet temperature is too cool, it

means too much refrigerant is flowing and
the evaporator fins will probably load up
with ice. In either case, the feedback
temperature sensor opens and closes the
expansion valve opening to achieve the
correct flow rate and evaporator outlet
temperature.

Fig. 26 Receiver/Drier

Also, the drier and filter in the receiver

remove the moisture and the dirt con-
tained in the refrigerant.
1) The receiver separates the gaseous
refrigerant from the liquid refrigerant
by the weight difference and ensures a
steady flow of liquid refrigerant be
supplied to the expansion valve.
2) The drier is simply a bag of desiccant,
such as zeolite, that is capable of
absorbing and holding moisture.

12
 GENERAL INFORMATION

Evaporator: This is the last component in B. Automotive Refrigeration System

the cycle, and where the air is finally
cooled. As the foggy mist of refrigerant 1. COMPRESSOR draws off gaseous refrig-
enters, the air passing over the evaporator erant from the evaporator and compresses
fins gives up its heat to evaporating it. This causes the refrigerant gas tem-
refrigerant. At the inlet the refrigerant is perature and pressure to rise rapidly.
liquid; it changes into gas at the outlet. 2. CONDENSER, through which the heated
refrigerant gas gives off heat to the engine
cooling air. The refrigerant gas cools off
and once again becomes a liquid.
3. RECEIVER/DRIER removes and traces of
moisture and filters out dirt in the system.
It also serves as a reservoir for excessive
refrigerant
4. EXPANSION VALVE controls liquid refriger-
ant into the evaporator cores, causing a
drop in pressure and, consequently, a drop
in temperature.
Fig. 28: Evaporator 5. EVAPORATOR, in which the released
refrigerant expands and flows through the
evaporator tubes. It removes heat from the
air blowing across the fins and tubes and
evaporates, causing the temperature
inside the car to be lowered gradually.

Fig. 29: Automotive Refrigeration System

13
 SAFETY PRECAUTIONS

1. Safety Precautions 5) When tightening and loosening fittings,

use two wrenches.
When repairing air conditioning systems, the
following precautions and rules must be 6) Pay special attention to the direction of
observed. receiver. Receiver inlet fitting must be
connected to the tube from condenser
A. Wiring outlet fitting.
1) Isolate the negative battery terminal to 7) Tighten coupling nuts according to speci-
prevent short circuits. fied torque.
2) All terminals and connectors should be
connected securely. Nut Size
Flare Nut Type O-Ring Nut Type
3) When wire harnesses are routed through (inch)
any hole in the vehicle, insert the rubber
bushing into the hole to protect harness. 2.0–3.0 kg-m 1.2–1.5 kg-m
0.375
(14.5–21.5 lbf•ft) (9–11 lbf•ft)
4) The air conditioner wire harness should be
fastened to the main harness with the vinyl 3.0–4.0 kg-cm 2.0–2.5 kg-m
tape or clamps. 0.5
(21.5–29.0 lbf•ft) (15–18 lbf•ft)
5) If disconnecting or moving original har-
nesses while repairing, they should be 4.0–5.0 kg-m 3.0–3.5 kg-m
0.625
(29.0–36.0 lbf•ft) (22–25 lbf•ft)
returned to the proper position.
6) Be careful not to pinch the original air
conditioner wire harnesses when installing
or repairing air conditioner parts. C. Refrigerant
7) When the lead wire is added to the wire 1) The following rules must be followed when
harness by soldering, use the same or handling refrigerant.
larger diameter lead wire, and cover the
a) Use suitable eye protection such as
soldering position with the vinyl tape.
safety goggles or glasses when
8) The wire harness should not be clamped handling the refrigeration or servicing
at any moving or high temperature compo- the refrigeration system.
nents.
b) Keep your skin from direct contact
9) Connecting portion of wire harness must with liquid refrigerant.
be away from the joint of fuel pipe.
c) Do not heat the refrigerant container
10) Be sure that the wire harness does not above 40°C (104°F).
touch the sharp corners or edges.
d) Do not discharge the refrigerant into
B. Piping an enclosed area having an open
flame.
1) Never use a torch when bending tubes.
When bending tubes, try to make the e) Do not allow the liquid refrigerant to
curve as wide as possible. touch bright metal. Refrigerant in
combination with moisture is corrosive
2) The insides of all air conditioner parts
and can tarnish bright metal and
must be free of moisture and dust. When
chrome surfaces.
removing the piping parts, apply the blind
plugs or caps on the fittings. f) Discharge the refrigerant very slowly
when purging a refrigeration system.
3) When cutting tubes, dress off the tube
Otherwise, the refrigeration oil will
with a file, and clean the inside of tube of
discharge together with refrigerant.
all burrs.
2) If liquid refrigerant contacts your eye or
4) Before making any hose and tube connec-
skin.
tions, apply a few drops of refrigeration oil
to the seat of coupling nuts and O-rings. a) Do not rub the eye or skin.

14
 SAFETY PRECAUTIONS

b) Splash large quantities of cool water 2) Parts mounted on the engine must be
to the eye or skin to raise the tempera- tightened to specified torque. (See vehicle
ture. service manual).

c) Tape on a sterile eye patch to avoid F. Others

the possibility of dirt entering the eye. 1) When repairing the air conditioning sys-
d) Apply clean petroleum jelly to the skin. tem, use fender and seat covers to protect
the paint and upholstery.
e) Rush to a physician or hospital for
immediate professional treatment. 2) When the air cleaner or water outlet are
removed from the engine, cover the engine
f) Do not attempt to treat the wound with the blind cover to keep free from dust
yourself. or dirt.
D. Safety Gaps 3) Never rotate the compressor if the refriger-
1) When installing the air conditioner parts, ant is not charged into the refrigeration
keep safety gaps or use insulators which system.
do not interfere with surrounding parts. 4) When storing the compressor as stock,
a) Fan shroud—Radiator hose evacuate the inside and charge the
5 mm (0.20 in.) or more refrigerant or dry nitrogen about 1-2 kg/
cm2 (14-28 psi) into compressor to prevent
b) Cooling fan (steel)—Radiator corrosion.
15 mm (0.59 in.) or more
5) After finishing repair work, check if each
Cooling fan (plastic)—Radiator component part of the vehicle operates as
20 mm (0.79 in.) or more usual.
c) Cooling fan—Fan shroud
2. Ultraviolet Rays and Ozone Layer
15 mm (0.59 in.) or more
Specified chlorofluorocarbons, chemically
d) Cooling fan—Crankshaft and idle
stable substances which are superior for heat
pulleys
resistance and non-combustibility, have the
4 mm (0.16 in.) or more
characteristics of being colorless and odorless
e) Cooling fan—Radiator hose without being inflammable, corrosive, or toxic.
15 mm (0.59 in.) or more For these reasons, they came to be used for a
f) Brake and Fuel pipes—Surrounding parts wide range of purposes such as refrigerants
15 mm (0.59 in.) or more for air conditioners and refrigeration units,
aerosol spray agents, cleaning agents for
g) Suction and discharge hoses— electronic systems, fire extinguisher materials,
Surrounding parts foam agents, and raw material for synthetic
15 mm (0.59 in.) or more (except resins.
clamping position or using rubber
cushion) On the contrary, the most important character-
istic of an alternative refrigerant is that the
h) High tension wire—Surrounding parts ozone depletion potential is small, and the
15 mm (0.59 in.) or more indispensable minimum condition is that it can
i) Loose side of V-belt—Radiator hose be used safely in each area.
20 mm (0.79 in.) or more CFC-12, which is used as a refrigerant for
2) After finishing repair work, be sure that the automotive air conditioners, is also subject to
air conditioner parts do not touch the restriction as a substance which depletes the
surrounding parts of the vehicle. ozone. For an alternative substance which
doesn’t include chlorine, a source of ozone
E. Mounting Parts depletion, HFC-134a is considered to be the
1) Never forget the spring washer when most suitable substance. Denso has devel-
installing the parts so that the vibration oped an automotive air conditioning system
does not loosen the bolt. which uses HFC-134a as a refrigerant in place
of CFC-12.

15
 TOOLS AND EQUIPMENT

Service Tool and Testers 1) When low pressure side valve (“LO”) is
opened and high pressure side valve
1. Service Tool Kit (“HI”) is closed.
A. Recovery/Recycling/Recharging Machine
B. Refrigerant Charging Hoses low pressure gauge

C. Refrigerant Leak Tester 3 2

4 (schrader valve must be opened)

1 high pressure gauge

2) When low pressure side valve (“LO”) is

closed and high pressure side valve
(“HI”) is opened.
Two circuits are established:

high pressure gauge

1 2

4 (schrader valve must be opened)

Figure 30: Charging Station
3 low pressure gauge

2. Handling of Service Tools 3) When low and high pressure gauges

A. Manifold Gauge Set are closed.

NOTE: When recovery/recycling/recharg- Two circuits are established:

ing equipment such as a Robinair Enviro
Charge Series 34700 or equivalent is used, 3 low pressure gauge
the manifold gauge set is included with the
1 high pressure gauge
system.
The hand valves (“LO” and “HI”) on the
manifold gauge set are used to open and B. Refrigerant Charging Hose
close the valve. The hand valve inscribed
“LO” is for the low pressure side valve and The charging hoses are classified into
“HI” is for the high pressure side valve. three colors.
(Fig. 31) Each charging hose must be handled as
follows:
1) The air conditioner manufacturer
recommends that the blue hose is
used for the low pressure side (suction
side), the green hose for refrigeration
side (center connecting port) and the
red hose for high pressure side
(discharge side).
2) HFC-134a charging hoses are
equipped with service couplers, which
allow you to install your charging
Figure 31: Manifold hoses to the charging valve on the
vehicle. These service couplers are
By opening or closing the high and low available from Robinair.
pressure hand valves, the following
circuits are established.

16
 TOOLS AND EQUIPMENT

2) How to Remove
a) Turn the hand valve completely
counter- clockwise.
b) Remove the service stop valve
from the discharge service valve.
c) Turn the hand valve clockwise
slightly to remove the residual
pressure in the charging hose.

Figure 32: Couplers

3) When the manifold gauge set is not in

use, connect the end of the hose to
the spare fitting of the refrigerant
charging hose. (Fig. 33)

Figure 34: Stop Valve

D. Gas Leak Tester (Detector)

The conventional gas leak detectors such
as the halide torch type and electronic
type cannot be used to detect a gas leak
Figure 33: Manifold Gauge Set of HFC-134a. Since the conventional
detector easily detects chlorine (Cl), which
C. Service Stop Valve is contained in CFC-12 but not contained
in HFC-134a.
The service stop valve is used to prevent
leakage of refrigerant or oil when removing Therefore, a new gas leak detector has
the “HI” side charging hose for the com- been developed to detect HFC-134a
pressor provided with the schrader valve.
(Fig. 34) This new gas leak detector has a higher
degree of sensitivity to the presence of
1) How to Install HFC-134a and also can be used for CFC-
12. (Fig. 35)
a) Before connecting the service stop
valve to the discharge service
valve of the compressor, turn the SE RE
FR
NS
hand valve completely counter- . M IGER HFC-134a CFC-12
OD AN
clockwise. E T

b) Install the service stop valve to the 15g (0.5oz)–

HI-SENS 6g (0.2oz)/yr.
discharge service valve and 30g (1oz)/yr.
connect the “HI” side charging
hose to it.
HFC-134a 40g (1.4oz)/yr.
c) Turn the hand valve clockwise until
the stem completely engages the
schrader valve. CFC-12 15g (0.5oz)/yr.

17
 TOOLS AND EQUIPMENT

Figure 35: Gas Leak Detector Figure 36: Charging Station (HFC-134a)

3. Robinair Enviro Charge 34700 Series

B. Specifications
This unit is the recommended A/C recover/
recycle station, it provides all-in-one service Voltage 115 V 60 Hz
for HFC-134a recovery, recycling and recharg-
Refrigerant Tank One 50-lb. refill-
ing.
able DOT ap-
A. Features proved

• Built-in manifold Operating Range 50° to 120°F

(11° to 49°C)
• Microprocessor controls
Recovery Rate 1/2 lb. per minute
• 4 cfm vacuum pump (.2 kg per minute)
• Refrigerant passes through the filter on the Recycling Rate 1 lb. per minute
way to the storage tank, providing UL flow rate
certified single pass recycling (.4 kg/min.) time
depends on
• Automatic recycling of refrigerant while
moisture content
system is being evacuated
Recycling Filter 43 cu. in. (710 cc)
• Moisture indicator changes color when
Quick Change
refrigerant is ready for reuse
Scale Resolution 1/100 lb.
• Refrigerant charge can be programmed or
controlled manually Pump Free Air Displacement 4 cfm (93 L/M)
• Automatic shut-off when all the refrigerant Dimensions 45” H x 22” W x
has been pulled from the system 28” D
Weight 167 lbs. (76 kg)
without tank

C. Replacement Parts
34430 Quick Change Recycling Filter
34750-50 Pound Refillable Tank
For additional information contact Robinair
at 1-800-368-6787.

18
 TORQUE AND BOLT SPECIFICATIONS

1. Standard Torque: Coupling Nut Type 2. Torque Specification for Bolts/Nuts/

Fittings Screws

Fitting Torque Diameter

Size of Tube (inch) Tightening Torque
N•m (kgf•cm, lbf•ft) X Bolt Strength
N•m (kgf•cm, lbf•ft)
Pitch
0.31 14 (140, 10) M6 X 1.0 5.4 (55, 4.0)
M8 X 1.25 12.7 (130, 9.4)
0.50 23 (230, 17) 4T
M10 X 1.25 25.0 (260, 18)
M12 X 1.25 47.1 (480, 34.8)
0.62 32 (330, 24)
M6 X 1.0 7.8 (80, 5.8)
M8 X 1.25 19.1 (195, 14.1)
6T
M10 X 1.25 39.2 (400, 29.0)
M12 X 1.25 71.6 (730, 52.8)

M6 X 1.0 ––––––––––––––––
M8 X 1.25 29.4 (300, 21.7)
8T
M10 X 1.25 60.8 (620, 44.9)
M12 X 1.25 107.8 (1100, 79.6)

19
 COMPONENT LOCATIONS AND POSITIONS

1. Interior Component Locations (All Models)

A. Heater and Cooling Unit

Fig. 37: Heater and Cooling Unit

20
 COMPONENT LOCATIONS AND POSITIONS

B. Cooling Unit Wire Harness

Fig. 38: Cooling Unit Wire Harness

C. Dash Wire Harness and Control Panel

Fig. 39: Dash Wire Harness and Control Panel

21
 COMPONENT LOCATIONS AND POSITIONS

D. Temperature Control Cable

Fig. 40: Temperature Control Cable

E. Fresh/Recirc. Damper Box

Fig. 41: Fresh/Recirc. Damper Box

22
 COMPONENT LOCATIONS AND POSITIONS

2. Raised Floor Measurements and Cutouts

A. Front Engine

Fig. 42: Front Engine Floor Measurements and Cutouts

B. Rear Engine

Fig. 43: Rear Engine Floor Measurements and Cutouts

23
 This table shows the
priority in which each
problem should be
inspected. After
indentifying the problem,
use the area of
inspection in number
TROUBLESHOOTING

priority, then repair or

replace as necessary.
1. Troubleshooting Table

AREA OF INSPECTION
PROBLEM

Refrigerant volume
manifold gauge set
Inspect refrigeration system with
Inspect drive belt tension
A/C control lever adjustment
Engine coolant volume
A/C fuses
Blower speed control switch
A/C switch
Pressure switch
Blower relay
Blower motor
Blower resistor
A/C thermistor
Compressor
Condenser
Receiver
A/C evaporator
A/C expansion valve
Heater radiator
Wiring or wiring connection
Blocked air inlet
hose kinked
Air leak from heater unit or air duct

No blower operation 1 3 2 5 4 6

No blower control 2 1 3 4

24
No air flow mode control 1

No air inlet control 1

Insufficient air flow 2 1

No cool air comes out 2 4 6 8 5 1 7 3 9

Cool air comes out intermittently 1 2 3 6 5 4

Cool air comes out only at high

2 3 1 5 4
engine speed
Insufficient cooling 1 3 2 8 4 5 7 6

No warm air comes out 2 1 3

Air temperature control not 1

functioning
 TROUBLESHOOTING

2. Troubleshooting by Manifold Gauge

Figure 44: Normal Reading

Condition A = Normal Reading

First, have the manifold gauge high and low The gauge indications shown in the following
pressure side valves tightly closed, and connect diagrams are taken under the same conditions
the charging hoses (red and blue) to the respective (ambient air 86° - 95°F, engine speed 1500 rpm,
compressor service valves. strongest cooling setting, maximum blower speed),
so it should be noted that the gauge readings will
In this case, if the service valves are the valve differ somewhat with the ambient conditions.
plunger type, always make sure to set the plungers
to the intermediate seat position (slightly toward NOTE: Gauge should indicate static pressures
back seat if the pointer vibrates) so as to enable before A/C operation both high and low pressure
taking measurements with the gauges. sides between 71~114 psi.
NOTE: Be sure to purge the air in the charging
hoses at the manifold gauge connection end by
utilizing the refrigerant pressure in the refrigerating
cycle.
If the refrigeration cycle is operating normally, the
reading at the low pressure side should generally
be around 21 ˜ 35 psi and at the high pressure side
around 199 ˜ 227 psi when ambient air temperature
is about 86° - 95°F, engine speed 1500 rpm,
strongest cooling setting, and blower operating at
top speed.

25
 TROUBLESHOOTING

Figure 45: Moisture Entered in the Cycle

Condition B = Moisture Entered in the Cycle

Condition Diagnosis
1. Periodic cooling and no cooling at the evaporator. 1. Receiver/drier in oversaturated condition.
Symptoms seen in refrigeration cycle 2. Moisture in refrigeration cycle freezes expan-
sion valve orifice and obstructs refrigerant
1. During operation, low side pressure alternately circulation.
becomes vacuum and normal.
When Abnormal: Remedy
Low Pressure Side: Vacuum
High Pressure Side: 99 ~ 142 psi 1. Replace receiver/drier.
When Normal: 2. Remove moisture in cycle by means of re-
Low Pressure Side: 21 ~ 35 psi peated evacuation.
High Pressure Side: 199 ~ 227 psi
3. Check expansion valve.
Cause
4. Recharge new refrigerant to the proper quantity.
1. The moisture in the refrigeration cycle freezes
in the expansion valve orifice and causes
temporary blocking.
After a time, the ice melts and condition
returns to normal.

26
 TROUBLESHOOTING

Figure 46: Insufficient Refrigerant

Condition C = Insufficient Refrigerant

Condition Diagnosis
1. Would desire more cooling. 1. Refrigerant in cycle insufficient.
Symptoms seen in refrigeration cycle 2. Refrigerant leaking.
1. High and low side pressures both low. Remedy
Low Pressure Side: 7 ~14 psi
High Pressure Side: 99 ~ 142 psi 1. Check for leakage with leak detector and
correct.
2. Bubbles seen in sight glass.
2. Evacuate and recharge refrigerant to proper
3. Air discharged from air conditioner slightly amount.
cold.
Cause
1. Gas leaking someplace in refrigeration cycle.

27
 TROUBLESHOOTING

Figure 47: Excessive Refrigerant or Insufficient Condenser Cooling

Condition D = Excessive Refrigerant or

Insufficient Condenser Cooling
Condition Diagnosis
1. Air conditioner fails to cool properly. 1. Refrigerant overcharged.

Symptoms seen in refrigeration cycle 2. Condenser cooling defective.

1. High and low side pressures both high. 3. Condenser fins clogged or fan belt loose.
Low Pressure Side: 35 ~ 50 psi 4. Radiator fan fluid coupling slipping or electric
High Pressure Side: 284 ~ 355 psi fan inoperative.
2. Bubbles cannot be seen in the sight glass. Remedy
Cause 1. Clean condenser.

1. Due to overcharging refrigerant into cycle, 2. Adjust fan belt to proper tension.
proper performance cannot be shown. 3. If 1 and 2 are in normal condition, check
2. Condenser cooling faulty. refrigerant quantity.
NOTE: If excessive refrigerant is to be discharged,
You must use a refrigerant recovery station.

28
 TROUBLESHOOTING

Figure 48: Air Entered in the Cycle

Condition E = Air Entered in the Cycle

Condition Remedy
1. Air conditioner fails to cool sufficiently. 1. Replace receiver.
Symptoms seen in refrigeration cycles 2. Check compressor oil contamination and
quantity.
1. High and low side pressures high.
Low Pressure Side: 35 ~ 43 psi 3. Recover refrigerant, evacuate and recharge
High Pressure Side: 284 ~ 355 psi. new refrigerant.
2. Low pressure side piping not cold when NOTE: The above cycle can be seen when after the
touched. cycle is opened, the refrigerant is charged without
evacuation.
Cause
1. Air entered in refrigeration cycle.
Diagnosis
1. Air in refrigeration cycle.
2. Evacuating insufficient.

29
 TROUBLESHOOTING

Figure 49: Expansion Valve Trouble or Improper Installation of Heat Sensitizing Tube

Condition F = Expansion Valve Trouble or

Improper Installation of Heat Sensitizing Tube
Condition Diagnosis
1. More cooling desired. 1. Excessive liquid refrigerant in low pressure
side piping.
Symptoms seen in refrigeration cycle
2. Expansion valve opened too far.
1. Low and high side pressures both high.
Low Pressure Side: 35 ~ 43 psi Remedy
High Pressure Side: 284 ~ 355 psi.
1. Check installed condition of heat sensitizing
2. Frost or heavy dew on low pressure side tube.
piping.
2. If remedy 1 is in normal condition, replace
Cause expansion valve.
1. Expansion valve trouble or heat sensitizing
tube improperly installed.
2. Flow adjustment not properly done.

30
 TROUBLESHOOTING

Figure 50: Refrigerant Fails to Circulate

Condition G = Refrigerant Fails to Circulate

Condition Remedy
1. Intermittent cooling 1. Allow to stand for some time and then resume
Symptoms seen in refrigeration cycle operation to decide whether the plugging is
due to moisture or dirt.
1. Vacuum shown at low side and very low
pressure shown at high side. a. If caused by moisture – Correct by refer-
Low Pressure Side: 27 in. Hg ring to instructions in condition B.
High Pressure Side: 71 ~ 85 psi b. If caused by dirt – Remove the expansion
2. Frost or dew formed on piping at inlet and valve and blow out the dirt with com-
outlet of expansion valve or receiver. pressed air. If unable to remove the dirt,
replace the expansion valve. Replace the
Cause receiver. Evacuate and recharge proper
1. Refrigerant flow obstructed by moisture or dirt amount of new refrigerant.
in the refrigerating cycle freezing or sticking on c. If caused by gas leakage in heat sensitiz-
the expansion valve orifice. ing tube Replace the expansion valve.
Diagnosis
1. Expansion valve orifice plugged.
2. Refrigerant does not circulate.

31
 TROUBLESHOOTING

Figure 51: Faulty Compression of Compressor

Condition H = Faulty Compression of

Compressor
Condition Remedy
1. Does not cool. 1. Disassemble and repair compressor. (Refer to
appropriate GM, Ford, or Spartan repair
Symptoms seen in refrigerating cycle manual.)
1. Low pressure side pressure too high.
2. High pressure side pressure too low.
3. Low pressure side: 56~85 psi
4. High pressure side: 99~142 psi
Cause
1. Leak in compressor.
Diagnosis
1. Compression faulty.
2. Valve leaking or broken, sliding parts (piston,
cylinder, gasket, connecting rod, etc.) broken.

32
 TROUBLESHOOTING

3. Visual and Audible Troubleshooting F. Do you hear noise near blower?

Questions Turn the blower motor to LOW, MEDIUM
A. Are there any loose V-belts? and HIGH speeds. If you hear any unusual
sounds or the motor rotation appears
If the V-belt is loose, it will slip and wear defective, make sure there are no foreign
out faster. Adjust to the recommended objects lodged in the blower or loose bolts
tension or replace with a new V-belt if and parts which need tightening as this
worn out. can sometimes be the cause of these
problems.
B. What if you hear noise near the compres-
sor? If no foreign objects are found, replace the
blower motor.
Check the compressor mounting bolts and
the bracket mounting bolts to see if they G. What should you see when checking
are loose. Tighten all loose bolts. refrigerant quantity at sight glass?
C. Do you hear noise inside the compressor? If a large flow of bubbles can be seen in
the sight glass, there is insufficient refriger-
This could be caused by a worn bearing or ant charged. Refrigerant should be replen-
lack of refrigeration oil in system. Remove ished to its proper level. Also check for oil
the compressor, disassemble, and make stains (as described previously) to make
all necessary repairs or replacements. sure there is no refrigerant leak.
D. Are condenser fins covered with dirt and If bubbles cannot be seen in the sight
dust? glass, even when the condenser is cooled
If the condenser fins are dirty, the cooling by pouring water, this is a sign that there is
effect will be greatly reduced. To prevent too much refrigerant in the system. There-
this from happening, wash off all dirt and fore, the excessive amount should be
dust. Be careful not to damage or bend removed/recovered. One should be very
fins if you are using a stiff brush to wash careful when taking out refrigerant from
condenser. the low pressure side service valve to
avoid removing too much which may
E. Do you see oil stains in the refrigerating cause the compressor oil to blow out.
cycle connections and joints?
Any place where an oil stain can be seen
usually indicates that refrigerant is leaking
from that spot. This is because the com-
pressor oil and the refrigerant will escape
out of the system together. Thus, the
location of the leak can be pinpointed by
the spot where the oil stain is found. At
this spot, all bolts should be retightened to
the proper torque and parts replaced, if
needed, to stop the leak.
Since compressor gasket joints and pipe
connectors are the most likely spots where
oil stains are found, special attention
should be given to checking these places.

33
 TROUBLESHOOTING

4. Troubleshooting Chart
CAUTION: When repairs are required on the compressor, condenser, discharge hose, receiver/
drier, or the condenser fan motor, please refer to the appropriate chassis manufacturer repair
manual.

Air flow normal Air mixed in

High pressure side
Too much refrigerant
pressure too high
Condenser covered with dirt
Pressure normal
Not enough refrigerant
High pressure side Compressor discharge valve broken
pressure too low Gasket broken (compressor)
Low pressure piping faulty (crushed/clogged)

Expansion valve opened too wide

Low pressure side
Heat sensitizing tube faulty contact
Compressor rotates pressure too high
Pressure abnormal Too much refrigerant
properly
Not enough refrigerant
Heat sensitizing tube gas leakage
Low pressure side
Evaporator frosted
pressure too Low
Low pressure piping faulty
Expansion valve clogged
High/Low pressure side
Too much refrigerant
pressure both too high

High/Low pressure side

Not enough refrigerant
pressure both too low
Compressor internal
Battery voltage low
defect
Rotor and starter interfering
Wiring open, connection loose
Compressor does not
Magnetic clutch Relay adjustment faulty, trouble
rotate properly
Coil layer short
Grounding defective
Slipping belt Coil open

Outside air entry through vents/windows

Others Heat control function faulty
Heater in ON state

Air flow insufficient Switch defective

Resistor defective
Foreign object lodged near suction port Battery voltage low
Blower and motor Evaporator frosted Fuse blown out
normal Filter clogged Wiring faulty, connection loose
Air duct clogged/loose Brush faulty contact

Blower and motor Blower motor related parts Blower mounting loose
defective Blower relations Blower hitting heater case
Blower deformed

34
 TROUBLESHOOTING

5. Insufficient Cooling
A. Compressor

Symptom Condition Possible Cause Remedy

Disc harg e pre ssu re Ra dia to r fa n air su ctio n Fan belt bro ke n or Re tig hte n or re pla ce
abnorma lly hig h. poor. lo ose .
Condense r and ra dia to r Cle an condense r and
fin s cove re d with dirt ra dia to r.
and dust.
No bubble s appear in Exc essive re frig era nt Re mo ve /re cove r
sig ht gla ss when charg ed. re frig era nt to pro per
condense r is coole d amo unt.
with wate r.
Pre ssu re at hig h- Air ente re d in Re mo ve /re cove r
pre ssu re sid e re frig era nt cycle . re frig era nt and afte r
abnorma lly hig h. Ju st su ffic ie nt eva cuatin g,
afte r sto ppin g re charg e re frig era nt.
comp re sso r, pre ssu re
dro ps quic kly to about
28 psi.
Suctio n pre ssu re Abnorma lly cold aro und Exp ansio n va lve Re in sta ll or re pla ce.
abnorma lly hig h. lo w-pre ssu re hose and openin g to o la rg e.
lo w-pre ssu re sid e
se rvic e va lve . Heat se nsitiz in g tu be
has poor conta ct.
Heat lo ad to o la rg e. Outsid e air te mp era tu re Cool th e condense r.
abnorma lly hig h.
Hig h-pre ssu re sid e Exc essive re frig era nt Re mo ve /re cove r
pre ssu re hig h but charg e. re frig era nt to pro per
su ctio n pre ssu re dro ps amo unt.
when condense r is
coole d.
Ju st afte r sto ppin g Faile d gaske t. Re pla ce.
comp re sso r, hig h- and
lo w-pre ssu re sid e Hig h- and lo w-pre ssu re Re pla ce va lve or
pre ssu re s become va lve bro ke n or fo re ig n re mo ve fo re ig n obje ct.
equal. obje ct lo dged in va lve .

Disc harg e pre ssu re Low-pre ssu re sid e Heat se nsitiz in g tu be Re pla ce
abnorma lly lo w. pre ssu re to o lo w. gas le aka ge.
Low-pre ssu re pip in g Exp ansio n va lve fro zen
not cold . or defe ctive
Larg e passa ge of Not enough re frig era nt Charg e to pro per
bubble s th ro ugh sig ht amo unt
gla ss.
If comp re sso r is Comp re sso r disc harg e Re pair or re pla ce
sto pped, hig h- and of su ctio n va lve bro ke n.
lo w-pre ssu re sid e Fore ig n obje ct stu ck in Disa sse mb le and
pre ssu re s imme dia te ly comp re sso r disc harg e re mo ve
equaliz e. va lve

35
TROUBLESHOOTING

Compressor (cont’d)

Symptom Condition Possible Cause Remedy

Suction pressure Large passage of Refrigerant insufficient. Charge to proper

abnormally low. bubbles through sight amount
glass.

High-pressure side Heat sensitizing tube Replace

pressure too low. Low- gas leakage.
pressure piping not
cold. Expansion valve frozen
or defective

Discharge port Evaporator frosted. Adjust stabilizer relay

temperature low, air not
coming out. Operate correctly
(blower speed and
temperature control
combination)

Expansion valve frosted. Receiver clogged. Clean (remove moisture)

or replace

Temperature difference Receiver clogged. Replace

at receiver front and rear
pipings. When
excessive, receivers rear
piping frosts.

Discharge and suction Heavy covering of dirt Condenser cooling Wash off dirt and dust to
pressure both high. and dust on condenser insufficient improve air passage.
fins.

No bubbles pass Refrigerant charged Remove/recover

through sight glass excessively. refri gerant to proper
when water is poured on quantity.
condenser.

Discharge and suction Large passage of Refrigerant insufficient. Charge to proper

pressure both low. bubbles through sight amount.
glass.

Gas leakage. Shaft seal becomes Gas leaking from shaft Replace shaft seal.
noticeably dirty and seal.
gaskets leaking.

Bolts get stained with Gas leaking from bolted Retighten bolts.
oil. parts.

Gasket joints get stained Gas leaking from joints. Replace gasket.
with oil.

Leakage from cracked Gas leaking from part. Replace cracked part.
part.

36
 TROUBLESHOOTING

B. Magnetic Clutch

Symptom Condition Possible Cause Remedy

No attraction. Wiring normal. Coil open. Replace.

Wiring parts open, Reconnect or replace

wiring or connection open wiring parts.
defective (gro und, fuse).
No attraction even when
cooler switch is on. Switch parts contact
defective, malfunction Repair or replace.
(thermostat, stabilizer,
relay, coo ler switch).

At switch ON, rotor Rotor or stator clearance

shows movement, and Repair or replace.
too large.
attracts when pushed.

Slips. Battery voltage low. Recharge battery.

Clutch slips when
rotating. Oil on clutch face. Clean o ff oil.
Coil layer short. Replace.

C. Expansion Valve

Symptom Condition Possible Cause Remedy

Valve outlet not cold. Temperature difference Heat sensitizing tube Replace expansion
at outlet and inlet cannot gas leakage. valve.
be sensed.
Amount of refrigerant in Repair gas leakage point
cycle very small. and charge refrigerant.

Valve inlet cold or High-pressure piping Receiver clogged. Replace.

frosted. from receiver outlet feels
cold.

Frosts. Expansion valve inside Replace expansion valve

clogged. and receiver.

37
 TROUBLESHOOTING

6. Abnormal Noise
Bearing worn or damaged
Compressor
Defective cylinder and/or shaft
Bearing worn or damaged
Magnetic clutch Stator and rotor contacting
Stator mounting bolts loose
Blower assembled upside down
Blower motor
Blower improperly tightened
Noise from
Crank Pulley Improperly tightened

Improperly installed
Idler pulley
Bearing worn or damaged
Bracket, clamp, etc., improperly tightened or installed
Piping parts
Safety gap not suitable

Symptom Condition Possible Cause Remedy

Compressor noisy. Noise from inside Bearing w orn or Disassemble and

compressor. damaged. replace defective parts.
Defective cyl inder
and/or shaft.

Magnetic clutch noisy. Rattling noise when Bearing w orn or Replace bearing.
magnetic clutch is not damaged
engaged.

Noise from piping. Piping not secured. Piping vibrating. Secure piping.
Pulsating noise
resonates into body.

Noise from condenser. Condenser vibration Condenser mounting Secure by inserting

prominent. stay resonating with rubber between stay
body. and body.

Noise produced by Rattles when touched, Bracket cracked or Replace.

bracket. continuous rattling broken.
heard when operating.
Mounting bolts loose. Retighten bolts.

Idler pulley noisy. Clattering no ise Bearing broken. Replace.

produced.
Rattles when touched. Bracket cracked or Replace or retighten.
loose.

Noisy crankshaft pulley. Rattles. Improperly installed. Retighten or replace.

V-Belt noisy. V-Belt deflection big. V-Belt lo ose. Adjust tension.

V-Belt side surface torn. V-Belt center Align center.
misaligned.

38
 COMPONENT TESTING

Note: Please refer to the appropriate GM, Ford,

Freightliner, or Spartan (thru mid-1998) manuals
when On-Vehicle Diagnosis indicates that the
problem is caused by the following components:
1. Compr essor and Magnetic Clutch
2. Receiver/Drier
3. Models with Electric Fan Motor for Condenser

1. Blower/Cooling Unit
A. On Vehicle Inspection of Expan-
Figure 53: HVAC Cover
sion Valve
Inspect A/C system visually and audibly .
Next, inspect the system with a ROBINAIR
(manifold gauge) or equivalent equipment.
1) While tur ning A/C switch “ON” and
BLOWER switch “HI”, run engine at
1,500 RPM for at least five (5) minutes
and check A/C performance in
RECIRC mode.
2) If expansion valve is clogged, the low
pressur e reading will dr op. If nor mal,
the pr essur e will r emain the same. Figure 54: Fresh/Recirc Air Box

3) If the low pr essur e reading is nor mal 4) Remove fresh/recirculate air box. (Fig. 54)
and A/C is not cooling, check for
malfunction of expansion valve. 5) Disconnect wir e har ness at: (Fig. 55)
• Three (3) r elays
B. Blower/Cooling Unit Removal
• Blower
1) Disconnect negative cable fr om • Servo motor
batter y.
• Two (2) connectors from thermostat
• Blower r esistor
• Fresh/r ecir culate connector
• Pressur e switch
• Main har ness connector

Figure 52: Battery Cable

2) Remove refrigerant from the system using

ROBINAIR or equivalent equipment.
3) Remove HV AC cover on passenger
Figure 55: Blower/Cooling Unit
side.

39
 COMPONENT TESTING

6) Remove suction and liquid lines fr om 12) Carefully slide blower/cooling unit
cooling unit. (Fig. 56) assembly r ear war d.
NOTE: Seal lines to pr event moistur e C. Blower/Cooling Unit Disassembly
from entering into the A/C system. (Fig. 58)

Figure 56: Liquid and Suction Hoses

7) Remove bracket fr om heater to

evaporator case. (Fig. 57)
8) Remove the six (6) mounting scr ews
and washers holding the blower/
cooling unit to the bulkhead. (Fig. 57) Figure 58: Blower/Cooling Unit (disassembled)

1) Remove thr ee (3) blower motor mount-

ing scr ews fr om the case.
2) Remove blower motor vent tube fr om
upper case.
3) Remove blower motor .
4) Remove ther mostat fr om upper case.
5) Remove nine (9) scr ews fr om cooling
unit case.
6) Remove two (2) clips fr om cooling unit
Figure 57: HVAC Screw Location case.

9) Remove passenger far -right air vent 7) Remove upper and lower case halves
grille assembly . from evaporator cor e.

10) Remove scr ew securing the heater 8) Remove packing fr om expansion valve
unit by r eaching thr ough the vent hole sensing tube located on the evapora-
in the upper right cor ner of the dash. tor suction tube.

11) Loosen the two (2) scr ews securing 9) Remove “C” clip fr om sensing tube.
the heater unit to the engine compart- 10) Disconnect liquid tube fr om the inlet
ment cover (or wood support - diesel fitting of the expansion valve.
models).
11) Remove expansion valve.
NOTE: These two screws may be removed
by lifting the instrument panel and reach-
ing under the dashboard (or HVAC cover
on diesel models).

40
 COMPONENT TESTING

D. Evaporator Core Inspection 8) Install two (2) clips.

1) Inspect evaporator cor e fins for 9) Install blower motor and vent tube.
blockage. 10) Reconnect wir e har ness. (Fig. 60)
• If fins ar e clogged, clean with
compr essed air .
• Do not use water to clean evapo-
rator cor e.
2) Inspect fittings for cracks or
scratches. Repair or r eplace as
requir ed.

E. Blower/Cooling Unit Assembly

(Fig. 59)
1) Connect the expansion valve to the
evaporator and tor que to 23 N•m (235 Figure 60: Harness Connections
kgf•cm, 17 lbf•ft).
F. Blower/Cooling Unit Installation
1) Install blower/cooling unit with six (6)
screws.
2) Install heater to evaporator case
bracket.
3) Reconnect wir e har ness. (Fig. 60)
4) Reconnect suction hose and tor que to
32 N•m (325 kgf•cm, 24 lbf•ft)
5) Reconnect liquid hose and tor que to
13 N•m (135 kgf•cm, 10 lbf•ft).
6) Install fr esh/r ecir culate air box.
7) Install HV AC cover .
8) Reconnect negative cable to batter y.

Figure 59: Blower/Cooling Unit (disassembled) 9) Evacuate and char ge using ROBINAIR
or equivalent equipment.
2) Install expansion valve sensing bulb to
evaporator suction tube with “C” clip
and insulate with packing.
3) Connect the liquid tube to the evapo-
rator cor e and tor que to 13 N•m (135
kgf•cm, 10 lbf•ft).
4) Install lower case.
5) Install thermostat.
6) Install upper case.
7) Install nine (9) scr ews.

41
 COMPONENT TESTING

2. Compressor Fitting 4. Heater Hoses: On Vehicle Inspection

NOTE: DENSO supplied a suction side com- A. Inspect hoses for leakage.
pressor fitting on Ford chassis thru mid-1996
model year. B. Replace if necessar y.
(Only For d and GM chassis heater hoses
are DENSO supplied.)

Figure 61: Ford Compressor Fitting (thru mid-1996)

A. On Vehicle Inspection Figure 62: GM Hose Routing (thru mid-1996)

1) Inspect service valves for leakage

using a gas leak detector .
2) Replace if necessary HEATER HOSES LIQUID HOSE

B. Replacement
1) Recover r efrigerant fr om system.
2) Replace failed par t and tor que to 32
N•m (325 kgf•cm, 24 lbf•ft).
SUCTION HOSE

3) Evacuate and char ge using Robinair

char ging station or equivalent.

3. Refrigerant Hoses/Tubes Figure 63: GM Chassis (L29) Hose Routing (from mid-1996)

A. On Vehicle Inspection HEATER HOSES LIQUID HOSE

1) Inspect hoses/tubes for leakage using

a gas leak detector .
2) Replace if necessar y.

B. Replacement
1) Recover r efrigerant fr om system.
LIQUID HOSE #1
2) Replace failed par t and tor que to (CONNECTION TO
CONDENSER)
proper spec.
SUCTION HOSE LIQUID HOSE #1 RECEIVER/DRIER

• Suction Hose 32 N•m (325 Figure 64: GM Chassis (P12) Hose Routing (from mid-1998)
kgf•cm, 24 lbf•ft)
• Liquid Hose 13 N•m (135 kgf•cm,
10 lbf•ft)
3) Evacuate and char ge using Robinair
char ging station or equivalent.

42
 COMPONENT TESTING

2) Check r outing of the temperatur e

contr ol cable so it is fr ee of any sharp
bends or inter ference with linkages.

Figure 65: Ford Hose Routing (thru mid-1998)

HEATER
HOSES

Figure 68: A/C Control Cable Routing

B. Control Cable Adjustment

NOTE: On the control panel, check that the
control cable insulation extrudes no less than
1
/16” past the metal clamp on the control panel
LIQUID HOSE
LIQUID HOSE mounting base. If less than 1/16”, go to next
SUCTION HOSE
step. (Fig. 69)

Figure 66: Ford Hose Routing (from mid-1998)

5. Heater
A. On Vehicle Inspection and Ad-
justment
1) Inspect HV AC contr ol panel. Move the
temperatur e contr ol lever to see if
cable moves fr eely without binding
and has full range of travel.
Figure 69: Cable Adjustment at Control Panel

1) Loosen the tapping scr ew and push

the contr ol cable insulation for war d
past the metal clamp appr oximately
1
/16”. Retighten the tapping scr ew.
CAUTION: Do not overtighten the tapping
screw. This could result in damage to the
mounting base of the control panel.

Figure 73: A/C Control 67

43
 COMPONENT TESTING

2) On the bottom of the HV AC unit, 5) While holding the cam lever in the
locate the spring clip and car efully proper position, r echeck that the
remove the contr ol cable insulation. temperatur e contr ol lever on the
(Fig. 70) contr ol panel is in the maximum cool
position. (Fig. 71)
6) While holding the cam lever in the
maximum cool position, snap the
contr ol cable insulation into the spring
clip by pushing upwar d. (Fig. 73)

Figure 70: Cable Adjustment at Heater

3) Move the temperature control lever on

the control panel to the maximum cool
position (all the way to the left). (Fig. 71)

Figure 73: Spring Clip Connection of Cable

C. Heater Core Removal

1) Remove blower/cooling unit case (see
page 40).
2) Remove contr ol cable fr om heater
unit. (Fig. 74)

Figure 71: Max Cool Position of Control Panel

4) Looking at the bottom of the HV AC

unit, push and hold the cam lever with
the contr ol cable attached to the pin to
maximum cool (clockwise) position.
(Fig. 72)

Figure 80: Removing Control 74

3) Remove heater hose fr om heater cor e.

NOTE: Hoses should be marked so they
can be easily identified and reconnected to
their proper connections.

Figure 72: Bottom of HVAC Unit

44
 COMPONENT TESTING

E. Heater Core Installation

Follow r eversal of steps for r emoval.

6. Thermostat
A. Thermostat Operation
The ther mostat is wir ed in series with the
high-low side of the pr essur e switch and
prevents the evaporator fr om fr eezing over
by contr olling the gr ound to the coil of the
magnetic clutch r elay.
Figure 75: Heater Hose Location
When the thermostat is set to the max cold
4) Remove temperatur e contr ol damper position (full clockwise), the thermostat
door cam which is secur ed by one (1) contacts will be closed at evaporator
screw with a plastic washer . temperatures above 4.5°C (40.1°F) and open
between 1°C and 25°C (32.9°F and 36.5°F).
CAUTION: Do not attempt to remove heater
core without removing damper door cam. When the thermostat is set to the max
war m position (full counter clockwise), the
5) Remove plastic lever which is
contacts will be closed at evaporator
mounted over heater cor e.
temperatur es above 7.5 °C (45.5°F).
If the thermostat does not perform as
specified, r eplace the ther mostat.
NOTE: The ther mostat is pr eset at the
factory and should not be adjusted. This
information is supplied for diagnostic
purposes only .

B. Thermostat Removal
1) Remove and disassemble blower/
cooling unit.
2) Remove ther mostat fr om unit.
Figure 76: Bottom View of Heater Core

6) Remove heater cor e suppor t bracket.

7) Remove heater cor e tube bracket.
8) Carefully slide the heater casing
backwar ds towar d the passenger
compar tment until the heater cor e
tubes ar e clear of the bulkhead.
9) Pull out the heater cor e by sliding the
unit downwar d and away fr om the
heater core case.

D. Heater Core Inspection

Inspect the heater cor e and r epair or r eplace
as requir ed.

Figure 77: Blower/Cooling Unit (disassembled)

45
 COMPONENT TESTING

C. Thermostat Installation 8. Control Panel Removal

Follow r eversal of steps for r emoval. A. Disconnect negative cable fr om batter y.

7. A/C Control System: On Vehicle B. Open instr ument contr ol panel (if equipped).
Inspection
A. Inspect A/C Switch for continuity.
B. Inspect A/C Blower Speed Contr ol Switch
for continuity .
C. A/C Contr ol Levers Inspection
1) Inspect the contr ol lever at contr ol
panel for smooth operation.
2) Inspect the contr ol lever at HV AC for
smooth operation.
Figure 79: Control Panel Location
Blower speed control switch
C. Remove four (4) scr ews on contr ol panel
Terminal
bezel plate (if equipped). (Fig. 80)
No.
1 2 3 4 5
Switch
Position

Low

Medium
Low
Medium
Hi

Hi

Indicates there is continuity between these terminals Figure 80: Removal of Control Panel Bezel

Blower speed control switch connector D. Remove contr ol panel fr om r ear of dash
panel.
E. Remove contr ol cable fr om contr ol panel.
5 6 3 (Fig. 81)

1 2 7 8 4
Figure 78: Blower Speed Control Switch

D. A/C Contr ol Cable Inspection

Inspect contr ol cable for pr oper adjust-
ment and kinks.

Figure 81: Removal of Control Cable

46
 COMPONENT TESTING

F. Remove two (2) wir e har ness connectors B. Installation

from contr ol panel.
Follow r eversal of steps for r emoval.
NOTE: See Contr ol cable adjustment on
page 43.

9. Pressure Switch
A. Pressure Switch Operation
The pressure switch is a triple pressure
switch with a high and low pressure set of
contacts and a medium pressure set of
contacts. The high-low side is wired in series
with the thermostat and controls the ground
Figure 82: Removal of Subwire Harness
to the coil of the magnetic clutch relay. On
vehicles equipped with a condenser fan, the
medium side is wired in parallel with the
G. Remove and save metal support bracket water temperature switch and controls the
from contr ol panel (if equipped). ground to the coil of the condenser fan relay.

B. On Vehicle Inspection
1) Disconnect negative cable fr om
batter y.
2) Remove HV AC cover on passenger
side.
3) Confir m refrigerant char ge status with
ROBINAIR or equivalent equipment.
4) Disconnect the pr essur e switch
har ness connector fr om the cooling
Figure 83: Metal Support Bracket unit har ness.
High & Low Pressure

ON
A. Inspection
OFF OFF
Inspect contr ol panel for continuity .
29 34 298 384

Terminal
Medium Pressure

ON
No. 1 2 3 4 6 7 8 9 10 11
(-)
Mode Ground

OFF
A/C
(on) 177 220
Vent
(face) Units: PSI

B/L

Floor Switch
Off On On Off
DEF kg/cm2 (psi) kg/cm2 (psi)
Item
Recirc
(Button Depressed)

Fresh
Low Pressure
2.4 (34.1) 2.1 (29.9)
(Recirc Button Out)
Side
Indicates there is continuity between these terminals

Control Panel Connector High Pressure

21 (298.6) 27 (383.9)
Side
7 8 9 10 11 12

1 2 3 4 5 6 Medium Pressure
15.5 (220.4) 12.5 (177.8)
Side

Figure 84: Control Panel Circuit Figure 85: Pressure Switch Operation

47
 COMPONENT TESTING

5) Connect a jumper wir e between 2) Remove wire harness from pressure

terminals 13B and 14A of the cooling switch.
unit har ness.
3) Remove pressure switch from liquid line.

D. Installation
Follow r eversal of steps for r emoval.
2
3 4
1 2 3 4
1
10. Blower
41A 42A 43A 44A

A. On Vehicle Inspection
0.5GR
0.5WR
0.5Br
0.5Y

42A
44A 43A
41A

1) Blower and Fan Operation

44A 42A

41A 42A 43A 44A 43A 41A Connect positive (+) lead fr om batter y
13A 14A 15A 16A
to terminal #2 and negative (-) lead to
0.5WR
0.5GL
0.5Br
0.5GR

terminal #1 to confirm smooth opera-

15A 13A tion of motor .
16A 14A

1
Figure 86: Pressure Switch Connector 18A
2
6) With the A/C system at normal operat- 4B
ing pr essur es, check for continuity
between terminals 41A and 42A for
the high-low side and terminals 43A
and 44A for the medium side. M 1 4B 3LW
3L
7) If ther e is no continuity , replace the 2 18A
switch.
Figure 88: Blower and Fan Circuit
C. Pressure Switch Removal 2) Blower Resistor Inspection.
1) Remove and disassemble blower/ Inspect the r esistor for specification.
cooling unit. (Fig. 87)
Checking for proper resistance of the blower motor resistor

Pins 1 2 4 5
Resistance
Value

.5Ω

.8Ω

1.68Ω

Indicates there is continuity between these terminals

Blower Resistor connector

4 1

Figure 87: Blower/Cooling Unit (disassembled)

5 2

Figure 89: Blower Resistor

48
 COMPONENT TESTING

B. Blower and Fan Removal 11. Relays

1) Disconnect negative cable fr om Remove HV AC cover on passenger side to
batter y. access the following thr ee (3) r elays:
2) Remove HV AC cover on passenger A. Main Relay
side.
Inspect five 5-pin main r elay for continuity
3) Remove blower motor 2-pin connector. and r eplace the r elay as r equir ed.
4) Remove blower motor vent tube.
Terminal
30 85 86 87 87A
No.
5) Remove thr ee (3) scr ews mounting Battery
Voltage
blower motor to the case.
Not
6) Remove the blower motor and fan. Supplied

NOTE: If the blower motor or fan

replacement is r equir ed, follow the Supplied
steps below .
a) Remove clip fr om fan. Indicates there is continuity between these terminals
Indicates terminals to which battery voltage is supplied

b) Remove fan fr om blower motor . Main Relay connector

c) Replace fan or blower motor as

85
requir ed.

C. Blower Resistor Removal 87 87 30

1) Disconnect negative cable fr om 86

batter y. Figure 91: Main Relay

B. Blower HI Relay
Inspect 4-pin Blower HI Relay for continu-
ity and r eplace the r elay as r equir ed.

Terminal
No. 21A 2B 50 18B
Battery
Voltage

Not
Supplied

Supplied +
Figure 90: HVAC Component Location

2) Remove HVAC cover on passenger side. Indicates there is continuity between these
terminals
Indicates terminals to which battery voltage
is supplied
3) Disconnect 4-pin connector fr om
Blower High Relay connector
blower r esistor .
3L
4 18B
0.5YG
4) Remove two (2) scr ews fr om blower 2 2B

1 21A 0.5Br
resistor . 3 5O 3WB

5) Remove blower r esistor .

D. Installation 1 3
2B 18B

2 4
Follow r eversal of steps for r emoval. 21A 5O

Figure 92: Blower Hi Relay

49
 COMPONENT TESTING

C. Mg/Cl (Magnetic Clutch Relay) 5) Remove linkage r od fr om ser vo motor .

Inspect 4-pin Mg/Cl Relay for continuity 6) Remove wir e har ness fr om ser vo
and r eplace the r elay as r equir ed. motor.
7) Remove two (2) scr ews fr om ser vo
Terminal
No. 13A 4I 12A 4E motor.
Battery
Voltage 8) Remove ser vo motor fr om air box.
Not C. Air Intake Servo Inspection
Supplied

Check continuity of the ser vo accor ding to

the chart as shown.
Supplied +
To check for voltage at the Air Intake Servo Sub Harness female
connector, use chart below
Indicates there is continuity between these Main
terminals
Indicates terminals to which battery voltage Harness
is supplied 1 2 4
Pin
Switch .5YG .5YG .5YL
Magnetic Clutch Relay connector
Position
0.5LW
4 4E
0.5WR
Recirc
2 13A
0.5LW
(in)
1 4I

3 12A 0.5BW
Fresh
(recirc out)
Indicates terminals to which battery voltage is supplied
1 3
4I 4E
Air Intake Servo connector
2 4
13A 12A

M
Fig. 93: Magnetic Clutch Relay 4 3 2 1

12. Air Intake Servo 4 3 2 1

47B 46B 45B 47B 46B 45B

A. Air Intake Servo Operation

0.5YL

0.5YW

0.5YG

The air intake servo changes the air intake

door between the FRESH and RECIRC Fig. 94: Air Intake Servo Circuit
positions by r otating 180 ° in the clockwise
direction ever y time the RECIRC switch on D. Air Intake Servo Installation
the contr ol panel is depr essed (RECIRC
mode) or r eleased (FRESH mode). Follow r eversal of steps for r emoval.

NOTE: To check for pr oper operation of

the Air Intake Servo, the ignition switch
must be in the “ON” position.

B. Air Intake (Air Box Fresh/Recircu-

late) Servo Removal
1) Remove HV AC cover on passenger
side to access the servo.
2) Disconnect negative cable fr om
batter y.
3) Disconnect connector for air box
fresh/r ecir culate ser vo motor .
4) Remove fr esh/r ecir c air box.

50
 COMPONENT TESTING

13. Vent Mode Servo C. Vent Mode Servo Inspection

A. Vent Mode Servo Operation 1) With the har ness connected and the
ignition switch in the “ON” position,
The mode ser vo contr ols the distribution verify the following lever positions by
of outlet air between vent/face, bi-level, depressing the cor responding contr ol
foot, or defr ost. panel mode switch.

Figure 95: HVAC Wire Harness Connectors Figure 96: Vent Servo Positions

B. Vent Mode Servo Motor Removal 2) If no movement is detected, check the

following conditions:
1) Remove HV AC cover on passenger
side to access the servo. a) Battery voltage between pins 2D
and 5A.
2) Disconnect negative cable fr om
batter y. b) Continuity of both wir e har nesses
between the mode servo connec-
3) Remove passenger side floor/vent tor and contr ol panel connector .
cover.
c) Continuity of the contr ol panel.
4) Remove wir e har ness fr om ser vo (Refer to the contr ol panel testing
motor. section).
5) Remove linkage fr om ser vo motor . D. Vent Mode Installation
6) Remove thr ee (3) mounting scr ews Follow r eversal of steps for r emoval.
from ser vo motor .
7) Remove ser vo motor .

51
 REFRIGERANT LINE REPLACEMENT

1. On Vehicle Inspection 3. Torque Specifications

A. Check that hose and tube connections are A. Standard Torque for Coupling
not loose. Nut Type Fittings
B. Inspect hoses and tube for leakage.
• Use an electronic gas leak detector to Fitting Torque
Size of Tube (inch)
N•m (kgf•cm, lbf•ft)
check for leakage of refrigerant in the
A/C system. 0.31 14 (140, 10)

2. Refrigerant Lines Replacement 0.50 23 (230, 17)

A. Recover refrigerant from A/C system. 0.62 32 (330, 24)

Use a ROBINAIR or equivalent Recovery/

Recycling Machine to recover refrigerant in
the system before removing any compo-
B. Torque Specification for Bolts/
nent to prevent any release of refrigerant Nuts/Screws
into the atmosphere.
Diameter
Tightening Torque
B. Immediately cap the open fittings to X Bolt Strength
N•m (kgf•cm, lbf•ft)
prevent moisture, dust and air from Pitch
entering the system. M6 X 1.0 5.4 (55, 4.0)
M8 X 1.25 12.7 (130, 9.4)
DO NOT REMOVE the end caps on 4T
M10 X 1.25 25.0 (260, 18)
replacement hoses until just before M12 X 1.25 47.1 (480, 34.8)
installation. M6 X 1.0 7.8 (80, 5.8)
M8 X 1.25 19.1 (195, 14.1)
C. Replace faulty components as required. M10 X 1.25
6T
39.2 (400, 29.0)
M12 X 1.25 71.6 (730, 52.8)
D. Before connecting, apply a few drops of
compressor lubricant to “O” rings and M6 X 1.0 ––––––––––––––––
coupling nut fittings. M8 X 1.25 29.4 (300, 21.7)
8T
M10 X 1.25 60.8 (620, 44.9)
E. Securely torque connections to specifica- M12 X 1.25 107.8 (1100, 79.6)
tions to assure there is no refrigerant leak.
Be sure to use two (2) wrenches to avoid
twisting tubes.
F. Evacuate air in the system and recharge.
G. Inspect for leakage with electronic leak
detector.
H. Check air conditioning system operation
and performance.

52
 REFRIGERANT LINE REPLACEMENT

4. CHASSIS
A. GM Chassis: Liquid, Suction, and Heater Hoses (thru mid-1996)

Fig. 97: GM Chassis: Liquid, Suction, and Heater Hoses (thru mid-1996)

B. GM L29 Chassis: Liquid, Suction, and Heater Hoses (from mid-1996)

HEATER HOSES LIQUID HOSE

SUCTION HOSE

Fig. 98: GM Chassis (L29): Liquid, Suction, and Heater Hoses (from mid-1998)

53
 REFRIGERANT LINE REPLACEMENT

C. GM P12 Chassis
Liquid, Suction, and Heater Hoses

HEATER HOSES LIQUID HOSE #2

LIQUID HOSE #1
(CONNECTION TO
CONDENSER)

SUCTION HOSE LIQUID HOSE #1 RECEIVER/DRIER

Fig. 99: GM Chassis (P12) Liquid, Suction, and Heater Hoses

D. Ford Chassis (thru mid-1998)

Liquid, Suction, and Heater Hoses

Fig. 100 : Ford Chassis (thru mid-1998) Liquid, Suction, and Heater Hoses

54
 REFRIGERANT LINE REPLACEMENT

E. Ford Chassis (from mid-1998)

Liquid, Suction, and Heater Hoses

HEATER
HOSES

LIQUID HOSE
LIQUID HOSE
SUCTION HOSE

Fig. 101: Ford Chassis (from mid-1998) Liquid, Suction, and Heater Hoses

F. Freightliner Chassis/Spartan Chassis (thru mid-1998)

1) Liquid and Suction Hoses

LIQUID HOSE

RECEIVER DRIER

HEATER HOSES SUCTION HOSE

Fig. 102: Diesel Pusher Chassis Liquid and Suction Hoses

55
 REFRIGERANT LINE REPLACEMENT

2) Suction Tube

SUCTION TUBE
INSULATION

SUCTION HOSE SUCTION TUBE

CHASSIS RAIL

CHASSIS CROSS
MEMBER

Fig. 103: Diesel Pusher Chassis Suction Tube

56
 REFRIGERANT LINE REPLACEMENT

G. Spartan Chassis (mid-1998 and on)

Fig. 104: Spartan Chassis A/C System Overview

(1) Drive Belt Tension

Lock Nut
Compressor
Idle Pulley
(a) Check belt tension using a belt
New Belt tension gauge.
Belt Tension: 80 ± 10 lbs.
(b) Adjust as needed by loosening
PLACE GAUGE idle pulley lock nut and turning
HERE
adjusting bolt until belt reaches
specified tension.
(c) Tighten and torque the idle pulley
lock nut.
Tightening Torque: 39.2 N•m (29
Fig. 105: Belt Tension
lbf•ft)

57
 REFRIGERANT LINE REPLACEMENT

(2) On Vehicle Inspection: Compressor

Magnetic Clutch Compressor
Connector
(a) Inspect compressor and clutch
assembly for signs of oil.
(b) Check clutch bearings for abnor-
mal noise, grease leakage, or
excessive play.
Vehicle
Connector
(c) Check if clutch is energized when
positive (+) lead from battery is
applied directly to the clutch lead
wire and negative (-) lead to the
clutch ground wire.
Figure 106: Compressor Inspection–Magnetic Clutch
(d) Measure resistance of the stator
coil using an ohmmeter.
Standard Resistance @ 20˚C
(68˚F): 3.75 ± 0.2Ω
(3) On Vehicle Inspection: Compressor
(a) Install manifold gauge set. Charge Port Charge Port
(suction) (discharge)
(b) Run engine at approximately 1,500
RPM with compressor engaged.
(c) Check for abnormal noise or
abnormal pressures (high side too
low and low side too high).
(d) With engine off, check for any
leakage from shaft seal on com-
pressor. If defects are found,
replace compressor.
Figure 107: Compressor Inspection
(4) Compressor Removal
Bolts (M6 x l 88)
(a) Run engine at idle with A/C on for
approximately 5–10 minutes.
(b) Stop engine.
(c) Disconnect negative battery cable.
(d) Disconnect clutch lead wire.
(e) Recover refrigerant from A/C
system.
(f) Disconnect compressor hoses.
CAUTION: Cap ends of hoses IMMEDIATELY
after disconnecting from compressor to pre- Figure 108: Compressor Removal
vent moisture or other contaminants from
entering the system.
(g) Loosen compressor belt.
(h) Remove compressor mounting
bolts and the compressor.

58
 REFRIGERANT LINE REPLACEMENT

SCREW (5) Magnetic Clutch Disassembly

LEAD
WIRE (a) Remove the shaft bolt.
ROTOR
(b) Remove the pressure plate.
SHIM
(c) Remove the shims from the
BOLT
pressure plate.
(d) Remove the snap ring that secures
STATOR COMPRESSOR the rotor.
SNAP
SNAP
RING (e) Remove the rotor from the com-
RING pressor shaft by carefully tapping
PRESSURE
PLATE
with a plastic hammer.
Figure 109: Magnetic Clutch (f) Disconnect stator lead wire from
the compressor body.
(g) Remove the snap ring that secures
the stator.
(h) Remove the stator.
(6) Magnetic Clutch Assembly
Follow the steps in Paragraph (5) in
reverse order for assembly.
IMPORTANT: DO NOT reuse snap rings. Use
new snap rings to secure rotor and stator.
Shaft Bolt Tightening Torque: 14 N•m
(10 lbf•ft)
Check air gap between pressure plate
and rotor.
Standard Clearance: 0.5 ± 0.15 mm
(0.020 ± 0.0059 in.)
If the clearance is not within specified
range, change the number of shims
until the required clearance is reached.
(7) Compressor Installation
Bolts (M6 x l 88)
Follow the steps in Paragraph (4) in
reverse order for installation.
Tightening Torques:
Compressor Mounting Bolts: 24.5
N•m (18.1 lbf•ft)
Compressor Hoses: 9.8 N•m (7.2
lbf•ft)
After installation, evacuate air in the
system and recharge.
HFC-134a: 48oz. ± 2 oz.
Inspect system for leaks using a
Figure 110: Compressor Installation refrigerant leak detector. Check air
conditioning system for proper opera-
tion and performance.

59
REFRIGERANT LINE REPLACEMENT

(8) On Vehicle Inspection: Condenser Fan

(a) Check if condenser fan operates when air conditioning system is on. If fan is rotating in the
proper direction, it will be pulling air through the condenser.
(b) Check if the fan operates when the positive (+) lead wire from the battery is applied directly
to the fan wire and the negative (-) lead wire is applied to the fan ground wire. If the fan fails
to operate when wired directly, replace the fan. If fan operates normally when wired directly
but fails to operate when air conditioning system is on, confirm proper wiring connection
where interface harness (including condenser fan relay) connects dash A/C to chassis.
The dash A/C system output (to energize the magnetic clutch) is the black wire with white
tracer (BW). It is also used to energize the condenser fan relay.

(9) Condenser Fan Removal

Washer (2)
(a) Disconnect 2-Pin connector from Lock Washer (2)
fan. Nut (M6) (2)

(b) Remove four (4) nuts securing fan Adapter Bracket

to fan bracket. Lock Washer (4)

(c) Remove fan.

Nut (M6) (4)

Fan Bracket
Washer (4) Washer
Bolt (M6 x 25) (2)
Condenser Fan

Figure 111: Condenser Fan

(10) On Vehicle Inspection: Condenser

(a) Inspect condenser fins for blockage or damage. If clogged, wash with water and blow with
compressed air. If fins are bent, straighten with a fin straightening tool.
(b) Check hose connections for leakage using a refrigerant leak detector. Repair as needed.

60
 REFRIGERANT LINE REPLACEMENT

(11)Condenser Removal
(a) Recover refrigerant from air
conditioning system.
(b) Disconnect hoses from condenser.
CAUTION: Cap ends of hoses IMMEDIATELY
after disconnecting from condenser to prevent
moisture or other contaminants from entering
the system.
(c) Disconnect 2-Pin connector from
condenser fan.
(d) Remove fan and fan bracket
together by removing two (2) nuts
and two (2) bolts securing fan
bracket to condenser bracket.

Fig. 112: Condenser Removal

Bolt (M6 x l 20) (e) Remove two (2) bolts securing

Flat Washer
condenser to upper condenser
bracket.
Upper Condenser
Mounting Bracket

Bolt (M6 x l 20)

(f) Remove bolts securing upper
Flat Washer
condenser bracket to frame rails
and slide bracket forward.
(g) Lift condenser out of lower
Condenser bracket and remove.
(12)Condenser Installation
Follow the steps in Paragraph 11 in
reverse order for installation.
Fig. 113: Condenser Removal
Tightening Torques:
Upper Condenser Bracket to Side
Rails: 280 N•m (200 lbf•ft)
Discharge Hose: 9.8 N•m (7.2 lbf•ft)
Liquid Hose: 7.8 N•m (5.8 lbf•ft)
If the condenser was replaced, add oil
to compressor.
ND Oil 8: 40–50 cc (1.4–1.7 oz.)
After installation, evacuate the system
and recharge.
HFC-134a: 48 oz. ± 2 oz.
Inspect system for leaks with a refrig-
erant leak detector. Check the system
for proper operation and performance.

61
 REFRIGERANT LINE REPLACEMENT

(13)On Vehicle Inspection: Receiver/Drier

(a) Check that bolts securing hoses and tubes are not loose.
(b) Check connections for leakage with a refrigerant leak detector and repair if needed.

(14)Receiver/Drier Removal
(a) Recover refrigerant from A/C
system.
(b) Disconnect hoses from receiver/ Bolt (M6 x l 25)
drier.
CAUTION: Cap ends of hoses IMMEDIATELY
after disconnecting from condenser to prevent
moisture or other contaminants from entering
the system. Receiver Drier

Liquid Hose #2

(Liquid Hose #1)

To Cooling Unit

Fig. 114: Receiver/Drier Removal

(c) Remove receiver/drier from

receiver/drier bracket.
Receiver Drier
(15)Receiver/Drier Installation
Follow the steps in Paragraph 14 in
reverse order for installation. Bolt (M6 x l 16)

Tightening Torques for Liquid Hoses: Receiver Drier

5.4 N•m (4.0 lbf•ft)
If the receiver/drier was replaced, add
oil to the compressor.
Bulkhead

ND Oil 8: 20 cc (0.7 oz.)

After installation, evacuate the system Fig. 115: Receiver/Drier Installation
and recharge.
HFC-134a: 48 oz. ±2 oz.
Inspect system for leaks with a refrig-
erant leak detector. Check the system
for proper operation and performance.

62
 REFRIGERANT CHARGING

1. About Certification 2. Each person authorized by the estab-

lishment to perform that service must
A. Ozone Layer and CFCs be properly trained and certified.
Recent scientific findings indicate that E. SAE Standards
CFCs, like CFC-12 as well as bromines
from halons used in fire extinguishers, are SAE (The Society of Automotive Engi-
depleting the Earth’s protective ozone neers) established 3 standards regarding
layer located in the stratosphere some 10 refrigerant recovery and recycling, all of
to 30 miles above this planet’s surface. which are mentioned in Section 609 of the
Clean Air Act.
This ozone layer filters out most of the
harmful ultraviolet rays from the sun. J1989 Standard
B. Montreal Protocol This standard establishes guidelines for
the use of recovery/recycling equipment
In 1985 scientists confirmed a large hole in when servicing automotive air-conditioning
the ozone layer and on September 16, systems.
1987, the United States and 22 industrial
countries signed an agreement in J1990 Standard
Montreal, Canada, known as the “Montreal
Protocol”. This standard is for equipment and all
recovery/recycling equipment must meet
This agreement restricted CFC production SAE J1990.
to 1986 levels beginning from July 1989.
J1991 Standard
C. London Meeting
This standard is for a purity of recycled
Because the ozone layer depletion was refrigerant and recovery/recycling equip-
worse than predicted, a reassessment ment must have UL (Underwriter’s Labora-
meeting was held in London in June 1990. tories) approval to meet J1991.
At this meeting all the member nations
agreed to accelerated cutbacks of CFCs
with a total phaseout by the year 2000.

D. Federal Clean Air Act

In relation to these agreements, President
Bush signed Section 609 of the amended
Clean Air Act on November 15, 1990.
The Section 609 states that persons
servicing motor vehicle air conditioning
systems must be properly trained and
certified.
Some states and jurisdictions have
adopted their own deadlines and regula-
tions in addition to federal requirements.
Effective January 1, 1990 the federal law
requires that:
1. Each affected establishment shall
certify that the establishment has
acquired and is properly using ap-
proved refrigerant recycling equip-
ment.

63
 REFRIGERANT CHARGING

2. Section 609 of the Clean Air Act

Amendments of 1990
The most important part of the amendments to
Section 609 of the Federal Clean Air Act have
to do with servicing motor vehicle air condi-
tioning and technician certification. The act
states:
Servicing Motor Vehicle Air Conditioners–
Effective January 1, 1992, no person repairing
or servicing motor vehicles for consideration
may perform any service on a motor vehicle air
conditioner involving the refrigerant for such
air conditioner without properly using ap-
proved refrigerant recycling equipment and no
such service unless such person has been
properly trained and certified. The require-
ments of the previous sentence shall not apply
Fig 116: Mobile Air Conditioning Society Certificate
until January 1, 1993 in the case of a person
repairing or servicing motor vehicles for
consideration at an entity which performed
service on fewer than 100 motor vehicle air
conditioners during calendar year 1990 and if
such person so certifies to the Administrator
by January 1, 1992.

Certification
(1) . . . each person performing service on
motor vehicle air conditioners for consid-
eration shall certify to the Administrator–
that such person has acquired, and is
properly using, approved refrigerant
recycling equipment in service on motor
vehicle air conditioners involving refriger-
ant and that each individual authorized by
Fig. 117: Automotive Service Excellence Certificate
such person to perform such service is
properly trained and certified;
(2) Effective January 1, 1993 each person . . .
Shall submit a certification under para-
graph (1) (A).
(3) Each certification under this subsection
shall contain the name and address of the
person certifying under this subsection
and the serial number of each unit of
approved recycling equipment acquired by
such person and shall be signed and
attested by the owner or another respon-
sible officer. Certifications under para-
graph (1)(A) may be made by submitting
the required information to the Administra-
tor on a standard form provided by the
manufacturer or certified refrigerant
recycling equipment. Fig. 118: California Air Quality Management Certificate

64
 REFRIGERANT CHARGING

3. Evacuating and Charging Refrigerant

CAUTION: To prevent the release of refrigerant
into the atmosphere, charging hoses equipped
with stop valves must be used when installing
the manifold gauge set to the A/C system.

A. Install Manifold Gauge Set With

Stop Valves
Make sure the correct hoses are con-
nected to the high pressure sides and low
pressure sides.
Fig. 120: Ford Chassis (thru mid-1998)
Do not apply lubricant to connection
seating area.
1) Close the stop valves on manifold
gauge charging hoses.
2) Close both shut-off valves on manifold
gauge set.
3) Remove caps from charge ports and stop
valves on compressor service valves.
4) Connect charging hoses with stop
valves to charge ports.
a) Tighten fittings by hand.
Fig. 121: Ford Chassis
b) Make sure the correct hoses are
connected to the high pressure
side and low pressure sides.
c) Do not apply lubricant to connec-
tion seating area.
NOTE: On Ford Chassis (with stop valve on
compressor fitting) viewed from the rear of engine,
turn the stop valve in the clockwise direction four
full turns (half open).
5) Open stop valves on both charging hoses.

Fig. 122: Freightliner, and Spartan Chassis

B. Evacuate Refrigeration System

1) Connect the center hose of the
manifold gauge set to the vacuum
pump. (Fig. 123)
2) Open both high and low hand valves;
then run the vacuum pump.
NOTE: If opening the low pressure hand valve
Fig. 119: GM Chassis (thru mid-1996) causes the high pressure gauge to go into the
vacuum range, this does not mean there is block-
age in the system.

65
 REFRIGERANT CHARGING

3) After ten (10) minutes or more, make

sure the low pressure gauge indicates
750 mmHg (30 in. Hg) or more of
vacuum.
NOTE: If the reading is not 750 mmHg (30 in. Hg)
or more of vacuum, close both hand valves of the
manifold gauge set and stop vacuum pump. Check
the system for leaks and make necessary repairs.
4) Close both high and low hand valves;
then stop the vacuum pump.
5) Leave the system in this condition for
five (5) minutes or longer, and check
that there is no change in the gauge
indicator. Fig. 124: Purging the System

D. Inspect Refrigeration System for

Leaks
After evacuating the air in system, check
the system for leakage.
1) Open the high pressure hand valve
and charge refrigerant.
2) When the low pressure gauge indi-
cates 98 KPa (1 kg/cm2, 14 Psi), close
the high pressure hand valve.
3) Using a leak detector, check the
system for leaks.
4) If a leak is found, repair the faulty
component or connection, and evacu-
ate air in refrigerant system.

Fig. 123:System Evacuation CAUTION: Use refrigerant recovery/recycling

machine to recover the refrigerant when re-
placing parts.
C. Install Charging Cylinder
NOTE: When handling the charging cylinder,
always follow the directions given in the instruction
manual.
1) Charge the proper amount of refriger-
ant in charging cylinder.
2) Connect the center hose to charging
cylinder.
CAUTION: Do not open both high and low
hand valves of manifold gauge set.
3) Press on the schrader valve, which is
on the side of the manifold gauge, and
expel the air inside the center hose.
(Fig. 124)
Fig. 125:System Leak Check

66
 REFRIGERANT CHARGING

E. Charge Refrigerant Into Refriger- 3) Disconnect charging hoses from

ant System charging ports on compressor service
valves.
After refrigerant leak check, if there is no
leak, charge the proper amount of refriger- G. Install Caps to charge ports and
ant into the refrigeration system. stop valves on compressor ser-
CAUTION: Never run the engine when charg-
vice valves
ing the system through the high pressure side 4. Refrigerant Volume
and do not open the low pressure hand valve
when the system is being charged with liquid A. Refrigerant Volume Inspection
refrigerant.
1) Run engine at approximately 1,500
1) Open the high pressure hand valve RPM.
completely. 2) Operate A/C “ON” and Blower “HI” for
2) Charge specified amount of refriger- at least five (5) minutes.
ant; then close the high pressure hand 3) Open front hood and inspect sight
valve. glass on the receiver/drier for the
following conditions:
NOTE: A fully charged system is indicated by the
sight glass being free of any bubbles. a) Bubbles in Sight Glass
Refrigerant = Insufficient
(See the following Refrigerant Volume Section for
Sight Glass Inspection.) Bubbles in sight glass may indi-
cate normal when ambient tem-
perature is higher than 95°F (35°C)
if the A/C cooling performance is
satisfactory.
Remedy = Check for gas leakage
in the system, repair as required
and recharge the system to the
specified amount.
b) No Bubbles in Sight Glass
Refrigerant = None, enough or
overcharged
Remedy = Refer to steps (c) and (d).
c) No Temperature Variance Between
Compressor Inlet and Outlet
Refrigerant = Empty or nearly
empty
Remedy = Evacuate and recharge
Fig. 126: Checking Charge Amount
system to the specified amount;
then check for gas leak in the
F. Remove Manifold Gauge Set system.
From Service Valves d) Temperature Between Compressor
1) Close both hand valves of manifold Outlet and Inlet Differ Abnormally
gauge set. Refrigerant = Proper or over-
charged
2) Close hand valves of both stop valves.
Remedy = Refer to steps (e) and (f).
NOTE: On Ford chassis (with stop valve on com- e) Sight Glass Stays Clear Immedi-
pressor fitting) turn the stop valve in the counter ately After A/C Is Turned Off
clockwise direction until it is fully back seated (four Refrigerant = Overcharged
turns).

67
 REFRIGERANT CHARGING

Remedy = Recover excess refrig- 5. Insert a dry bulb thermometer in the cool
erant to proper volume. Refer to air outlet, and place the psychrometer (dry
step (f). and wet bulb thermometer) close to the
inlet of cooling unit.
f. Sight Glass Foams and Becomes
Clear When A/C Is Turned Off
Refrigerant = Normal
B. Refrigerant Volume
1) Gas Front Engine Models:
Ford = 2.8 lbs.
GM = 2.0 lbs.
2) Diesel Models:
Freightliner = 3.8 lbs.
Spartan (thru mid-1998) = 4.2 lbs.
Spartan (from mid-1998) using com-
plete DENSO system= 3.0 lbs.
Fig. 127:Performance Testing
5. Performance Test
6. The high pressure gauge reading should
After completing repairs, make sure to carry
be within the specified pressure range,
out the performance test of the air condition-
14.0 - 16.0 kg/cm2 (199-227 psi)..
ing system as follows:
NOTE: If the gauge indicates too high, pour water
A. Procedure on the condenser, or if it is too low, cover the front
1. Connect the high and low side charging surface of condenser.
hose of manifold gauge set to the hose 7. The dry bulb thermometer at the air inlet
fittings of compressor. should be within 25-35°C (77-95°F).
2. Run the engine, and keep the compressor With the above conditions, operate air
speed at 1,500 RPM. conditioning system until a stabilized
3. Operate the air conditioner, and set the condition on high and low pressure
blower switch at “HI,” the temperature gauges and the thermometers have been
lever at “COOL” and in “recirc” mode. established.
4. Keep all windows and doors open.

68
 REFRIGERANT CHARGING

8. Calculate the relative humidity from the psychrometric graph by comparing the wet and dry bulb
readings of the psychrometer at the air inlet. (Fig 128)

30
HOW TO READ THIS GRAPH: (86)

)
(%
Y
After measuring the temperatures of the wet- and

IT
ID
dry-bulb thermometers at the evaporator air inlet,

M
HU
relative humidity can be obtained.

VE
25

TI
Example: Supposing dry- and wet-bulb tempera-

LA
tures at the evaporator air inlet are 25˚C (77˚F) and (77)

RE
90
19.5 ˚C (67˚F) respectively. The point of intersection
)

80
of the dotted lines in the graph is 60%. (˚F
C 70
e˚ 20
60
ur
rat (68)
pe 50
m
Te 15
ulb (59) 40
etB
W 10 0
10 0 30
9
(50) 80
5 70
60
20
0 (41) 50
40
(32) 10
30
20
10

-5 0 5 10 15 20 25 30 35 40
(23) (32) (41) (50) (59) (68) (77) (86) (95) (104)

Dry Bulb Temperature ˚C (˚F)

Fig. 128: Psychrometric Graph

9. Measure the dry-bulb temperature at the cool air outlet, and calculate the difference between the
inlet dry bulb and outlet dry bulb temperatures (Fig. 129).
10. Check that the intersection of the relative humidity and temperature difference is above the line. If
the intersection is within the two lines, cooling performance is satisfactory.

˚C ˚F
between inlet and outlet

22 39.6
Temperature difference

20 36
18 32.4
16 28.8
14 25.2
12 21.6
10 18

50 60 70
Relative Humidity (%)

Fig. 129: Temperature Difference

69
 WIRING DIAGRAMS

Main Relay Blower High Relay

Terminal Terminal
30 85 86 87 87A No. 21A 2B 50 18B
No.
Battery Battery
Voltage Voltage

Not Not
Supplied Supplied

Supplied Supplied +

Indicates there is continuity between these terminals Indicates there is continuity between these
terminals
Indicates terminals to which battery voltage is supplied
Indicates terminals to which battery voltage
is supplied
Main Relay connector
Blower High Relay connector
85
3L
4 18B
87 87 30 0.5YG
2 2B

86
NO NC 1 21A 0.5Br

3 5O 3WB

2A
87 86 85 87A 30

1A 5B 4A 1A 2A 3A 5B 4A
1 3
2B 18B
3LR
0.5YG
0.5RB
0.5WB
3LW

3A

2 4
21A 5O

Fig. 130: Main Relay Fig. 131: Blower High Relay

L = BLUE
G = GREEN
R = RED
Y = YELLOW
W = WHITE
B = BLACK
Br = BROWN

70
 WIRING DIAGRAMS

Magnetic Clutch Relay Mode Servo

Terminal
No. 13A 4I 12A 4E
Battery A
Voltage M M

Not
Supplied 7 6 5 4 3 2 1

FOOT

FACE
DEF

B/L

(+)
(-)
2 3 4 5 6 7 1
9A 8A 7A / 6A 5 A 2O

0.5RW
0.5YB
0.5GW

0.5YR

0.5WB
0.5YG
5A 6A / 7 A 8A 9A 2O
Supplied +

Indicates there is continuity between these

terminals Fig. 133: Mode Servo
Indicates terminals to which battery voltage
is supplied

Magnetic Clutch Relay connector

0.5LW
4 4E
0.5WR
2 13A

1 4I 0.5LW

3 12A 0.5BW

1 3
4I 4E

2 4
13A 12A

Fig. 132: Magnetic Clutch Relay

L = BLUE
G = GREEN
R = RED
Y = YELLOW
W = WHITE
B = BLACK
Br = BROWN

71
 WIRING DIAGRAMS

Air Intake Servo Pressure Switch

To check for voltage at the Air Intake Servo Sub Harness female
connector, use chart below

Main
Harness
1 2 4
Pin
Switch .5YG .5YG .5YL
Position
2
Recirc 3 4
(in) 1 2 3 4
1

Fresh 41A 42A 43A 44A

(recirc out)

0.5GR
0.5WR
0.5Br
0.5Y
42A
44A 43A
Indicates terminals to which battery voltage is supplied 41A

Air Intake Servo connector

44A 42A
M
41A 42A 43A 44A 43A 41A
4 3 2 1
13A 14A 15A 16A

0.5WR
0.5GL
0.5Br
0.5GR
4 3 2 1
47B 46B 45B 47B 46B 45B
15A 13A
0.5YL

0.5YW

0.5YG

16A 14A

Fig. 134: Air Intake Servo Fig. 135: Pressure Switch

L = BLUE
G = GREEN
R = RED
Y = YELLOW
W = WHITE
B = BLACK
Br = BROWN

72
 DENSO SALES CALIFORNIA, INC.
TECHNICAL SERVICE DEPARTMENT
First Issue: January 1999
DSCA P/N: LA990009-0427

Printed in USAv

© 2005 DENSO SALES CALIFORNIA, INC.

All Rights Reserved. This book, or parts thereof, may not be reproduced or copied in any form with-
out the written permission of the publisher. DENSO SALES CALIFORNIA, INC. reserves the right to
make changes without prior notice
DSCA Part Number: LA990009-0427