Information Sheet M2.

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SERVICING THE A/C SYSTEM

Learning Objectives:
After reading this information sheet, you will be able to:
 use a manifold gauge;
 recover refrigerant;
 evacuate an A/C system;
 test A/C system for leak; and
 charge the A/C system with refrigerant.

INTRODUCTION
An automotive A/C system is under pressure and contains potentially
lethal materials. Servicing an A/C system is not simply a matter of opening the
system and adding refrigerant. You must take special precautions to prevent
accidents.
Follow these steps to ensure safe and accurate servicing of the A/C
system:
1. Always bear in mind that the A/C system has both a high-pressure and a
low-pressure side. Use a manifold gauge to check the system’s
pressures. If the system pressure is too high or low, the A/C system will not
perform properly, and might explode.
2. You have learned in our past lesson that refrigerant can harm the
environment, so never allow the refrigerant to be released into the air. Use
necessary equipment to recover the discharged refrigerant.
3. Evacuate the trapped moisture in the A/C system. Any moisture in the
system will greatly affect its performance and dangerous chemical
compounds may form.
4. Always check the system for leaks in order to prevent the escape of
refrigerant into the atmosphere. Repair any leak if you find any before
charging the system with refrigerant.

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5. Recharge the A/C system with the correct type and amount of refrigerant.
Let us discuss each step in detail.
CHECKING THE SYSTEM PRESSURE
We will start with servicing the A/C system by checking its pressure with
the use of a manifold gauge. A manifold gauge is a calibrated device which
measure both low and high-side A/C system pressure. This device will allow
you to perform four important tasks:
1. Monitor the pressure inside the A/C system.
2. Observe the flow of refrigerant into the system during charging.
3. Control the flow of refrigerant into the system during charging.
4. Access the system during discharging and evacuation.

Figure 1 Parts of a Manifold Gauge

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 A typical manifold gauge is shown in Figure 1. It is composed of a
pressure gauge (red) and a compound gauge (blue) connected to a common
pipe called the manifold.
Aside from the two gauges, there are also three (3) service hoses
connected to the manifold. The low-pressure service hose (blue) connects to the
low-pressure side of the A/C system through the LP coupler and with this
connection, you can read the low-side system pressure in the compound gauge
(blue). The high-pressure service hose (red) connects to the high-pressure side
of the A/C system through the HP coupler and with this connection, you can
read the high-side system pressure in the pressure gauge (red).
The hand valves open and close passageways to the center port and its
service hose (yellow). Opening the blue hand valve will open the passageway
from the low-pressure (blue) service hose to the yellow service hose. On the
other hand, opening the red hand valve will open the passageway from the
high-pressure (red) service hose to the yellow service hose.
As previously stated, we will start with servicing the A/C system by
checking its pressure with the use of a manifold gauge. Remember that this
procedure is done if the cooling performance of the A/C system is outside the
permissible range. The steps are as follows:
1. Make sure that the engine and the A/C are stopped.
2. Close both low and high-pressure hand valve.
3. Close both LP and HP Coupler shut-off valve (if equipped).
4. Connect LP Coupler to the low-pressure service valve of the A/C system.
5. Open LP Coupler shut-off valve.
6. Connect HP Coupler to the high-pressure service valve of the A/C system.
7. Open the HP Coupler shut-off valve.
8. Start and warm-up the engine.
9. Set the A/C control panel as specified in the manufacturer’s test
conditions.
10. Approximately 10 minutes after the start of A/C operation, make sure that
refrigerant pressure is stable.

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11. Observe the low pressure and the high pressure gauge and take note of
the readings.
12. Compare the results to manufacturer’s specifications. If the result is
outside the permissible range, diagnose and repair the system as needed.

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 ACTIVITY 12
CHECKING SYSTEM PRESSURE

Name: Course, Year-Section:

Direction:
1. Print pages 4 & 5 of this information sheet and use it as your answer sheet.
2. In reference to the specifications in Table 1, give the corresponding pressure
readings by drawing a needle in the face of the gauge in each item.
Remember, 100 kPa is approximately equal to 1 kg/cm2.
3. Take a picture of your work and send it to [email protected].

Table 1. Mitsubishi Mirage Pressure Permissible Range

Garage ambient temperature in 0C 20 25 30 35 40 45 50
660- 880- 1100- 1310- 1530- 1750- 1970-
High-pressure side in kPa
1190 1400 1620 1840 2060 2270 2490
110- 160- 210- 260- 310- 360- 410-
Low-pressure side in kPa
290 340 390 440 480 530 580

1. Ambient temperature: 200C

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2. Ambient temperature: 300C

3. Ambient temperature: 400C

4. Ambient temperature: 500C

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 Manifold gauge readings can show problems in the A/C system. The
following examples of gauge readings are from the AriaZone Automotive A/C
Training Manual. Your familiarity with the said gauge readings will greatly help
you diagnose various problems in the A/C system.

Figure 2. Normal pressure readings.

Figure 2 shows normal pressure reading in the low-pressure and high-

pressure side of the A/C system. We can judge that the readings are normal if
it falls within the range specified in Chart 1 & 2.
For example, if the ambient temperature is 250C, the permissible low-
pressure reading is approximately between 1.7 to 2.4 bars while the
permissible high-pressure reading is approximately between 11 to 15 bars.
It is possible that both low and high pressure readings are normal but
the A/C system is not cooling. One possible cause for this particular problem is
that the air vent is open which allows warm air from the outside to enter the
passenger compartment. In this case, make sure that the vent/ recirculate
selector switch is in the recirculate position.
It is also possible that the evaporator core is clogged which restricts the
flow of air coming from the blower motor. This causes ice to form in the surface
of the evaporator which blocks air flow. In this case, the refrigerant must be

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recovered; the evaporator removed, cleaned, and re-installed; and the A/C
system evacuated and then charged with the proper amount of refrigerant.

Chart 1 SUCTION PRESSURE vs AMBIENT TEMPERATURE CHART

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Chart 2. DISCHARGE PRESSURE vs AMBIENT TEMPERATURE.

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 Figure 3

We can see on Figure 3 that the low and high-pressure reading is

approximately 0.2 and 5 bars respectively. This readings can be considered
normal if the ambient temperature is very low.
But if the ambient temperature is between 15 to 35 0C, we can judge that
the quantity of refrigerant in the A/C system is very low, about 70-75% less. It
is possible that the system has leak/s, or there is a blockage in the high-
pressure side between the compressor, condenser, and filter-drier, provided
that the high-pressure service valve is located between the receiver-drier and
the expansion valve. In addition, if you encounter this type of pressure
readings on A/C systems with variable compressors, you must also look for
clogging between the filter-drier and the evaporator, and for an expansion valve
that is partially stuck closed or blocked.
In order to rectify this problem, you must first check if the system has
any leak using any suitable method. Then you have to recover any refrigerant
remaining in the A/C system; remove and replace the expansion valve and the
receiver-drier; remove and clean/ flush/ the evaporator and the condenser

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(replace if necessary); install the components; evacuate the system; check the
system for leak; and charge with proper amount of refrigerant.

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 Figure 4

Figure 4 shows that the A/C system, at 25 0C of ambient temperature,

have low and high pressure reading of approximately 3.5 bars and 29 bars
respectively. We can judge that these readings are too high in reference to
Charts 1 and 2.
The possible causes of this problem are excess refrigerant charged into
the A/C system, air in the A/C system, insufficient airflow through the
condenser and clogged condenser fins which can all cause the condenser to
overheat and the evaporator to provide insufficient cooling.
If the system uses a variable displacement compressor, it is possible that
its regulator valve is defective and is stuck in its maximum delivery position.
In this case, the refrigerant must be recovered and the condenser must
be cleaned and flushed. It is also a good practice to replace the receiver/ drier.
After that, the system must be evacuated and charged with the proper amount
of refrigerant.

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 Figure 5

The pressure gauge reading on both low and high pressure side of the
A/C system on Figure 5 shows an equal reading of 5 bars. This means that the
refrigerant is not circulating and your customer will likely complain that there
is no cooling when the A/C is switched ON.
The common cause of this problem is that the A/C compressor is not
operating due to a defective magnetic clutch or, in the case of variable
displacement compressors, the regulator valve is defective.
To confirm a defective magnetic clutch, try to connect it directly to the
battery. If the magnetic clutch engages with this procedure, the cause of the
problem is probably electrical in nature such as loose wiring connections,
blown fuse, defective relay, etc. You must refer to the specific wiring diagram in
order to trace the inoperative electrical component. In contrast, the magnetic
clutch itself is defective if it does not engage when connected directly to the
battery.
If the magnetic clutch itself is defective, the compressor must be removed
in order to replace the defective part. Make sure that you recover all refrigerant
before removing the compressor. Reinstall the compressor after replacement of

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the defective part, evacuate the system, test for leaks, and charge the A/C
system with the proper amount of refrigerant.

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 Figure 6

It can be seen on Figure 6 that the low-pressure gauge reading is high

while the high-pressure gauge reading is low. The customer may complain little
or no cooling from the A/C system.
One possible cause of this problem is that the compressor is defective
and is not producing enough compression and suction. It is also possible that
the expansion valve is stuck open. Remove the compressor if you suspect that
it is at fault and test it manually to verify its condition. Also, replace the
expansion valve with a new one. Remember to recover all refrigerant before
removing any A/C component. Once the inoperative parts are replaced,
evacuate and charge the system with the right amount of refrigerant.

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 Figure 7

Figure 7 shows that the low pressure gauge reading is very low while the
high pressure gauge displays a very high reading. It is possible that moisture
or dirt has entered the system. When moist is present in the system, it will
freeze after passing through the expansion valve and will block the flow of
refrigerant. Blockage of ice or dirt in the expansion valve will drastically
increase the pressure in the high side of the system and an almost vacuum
reading in the low side.
This type of trouble will require the recovery of the refrigerant and
flushing of the A/C system. Evacuate the system in order to remove any air
and moisture and charge it with the proper amount of refrigerant.

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RECOVERING THE REFRIGERANT
Before making any repairs or removal of A/C component, make sure to
remove the refrigerant from the A/C system and store it in the refrigerant tank.
This operation is known as recovery and will require the use of a recovery
machine (Figure 8).
Once refrigerant has been recovered, the station will display the weight of
the refrigerant that was removed. Note the weight or quantity of the refrigerant
removed because this can indicate leaks or overcharging. Open the vehicle’s
A/C system only after recovering the refrigerant.
During the recovery process, both refrigerant and oil are collected from
the system. The oil must be drained and measured for replacement with new
oil later.

Figure 8. REVOVERING THE REFRIGERANT

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EVACUATING THE A/C SYSTEM
After repairs have been performed, or if a system has been open for a
long period of time, the system must be evacuated to remove moisture and
ensure that it will hold a vacuum. The minimum time any system should be
evacuated is 30 minutes. The longer the system has been open, the longer it
should be evacuated.
The A/C system is evacuated by creating a vacuum within it. Negative
pressure reduces the boiling point of any water in the system, causing it to
turn from a liquid to a vapor. When the water turns to vapor, it can be drawn
out from the system. All water must be removed from the system, because if
water mixes with the refrigerant, hydrochloric acid forms. Hydrochloric acid is
very corrosive and will damage the A/C system components.
Below are the general steps in evacuating the A/C system:
1. Connect the manifold gauge service hoses to the A/C system’s service
valves.
a. Connect the blue service hose of the manifold gauge to the low pressure
service valve of the A/C system.
b. Connect the red service hose of the manifold gauge to the high pressure
service valve of the A/C system.
2. Connect the yellow service hose of the manifold gauge to the vacuum pump.
3. Turn on the vacuum pump.
4. Open both hand valves of the manifold gauge.
5. After 15 minutes, close both hand valves of the manifold gauge and turn off
the vacuum pump.
6. Observe pressure gauge readings for 5 minutes and make sure that it holds
vacuum. If it does not hold vacuum, leak is present in the system. Repair
the leak before proceeding to the next step.
7. If there is no leak, continue evacuating the system for another 15 minutes.
8. Close both hand valves and turn off the vacuum pump.
9. Remove the yellow service hose from the vacuum pump and proceed with
“CHARGING THE A/C SYSTEM.”
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CHARGING THE A/C SYSTEM
This process is done after the system is repaired and evacuated. Its main
purpose is to refill the A/C system with refrigerant.
1. Place the service tank on a weighing scale and take note of its weight.
2. Connect the yellow service hose of the manifold gauge to the service tank.
3. Open the hand valve of the service tank.
4. Purge the air from the yellow service hose.
5. Open the low pressure hand valve until readings on both gauges indicate
approximately 5 bars.
6. Start the engine and let it warm up.
7. Turn ON the A/C and the blower switch to maximum speed.
8. Raise engine speed to about 1500 rpm.
9. Slowly add the specified amount of refrigerant by opening the low
pressure hand valve. At the same time, observe the weight of the service
tank.
10. Close the low pressure hand valve when the service tank lose weight
equivalent to the amount of refrigerant specified by the manufacturer.
11. Bring the engine to idle speed.
12. Turn off the A/C system and shut down the engine.
13. Remove the manifold connection from the A/C system.
14. Install the caps of the low and high pressure service valves.

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