GROUP SIX

EVALUATING AND DIAGNOSING CAR HVAC

 GROUP MEMBERS
NAME REGISTRATION NUMBER
KIVUNIKE KEPHAH 23/U/APE/2051/PE
OWING-JIRI SAMUEL 22/U/APD/1985/PD
GIRAMIYA JUDITH 23/U/APE/1953/PE
LULIKA JOSHUA 23/U/APE/2107/PE
OKANYA MATTHEWS 23/U/APD/2425/PD
WAAKO ZEPHANIA 22/U/APD/2100/PD
NDYASIIMA ODENS 22/U/APD/1065/GV
SUB TOPICS

• Air conditioning not cooling enough

• Low refrigerant charge
• Refrigerant charging
• Refrigerant overcharge
• Air in refrigerant circuit
• Moisture in the refrigeration circuit
• Insufficient air from vents
• Smells and odors
• AC making abnormal noise
• AC goes from cold to Hot
• Common problems with compressors and clutches
• Common problems with condensers and Evaporators
• Common problems with metering devices and dryers
The poor performance of an AC system is generally caused by multifunctioning, mechanical faults, leakages,
and improper servicing. The problem might vary depending on the type of car and the manufacturer’s
settings but here are some of the most common problems and their remedies.
1.Air Conditioning not cooling enough.
The lack of precious cold air in an AC can be caused by;

a). The refrigerant leak caused by a failed O-ring, seal, hose, or any component
b). A clogged expansion tube or refrigerant charging hose
c). Failed compressor or compressor clutch
d). Failed blower motor or blower motor resistor
e). Damaged or failed condenser or evaporator
f). Vacuum leaks
g). Failed electrical component like switch, fuse, relay, control module, blend door, or solenoid
h). Blocked filter at the dryer or expansion valve.
i). Condenser fan motor issue, less heat transfer available for a given mass of refrigerant.
j). Compressor capacity control faulty leading to less coolant effect across the thermostatic expansion valve.
Troubleshooting & Diagnosis;

Diagnosing an air conditioning cooling problem is best done by connecting a gauge set to the high and low-pressure
service fitting on the system. Refer to the table below for the common remedies;
Low side High Side Cabin Temperature Possible Cause
Low Low Warm Low refrigerant charge
High High Warm Overcharge of refrigerant
High High Some cool Overcharge or Air in the system
Normal Normal Warm Too much oil or moisture in the system
Low Low Warm Expansion valve stack closely, orifice tube plugged
High Low Warm Compressor or control valve failed
2. Low refrigerant charge

Undercharge Symptoms Remedies

• Low discharge and suction pressure. • Check for leaky points by halide torch or soap
solution or electronic leak detectors.
• Compressor motor getting tripped by low
pressure cut out trip. • Charge the system.
• Large bubbles in the liquid sight glass. • Achieve the correct pressure gauge reading.
• Compressor discharge temperature high.
3. Refrigerant Charging

Below are the guidelines whenever it is necessary to recharge your AC system:

a) Determine the correct refrigerant for your vehicle.
Use R-134a for R-134a systems only and R-1234yf in R-1234fy systems only. Do not mix refrigerants.

b) Determine the correct ambient air temperature using the manufacturer’s manual or on the web. Do not charge
the vehicle if the temperature is below 55°F . Below is the Temperature pressure chart for R-134a.

Ambient Temperature °F / °C Low-Pressure Gauge High-Pressure Gauge

65°F (18°C) 25-35 psi / 172-241 kPa 135-155 psi / 931-1069 kPa
70°F (21°C) 35-40 psi / 241-276 kPa 145-160 psi / 1000-1103 kPa
75°F (24°C) 35-40 psi / 241-310 kPa 150-170 psi / 1034-1172 kPa
80°F (27°C) 40-50 psi / 276-345 kPa 175-210 psi / 1207-1448 kPa
85°F (29°C) 45-55 psi / 310-379 kPa 225-250 psi / 1551-1724 kPa
90°F (32°C) 45-55 psi / 310-379 kPa 250-270 psi / 1724-1862 kPa
95°F (35°C) 50-55 psi / 345-379 kPa 275-300 psi / 1896-2068 kPa
100°F (38°C) 50-55 psi / 345-379 kPa 315-325 psi / 2172-2241 kPa
105°F (41°C) 50-55 psi / 345-379 kPa 330-335 psi / 2275-2310 kPa
110°F (43°C) 50-55 psi / 345-379 kPa 340-345 psi / 2344-2379 kPa
c) Attach the charging hose to the refrigerant can. Slowly open the valve to release some little refrigerant hat will blow
out air from the hose which is not needed in the AC system. Close the valve and quickly attach the hose to the low
pressure side of the AC system. Note; The charging hose is attached to the low pressure side which is always found
on the compressor side. ( You should be able to identify it by color, size { larger tubing }, or in the service manual).
The high pressure fitting is always on the side of the condenser.
d) Start the engine and turn on the AC to maximum. The compressor must be running to suck the refrigerant through
the service hose.
e) Once all connections are fine, turn on the hose valve to release fresh charge into the system. Monitor the charging
with high/low pressure gauge.
Low pressure gauge; Stop charging when the reading is between 25 to 40 psi. Beyond that it will be overcharged.
High pressure gauge; It should be between 200 to 225psi. The AC should be cooling normally now.
g) Turn off the hose valve and switch off the engine when charging is done. You will notice the reading of the gauges
will be the same in a few minutes when the gauges are still fixed.
h) Remove the charging hose from the service ports and close the caps of the ports.
Note;
- Use a gauge to avoid under/over charging.
- Check the service manual for more specific service guidelines

4. Refrigerant overcharge
AC should not be overcharged as it may damage the compressor. Weigh the charge and use a gauge when
recharging.

Symptoms of overcharging;

a. High compressor discharge pressure.

b. Full level clear sight glass.
c. The compressor is running cold.
d. Excess frost on the compressor suction.
e. Unusually large compressor noise while running due to liquid refrigerant entering into the compressor suction.

Remedy:

Release the excess refrigerant into a recovery bottle and avoid any leaks directly into the atmosphere
5. Air in the Refrigerant Circuit
This air can cause;

a. Compressor overheating with high discharge pressure and normal condensing temperature.
b. The appearance of small bubbles in the sight glass.
c. Condensing pressure high.
d. Cooling capacity reduced.
e. Pressure gauge of the condenser jumps indefinitely

Reasons for air in the refrigerant;

a. Air may enter while charging of the refrigerant.

b. Air may enter while carrying out routine maintenance.
c. If the suction pressure goes below atmospheric pressure, during system evacuation, then air may enter from
leaky gaskets or loose connections.

Remedy:
- Use a vacuum pump to purge the AC system prior to recharging Vaccum pump shpuld ru for about 30mins to
properly evacuate the system.
- Air in the system can be collected using the condenser. Close the condenser valve as the compressor is running.
Vent he collected air through the venting valve and immediately close the valve
6. Moisture in the Refrigeration Circuit
Moisture can cause;

a. Evaporator starving of refrigerant and rapid rise in condenser pressure causes a compressor to short cycle.
b. Icing at the expansion valve filter. When the expansion valve freezes, refrigerant flow is reduced, and cooling is
also reduced.
c. Moisture can cause corrosion and damage to the motor windings.

Remedy;

a. Clean expansion valve filter.

b. Renew drying agent or the dryer unit.
7. Insufficient air from the vents

Main causes Remedy

-Clogged passenger compartment air filter • Check the condition of air filters
-The blower hose that supplies air to the blower unit • Ensure no blockage in hoses
is loose or blocked
• Fun should be inspected for any mechanical faults
- Ventilation fan is not blowing
• Check the motor that runs the fun for mechanical
- Faulty blower motor/ electrical faults faults, check for power supply, check for blown
fuses
8.Smell and Odors.
Caused by growth of bacteria, fungi, mold, and other micro organisms on filters, evaporator coils and heater box.
This is due to the decomposition of dust, dirty, and other solid material trapped by these components hence
producing bad smells.

Remedy;
-Replace the air filter
-Add antibacterial solution to the evaporator area to kill mold.

9. Abnormal noise from AC system

Caused by;
- Leave sand other debris blocking the system
- Cross contaminated refrigerant, air in the system or wrong type of compressor lubricant
- Hoses or any parts rattling against other engine parts.
- Major component could be in failure e.g. worn out bearing

Remedy;
- Check the system for any substances trapped like leaves
- Use the correct refrigerant and lubricants
- Check hoses and support brackets for proper positioning
- You may do a general check up of the whole system for failed parts, replace where necessary
10. The AC goes from cold to hot.
This could be a result of ;
- A blocked expansion valve preventing refrigerant from reaching the evaporator
- Compressor cycles quicky from on and off due to a faulty thermostat and low refrigerant

Remedy;
Test the system pressure
Check components for blockage and multifunction.
11. Problems with compressors and clutch.
a) Low suction pressure

Causes Repair
• Refrigerant shortage • Recharge
• Worn compressor piston • Replace compressor
• Compressor leakage ( in valve or gasket) • Replace gasket, change valve plate
• Flattened hose • Change hose or remold the flattened
• Moisture in system • Replace drier. ( Check previous chapter on how to
handle this)
• Trash in expansion valve
• Clean or replace valve
b) High suction pressure

Cause Remedy
Loose expansion valve Tighten it
Overcharged system Discharge extra refrigerant
Expansion valve stuck open Change valve
Compressor reed valve Change reed valve
Leaking head gasket on compressor Replace gasket

c) Low discharge pressure

Leak in system Tighten, replace gasket

Defective expansion valve Fix it / replace with new one
Suction valve closed Open it
Plugged receiver drier Replace drier
Leaking suction valve Fix / replace with new valve
Bad reed valve Replace reed valve
 d) High discharge pressure

Problem/ Possible cause Repair

Air in system Discharge and recharge the system
Clogged condenser Clean the condenser
Discharge valve closed Open it
Overcharged system Remove extra refrigerant
Insufficient condenser air Install a fun (in the Centre of condenser)
Loose fan belt Tighten ( tension) the belt

e) Compressor not working

Problem/ Possible cause Repair

Broken clutch wire or no power supply Repair the wire. Check power supply
Faulty compressor piston Replace the compressor
Broken belt Replace with a new belt
Bad thermostat Fix a new thermostat
Faulty clutch coil Replace clutch coil
Low refrigerant (Low pressure switch has cut off Add refrigerant/ Recharge
clutch power
f) Compressor clutch not engaging

Possible problem Remedy

Refrigerant too low Recharge the system
Electrical fault Check the power system and its
components

g) Short cycling of the compressor

The compressor is repeatedly running for few minutes and then cutting off
Reasons could be;
 Refrigerant charge is too low
 Low pressure cut out is not properly adjusted
 Clogging of evaporator
 Filter shocked/ clogged
 Moisture in the system

h) Frosting at suction of the compressor;

It means the liquid is reaching the suction of the compressor and is absorbing heat from the
surroundings resulting into formation of ice formation. This could be a result of;
 Thermostat valve stuck in one position > Replace it
 Superheat setting is low or not proper > Do a reset
 Refrigerant overcharge > Offload the extra charge
 Fan tripped/ damaged > Put the fun in order
 12. Common problems with condenser.
They are mainly in three categories; Leaks, Airflow restrictions, and Refrigerant flow restrictions
- Leaks may develop due to corrosion, excessive vibration making some parts loose, and physical damages
- Refrigerant flow restrictions are always a result of contamination, debris and any trapped material in the system
- Inadequate air flow due to faults in the fan, obstructions, damaged air intake shrouds
Apply the necessary remedy as explained in many cases above

13. Common problems with evaporator

Problem/ Possible cause Remedy

Frozen coil, switch set too high Adjust the thermostat switch
Drive belt slipping Tension the belt
Hot air leaks into the car Check for holes and open vents
Plugged receiver drier Replace drier
Broken Capillary tube Replace expansion valve
Low refrigerant charge Recharge
Defective expansion valve Replace with a new one
Frozen expansion valve Evacuate and replace drier
14. Common problems with metering devices
Metering devices are mainly orifice tubes and thermostatic expansion valve. Both have same symptoms which are indicated by
low gauge pressure caused by a clogged screens of the two components ( orifice tube screen, & inlet and outlet screens).
Examine the screens for any pieces of clogged material;
 If the blockage is grey/ brown then its probably a ruptured discant bag in the receiver/ drier or accumulator
 If its shiny metal chip then the compressor might be failing
 If the blockage is a black granular then it’s a residue in the hose caused by a reaction between moisture and the refrigerant
forming an acid which breaks down hoses and seals

15. Common problems with receiver/ dryer

As explained above, moisture can form acid which can destroys the discant bag leading to failure of the dryer to perform. This
is because the discant can saturate within the refrigerant and once saturation is reached no more moisture can be absorbed.
Replace the dryer once detected faulty.
Thank You