Service Manual2009 Aveo MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SECTION 7B

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

Caution : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

SPECIFICATIONS

General Specifications - V5 System -

Application		Unit	Description
Compressor		-	V5
Receiver-Dryer		-	AL R/DRIER
Refrigerant	Type	-	R-134a System
Refrigerant	Capacity	g	520±20 (RHD : 570±20)
Refrigerant Oil in A/C System	Type	-	UNION CARBIDE UCON 488 PAG OIL (ISU513)
Refrigerant Oil in A/C System	Capacity	cc (ml)	200
A/C Cooling Capacity (Airflow rate 6.8 m/s)		Kcal/h	11,000-5%

General Specifications - SP10 System -

Application		Unit	Description
Compressor		-	SP-10.4PK
Receiver-Dryer		-	AL R/DRIER
Refrigerant	Type	-	R-134a System
Refrigerant	Capacity	g	520±20 (RHD : 570±20)
Refrigerant Oil in A/C System	Type	-	UNION CARBIDE RL897 PAG OIL (ISU105)
Refrigerant Oil in A/C System	Capacity	cc (ml)	150
A/C Cooling Capacity (Airflow rate 6.8 m/s)		Kcal/h	11,000-5%
A/C Compressor ON/OFF Condition	Evaporator Thermistor Temperature	°C (°F)	Down below 2.0 °C (35.6 °F) : OFF Go over 4.0 °C (39.2 °F) : ON

Fastener Tightening Specifications

Application	N•m	lb-ft	lb-in
Air Cleaner Housing Assembly Retaining Bolts	12	-	106
Compressor Bracket Bolt	27	20	-
Control Assembly Retaining Screws	3	-	27
Expansion Valve Retaining Bolt	12	-	106
Heater/Air Distribution Case Assembly Retaining Screws	4	-	35
Liquid Evaporator Pipe Connector Block Retaining Nut	15	11	-
Liquid Pipe Connector Block to Condenser	14	10	-
Pressure Transducer	8	-	71
Refrigerant Discharge Hose Connector Block Bolt	16	12	-
Refrigerant Discharge Hose Support Clamp Bolt	8	-	71
Refrigerant Suction Hose and the Refrigerant Discharge hose to Compressor Connector Block Retaining Nut (V5 Compressor Only)	33	24	-
Refrigerant Suction Hose to Compressor Connector Block Retaining Bolt (SP10 Compressor Only)	33	24	-
Refrigerant Discharge Hose to Compressor Connector Block Retaining Bolt (SP10 Compressor Only)	33	24	-
Refrigerant Suction Hose Connector Block Retaining Nut	15	11	-
Condenser Mount Bolt	7-10	-	62-89

SPECIAL TOOLS

Special Tools Table

	J-5403 Snap Ring Pliers
	J-6083 Snap Ring Pliers
	J-8092 Driver Handle
	J-8433-1 Puller Crossbar
	J-8433-3 Forcing Screw
	J-9398-A Bearing Remover
	J-9481 Bearing Installer
	J-9553-1 O-Ring Remover
	J-9625-A Pressure Test Set
	J-23128-A Seal Seat Remover and Installer
	J-35372 Support Block
	J-33011 O-Ring Installer
	J-33013-B Hub and Drive Plate Remover and Installer
	J-34993 Cylinder Alignment Rods
	J-33017 Pulley Rotor and Bearing Assembly Installer
	J-33019 Bearing Staking Tool Set Includes: J-33019-1 Bearing Staking Guide J-33019-2 Bearing Staking Pin
	J-33020 Pulley Puller
	J-34614 Shaft Seal Protector
	J-33022 Shaft Nut Socket
	J-33023-A Puller Pilot
	J-33024 Clutch Coil Installer Adapter
	J-33025 Clutch Coil Puller Legs
	J-34992 Compressor Holding Fixture
	J-33027 Clutch Hub Holding Tool
	J-42428 Compressor Holding Fixture
	DW-610-010 Clutch Hub Holding Tool (for SP10 compressor)

SCHEMATIC AND ROUTING DIAGRAMS

A/C Refrigerant System - Typical -

Compressor
Condenser
Receiver-Dryer
Evaporator
Expansion Valve

A/C Airflow - Typical -

A/C Schematic

Power, Ground and Intake Actuator

A/C Compressor Control - Sirius D42R

A/C Compressor Control - HV240

A/C Compressor Control - MR140

A/C Compressor Control - MT80

DIAGNOSIS

GENERAL DIAGNOSIS

Testing the Refrigerant System

If you suspect a problem in the refrigerant system, check for the following conditions:

Check the outer surfaces of the radiator and the condenser cores to be sure that the airflow is not blocked by dirt, leaves, or other foreign material. Check between the condenser and the radiator, as well as all outer surfaces.
Check for restrictions or kinks in the condenser core, the hoses, and the tubes.
Check the operation of the blower fan.
Check all the air ducts for leaks or restrictions. A low airflow rate may indicate a restricted evaporator core.
Check for slippage of the compressor clutch.
Check the drive belt tension.

Insufficient cooling "Quick Check" Procedure

Perform the following "hand-feel" procedure to get a quick idea of whether the air conditioning (A/C) system has the proper charge of Refrigerant-134a. The air temperature must be above 21°C (70°F) for most models.

Warm up engine. Run the engine at idle.
Open the hood and all the doors.
Turn the A/C switch ON.
Set the temperature control to the full cold position.
Set the blower speed switch on 4.
"Hand-feel" the temperature of the evaporator outlet pipe. The pipe should be cold.
Check for other problems. Refer to "Testing the Refrigerant System" in this section.
Leak check the system. Refer to "Leak Testing the Refrigerant System" in this section. If you find a leak, discharge the system and repair the leak as required. After completing the repair, evacuate and charge the system.
If there is no leak, refer to "Insufficient Cooling Diagnosis" in this section.

A/C Performance Test - V5 System -

RELATIVE HUMIDITY ( % )	AMBIENT AIR TEMPERATURE		LOW SIDE PRESSURE		ENGINE SPEED (RPM)	CENTER DUCT AIR TEMPERATURE		HIGH SIDE PRESSURE
.	°C	°F	Psi	Kpa	.	°C	°F	Psi	Kpa
.	21	70	25	170	.	4	39	162	1117
20	27	81	26	180	2000	6	43	210	1448
.	32	90	30	210	.	8	46	263	1810
.	38	100	36	250	.	12	54	325	2240
.	21	70	25	170	.	5	41	165	1138
30	27	81	26	180	2000	7	45	225	1551
.	32	90	32	220	.	10	50	278	1920
.	38	100	39	270	.	15	59	336	2320
.	21	70	25	170	.	6	43	176	1214
40	27	81	28	190	2000	8	46	235	1620
.	32	90	33	230	.	11	52	286	1970
.	38	100	42	290	.	16	61	342	2360
.	21	70	25	170	.	7	45	190	1310
50	27	81	29	200	2000	9	48	238	1640
.	32	90	36	250	.	13	55	292	2010
.	38	100	46	320	.	18	64	364	2510
.	21	70	25	170	.	8	46	195	1345
60	27	81	29	200	2000	9	48	244	1680
.	32	90	39	270	.	14	57	312	2150
.	38	100	52	360	.	21	70	380	2620
.	21	70	26	180	.	8	46	200	1379
70	27	81	33	230	2000	10	50	249	1720
.	32	90	42	290	.	15	59	318	2190
.	38	100	54	370	.	21	70	384	2650
.	21	70	26	180	.	9	48	213	1469
80	27	81	33	230	2000	12	54	254	1750
.	32	90	46	320	.	17	63	325	2240
.	21	70	26	180	.	9	48	225	1551
90	27	81	35	240	2000	13	55	261	1800
.	32	90	49	340	.	19	66	341	2350

* Test Conditions : Doors & hood opened, A/C ON, Recirculation mode, Full Cool with maximum Blower speed, No Sunlight, Wind velocity at 8km/h (5 mph).

A/C Performance Test - SP10 System -

Air Mode	Ambient Air Temperature °C (°F)	Low Side Pressure kPa (psi)	Engine Speed (RPM)	Center Duct Air Temperature °C (°F)	High Side Pressure kPa (psi)
Recirculation Mode	.	270 (39)	880	15.7 (60.3)	1924 (279)
	38 (100)	116 (17)	1900	4.2~4.9 (39.6~40.8)	1238 (180)
	.	131 (19)	2400	4.2~7.1 (39.6~44.8)	1170 (170)
	.	108 (16)	3300	6.4~7.1 (43.5~44.8)	1072 (155)
Outside Air Mode	.	441 (64)	880	26.3 (79.3)	2138 (310)
	38 (100)	253 (37)	1900	16.7 (62.1)	1436 (208)
	.	229 (33)	2400	15.4 (59.7)	1376 (200)
	.	200 (29)	3300	14.6 (58.3)	1390 (202)

Pressure-Temperature Relationship of R-134A

Temperature °C (°F)*	Pressure kPa (psi)*	Temperature °C (°F)*	Pressure kPa (psi)*
-8.89 (16)	105.70 (15.33)	37.78 (100)	856.84 (124.27)
-7.78 (18)	114.87 (16.66)	38.89 (102)	886.56 (128.58)
-6.67 (20)	124.32 (18.03)	40.00 (104)	916.35 (132.98)
-5.56 (22)	134.11 (19.45)	41.11 (106)	947.92 (137.48)
-4.44 (24)	144.24 (20.92)	42.22 (108)	979.64 (142.08)
-3.33 (26)	154.65 (22.43)	43.33 (110)	1012.11 (146.79)
-2.22 (28)	165.48 (24.00)	44.44 (112)	1045.21 (151.59)
-1.11 (30)	176.65 (25.62)	45.56 (114)	1079.14 (156.51)
0.00 (32)	188.16 (27.29)	46.67 (116)	1113.75 (161.53)
1.11 (34)	200.02 (29.01)	47.78 (118)	1149.12 (166.66)
2.22 (36)	212.30 (30.79)	48.89 (120)	1185.18 (171.89)
3.33 (38)	224.98 (32.63)	50.00 (122)	1222.07 (177.24)
4.44 (40)	238.08 (34.53)	51.11 (124)	1259.72 (182.70)
7.22 (45)	272.49 (39.52)	52.22 (126)	1298.12 (188.27)
10.00 (50)	309.58 (44.90)	53.33 (128)	1337.35 (193.96)
12.77 (55)	349.51 (50.69)	54.44 (130)	1377.35 (199.76)
15.56 (60)	392.33 (56.90)	57.22 (135)	1480.91 (214.78)
18.33 (65)	438.18 (63.55)	60.00 (140)	1589.57 (230.54)
21.11 (70)	487.27 (70.67)	62.78 (145)	1703.62 (247.08)
23.89 (75)	539.67 (78.27)	65.56 (150)	1823.04 (264.40)
26.67 (80)	609.38 (88.38)	68.33 (155)	1948.04 (282.53)
29.44 (85)	655.09 (95.01)	71.11 (160)	2078.77 (301.49)
32.22 (90)	718.39 (104.19)	73.89 (165)	2215.29 (321.29)
35.00 (95)	785.61 (113.94)	76.67 (170)	2357.81 (341.96)

* All values rounded to two decimal places.

EVAPORATOR RANGE: From -6.67 to 7.22°C (20 to 45°F), the temperatures represent the gas temperatures inside the coil and not on the coil surfaces. Add 1.67 to 5.56°C (3 to10°F) the temperature for coil and air-off temperatures.

CONDENSER RANGE: From 110 to 160°F, temperatures are not ambient. Add 19.4 to 22.2°C (35 to 40°F) for proper heat transfer, then refer to the pressure chart.

Example:

32°C (90°F) ambient temperature + 22°C (40°F) = 54°C (130°F)

Condenser temperature = 1379 kPa (200 psi)

Based on 48.3 km/h (30 mph) airflow.

Leak Testing The Refrigerant System

Test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the lines or the connections. Leaks are commonly found at the refrigerant fittings or at the connections. Leaks are commonly caused by the following problems:

Improper torque.
Damaged O-ring seals.
Dirt or lint on the O-ring seals.

Liquid Leak Detectors

Use a liquid leak detector solution on locations such as fittings. Apply the solution to the area in question with the swab that is supplied with the solution. Look for bubbles to appear. This will indicate the existence and location of any leak.

For areas where this is not practical, such as sections of the evaporator and the condenser, an electronic leak detector is more useful.

Electronic Leak Detectors

Follow the manufacturer's instructions for calibration, operation, and maintenance of an electronic leak detector. Battery condition is especially important to the accuracy of a portable model. Set the detector to R-134a before beginning the test.

Important : Electronic leak detectors are sensitive to windshield washing solutions, solvents and cleaners, and certain vehicle adhesives.

Surfaces must be clean to prevent false readings. Make sure that all surfaces are dry to prevent damage to the detector.

General Testing Instructions

Follow the entire path of the refrigerant system.
Completely circle each joint at 25 to 50 mm (1 to 2 inches) per second.
Hold the probe tip within 6 mm (1/4 inch) of the surface.
Do not block the air intake.

The audible tone changes from one to two clicks per second into a solid alarm if there is a leak. Adjust the balance control to maintain one to two clicks per second.

Test all of the following areas, even after one leak has been confirmed:

Evaporator inlet and outlet.
Receiver-drier inlet and outlet.
Condenser inlet and outlet.
Brazed and welded areas.
Damaged areas.
Hose couplings.
Compressor rear head.
All fittings and joints.

Testing Service Ports/Access Valves

The sealing cap is the primary seal for the service ports. This cap contains a special leak-free O-ring. Make sure that this cap is not missing or loose. Always use the correct cap.

Testing the Evaporator Core

Leaks in the evaporator core are difficult to find. Test the evaporator core using the following procedure:

Run the blower fan at speed setting 4 for at least 15 minutes.
Turn the blower to the OFF position.
Wait for 10 minutes.
Remove the blower motor resistor. Refer to "Blower Motor Resistor" in this section.
Insert the leak detector probe as close as possible to the evaporator core. The detector will indicate a leak with a solid alarm.
Use a flashlight to search for refrigerant oil in the core surface.

Testing the Compressor Shaft Seal

Blow shop air behind and in front of the compressor clutch/pulley for at least 15 seconds.
Wait 1 to 2 minutes.
Probe the area in front of the pulley. If the detector emits a solid alarm, there is a leak.

Air Conditioning System Diagnosis

Insufficient Cooling Diagnosis - 1.4D/1.5S V5 System -

Step	Action	Value(s)	Yes	No
1	Can you verify the customer complaint?	-	Go to Step 2	System OK
2	Check the A/C fuse. Check the blower fan operation. Check the engine cooling fan operation. Check the A/C compressor belt. Check the A/C condenser for restricted airflow. Check the clutch coil connection. Repair or replace any components as needed. Check the discharge air temperature with the A/C turned on. Is the discharge air temperature normal?	At least 7°C (13°F) below ambient air temperature	System OK	Go to Step 3
3	Turn the ignition switch to LOCK. Connect the high and the low pressure gauges. Are both pressures within the value specified?	69-345 kPa (10-50 psi)	Go to Step 4	Go to Step 5
4	Check the A/C system for leaks. Repair any refrigerant leaks as needed. Recover, evacuate, and recharge the A/C system. Are both pressures above the value specified?	345 kPa (50 psi)	Go to Step 7	-
5	Observe the two pressure gauges. Are both pressures below the value specified?	69 kPa (10 psi)	Go to Step 6	Go to Step 7
6	Add 0.45 kg (1 pound) of refrigerant R-134a. Check the A/C system for leaks. Repair any refrigerant leaks as needed. Recover, evacuate, and recharge the A/C system. Are both pressures above the value specified?	345 kPa (50 psi)	Go to Step 7	-
7	Start the engine and allow it to run at idle. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to fresh air (indicator lamp OFF). The blower motor to 4. The temperature to full cold. Does the A/C compressor clutch engage?	-	Go to Step 8	Go to Step 10
8	Check for a knocking noise from the A/C compressor. Cycle the A/C compressor ON and OFF in order to verify the source of the noise. Do you hear a loud knocking noise?	-	Go to Step 9	Go to Step 13
9	Recover the A/C system refrigerant. Replace the A/C compressor. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the compressor running normally?	-	Go to Step 13	-
10	Turn the ignition switch to LOCK. Disconnect the A/C compressor clutch coil connector. Connect a jumper wire from ground to one A/C compressor clutch coil terminal. Connect a fused jumper wire from the positive battery terminal to the other A/C compressor clutch coil terminal. Does the A/C clutch engage?	-	Go to Step 11	Go to Step 12
11	Repair the electrical circuit to the A/C compressor clutch coil. Does the A/C clutch engage?	-	Go to Step 8	-
12	Replace the A/C compressor clutch coil. Does the A/C clutch engage?	-	Go to Step 8	-
13	Important : Perform this test under garage conditions; 21-32°C (70-90°F) and no sun load. Follow this test carefully for accurate results. Close all of the windows and the doors of the vehicle. Close all of the windows and the doors of the vehicle. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Start the engine and allow it to run at idle for 5 minutes. Feel the evaporator inlet and outlet pipes. Is there a noticeable difference in the temperature of the evaporator inlet and outlet pipes?	-	Go to Step 15	Go to Step 14
14	Turn the ignition switch to LOCK. Recover the A/C system refrigerant. Examine the high-pressure pipe for an obstruction. Examine the expansion valve for a malfunction if there is no obstruction. Repair the obstruction or replace the expansion valve as needed. Evacuate and recharge the A/C system. Check the A/C system for leaks. Note the discharge air temperature with the A/C ON. Is the discharge temperature normal?	At least 7°C (13°F) below ambient air temperature	Go to Step 15	Go to Step 13
15	Record the low and the high side pressures after the A/C system has been operating for 5 minutes or more and the engine cooling fan is ON. Locate the intersection of the low and the high side pressures. Refer to "Low- and High-Side Pressure Relationship Chart" in this section. Do the low and the high side pressures intersect in the white area of the chart?	-	System OK	Go to Step 16
16	Check the high-side and low-side pressures. Do the low- and the high-side pressures intersect in the gray area of the chart?	-	Go to Step 17	Go to Step 20
17	Feel the liquid pipe between the condenser and the expansion valve. Is the pipe cold?	-	Go to Step 18	Go to Step 19
18	Examine the condenser for any restriction of the airflow. Check the cooling fans for proper operation. Remove the restriction or repair the fan(s) as required. Is the pipe temperature normal now?	-	Go to Step 13	-
19	Recover, evacuate, and recharge the A/C system. Check the A/C system for leaks. Is the system leak tight?	-	Go to Step 13	-
20	Observe the readings on the pressure gauges. Are the A/C compressor high- and the low-side pressures within the specified value of each other?	207 kPa (30 psi)	Go to Step 21	Go to Step 26
21	Run the engine at 3,000 rpm. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Close all of the windows and the doors of the vehicle. Turn the A/C switch ON and OFF every 20 seconds for 3 minutes. Are the A/C compressor high- and the low-side pressures within the specified value of each other?	207 kPa (30 psi)	Go to Step 22	Go to Step 13
22	Observe the pressure rise on both gauges and the temperatures of both the compressor suction pipe and the discharge pipe. Is the pressure rise on both gauges slow and the suction pipe warm with the discharge pipe very hot?	-	Go to Step 25	Go to Step 23
23	Turn the ignition switch to LOCK. Confirm that the compressor clutch is disengaged. Attempt to turn the clutch driver (not the pulley). Can you turn the clutch driver freely by hand?	-	Go to Step 25	Go to Step 24
24	Start the engine. Observe the low-side pressure gauge while running the engine between 3,000 and 3,800 rpm. Does the low-side pressure rise rapidly?	-	Go to Step 32	Go to Step 25
25	Recover the A/C system refrigerant. Replace the A/C compressor. Evacuate and recharge the A/C system. Is the compressor functioning normally?	-	Go to Step 13	-
26	Check the low-side pressure. Is the low-side pressure within the specified value?	172-241 kPa (25-35 psi)	Go to Step 27	Go to Step 32
27	Feel the high-side pipe leading up to the expansion valve connecting block. Is the pipe cold before the connecting block?	-	Go to Step 28	Go to Step 29
28	Check for a restriction in the high-side pipe before the expansion valve. Repair or replace the high-side pipe. Is the pipe performing normally?	-	Go to Step 13	-
29	Add the specified amount of refrigerant to the A/C system. Does the cooling performance improve?	0.40 kg (14 ounces)	Go to Step 30	Go to Step 31
30	Check the A/C system for leaks. Repair any refrigerant leaks, as needed. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the system leak free?	-	Go to Step 13	-
31	Recover the refrigerant. Check the expansion valve for obstructions. Repair or replace the expansion valve, as required. Evacuate and recharge the system. Leak check the system. Is the system leak free?	-	Go to Step 13	-
32	Important : Perform this test exactly as described to obtain accurate results. Run the engine for 5 minutes at 2,000 rpm. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to recirculate (indicator lamp ON). The blower motor to 1. The temperature to full cold. Close all of the windows and the doors of the vehicle. Open the vehicle hood. Is the low-side pressure within the specified value?	172-241 kPa (25-35 psi)	Go to Step 13	Go to Step 33
33	Recover the A/C system refrigerant. Replace the A/C compressor control valve. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the system free from leaks?	-	Go to Step 13	-

Insufficient Cooling Diagnosis - 1.2 SOHC/DOHC SP10 System -

Step	Action	Value(s)	Yes	No
1	Can you verify the customer complaint?	-	Go to Step 2	System OK
2	Check the A/C fuse. Check the blower fan operation. Check the engine cooling fan operation. Check the A/C compressor belt. Check the A/C condenser for restricted airflow. Check the slippage of the compressor clutch. Repair or replace any components as needed. Check the A/C system operation. Is the A/C system operation normal?	-	System OK	Go to Step 3
3	Turn the ignition switch to LOCK. Connect the high and the low pressure gauges. Are both pressures within the value specified?	Low Side Pressure: 200 kPa (29 Psi) High Side Pressure: 1,500 kPa (217.5 Psi)	Go to Step 8	Go to Step 6
4	Are both pressures above the specified value?	↑	Go to Step 5	-
5	Are both pressures within the specified value?	↑	Go to Step 8	Go to -
6	Are both pressures below the specified value?	↑	Go to Step 7	Go to Step 4
7	Add the refrigerant R-134a. Check the A/C system for leaks. Repair any refrigerant leaks as needed. Recover, evacuate, and recharge the A/C system. Are both pressure within the specified value?	↑	Go to Step 8	-
8	Start the engine and allow it to run at idle. Set the A/C controls to following positions. The A/C switch to the ON position. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Does the A/C compressor clutch engage?	-	Go to Step 9	Go to Step 11
9	Check for a knocking noise from the A/C compressor. Cycle the A/C compressor ON and OFF in order to verify the source of the noise. Do you hear a loud knocking noise?	-	Go to Step 10	Go to Step 14
10	Recover the A/C system refrigerant. Replace the A/C compressor. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the repair complete?	-	Go to Step 14	-
11	Turn the ignition switch to Lock. Disconnect the A/C compressor clutch coil connector. Connect a jumper wire from ground to one A/C compressor clutch coil terminal. Connect a fused jumper wire from the positive battery terminal to the other A/C compressor clutch coil terminal. Does the A/C clutch engage?	-	Go to Step 12	Go to Step 13
12	Repair the electrical circuit to the A/C compressor clutch coil. Does the A/C clutch engage?	-	Go to Step 20	Go to Step 13
13	Replace the A/C compressor clutch coil. Does the A/C clutch engage?	-	Go to Step 9	Go to Step 10
14	Important : Perform this test under garage conditions; 21-32°C (70-90°F) and no sun load. Follow this test carefully for accurate results. Close all of the windows and the doors of the vehicle. Close all of the windows and the doors of the vehicle. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Start the engine and follow it to run at idle for 5 minutes. Feel the evaporator inlet and outlet pipes. Is there a noticeable difference in the temperature of the evaporator inlet and outlet pipes?	-	Go to Step 16	Go to Step 15
15	Recover the A/C system refrigerant. Replace the expansion valve as needed. Evacuate and recharge the A/C system. Check the A/C system for leaks. Note the discharge air temperature with the A/C ON. Is the discharge temperature normal?	-	Go to Step 16	Go to Step 18
16	Feel the liquid pipe between the condenser and the expansion valve. Is the pipe cold?	-	Go to Step 19	Go to Step 17
17	Remove the restriction of the high pressure side. Check the A/C system for leaks. Is the repair complete?	-	System OK	-
18	Recover the A/C system refrigerant. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the repair complete?	-	System OK	-
19	Run the engine at 3,000 rpm. Run the engine at 3,000 rpm. Close all of the windows and doors of the vehicle. Set the A/C controls to the following positions: The A/C switch to the ON position. The fresh air control switch to fresh air. The blower motor to 4. The temperature to full cold. Turn the A/C switch ON and OFF every 20 seconds for 3 minutes. Are the A/C compressor high and the low side pressures within the specified value of each other?	Low Side Pressure: 200 kPa (29 psi) High Side Pressure: 1,500 kPa (217.5 psi)	System OK	Go to Step 22
20	Turn the ignition switch to LOCK. Turn the ignition switch to LOCK. Turn the A/C switch to the OFF position. Attempt to turn the clutch driver (not the pulley). Can you turn the clutch driver freely by hand?	-	Go to Step 23	Go to Step 21
21	Recover the A/C system refrigerant. Replace the A/C compressor. Evacuate and recharge the A/C system. Is the repair complete?	-	System OK	-
22	Add the refrigerant R-134a. Does the cooling performance improve?	-	System OK	Go to Step 23
23	Recover the A/C system refrigerant. Replace the compressor. Evacuate and recharge the A/C system. Check the A/C system for leaks. Is the repair complete?	-	System OK	-

SYMPTOM DIAGNOSIS

Pressure Test Chart - R-134A System -

Test Results	Related Symptioms	Probable Cause	Remedy
Discharge (high) pressure abnormally high	After stopping the compressor, the pressure drops about 299 kPa (28 psig) quickly, then falls gradually.	Air in the system.	Recover, evacuate and recharge the system with the specified amount of refrigerant.
	The condenser is excessively hot.	Excessive refrigerant in the system.	Recover, evacuate and recharge the system with the specified amount of refrigerant.
	Reduced or no airflow through the condenser.	Condenser or the radiator fins are clogged.	Clean the condenser or the radiator fins.
	.	Condenser or the radiator fan is not working properly.	Check the voltage and the fan rpm. Check the fan direction.
	Line to the condenser is excessively hot.	Restricted flow of refrigerant in the system.	Locate and repair the restriction.
Discharge pressure abnormally low	The condenser is not hot.	Insufficient refrigerant in the system.	Check the system for a leak. Charge the system.
	High and low pressures are balanced soon after stopping the compressor.	Faulty compressor pressure relief valve.	Repair or replace the compressor.
	Low-side pressure is higher than normal.	Faulty compressor seal.	.
	The outlet of the expansion valve is not frosted.	Faulty expansion valve.	Replace the expansion valve.
	Low pressure gauge indicates vacuum.	Moisture in the system.	Recover, evacuate, and recharge the system.
Suction (low) pressure abnormally low	Condenser is not hot.	Insufficient refrigerant in the system.	Repair the leaks. Recover, evacuate, and recharge the system.
	The expansion valve is not frosted and the lowpressure line is not cold.	Faulty expansion valve.	Replace the expansion valve.
	Low-Pressure gauge indicates a vacuum.	Frozen expansion valve.	.
	Discharge temperature is low and the airflow from the vents is restricted.	Evaporator is frozen.	Clear the restricted evaporator case drain.
	The expansion valve is frosted.	Expansion valve is clogged.	Clean or replace the expansion valve.
	The receiver-dryer outlet is cool and the inlet is warm.	Receiver-dryer is clogged.	Replace the receiver-dryer.
Suction pressure abnormally high	Low-pressure hose and check joint are cooler than the temperature around the evaporator.	Expansion valve is opened for too long.	Replace the expansion valve.
Suction pressure abnormally high	.	Capillary tube is loose.	.
Suction pressure abnormally high	Suction pressure is lowered when the condenser is cooled by water.	Excessive refrigerant in the system.	Recover, evacuate, and recharge the system.
	High and low pressure are equalized as soon as the compressor is stopped and both gauges fluctuate while the compressor is running.	Faulty gasket.	Repair or replace the compressor.
	.	Faulty high-pressure valve. (V5 compressor only)	.
	.	Foreign particles stuck in the high-pressure valve. (V5 compressor only)	.
Suction and discharge pressure abnormally high	Reduced airflow through the condenser.	Clogged condenser or radiator fins.	Clean the condenser and the radiator.
	.	Radiator cooling fans working improperly.	Check the voltage and the radiator cooling fan rpm. Check the fan direction.
	Condenser is excessively hot.	Excessive refrigerant in the system.	Recover, evacuate, and recharge the system.
Suction and discharge pressure abnormally low	Low-pressure hose and metal end areas are cooler than the evaporator.	Clogged or kinked low-pressure hose.	Repair or replace the low-pressure hose.
Suction and discharge pressure abnormally low	Temperature around the expansion valve is low compared to that around the receiver-dryer.	Clogged high-pressure line.	Repair or replace the high-pressure line.
Refrigerant leaks	The compressor clutch is dirty.	Leaking compressor shaft seal.	Repair or replace the compressor.
	The compressor bolts are dirty.	Leaking around a compressor housing bolt.	Tighten the bolt(s) or replace the compressor.
	The compressor gasket is wet with oil.	Leaking compressor gasket.	Repair or replace the compressor.

Low and High Side Pressure Relationship Chart

COMPONENT LOCATOR

V5 Compressor

Rear Head Compressor
Control Valve O-Ring
Rear Head Gasket
Valve Plate
Suction Reed
Clutch Coil
Retaining Ring
Drive Plate Clutch
Pulley Bearing
Clutch Hub Key
Shaft Nut
Seal Retaining Ring
Shaft Lip Seal
Shaft Seal O-Ring
Compressor Housing
Compressor Control Valve
Pressure Relief Valve
Pulley Bearing to Head Retaining Ring
Rotor Pulley
Through-Bolt
Through-Gasket
Compressor Housing-to-Cylinder O-Ring
Shaft and Guide Pin Assembly Cylinder
Rear Head O-Ring
Thrust Washer
Race
Bearing
Oil Drain Plug
Clutch and Hub Keyway
Compressor Shaft
Pressure Relief Valve O-ring
Adaptor Compressor
Adaptor Bolt

SP10 Compressor

Shaft Bolt
Shaft Bolt Washer
Clutch & Drive Assembly
Air Gap Shim
Retaining Ring
Pulley & Bearing Assembly
Retaining Ring
Coil & Housing Assembly
Through Bolt
Retaining Ring
Lip Seal Assembly
Front Head
Front Head Gasket
Discharge Reed Retainer
Discharge Reed
Front Valve Plate
Suction Reed
Parallel Locating Pin
Front Compressor Cylinder
Swash Plate & Shaft Assembly
Piston Shoe
Piston Assembly
Thrust Bearing
Thrust Bearing
Cylinder O-Ring
Bushing
Roll Locating Pin
Rear Compressor Cylinder
Main Shaft Bearing
Rear Valve Plate
Rear Head Gasket
Rear Head