For 1990-2009 cars

Step | Action | Value | Yes | No
--- | --- | --- | --- | ---
1 | Were you sent here from the A/C System Performance Test? | -- | Go to Step 2 | Go to Air Conditioning (A/C) System Performance Test
2 | Caution: Refer to Moving Parts and Hot Surfaces Caution in the Preface section. Feel the liquid line before the expansion device. Is the liquid line cold before the expansion device? | -- | Go to Step 3 | Go to Step 8
3 | Feel along the surfaces of the following high side components for a sudden drop in temperature. The high side components should feel warm/hot from the compressor all the way to the expansion device.

• | The compressor discharge hose

• | The condenser

• | The liquid line between the condenser and the expansion device

Is there an abrupt drop in temperature noted along the surfaces of any of the listed components?

--

Go to Step 7

Go to Step 4

4 |

1. Feel the liquid line at the expansion device location for extreme cold, possibly accompanied by heavy frost.
2. Feel along the liquid line after the expansion device location for warm temperature.

Is the liquid line extremely cold at the expansion device location and warm after the expansion device location?

--

Go to Step 11

Go to Step 5

5 | Feel along the surfaces of the following low side components for a sudden change in temperature.

• | The evaporator inlet tube between the expansion device and the evaporator core

• | The evaporator outlet tube between the evaporator core and the compressor

• | The accumulator

• | The compressor suction hose

Is there an abrupt temperature change felt along the surfaces of any of the listed components?

--

Go to Step 7

Go to Step 6

6 | Feel along the surfaces of low and high side components to compare the overall temperatures.

• | The evaporator inlet tube between the expansion device and the evaporator core

• | The evaporator outlet tube between the evaporator core and the accumulator

• | The accumulator

• | The compressor suction hose

• | The compressor discharge hose

• | The condenser

• | The evaporator inlet tube between the condenser and the expansion device

Are the overall temperatures of the low and high side components close to the same - both only mildly warm?

--

Go to Step 14

Go to Step 8

7 |

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the restriction from the component, or replace the component which produced an abrupt temperature drop.

Is the repair complete?

--

Go to Step 9

--

8 |

1. Recover the refrigerant and evacuate the system. Refer to Refrigerant Recovery and Recharging .
2. Record the weight of the recovered refrigerant.

Is the weight of the recovered refrigerant charge equal to or above the specified value?

0.57 kg (1.26 lb)

Go to Step 9

Go to Step 10

9 | Recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Is the cooling performance improved? | -- | Go to Step 21 | Go to Step 10
10 |

1. Leak test the system. Refer to Leak Testing .
2. Repair any leaks.

Is the repair complete?

--

Go to Step 21

--

11 |

1. The expansion device is restricted.
2. Replace the expansion device. Refer to Expansion (Orifice) Tube Replacement .
3. If the expansion device was restricted, note the type of debris present.

Are there metal flakes present?

--

Go to Step 12

Go to Step 13

12 |

1. Remove the compressor hose assembly from the vehicle. Refer to Compressor Hose Assembly Replacement .
2. Inspect the hose/line for debris by blowing shop air through one end of the hose while covering the other end with a shop towel.
3. Note the amount of debris collected in the shop towel.

Is there a large amount of debris collected in the shop towel?

--

Go to Step 18

Go to Step 20

13 | If the expansion device was restricted with a brown/black residue, perform the following:

1. Flush the A/C system. Refer to the J 43600 Operation Manual.
2. Replace the accumulator. Refer to Air Conditioning Accumulator Replacement .

Are the repairs complete?

--

Go to Step 21

--

14 |

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Disconnect the compressor hose from the compressor. Refer to Compressor Hose Assembly Replacement .
3. Inspect for the presence of debris in the compressor suction port.

Is there debris present in the compressor suction port?

--

Go to Step 15

Go to Step 19

15 |

1. Remove the debris from the suction port.
2. Inspect the expansion device for damage or debris. Refer to Expansion (Orifice) Tube Replacement .

Is there evidence of damage or debris?

--

Go to Step 17

Go to Step 16

16 | If the expansion device does not show any signs of damage or debris: If the expansion device does not show any signs of damage or debris:

1. Remove the compressor hose assembly from the vehicle. Refer to Compressor Hose Assembly Replacement .
2. Inspect the hose/line for debris by blowing shop air through one end of the hose while covering the other end with a shop towel.
3. Note the amount of debris collected in the shop towel.

Is there a large amount of debris collected in the shop towel?

--

Go to Step 18

Go to Step 19

17 |

1. Replace the expansion device. Refer to Expansion (Orifice) Tube Replacement .
2. If the expansion device was restricted, note the type of debris present.

Are there metal flakes present?

--

Go to Step 12

Go to Step 13

18 | If there was a large amount of debris collected in the shop towel from the compressor hose assembly:

1. Replace the accumulator. Refer to Air Conditioning Accumulator Replacement .
2. Install an A/C refrigerant filter. Refer to Air Conditioning Evaporator Thermal Expansion Valve Screen Replacement .

Is the repair complete?

--

Go to Step 19

--

19 | Install the compressor hose assembly. Refer to Compressor Hose Assembly Replacement . Are the repairs complete? | -- | Go to Step 21 | --
20 |

1. Install the compressor hose assembly. Refer to Compressor Hose Assembly Replacement .
2. Install an A/C refrigerant filter. Refer to Air Conditioning Evaporator Thermal Expansion Valve Screen Replacement .
3. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

Are the repairs complete?

--

Go to Step 21

--

21 |

1. Record the low and high side pressures and the IP panel outlet air temperature after repairs are performed.
2. Compare the pressures and IP panel outlet temperature to those listed in the A/C Performance Chart. Refer to Air Conditioning (A/C) System Performance Test .

Are the readings within the specified ranges?

--

Go to Step 22

Go to Air Conditioning (A/C) System Performance Test

22 | Operate the system in order to verify the repair. Did you correct the condition? | -- | System OK | Go to Symptoms - HVAC Systems - Manual in HVAC Systems-Manual