For 1990-2009 cars

Table 1: | Gray Area Diagnosis and Service
Table 2: | Striped Area Diagnosis and Service

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Connect the J 39500-B . Are the pressures greater than the specified values? | 350 kPa (50 psi) | Go to Step 2 | Go to Step 6
2 | Inspect and correct for a blown Air Conditioner (A/C) fuse. Does the complaint persist? | -- | Go to Step 3 | System OK
3 | Inspect and correct for the following conditions:

• | Disconnected A/C clutch wire

• | Proper A/C clutch rotation

Refer to HVAC Compressor Clutch Does Not Engage . Does the complaint persist?

--

Go to Step 4

System OK

4 | Inspect and correct for the following conditions:

• | Condenser restrictions

• | Radiator restrictions

Refer to Engine Overheating in Engine Cooling.

Does the complaint persist?

--

Go to Step 5

System OK

5 |

1. Read the DCS for Bulletins and Hints.
2. Follow the procedures indicated.

Does the complaint persist?

--

Go to Step 8

System OK

6 |

1. Add 0.453 kg (1 lb) of refrigerant.
2. Perform a leak check. Refer to Leak Testing .

Did you find a leak?

--

Go to Step 7

System OK

7 |

1. Repair the leak.
2. Inspect the system performance. Refer to System Performance Test .

Does the complaint persist?

--

Go to Step 1

System OK

8 | Perform an A/C Performance Check using the following steps:

1. Ensure that the ambient temperature is at least equal to the specified value.
2. Ensure that the engine is idling at normal operating temperature.
3. Turn the A/C to the ON position.
4. Select the coldest setting.
5. Select the MAX blower speed.
6. Record the A/C pressures.
7. Record the A/C temperatures.
8. Refer to System Performance Test .

Does the A/C performance meet the requirement on the Performance Chart?

5 °C (41 °F)

Go to Step 9

Go to HVAC High Side vs. Low Side Pressure Chart

9 | Was the customer complaint made due to high temperature and/or high humidity? | -- | Go to Step 10 | System OK
10 | Perform a leak test. Refer to Leak Testing . Did you find a leak? | -- | Go to Step 11 | System OK
11 | Recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Does the complaint persist? | -- | Go to Step 8 | System OK

### High Side vs. Low Side Pressure Table

#### Gray Area Diagnosis and Service

Problem | Action
--- | ---
Important: The V5 clutch may cycle if the discharge pressure exceeds 2758 kPa (400 psi).
Improper condenser operation | Improper condenser operation may result from one of the following causes:

• | Extremely high ambient humidity

• | Insufficient air flow across condenser

• | Damaged or dirty condenser fins

• | Faulty fan relay

High side refrigerant restriction |

1. Feel liquid line before expansion tube (orifice). A cold line indicates restriction in the high side.
2. Inspect for a frost spot in order to locate the restriction.
3. Repair the line as necessary.

Refrigerant system overcharged (high discharge and high suction pressures) | The clutch may cycle ON/OFF and cause compressor noise. Refer to air in system.
Expansion tube (orifice) blocked | Low suction pressures.
Air in system (High discharge and high suction pressures). |

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Inspect the expansion (orifice) tube for blockage. Refer to Expansion (Orifice) Tube Replacement . Clean or replace the tube as required.
3. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
4. Leak test the system. Refer to Leak Testing .

#### Striped Area Diagnosis and Service

Problem | Action
--- | ---
The compressor is damaged internally. |

• | If the suction pressure and the discharge pressure are equal and if these pressures do not change when you turn the A/C mode ON and OFF, the compressor may be internally damaged.

• | Signs of internal compressor damage include the following:

- | Excess heat at the clutch surfaces

- | A free wheeling clutch driver

• | When replacing the compressor, follow the component replacement procedures in order to maintain correct oil charge in the system.

The expansion tube (orifice) is missing. | Feel the liquid line after the expansion tube. If the line is warm, recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Inspect the system for proper installation of the expansion tube. Refer to Expansion (Orifice) Tube Replacement . If the expansion tube or the O-ring is missing, replace the expansion tube.
The compressor runs at minimum stroke. |

• | If the compressor discharge pressures remain only 10-30 psi above the suction pressure, the compressor may be at minimum stroke.

• | Run the engine at approximately 3000 RPM for 3 minutes until pressures become normal. During this period, cycle the mode lever from vent to A/C every 20 seconds. If no change occurs, perform the control valve low load test below.

The compressor control valve is set improperly. | The low load test creates a low cooling load that causes the V5 compressor to go toward a minimum stroke. Minimum stroke is necessary in order to evaluate the control valve set point. Perform the low load test using the following procedure:

1. Start the engine.
2. Run the engine at a fast idle.
3. Open the hood.
4. Close the windows and the doors.
5. Set the A/C controls to LOW blower and MAX cooling.
6. Record the test results.
7. Evaluate the test results as follows:

• | If suction pressure is 25-35 psi, the control valve is functioning properly.

• | If the suction pressure is outside the limits of 25-35 psi, replace the control valve.

The refrigerant system is undercharged. |

1. The refrigerant may be undercharged when the suction pressure is below 35 psi during the high load test.
2. The suction line before the accumulator will be warm if the charge is low.
3. Add 1 lb of refrigerant.
4. Recheck the pressure. Verify that the pressure is in the white area on the chart. Then find and correct the leak.
5. Recover and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .

The expansion tube (orifice) is blocked. |

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Inspect the expansion (orifice) tube for blockage. Refer to Expansion (Orifice) Tube Replacement . Clean or replace as required.
3. Evacuate the system to a vacuum. Improper evacuation of the system prior to recharge will cause air to remain in the system.
4. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
5. Leak test the system. Refer to Leak Testing .