Module 4: Diagnosis of Malfunction in Refrigeration Cycle

(INSPECTION/TEST)

Objective: At end of the module the student should be able to:

a. identify and familiarize the components of HVAC system.
b. perform the visual and aural inspection of air conditioner system.
c. perform the inspection and diagnosis with manifold gauge.
d. perform leak test, performance test, discharging and recharging of refrigerant using
recycling machine.

LESSON 1

A. Diagnosis of Malfunction in Refrigeration Cycle

Figure 1.90

1) Importance of checking pressure

Checking the refrigerant pressure while the air conditioning is functioning allows
you to assume the trouble area or the cause. Therefore, it is important to confirm the
appropriate value and to diagnose the trouble.
2. Trouble seeking by using manifold gauge
When performing the trouble diagnosis by using a manifold gauge, follow the
conditions below.

 Engine coolant temperature: After warm-up

 Blower speed selector: HI
All doors: Fully opened

 Temperature selector: MAX. COOL
 Airflow selector: "FACE"  A/C switch: ON
 Air inlet selector: "RECIRC"

 A/C inlet temperature: 30 to 35°C (86
 Engine speed: 1,500 rpm (R-134a) to 95°F)

NOTICE:
For the vehicle with EPR, since the low-pressure side is controlled with EPR,
abnormal values may not be indicated directly on the gauge pressure.

LEARNING ACTIVITY:
QUIZ: Answer the following questions.
Name: ____________________________ Year and Section:____ Date:____________
Course: __________________________

Answer the following comprehensively:

A. The importance of checking Pressure

B. The Conditions to follow when performing trouble shooting

LESSON 2

B. Inspection with Manifold Gauge

1) Normal
If the refrigeration cycle is normal, the
gauge pressure values are as shown:
 Low pressure side :
2
 0.15 to 0.25 MPa (1.5 to 2.5kgf/cm )
 High pressure side :
2
 1.37 to 1.57MPa (14 to 16 kgf/cm )
Figure 1.91

2) Insufficient refrigerant amount

Figure 1.92

If the refrigerant amount is insufficient, the gauge pressure for both the low-pressure
and high-pressure side will show as being lower than the normal value.
a) Symptom
 Pressure is low at both low-pressure and high-pressure side
 Bubbles can be seen in the sight-glass
 Insufficient cooling
b) Cause
 Refrigerant volume is low
 Gas leak
c) Remedy
 Check for gas leakage and repair
4
 Replenish the refrigerant
3) Excessive refrigerant or insufficient condenser cooling

Figure 1.93

If there is excessive refrigerant or the condenser cooling is insufficient, the gauge

pressure for the both the low-pressure and high-pressure side shows as being higher than
the normal value.
a) Symptom
 Pressure is high at both low-pressure and high pressure side.
 Bubbles not observed in the sight-glass, even at low speed operation.
 Insufficient cooling.
b) Cause
 Excessive refrigerant.
 Poor condenser cooling.
c) Remedy
 Adjust to correct refrigerant amount.
 Clean the condenser.
 Inspect the vehicle cooling system (electric fan, etc.).
4) Moisture in refrigeration cycle

Figure 1.94

When moisture infiltrates the cycle, the gauge pressure is normal at the start of the air
conditioning operation. After a period of time, the low-pressure side gradually indicates a
vacuum pressure. After several seconds to several minutes, the gauge pressure is restored
to a normal value. This cycle is repeated. This symptom occurs when the moisture
infiltrated repeats a freezing and melting cycle near the expansion valve.
a) Symptom
 Normal operation at the start of air conditioner operation. After a period of
time, the low-pressure side gradually indicates vacuum pressure.
 b) Cause
 Moisture infiltration.
c) Remedy
 Replace the receiver.
 Thoroughly evacuate the cycle before refrigerant charging. This removes the
moisture from the cycle.
5) Compression defect in compressor

Figure 1.95

When a compression defect occurs in the compressor, the gauge pressure at the low
pressure side is higher than the normal value. The gauge pressure at the high pressure side
is lower than the normal value.
a) Symptom
 Low-pressure side is high, high-pressure side is low.
 Turning off the air conditioner immediately restores the high-pressure side and
low-pressure side to the same pressure.
 Compressor unit is not hot to the touch.
 Insufficient cooling.
b) Cause
 Compressor defect.
c) Remedy
 Inspect and repair the compressor.
6. Clog in refrigeration cycle

Figure 1.96

When the refrigerant fails to circulate (due to a clog in the refrigerant cycle), the gauge
pressure at the low pressure side indicates a vacuum pressure. The gauge pressure at the
high-pressure side becomes lower than the normal value.
a) Symptom
 For a complete clog, the low-pressure side immediately indicates a vacuum
pressure (Fails to cool.).
 For clogging tendency, the low-pressure side gradually indicates a vacuum
pressure (Cooling depends on the degree of clogging.).
 Temperature difference occurs before and after the clogged section.
b) Cause
 Dust or frozen moisture is blocking an expansion valve, EPR or other orifice
preventing the flow of refrigerant.
 Gas leak in heat-sensing rod.
c) Remedy
 Clarify the cause of the clog. Replace the part causing the clog.
 Implement thorough evacuation of the cycle.
7) Air in refrigeration cycle

c
Figure 1.97

When air infiltrates the refrigeration cycle, the gauge pressure at both the low-pressure
and high-pressure side is higher than the normal value.
a) Symptom
 Pressure is high at both low-pressure and high pressure side.
 Cooling performance decreases in proportion to the increase in the low-pressure.
 If the refrigerant amount is correct, the flow of bubbles at the sight-glass is the
same as during normal operation.
b) Cause
 Air infiltration.
c) Remedy
 Replace the refrigerant.
 Implement thorough evacuation of the cycle.
8) Excess opening of expansion valve

Figure 1.98

When the expansion valve opening is too wide, the gauge pressure at the low-pressure
side becomes higher than the normal value. This decreases the cooling performance.
a) Symptom
 Pressure at low-pressure side rises and the cooling performance decreases
(Pressure at highpressure side shows almost no change.).
 Frost adhering to the low-pressure pipe.
b) Cause
 Operating defect in expansion valve.
c) Symptom
 Inspect and repair the installation condition of the heat sensing tube.
LEARNING ACTIVITY:
QUIZ: Answer the following questions.
Name: ____________________________ Year and Section:____ Date:____________
Course: __________________________

Identify the following condition :

INSPECTION WITH MANIFOLD GUAGE

1.

2.
3.

4.
5.

6.
7.

8.
SUMMARY
In Module 4 discusses the components, function and operation of HVAC system.
. The concept/fundamentals of trouble shooting of car air conditioning and the
essentials of performing leak test, performance test, discharging and recharging of
refrigerant using recycling machine.

REFERENCES:

Books:

Author Title
NISSAN Service manual
NIPPONDENSO Training Manual
Subaru Impressa Service manual
Gills, Tim Automotive Service third edition
Hayness Automotive Heating and Air Conditioning
Hayness Air Conditioning Systems
Csrriggan, Russel Automotive Heating and Air Conditioning
& Eichelberger, John
Schnubel, Mark Automotive Heating & Air – conditioning (Classroom Manual)
3rd edition

Online Resources:

1. www.cdxetextbook
2. http://toc.electude.com
Heater, Ventilation and Air-conditioning (HVAC) | 8. Inspection/Test 15

Aircon, SRS and Immobilizer AT 4055

 SUMMARY

 "Air conditioner" is the general term for the equipment that maintains the air in a room at a
comfortable temperature and humidity. It controls the temperature of the vehicle interior. It
functions as a dehumidifier, in addition to its heating and cooling temperature control
functions.
 Natural flow-through ventilation refers to the intake of external air into the vehicle's interior
due to the air pressure generated by the vehicle's movement.
 Forced air ventilator (boost ventilator) use an electric fan to force air through the vehicle.
The air intake vents and exhaust vents are located in the same general areas as the vents in a
natural flow-through ventilation system.
 Clean air filter is used to purify the intake air, a filter is attached to the intake port of the air
conditioner
 An air purifier is a device that removes cigarette smoke, dust, etc., to clean the air of the
vehicle interior.
 Refrigerant is a heat exchanging substance that circulates in the refrigerant cycle. It removes
the heat when it evaporates and releases its heat when it liquidizes.
 The water valve is installed in the engine's coolant circuit and controls the amount of engine
coolant that is allowed to enter the heater core.
 The compressor compresses the refrigerant and changes it into hightemperature, high
pressure gas before sending it to the condenser.
 Swash plate type compressor has a number of paired pistons are set on the swash plate at
intervals2 of 72° for a 10-cylinder compressor or at intervals of 120° for a 6-cylinder
compressor. When one side of a piston is in a compression stroke, the other is in a suction
stroke.
 Scroll type compressor has a fixed scroll and rotating scroll which moves to make their
volume smaller gradually.
 The pressure relief valve opens if the pressure at the high-pressure side rises to between 3.43
MPa (35 kgf/cm²) and 4.14 MPa (42.4 kgf/cm²) to reduce the pressure.
 The shaft seal is at the shaft that turns the compressor. When the shaft seal is deteriorated or
damaged, the refrigerant will leak.
 Compressor oil is necessary to lubricate the moving parts of the compressor. Compressor oil
lubricates the compressor by dissolving in the refrigerant and circulating throughout the
refrigeration circuit.
 A magnetic clutch is driven by engine through the drive belt. It is a device used to connect
and disconnect the engine and the compressor.
 The condenser is used for cooling and removing the heat from the refrigerant gas.It is
 installed at the front end of the vehicle to enable forcible cooling.
 A receiver is a device to store the refrigerant liquidized by the condenser temporarily, and it
supplies the required amount of refrigerant to the evaporator.
 A dryer has a desiccant and strainer in itself, and eliminates foreign matter or moisture in the
 SUMMARY

refrigeration cycle.
 A sight-glass is an inspection hole used to observe the refrigerant flowing inside the
refrigeration cycle and to check the level of the refrigerant.
 The expansion valve is a device that receives a liquid refrigerant, after passing through the
receiver/dryer, and injects the refrigerant out from an orifice to cause the liquid refrigerant
to suddenly expand and become a low-temperature, low-pressure refrigerant mist.
 The evaporator is opposite of the condenser. This is where the expansion valve discharges
the low temperature, low-pressure mist and cools the air around the evaporator.
 The pressure switch control detects the abnormal rise of refrigerant pressure and turns off
the magnetic clutch to protect the components in the refrigeration cycle and stops the
compressor from operating.
 Wire cable type damper is constructed so that the movement of a selector directly activates
the dampers through the use of wire cable.
 Motor type damper uses motor to operate the dampers to the proper position.
 The auto A/C system is activated by setting the desired temperature with the temperature
selector and pressing the AUTO switch. The system immediately adjusts and maintains the
temperature at the set level with the automatic control of the ECU.
 The ambient temperature sensor uses the thermistor. It is installed at the front of the
condenser and it detects the exterior temperature.
 The solar sensor uses a photodiode and is installed in the upper portion of the instrument
panel. It detects the amount of sunlight.
 The evaporator temperature sensor uses the thermistor and is installed on the evaporator. It
detects the surface temperature of the air passing through the evaporator.
 The water temperature sensor uses the thermistor. It detects the coolant temperature based
on the engine water temperature sensor.
 The duct sensors use the thermistor and are installed at inside of the side register. It detects
the temperature of the air blown toward the side register and precisely controls the air
temperature of the individual airflow.
 Smog ventilation sensor is installed in the front portion of the vehicle and detects the level
of CO (carbon monoxide), HC (hydrocarbons), and NOx (oxides of nitrogen) to control
switching between FRESH and RECIRC.
 The air mix servomotor controls the operation of the servomotor that causes the air mix
 damper to shift from HOT to COOL or vice versa.
 The air inlet servomotor controls the servomotor that shifts the air inlet damper to change
FRESH to RECIRC position or vice versa.
 The airflow servomotor operates in accordance to the position of the airflow control switch.