A/c System General Servicing Dodge Aries I

GENERAL PROCEDURES

Some models have compressor-mounted service valves that allow oil checking by isolating the compressor. On all others, system must be discharged using approved refrigerant recovery/recycling equipment and compressor may need to be removed to check oil. After oil level is checked and adjusted, A/C system must be evacuated and recharged.

ISOLATING COMPRESSOR

1. Connect manifold gauge set to service valves on compressor. Close both gauge valves. Open both service valves to the mid-position.
2. Start engine and operate air conditioning. Turn suction service valve slowly clockwise toward front-seated position. When suction pressure is reduced to zero or less, stop engine and quickly close suction service valve (front-seated).
3. Front-seat the discharge valve. Loosen oil check plug slowly to release any internal pressure. Service valves can now be removed from compressor and compressor removed from vehicle (if necessary). Purge compressor after servicing.

PURGING COMPRESSOR

1. Remove gauge set and place caps on service valve ports. Back-seat the suction service valve to allow refrigerant to enter compressor.
2. Loosen discharge port valve slightly. Loosen valve port cap to allow refrigerant to force out air from compressor. Back-seat the discharge valve and tighten the port cap. Compressor is ready for service.

REFRIGERATION OIL

Only new, pure, moisture-free refrigeration oil should be used in the air conditioning system. This oil is highly refined and dehydrated (moisture content less than 10 parts per million). Refrigeration oil container must be kept tightly closed at all times when not in use, or moisture will be absorbed from the air and introduced into the refrigeration system.

CHRYSLER WITH C-171 6-CYLINDER COMPRESSOR

When inspecting the system to determine oil loss, check for signs of leaking (a wet, shiny looking spot on system components). If a component is removed after the system has been operated, some oil will remain in the component. If oil leak is noted or component replacement is required, oil will have to be restored to original level, as follows

DURING SYSTEM DISCHARGING

1. Slowly discharge system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant hoses at compressor. Remove compressor mounting bolts, and remove compressor.
2. Remove suction port on top of compressor, and drain oil. Add proper amount of refrigerant oil to compressor (total system capacity minus amount retained in components that have not been replaced). See C-171 COMPONENT REFRIGERANT OIL CAPACITIES table below.
3. Install compressor. Evacuate and recharge A/C system. Perform leak test.

C-171 COMPONENT REFRIGERANT OIL CAPACITIES

DURING COMPRESSOR REPLACEMENT

Discharge system using approved refrigerant recovery/recycling equipment. A new compressor contains 9-10 ounces of new refrigeration oil. To prevent possible damage or loss of cooling capacity due to excessive oil in system, drain 4 ounces of the oil from new compressor prior to installing it. This will maintain total system charge of 9-10 ounces.

DURING COMPONENT REPLACEMENT

When replacing components other than (or in addition to) the compressor, oil must be added to new component to maintain system charge at 9-10 ounces. If evaporator is replaced, add 2 ounces to new evaporator prior to installation. If condenser is replaced, add one ounce to new condenser. If filter-drier is replaced, add one ounce to new filter-drier.

OIL LEAK IS SUSPECTED OR COMPONENTS ARE REMOVED FROM SYSTEM

Discharge system using approved refrigerant recovery/recycling equipment and remove components as necessary. Remove suction and discharge lines from compressor. Remove compressor and clutch assembly from vehicle. Turn compressor upside down, and drain oil from suction and discharge ports. Add 5 ounces of new oil to compressor and reinstall. Add refrigeration oil to other replacement components as specified during component replacement.

Chrysler Motors/Nippondenso 6-Cyl. Compressor Oil Check. Scheme 2

WITH COMPRESSOR FAILURE & SYSTEM CONTAMINATED

If either of these situations exists, discharge system using approved refrigerant recovery/recycling equipment and remove compressor, receiver-drier and "H" valve. Inspect "H" valve screen for contaminants. Clean and replace as necessary. Flush entire system. Install a new compressor (if necessary) and a new receiver-drier. New compressors are charged with proper amount of oil, 9-10 ounces. If reinstalling old compressor, add 9-10 ounces of new refrigeration oil through suction port. Evacuate and charge system.

BEFORE OPENING THE SYSTEM

Before disconnecting any lines or fittings, the system must be completely discharged using approved refrigerant recovery/recycling equipment.

DISCONNECTING LINES & FITTINGS

1. After system is discharged, carefully clean entire area around coupling nut to prevent dirt entering system. Always use 2 wrenches to avoid twisting or distorting lines and fittings (hold fitting with one wrench while loosening coupling nut with the other).
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT-1056) to open or close. See procedure under Connecting Lines and Fittings.
3. Cap or plug all LINES and FITTINGS immediately to prevent entry of air and moisture into system. Do not remove these caps until connections are being made.

COMPONENT REPLACEMENT

When components are replaced, system oil level must be adjusted. Add refrigeration oil to replacement component. See Compressor Oil Check article, as well as, Component Oil Replacement Quantities chart under A/C SYSTEM SERVICE SPECIFICATIONS - CAR or TRUCK in this article.

CONNECTING LINES & FITTINGS

A new "O" ring should be used in all instances when connecting lines and fittings (dip "O" ring in clean refrigeration oil and make certain it is not twisted during installation). Always use two wrenches to avoid twisting or distorting lines and fittings. Tighten coupling nuts securely.

PLACING SYSTEM IN OPERATION

After component replacement and/or system servicing has been completed and all connections have been made, proceed as follows

1. Evacuate the system using vacuum pump.
2. Charge the system with R-12. See Refrigerant Capacity chart under A/C SYSTEM SERVICE SPECIFICATIONS - CAR or TRUCK in this article.
3. Leak test the system, with particular attention to all new connections and components.
4. Make a performance test of the system. Never assume that a recharging has automatically corrected a problem.

DIAGNOSTIC PROCEDURES

Diagnosis is an important first step in A/C system servicing. To save time and effort, systems should be carefully checked to identify the causes of poor performance. By using the following diagnostic charts, defective components or system damage can be quickly located. To identify problems that are specific to one system, refer to the repair section of this manual. The charts in this section apply to all systems.

PREPARATION FOR TESTING

1. Attach Low and High side gauges.
2. Start engine and allow it to warm up.
3. Set system to COOL and blower to HIGH.
4. Open car doors and hood.
5. Run at fast idle for 2-3 minutes.

ALTITUDE PRESSURE VARIATIONS

ALTITUDE VACUUM VARIATIONS

OPERATIONAL TEST GAUGE READINGS

NORMAL SYSTEM OPERATING PRESSURES (PSI) (1)

AIR CONDITIONING SYSTEM PERFORMANCE CHECK. Scheme 3

Ambient Temperature/Pressure Chart. Scheme 4

Evaporator Temperature/Pressure Chart. Scheme 5

A/C SYSTEM DIAGNOSIS WITH GAUGES

AIR CONDITIONING DIAGNOSIS WITH GAUGES FOR SYSTEMS WITH INSUFFICIENT OR NO COOLING

A/C SYSTEM SERVICE SPECIFICATIONS - CAR MODELS

SYSTEM REFRIGERANT CAPACITIES

COMPONENT OIL REPLACEMENT QUANTITIES

COMPRESSOR BELT TENSION (Lbs.) (1)

COOLING SYSTEM CAPACITIES

A/C SYSTEM SERVICE SPECIFICATIONS - TRUCK MODELS

SYSTEM REFRIGERANT CAPACITIES

COMPRESSOR BELT TENSION (Lbs.) (1)

COMPONENT OIL REPLACEMENT QUANTITIES

COOLING SYSTEM CAPACITIES