COMPRESSOR OIL CHECK
| CAUTION | When discharging air conditioning system, use only approved refrigerant recovery/recycling equipment. Make every attempt to avoid discharging refrigerant into the atmosphere. |
Note. 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 C-171 & A-590 6-CYLINDER
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
Scheme 1
Scheme 1: CHRYSLER C-171 & A-590 6-CYLINDER
During System Discharging
- Slowly discharge system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant hoses at compressor. Remove compressor mounting bolts, and remove compressor.
- 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.
- Install compressor. Evacuate and recharge A/C system. Perform leak test.
| Component | Ounces |
|---|
| Condenser | 1.0 |
| Evaporator |
| Front | 2.0 |
| Rear (If Equipped) | 2.0 |
| Receiver-Drier | 1.0 |
C-171 COMPONENT REFRIGERANT OIL CAPACITIES
During Compressor Replacement
Discharge system using approved refrigerant recovery/recycling equipment. A new C-171 compressor contains 9-10 ounces of new refrigeration oil. A new A-590 compressor contains 7-7.3 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 (for C-171), or 7-7.3 ounces (for A-590). If evaporator is replaced, add 2 ounces to new evaporator prior to installation. If condenser is replaced, add 1 ounce to new condenser. If filter-drier is replaced, add 1 ounce to new filter-drier.
If 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.
Scheme 2
Scheme 2: If Oil Leak Is Suspected or Components Are Removed From System
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 the proper amount of oil: 9-10 ounces in the C-171, and 7-7.3 ounces in the A-590. 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.
- After system is discharged, carefully clean entire area around coupling nut to prevent dirt from entering system. Always use 2 wrenches to avoid twisting or distorting lines and fittings. Hold fitting with one wrench while loosening coupling nut with second wrench.
- Immediately cap or plug all LINES and FITTINGS. DO NOT open lines. Remove caps only when 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 "SERVICE SPECIFICATIONS" in this section.
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 2 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
- Evacuate system using vacuum pump.
- Charge system with R-12. See REFRIGERANT CAPACITY in this section.
- Leak test system. Give particular attention to all new connections and components.
- Perform performance test of system. Never assume 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.
ALTITUDE PRESSURE VARIATIONS
| Altitude (Ft. Above Sea Level) | Absolute Pressure of Atmosphere (psi) | (1) Gauge Altitude Correction (psi) |
|---|
| 0 | 14.7 | 0 |
| 1000 | 14.2 | 0.5 |
| 2000 | 13.7 | 1.0 |
| 3000 | 13.2 | 1.5 |
| 4000 | 12.7 | 2.0 |
| 5000 | 12.2 | 2.5 |
| 6000 | 11.7 | 3.0 |
| 7000 | 11.3 | 3.4 |
| 8000 | 10.9 | 3.8 |
| 9000 | 10.5 | 4.2 |
| 10,000 | 10.1 | 4.6 |
| (1) Subtract correction shown from gauge readings. |
| (1) | Subtract correction shown from gauge readings. |
ALTITUDE PRESSURE VARIATIONS
ALTITUDE VACUUM VARIATIONS
| Altitude (Ft. Above Sea Level) | Complete Vacuum (In. Hg) | (1) Gauge Altitude Correction (In. Hg) |
|---|
| 0 | 29.92 | 0 |
| 1000 | 28.92 | +1.0 |
| 2000 | 27.82 | +2.1 |
| 3000 | 26.82 | +3.1 |
| 4000 | 25.82 | +4.1 |
| 5000 | 24.92 | +5.0 |
| 6000 | 23.92 | +6.0 |
| 7000 | 23.02 | +6.9 |
| 8000 | 22.22 | +7.7 |
| 9000 | 21.32 | +8.6 |
| 10,000 | 20.52 | +9.4 |
| (1) Add correction shown to gauge readings. |
| (1) | Add correction shown to gauge readings. |
ALTITUDE VACUUM VARIATIONS
PREPARATION FOR TESTING
- Attach Low and High side gauges.
- Start engine and allow it to warm up.
- Set system to COOL and blower to HIGH.
- Open car doors and hood.
- Run at fast idle for 2-3 minutes.
OPERATIONAL TEST GAUGE READINGS
| Application | Low Side Gauge (Suct.) | High Side Gauge (Disc.) |
|---|
| Chrysler Motors |
| 1980 (Thermostatic Switch) | 10-30 | 140-240 |
| 1981-83 (Thermostatic Switch) |
| Front Wheel Drive | 20-30 | 140-240 |
| Rear Wheel Drive | 20-30 | 115-240 |
| 1984-87 (Thermostatic Switch) |
| Front Wheel Drive | 180-235 | 16-30 |
| Rear Wheel Drive | 12-22 | 170-210 |
| (1) Pressure readings given are for a system in good operating condition, at sea level and an ambient temperature of 80° F (27°C). |
| (1) | Pressure readings given are for a system in good operating condition, at sea level and an ambient temperature of 80° F (27°C). |
NORMAL SYSTEM OPERATING PRESSURES (PSI) (1)
Air Conditioning System Performance Check. Scheme 3
Scheme 3: Air Conditioning System Performance Check
Ambient Temperature/Pressure. Scheme 4
Scheme 4: Ambient Temperature/Pressure
Evaporator Temperature/Pressure. Scheme 5
Scheme 5: Evaporator Temperature/Pressure
| LOW SIDE GAUGE | HIGH SIDE GAUGE | OTHER SYMPTOMS | DIAGNOSIS |
|---|
| Normal | Normal | (1) No or few bubbles in sight glass. High side gauge may go high. Low side gauge does not fluctuate with compressor on/off cycle. | Some Air and Moisture in System. |
| Normal | Normal | Cools okay in morning but not during hot part of day. Tiny bubbles in sight glass | Excessive Moisture |
| Normal | Normal | Discharge air warm when low side gauge drops into vacuum. Thermostatic switch system only-compressor cycles off and on too rapidly. | Defective Thermo- static Switch |
| Normal | Normal | Cycling clutch systems only-Compressor doesn't turn on soon enough. Discharge air becomes warm as low side pressure rises. | Misadjusted Thermo- static Switch or Defective Pressure Sensing Switch |
| Low | Low | Bubbles in sight glass. Outlet air slightly cool. | Low R-12 Charge |
| Low | Low | Sight glass clear or oil- streaked. Outlet air very warm. | Excessively Low R-12 Charge |
| Low | Low | Outlet air slightly cool. Sweating or frost at at expansion valve. | Expansion Valve Stuck Closed. Screen Plugged or Sensing Bulb Malfunction. |
| Low | Low | Bubbles in sight glass. Outlet air slightly cool. | Low R-12 Charge |
| Low | Low | Sight glass clear or oil- streaked. Outlet air very warm. | Excessively Low R-12 Charge |
| Low | Low | Outlet air slightly cool. Sweating or frost at expansion valve. | Expansion Valve Stuck Closed. Screen Plugged or Sensing Bulb Malfunction. |
| Low Low | Low High | Outlet air slightly cool. High side line cool to touch. Sweating or frost on high side. Evaporator outlet pipe cold. Low side goes into vacuum when blower is disconnected. | Restriction on High Side STV Stuck Open |
| High High | Low Low | Evaporator outlet pipe warm. Outlet air warm. Noise from compressor. | STV Stuck Open Compressor Malfunction |
| High | High | Outlet air warm. Liquid line very hot. Bubbles in sight glass. | Condenser Malfunction or R-12 Overcharge. |
| High | High | Outlet air slightly cool. Bubbles in sight glass. | Large Amount of Air and Moisture in System. |
| High | High | Outlet air warm. Evaporator outlet sweating and frost. | Expansion Valve Stuck Open |
| (1) If equipped with a low refrigerant charge protection system, compressor operation may have stopped. |
| (1) | If equipped with a low refrigerant charge protection system, compressor operation may have stopped. |
AIR CONDITIONING DIAGNOSIS WITH GAUGES FOR SYSTEMS WITH INSUFFICIENT OR NO COOLING
SPECIFICATIONS
| Application | Ounces |
|---|
| Dodge & Plymouth |
| Dakota, Pickup & Ramcharger | 42 |
| Vans |
| FWD Models | 38 |
| RWD Models |
| Front System Only | 48 |
| Front & Rear Systems | 64 |
SYSTEM REFRIGERANT CAPACITIES
| Component | Ounces |
|---|
| Compressor |
| Chrysler Motors |
| FWD Van |
| A-171 Model | 7 |
| A-590 Model | 7 |
| RWD Van & Pickup | 5 |
COMPRESSOR OIL REPLACEMENT QUANTITIES
| Component | Ounces |
|---|
| Accumulator | (1) |
| Condenser | 1 |
| Evaporator |
| Chrysler Motors Systems | 2 |
| All Other Systems | 3 |
| Receiver-Drier | 1 |
| (1) On all other models, add amount drained plus 1 ounce. |
| (1) | On all other models, add amount drained plus 1 ounce. |
COMPONENT OIL REPLACEMENT QUANTITIES
| Application | New Belt | Used Belt |
|---|
| Dodge & Plymouth |
| FWD Models |
| 2.2L | 105 | 80 |
| 2.6L | 115 | 80 |
| RWD Models | 120 | 65 |
| (1) Using standard strand tension gauge. |
| (1) | Using standard strand tension gauge. |
COMPRESSOR BELT TENSION (Lbs.) (1)
| Application | Quarts (Liters) |
|---|
| Dodge & Plymouth |
| 2.2L (2) | 8.5 (8.1) |
| 2.5L (2) | 9.5 (9.0) |
| 3.7 & 3.9L (3) |
| W/19" or 22" x 18" Radiator | 12.0 (11.4) |
| W/26" x 18" Radiator (4) | 13.0 (12.4) |
| 5.2L (3) |
| W/22" x 18" Radiator | 16.0 (15.2) |
| W/26" x 18" Radiator (4) | 17.0 (16.2) |
| W/26" x 20" Radiator | 17.5 (16.6) |
| 5.9L (3) |
| Exc. 1 Ton Van |
| W/22" x 18" Radiator | 14.5 (13.8) |
| W/26" x 18" Radiator (4) | 15.5 (14.7) |
| W/26" x 20" Radiator | 16.0 (15.2) |
| 1 Ton Van | 18.0 (17.0) |
| (1) All figures shown are actual but may vary 15% due to system variations. (2) Capacity includes heater and coolant reservoir system. (3) On Van, add 2 qts. with A/C or Max Cooling. (4) On Pickup models, add 1 qt. (.9L) with A/C or Increased Cooling. |
| (1) | All figures shown are actual but may vary 15% due to system variations. |
| (2) | Capacity includes heater and coolant reservoir system. |
| (3) | On Van, add 2 qts. with A/C or Max Cooling. |
| (4) | On Pickup models, add 1 qt. (.9L) with A/C or Increased Cooling. |
COOLING SYSTEM CAPACITIES (1)
