HVAC Systems - General Servicing: Other Dodge Stratus I

USING R-134a REFRIGERANT

Note. Always refer to underhood A/C specification label in engine compartment or A/C compressor label while servicing A/C system. If engine compartment/compressor label specifications differ from specifications in this article, use underhood/compressor label specifications.

HANDLING/SAFETY PRECAUTIONS

1. Always work in a well-ventilated, clean area. Refrigerant is colorless and invisible as a gas. Refrigerant is heavier than oxygen and will displace oxygen in a confined area. Avoid breathing refrigerant vapors. Exposure may irritate eyes, nose and throat.
2. Always wear eye protection when working around A/C system and refrigerant. The system's high pressure can cause severe injury to eyes and skin if a hose were to burst. If necessary, wear rubber gloves or other protective clothing.
3. Refrigerant evaporates quickly when exposed to atmosphere, freezing anything it contacts. If liquid refrigerant contacts eyes or skin (frostbite), DO NOT rub eyes or skin. Immediately flush affected area with cool water for 15 minutes and consult a doctor or hospital.
4. Never use R-134a in combination with compressed air for leak testing. Pressurized R-134a in the presence of oxygen (air concentrations greater than 60 percent by volume) may form a combustible mixture. DO NOT introduce compressed air into R-134a containers (full or empty), A/C system components, or service equipment.
5. DO NOT expose A/C system components to high temperatures (steam cleaning for example), as excessive heat will cause refrigerant system pressure to increase. Never expose refrigerant directly to open flame. If refrigerant needs to be warmed, place bottom of refrigerant tank in warm water. Water temperature MUST NOT exceed 125°F (52°C). WARNING: When R-134a is exposed to an open flame, drawn into engine, or detected with a Halide (propane) leak tester, a poisonous gas is formed. Keep work areas well ventilated.
6. Use care when handling refrigerant containers. DO NOT drop, strike, puncture, or incinerate containers. Use Department Of Transportation (DOT) approved (DOT 4BW or DOT 4BA) refrigerant containers.
7. Never overfill refrigerant containers. The safe filling level of a refrigerant container MUST NOT exceed 60% of the container's gross weight rating. Store refrigerant containers at temperatures less than 125°F (52°C).
8. R-134a refrigerant is sold and stored in 30- or 50-pound Light Blue containers, while Freon (R-12) is stored in White colored containers.
9. Refrigerant R-12 and R-134a must never be mixed, as they and their desiccants and lubricants are not compatible. If the refrigerants are mixed, system cross-contamination or A/C system component failure may occur. Always use separate servicing and refrigerant recovery/recycling equipment.
10. Read and follow equipment manufacturer's instructions for all service equipment to be used. The Material Safety Data Sheet (MSDS), provided by refrigerant manufacturer/supplier, contains valuable information regarding the safe handling of refrigerants.

IDENTIFYING R-134a SYSTEMS & COMPONENTS

To prevent refrigerant cross-contamination, use following methods to identify R-134a based systems and components

Fittings & "O" Rings

All R-134a based A/C systems use 1/2" - 16 ACME threaded fittings (identifiable by square threads) and quick-connect service ports. (Scheme 4)

Scheme 4

REFRIGERANT OILS

Refrigerant R-12 based systems use mineral oil, while R-134a systems use synthetic Polyalkylene Glycol (PAG) oils. Using a mineral oil based lubricant with R-134a will result in A/C compressor failure due to lack of proper lubrication. See the REFRIGERANT OIL APPLICATION table for specific refrigerant oil applications.

Note. Synthetic/PAG oil absorbs moisture very rapidly, 2.3-5.6 percent by weight as compared to a mineral oil absorption rate of .005 percent by weight.

REFRIGERANT OIL APPLICATION

SCHRADER-TYPE VALVES

Schrader valve is similar in construction and operation to a tire valve. (Scheme 5) When a test gauge hose is attached (hose has built-in valve core depressor), Schrader stem is pushed inward to the open position and allows system pressure to reach the gauge.

If test hose being used does not have a built-in core depressor, an adapter must be used. Never attach hoses or adapters to a Schrader valve unless it is first connected to manifold gauge set.

Schrader Service Valve (Compressor Location Shown). Scheme 5

SPECIAL VALVE CONNECTORS

On some models, thread size on high-side service valve (3/8" - 24 threads) is different from thread size on low-side service valve (7/16" - 20 threads). Special adapters are required to make this connection. (Scheme 6) These adapters are available in 45-degree and 90-degree angles in addition to straight-fixed and flexible adapters.

Flexible High Side Adapter. Scheme 6

R-134a SERVICE VALVES/PORTS

All vehicles with R-134a refrigerant use quick-disconnect service valves/ports. All R-134a systems use quick-disconnect fittings with sealing caps that thread into inside of service port instead of onto outside of service port.

The high side uses a large service port, and the low side uses a small service port. (Scheme 4) The R-134a service ports have internal metric threads to help prevent the accidental connection of R-12 servicing equipment.

There are 2 types of quick-disconnect service couplings which can be used on R-134a systems. One type of service coupling depresses service port valve when connection is made. The other type connects onto service port but will not depress service port valve until a knob is rotated. (Scheme 7)

Scheme 7

SERVICE EQUIPMENT

Because R-134a is not interchangeable with R-12, separate sets of hoses, gauges and recovery/recycling equipment are required to service vehicles. This is necessary to avoid cross-contamination and damaging system.

All equipment used to service systems using R-134a must meet SAE standard J1991. The service hoses on the manifold gauge set must have manual (turn wheel) or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere.

For identification purposes, R-134a service hoses must have a Black stripe along their length and be clearly labeled SAE J2196/134a. The low pressure test hose is Blue with a Black stripe. The high pressure test hose is Red with a Black stripe. The center test hose is Yellow with a Black stripe.

Note. Refrigerant R-12 service hoses will ONLY be labeled SAE J2196.

All R-134a manifold gauge sets can be identified by one or all of the following

1. Labeled FOR USE WITH R-134a on set.
2. Labeled HFC-134 or R-134a on gauge face.
3. Light Blue color on gauge face.

In addition, pressure/temperature scales on R-134a gauge sets are different from R-12 manifold gauge sets.

MANIFOLD GAUGE SET

A manifold gauge set is used to determine system's high-side and low-side pressures, correct refrigerant charge, system diagnosis and operating efficiency. High (discharge) and low (suction) pressures must be compared to determine system operation. Manifold gauge sets for the 2 refrigerant types are basically the same except for fittings at ends of hoses. Fittings are different to ensure connection only to appropriate refrigerant system.

Low-Side Gauge

Low-side gauge, which may have a Blue identifying feature, is used to measure low-side (suction) pressure. Low-side gauge is also called a compound gauge because it can measure pressure and vacuum. Pressure scale ranges from 0 to 150 psi; vacuum scale ranges from 0 to 30 in. Hg.

High-Side Gauge

High-side gauge, which may have a Red identifying feature, is used to measure high-side (discharge) pressure. Gauge scale ranges from 0 to 500 psi.

CONNECTING GAUGE SET

Note. R-134a quick disconnect service couplings are connected in the same sequence as Schrader-type service valves.

1. Put on safety goggles, and cover vehicle's fender. Slowly remove protective caps from Schrader valves to check for leaky valves. CAUTION: Ensure hand valves on manifold gauge set and the hose-end shutoff valves are closed before attaching test hoses to Schrader valves.
2. Ensure service hoses are equipped with valve core depressor to match Schrader valve. If not, install special adapters for this purpose. If the high-side service hose connector will not fit on high-side Schrader valve, a special adapter must be used. See «SPECIAL VALVE CONNECTORS»(ref-39468-S33085037672001080200000) .
3. Ensure both manifold gauge hand valves are closed. Connect low-side service hose to low-side (suction) service valve, and finger tighten connections. Connect high-side service hose to high-side (discharge) service valve, and finger tighten connections.

Note. After test gauges are installed, test hoses must be purged of all air before proceeding with testing.

STABILIZING A/C SYSTEM

1. Once manifold gauge set is attached to system and test hoses have been purged, system is ready for testing. Place all test hoses, gauge set and other equipment away from all moving parts of engine.
2. Start engine, and turn A/C controls to maximum cooling position (full cold or MAX A/C). Set blower fan on high speed. Open doors and/or windows. Operate system for 5-10 minutes. System should now be stabilized and ready for test readings.

PRESSURE-TEMPERATURE RELATIONSHIP

A refrigerant, when confined in an enclosed space, increases in pressure as the temperature increases. Conversely, if the temperature is lowered, the pressure also decreases.

Depending on temperature, a corresponding pressure will exist in such an enclosed space. For example, at 70°F (21.1°C) a gauge will indicate about 71.0 psi (5.0 kg/cm 2 ). The R-134a PRESSURE-TEMPERATURE RELATIONSHIP table shows this relationship.

R-134a PRESSURE-TEMPERATURE RELATIONSHIP

PRESSURE GAUGE READINGS

The pressure gauge readings used represent an expansion valve type system using a Nippondenso 10-cylinder compressor. (Scheme 8)- (Scheme 16). Gauge indications will vary depending on system configuration and compressor application.

Temperature and humidity, as well as other factors, affect pressure gauge readings. Compared to R-12 systems, pressure readings on R-134a systems are generally lower for low-side pressure and higher for high-side pressure. Pressure gauge readings should be used only as a guide.

Normally Functioning R-134a A/C System. Scheme 8

Some Moisture In R-134a System. Scheme 9

Low R-134a Charge. Scheme 10

Poor R-134a Refrigerant Circulation. Scheme 11

No R-134a Refrigerant Circulation. Scheme 12

Insufficient Cooling Of Condenser Or R-134a Refrigerant Overcharge. Scheme 13

Air In R-134a System. Scheme 14

Expansion Valve Improperly Mounted Or Heat Sensing Tube Defective (Opening Too Wide). Scheme 15

Compressor Malfunction. Scheme 16

REFRIGERANT RECOVERY/RECYCLING

Refrigerant recovery/recycling equipment is used to remove refrigerant from vehicle's A/C system without polluting atmosphere. To remove and recycle refrigerant, ALWAYS follow instructions provided with the refrigerant recovery/recycling equipment being used.

The removed refrigerant is filtered, dried and stored in a tank within the recovery/recycling equipment until it is ready to be pumped back into the vehicle's A/C system.

Manufacturer recommends using refrigerant recovery/recycling equipment which meets SAE standard J1991. Always use instructions provided with the recovery/recycling equipment being used.

EVACUATING A/C SYSTEM

1. Close both valves on manifold gauge set. Connect manifold gauge set to high-side and low-side service valves. See «SERVICE VALVE LOCATIONS»(ref-39468-S06371949282001080200000) under SYSTEM SERVICE VALVES. Connect a hose to center connector on manifold gauge set and evacuation pump.
2. Fully open both valves on manifold gauge set. Start evacuation pump, and operate it until a vacuum reading of 28 in. Hg is obtained on low-side gauge. If vacuum reading of 28 in. Hg cannot be reached,check for defective evacuation pump or leak in A/C system or gauge set. Repair or replace as necessary.
3. When specified vacuum reading has been reached, close both valves on manifold gauge set. Turn off evacuation pump. Observe low-side gauge. Any loss of vacuum in 30 minutes indicates a system leak. See «LEAK TESTING»(ref-39468-S25508978442001080200000) . Repair any leaks.
4. If vacuum remains steady, open valves, and continue operating evacuation pump for an additional 10 minutes. Close both valves, and stop evacuation pump.

CHARGING A/C SYSTEM

1. With manifold gauge set connected, attach refrigerant container(s) to hose on center connector of manifold gauge set. Fully open refrigerant container valve(s), purge air from center hose, and close valves.
2. Start and operate engine. Place A/C-heater controls on maximum cold setting with blower fan on low speed. Slowly open low-side (suction) gauge valve and maintain a pressure reading of 50 psi (3.5 kg/cm 2 ) or less.
3. Operate engine at 1300 RPM. Adjust low-side gauge valve so pressure does not exceed 50 psi (3.5 kg/cm 2 ). When proper amount of refrigerant has been added, close valve on manifold gauge set. Stop engine, and disconnect gauge set.

Bubble Solution Detector

This is a solution applied externally at suspected leak points. Leaking refrigerant will cause the detector to form bubbles and foam. A soap and water solution also works well.

Dye Solution

This is a colored solution that may be introduced into the A/C system. The dye will show up and color components at leak points. Some manufacturers offer refrigerant containing a Red dye. This dye-containing refrigerant is installed by normal charging procedures. Other dye solutions are visible with a Black light only.

Electronic Detector

This instrument will draw in any leaking refrigerant through a test probe, and then sound an alarm or create a flashing light if refrigerant is found. It is the most sensitive of the leak detectors used. (Scheme 17)

Electronic Leak Detector. Scheme 17