Fluorescent Leak Detector
Fluorescent dye will assist in locating any leaks in the A/C system.
- Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
- Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C compressor shaft seal The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
- Follow the instructions supplied with the J 42220 .
- To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved fluorescent dye cleaner J 43872 .
Fluorescent Dye Injection
- Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
- R-134a leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
- With the A/C system charged, add J 41447 to the A/C system using J 41459 . Follow the instructions provided with J 41459 .
- To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 .
Halogen Leak Detector
| CAUTION | Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result. |
Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.
| IMPORTANT | Halogen leak detectors are sensitive to the following items: Windshield washing solutions Many solvents and cleaners Some adhesives used in the vehicle |
Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.
| IMPORTANT | Follow a continuous path in order to ensure that you will not miss any possible leaks. Test all areas of the system for leaks. |
Follow the instructions supplied with the J 39400-A.
Defrosting Insufficient
| Step | Action | Yes | No |
|---|---|---|---|
| 1 | Start the engine. Select the DEFROST mode. Select the maximum blower speed. Does sufficient air flow from the defroster outlets? | Go to Step 2 | Go to Step 10 |
| 2 | Measure the engine operating temperature. Does engine reach normal operating temperature? | Go to Step 3 | Go to Step 4 |
| 3 | Select the minimum blower speed. Select the maximum temperature setting. Feel the temperature of the inlet and outlet hoses at the heater core. Does the inlet hose feel warmer than the outlet hose? | Go to Step 5 | Go to Step 12 |
| 4 | Repair the low engine temperature concern. Refer to Engine Fails To Reach Normal Operating Temperature in Engine Cooling. Is the repair complete? | Go to Step 14 | |
| 5 | Is the vehicle equipped with A/C? | Go to Step 6 | Go to Step 14 |
| 6 | Test the operation of the A/C compressor clutch. Does the A/C compressor clutch engage? | Go to Step 8 | Go to Step 7 |
| 7 | Repair the A/C compressor clutch. Refer to HVAC Compressor Clutch Does Not Engage in HVAC Systems-Manual. Is the repair complete? | Go to Step 14 | |
| 8 | Perform the A/C system performance test. Refer to Air Conditioning (A/C) System Performance Test . Is the A/C system operating within the specifications? | Go to Step 9 | Go to Step 11 |
| 9 | Inspect for correct operation of the recirculation door. Is the recirculation door operating correctly? | Go to Step 14 | Go to Step 13 |
| 10 | Repair the air delivery concern. Refer to Air Delivery Improper in HVAC Systems - Manual. Is the repair complete? | Go to Step 14 | |
| 11 | Repair the A/C performance concern. Refer to Symptoms - HVAC Systems - Manual . Is the repair complete? | Go to Step 14 | |
| 12 | Repair the heating concern. Refer to Heating Performance Diagnostic . Is the repair complete? | Go to Step 14 | |
| 13 | Repair the recirculation door concern. Is the repair complete? | Go to Step 14 | |
| 14 | Operate the system in order to verify the repair. Does the system operate correctly? | System OK | Go to Step 1 |
Defrosting Insufficient
Eliminating Air Conditioning Odor
Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor
- Debris is present in the HVAC module.
- Microbial growth on the evaporator core
When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the mirocbial growth must be eliminated. Perform the following procedure
Deodorize the evaporator core using Deodorizing Aerosol Kit.
Perform the following steps in order to deodorize the A/C system
- Ensure that the plenum that draws outside air into the HVAC module is clear of debris.
- Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
- Dry the evaporator core by performing the following steps: Start the engine. Select the maximum temperature setting. Select the recirculation mode. Run the blower motor on high for 10 minutes.
- Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
- Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
- Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
- Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
- Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
- Start the engine.
- Operate the blower motor on high for 15-20 minutes to dry.
- Reconnect the A/C compressor clutch coil electrical connector.
- Verify proper clutch operation.
Tools Required
J 43600 ACR2000 Refrigerant Station. See Special Tools .
| CAUTION | Refer to Breathing R-134a Caution in Cautions and Notices. |
| CAUTION | For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. |
Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.
Note. To avoid system damage use only R-134a dedicated tools when servicing the A/C system.
Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.
Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.
The J 43600 removes the Refrigerant-134a from the vehicle's A/C system. The recovery procedure uses one filtering cycle. The evacuation procedure uses an automatic multiple pass filtering cycle. These filtering cycles ensure a constant supply of clean, dry refrigerant for A/C system charging.
The Initial Set-Up Instruction Manual, provided with the J 43600 , contains specific procedures for proper recovery, evacuation and recharging.
Balancing
- The replacement compressor is shipped with the total system capacity of refrigerant oil.
- Before installing the compressor, the refrigerant oil will have to be partially drained: Refer to the amount of refrigerant oil recorded during the compressor removal. Subtract the amount recorded from the total system capacity. Refer to «Refrigerant System Capacities»(ref-200123-S21414919312005102000000) . The difference between the total system capacity and the recorded amount is the calculated amount to be drained from the replacement compressor.
- Drain the calculated amount of refrigerant oil from the replacement compressor.
Compressor Pressure Relief Valve Install
- Clean the pressure relief valve seat area on the A/C compressor.
- Lubricate the O-ring of the new pressure relief valve with clean refrigerant oil.
- Install the new pressure relief valve into the A/C compressor. Tighten: Tighten the pressure relief valve to 7 N.m (60 lb in).
J 39400-A Halogen Leak Detector