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24 - 8 HEATING AND AIR CONDITIONING

(2)The appropriate Powertrain Diagnostic Procedures Manual for diagnostic information.

(3)The Compressor Clutch DiagnosisÐVariable Displacement Compressor chart in this section.

(4)On 2.2 L Turbo III engines, check for battery voltage at the Thermal Limiter Switch located on the compressor.

If voltage is found at the cut-off and/or thermal limiter switch, reconnect switch. Then check for battery voltage between the compressor clutch connector terminals.

If voltage is detected, perform A/C Clutch Coil Tests. Refer to Clutch Coil Tests in this section.

CLUTCH COIL TESTS

(1)Verify battery state of charge. (Test indicator in battery should be green).

(2)Connect an ammeter (0-10 ampere scale) in series with the clutch coil terminal. Use a volt meter (0-20 volt scale) with clip leads measuring voltage across the battery and A/C clutch.

(3)With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle.

(4)The A/C clutch should engage immediately and the clutch voltage should be within two volts of the battery voltage. If the A/C clutch does not engage, test the fusible link.

(5)The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at clutch coil. This is with the work area temperature at 21°C (70°F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts.

If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed circuit for excessive voltage drop.

DIFFERENTIAL PRESSURE CUT-OUT SWITCH DIAGNOSIS

The Differential Pressure Cut-Out (DPCO) Switch (Fig. 2) monitors the liquid refrigerant pressure on the liquid side of the system. The DPCO is located on the expansion valve. The expansion valve is black in color when a variable displacement compressor is used. The DPCO turns off voltage to the compressor clutch coil when liquid refrigerant pressure drops to levels that could damage the compressor. The DPCO is a sealed factory calibrated unit. It must be replaced if defective.

DPCO SWITCH TEST

The work area must not be below 10°C (50°F) to test the compressor clutch circuit.

(1) With gear selector in park or neutral, and park brake set, start engine and allow to idle.

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(2)Raise hood and disconnect DPCO switch connector boot.

(3)Using a suitable jumper wire, jump across the terminals inside wire connector boot.

(4)If clutch does not engage, the wiring, fuse, relay, ambient switch, or high pressure cut-off switch can be defective. Refer to Group 8W, Wiring Diagrams.

(5)If clutch engages, connect a suitable manifold gauge set. Read low pressure gauge. At pressure 283 kPa (41 psi) and above, DPCO switch will complete the clutch circuit. If the low pressure gauge reads below 317 kPa (46 psi), the system is low on refrigerant charge or empty due to a leak. Refer to Testing For Refrigerant Leaks in the Refrigerant Service Procedures section.

(6)Install connector boot on switch and repeat step number 3. If the clutch does not engage, replace the DPCO switch.

AMBIENT SWITCH DIAGNOSIS

The ambient switch is a temperature sensor located in front of the condenser behind the grille. The ambient switch prevents the compressor from engaging in cold temperatures. The ambient switch is a sealed factory calibrated unit. It must be replaced if defective.

AMBIENT SWITCH TEST

(1)Disconnect ambient switch wire connector.

(2)Using a suitable ohm meter or continuity tester, test for continuity across the ambient switch terminals.

(a)At temperature above 10°C (50°F), the switch circuit should be complete.

(b)Chill the switch with ice to below 10°C (50°F) and test for continuity. The switch circuit should be open, with continuity not detected.

Replace ambient switch if defective.

CONDENSER FAN CONTROL SWITCH DIAGNOSIS

The Fan Control Switch is located on the plumbing discharge line at the A/C compressor (Fig. 3). The fan control switch cycles the radiator/condenser fan on and off by monitoring the compressor discharge pressure. The radiator top tank temperature sensor can over ride the function of the fan control switch. It can cycle the radiator/condenser fan on and off depending on the engine temperature.

FAN CONTROL SWITCH TEST

Review Safety Precautions and Warnings before proceeding. Connect a manifold gauge set to the refrigerant system service ports. Work area temperature can not be below 21°C (70°F).

Fig. 2 Differential Pressure Cut-Out Switch

Fig. 3 Condenser Fan Control Switch

WARNING: AVOID RADIATOR/CONDENSER FAN BLADES WHEN WORKING IN THE RADIATOR AREA. FAN IS CONTROLLED BY TEMPERATURE AND CAN START ANY TIME IGNITION IS ON. PERSONAL INJURY CAN RESULT.

(1)Disconnect fan control switch wire connector.

(2)Using a suitable jumper wire, jump across terminals in wire connector.

(3)Connect a suitable continuity tester across fan control switch terminals.

(4)Start engine and set idle at 1300 rpm. The radiator fan should run constantly.

(5)Set the A/C controls to A/C and high blower.

(6)If the high pressure gauge reads below 1102 kPa (160 psi) there should be no continuity across the switch terminals.

CAUTION: Do not allow engine to overheat when radiator air flow is blocked.

(7) Block radiator air flow with a suitable cover to increase the high side pressure to at least 1585 kPa

(230 psi). Electrical continuity should be detected across the fan control switch terminals.

(8) Remove cover from front of vehicle to allow high side pressure to decrease. When pressure drops below 1102 kPa (160 psi), continuity should cease.

If fan control switch is defective, replace it.

HIGH PRESSURE CUT-OUT SWITCH DIAGNOSIS

The High Pressure Cut Out (HPCO) switch is located on the rear cover of the Variable Displacement Compressor (Fig. 4). The function of the switch is to disengage the compressor clutch by monitoring the compressor discharge (high) pressure. The HPCO Switch is in the same circuit as the Differential Pressure Cut Out (DPCO) switch and Ambient Switch.

Fig. 4 Variable Displacement CompressorÐModel

6C17

HIGH PRESSURE CUT-OUT SWITCH TESTS

Review Safety Precautions and Warnings before proceeding with this operation.

Connect a suitable manifold gauge set to the refrigerant system service ports. Work area temperature can not be below 21°C (70°F).

(1)Raise hood of vehicle.

(2)With gear selector in park or neutral, and park brake set, start engine and allow to idle at 1300 rpm.

(3)Set the A/C controls to A/C and High blower.

(6)If the high pressure gauge reads below 2963

kPa (430 psi) 6138 kPa (20 psi) the compressor clutch should be engaged.

CAUTION: Do not allow engine to overheat when radiator air flow is blocked.

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(7)Block radiator air flow with a suitable cover to increase the high side pressure to at least 3100 kPa (450 psi). Compressor clutch should disengage.

(8)Remove cover from front of vehicle to allow high side pressure to decrease. When pressure drops below 1826 kPa (265 psi), compressor clutch should engage.

If High Pressure Cut-Out Switch is defective, replace it. Refer to Component Service Procedures in this Group.

BLACK EXPANSION VALVE TEST

Review Safety Precautions and Warnings before proceeding with this operation. The work area must be 21°C to 27°C (70°F to 85°F) when testing expansion valve. To test the expansion valve:

(1)Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level using the sight glass method.

(2)Disconnect and plug the vacuum line at the water control valve.

(3)Disconnect the wire connector at the differential pressure cut-off switch. Using a jumper wire, jump across the terminals inside the connector boot (Fig. 5).

Fig. 5 Differential Pressure Cut-Out Switch

(4)Close all doors, windows and vents to the passenger compartment.

(5)Set heater-A/C control to A/C, full heat, FLOOR, and high blower.

(6)Start the engine and hold the idle speed (1000 rpm). After the engine has reached running temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the evaporator.

(7)Discharge (high pressure) gauge should read 965 to 1655 kPa (140 to 240 psi) when the refrigerant charge is sufficient. If system cannot achieve proper pressure, replace the expansion valve. If pressure is correct, record reading and proceed with test.

HEATING AND AIR CONDITIONING 24 - 11

WARNING: PROTECT SKIN AND EYES FROM CONTACTING CO2 PERSONAL INJURY CAN RESULT.

(8) If discharge pressure is within specified range, freeze the expansion valve control head (Fig. 8) for 30 seconds. Use a super cold substance (liquid CO2).Do not spray R-12 Refrigerant on the expansion valve for this test. Refer to Refrigerant Recycling in the Refrigerant Service Procedures section. If compressor discharge (high) pressure does not drop by 15% or more than the pressure recorded in step 7, replace the expansion valve. Allow the expansion valve to thaw. The discharge pressure should stabilize to the pressure recorded in step 7. If the pressure does not stabilize, replace the expansion valve.

When expansion valve tests are complete, refer to Heater and A/C Performance Tests and remove all test equipment before returning vehicle to use.

HIGH PRESSURE RELIEF VALVE (HPR) DIAGNOSIS

The HPR valve prevents damage to the airconditioning system if excessive pressure develops. Excessive pressure may be caused by condenser air flow blockage, refrigerant overcharge, or air and moisture in the system.

(HPR) VALVE LOCATION

The HPR Valve is located on the compressor end plate. (Fig. 6).

Fig. 6 High Pressure Relief ValveÐVariable Dis-

placement Compressor

The high pressure relief valve vents only a small amount of refrigerant necessary to reduce system pressure and then reseats itself. The majority of the

Fig. 1 Fixed Displacement CompressorÐModel

10PA17

COMPRESSOR NOISE

Excessive noise that occurs when the airconditioning is being used, can be caused by:

²Loose bolts

²Mounting brackets

²Loose clutch

²Excessive high refrigerant system operating pressure

Verify compressor drive belt condition, proper refrigerant charge and head pressure before compressor repair is performed.

Fig. 2 Fixed Displacement CompressorÐModel

TR105

For noise diagnostic procedures, refer to the Compressor Noise and Compressor Clutch Diagnosis chart in this section.

COMPRESSOR CLUTCH INOPERATIVE

The air-conditioning compressor clutch electrical circuit is controlled by the engine controller. The controller is located in the engine compartment outboard of the battery.

If the compressor clutch does not engage: Verify refrigerant charge.

If the compressor clutch still does not engage check for battery voltage at the low pressure or differential