Professional Documents
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AIR CONDITIONING
CONTENTS
page page
GENERAL INFORMATION
New service ports are used to ensure that the sys- the operating instructions provided with the equip-
tem is not accidentally filled with the wrong refriger- ment for proper operation.
ant.
Due to the different characteristics of R-134a it re- REFRIGERANT OIL
quires all new service procedures. Refer to Refriger- R-134a refrigerant requires a special type of com-
ant Service Procedures in this section before making pressor oil. The system uses polyalklene glycol syn-
any repairs to the air conditioning system. thetic wax-free refrigerant oil SP-20 PAG. No other
Chrysler Corporation recommends that a oil should be used.
R-134a refrigerant Recovery/Recycling Station R-12 compressor oil can not be mixed with the
that meets SAE standard J2210 be used. Refer to R-134a compressor oil. They ARE NOT compatible.
J AIR CONDITIONING 3
WARNING: AVOID BREATHING A/C REFRIGERANT WARNING: R-134A SERVICE EQUIPMENT OR VEHI-
AND LUBRICANT VAPOR OR MIST. EXPOSURE MAY CLE A/C SYSTEM SHOULD NOT BE PRESSURE
IRRITATE EYES, NOSE AND/OR THROAT. WEAR TESTED OR LEAK TESTED WITH COMPRESSED
EYE PROTECTION WHEN SERVICING THE AIR AIR. SOME MIXTURES OF AIR AND R-134A HAVE
CONDITIONING REFRIGERANT SYSTEM. SERIOUS BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED
EYE INJURY CAN RESULT FROM EYE CONTACT PRESSURES. THESE MIXTURES ARE POTENTIALLY
WITH REFRIGERANT. IF EYE CONTACT IS MADE, DANGEROUS AND MAY RESULT IN FIRE OR EX-
SEEK MEDICAL ATTENTION IMMEDIATELY. PLOSION CAUSING INJURY OR PROPERTY DAM-
AGE.
WARNING: DO NOT EXPOSE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED CAUTION: Liquid refrigerant is corrosive to metal
WHEN REFRIGERANT IS BURNED. AN ELEC- surfaces. Follow the operating instructions supplied
TRONIC LEAK DETECTOR IS RECOMMENDED.
with equipment being used.
Never open or loosen a connection before discharg- When installing a refrigerant line avoid sharp
ing the system refrigerant. bends. Position the line away from the exhaust or
The A/C system must always be evacuated before any sharp edges which may chafe the line.
charging. Tighten fittings only to the specified torque. The
DO NOT open a refrigerant system or uncap a re- aluminum fittings used in the A/C system will not
placement component unless it is as close as possible tolerate over tightening.
to room temperature. This will prevent condensation When disconnecting a fitting use a wrench on both
from forming inside of a component which is cooler halves of the fitting. This will prevent twisting of the
than the surrounding air. refrigerant lines or tubes.
Before disconnecting a component from the system, Refrigerant oil will absorb moisture from the atmo-
clean the outside of the fittings thoroughly. sphere if left uncapped. DO NOT open an oil con-
Immediately after disconnecting a component from tainer until ready to use and install the cap
the system, seal the open fittings with a cap or plug. immediately after using. Store the oil only in a clean
Before connecting an open fitting always insall a moisture-free container.
new seal/gasket. Coat the fitting and seal with clean Keep service tools and the work area clean. Con-
refrigerant oil before connecting. tamination of A/C system through careless work hab-
DO NOT remove the sealing caps from a replace- its must be avoided.
ment component until ready to install.
4 AIR CONDITIONING J
Humidity has an improtant bearing on the tempra- (5) Insert a thermometer in the left center A/C out-
ture of the air delivered to the vehicle’s interior. It is let. Operate the engine for 5 minutes. The A/C clutch
important to understand the effect humidity has on may cycle depending on ambient temperatures.
the performance of the system. When humidity is (6) After 5 minutes note the discharge air temper-
high, the evaporator has to perform a double duty. It ature. If the clutch cycles, take the reading before
must lower the air temperature and the temperature the clutch disengages.
of the moisture carried in the air. Condensing the (7) Open the hood and disconnect vacuum line go-
moisture in the air transfers heat energy into the ing to the heater water control valve. Observe the
evaporator fins and tubing. This reduces the amount valve arm for movement as the line is disconnected.
of heat the evaporator can absorb from the air. High If it does not move repair vacuum circuit. Plug the
humidity greatly reduces the evaporator’s ability to vacuum line to prevent leakage.
lower the temperature of the air. (8) Operate the A/C for 2 more minutes and take
Evaporator capacity used to reduce the amount of the discharge air temperature reading again. On XJ
moisture in the air is not wasted. Wringing some of vehicles if the temperature increased by more than
the moisture out of the air entering the vehicle adds 2°C (5°F) check the blend air door cable for correct
to the comfort of the passengers. However, an owner operation.
may expect too much from their air conditioning sys- (9) Compare the discharge air temperature to the
tem on humid days. A performance test is the best A/C Performance (Temperature and Pressure) Chart.
way to determine whether or not the system is per- If discharge air temperature is high, refer to Refrig-
forming up to standard. This test also provides valu- erant Leak Testing and Refrigerant System Diagno-
able clues to the possible cause of trouble. sis Chart.
(10) Compare the compressor discharge and suc-
PERFORMANCE TEST tion pressures to the A/C Performance (Temperature
Air temperature in test room must be 21°C (70°F) and Pressure) Chart. If the discharge or suction pres-
minimum for this test. sure is not normal, check the operation of the refrig-
(1) Connect a Tachometer and manifold gauge set. erant system, referring to Refrigerant System
(2) Set A/C controls to Max A/C, temperature lever Diagnosis Chart.
on full cool and blower on high. The following charts have been developed for quick
(3) Start engine and adjust idle to 1,000 RPM with reference.
A/C clutch engaged.
(4) Engine should be warmed up with doors, win-
dows and hood closed.
PRESSURE DIAGNOSIS
J AIR CONDITIONING 7
PERFORMANCE DIAGNOSIS
8 AIR CONDITIONING J
LEAK TESTING REFRIGERANT If the A/C system has been open to the atmosphere,
it must be evacuated before the system can be
WARNING: REVIEW WARNINGS AND CAUTIONS IN charged. Moisture and air mixed with refrigerant will
GENERAL INFORMATION SECTION OF THIS raise the compressor head pressure above acceptable
GROUP BEFORE LEAK TESTING. operating levels. This will reduce the performance of
the air conditioner and damage the compressor. Mois-
If A/C system is not cooling properly, determine if ture will boil at near room temperature when ex-
system is fully charged. Refer to Refrigerant System posed to vacuum. To evacuate the refrigerant system
Diagnosis Chart. If the system is empty evacuate the use following procedure:
A/C system and charge system with 0.283 kPa (0.6 (1) Connect a suitable charging station and mani-
lbs. or 10 oz.) R-134a refrigerant. Refer to Charging fold gauge set to the vehicle.
Refrigerant System for instructions. To detect a leak (2) Open the low and high side valves and start
in the system, perform the following procedures. vacuum pump. When suction gauge reads 88 kPag
(1) Position the vehicle in a wind free work area. (26 in. Hg) vacuum or greater, close all valves and
This will aid in detecting small leaks. turn off vacuum pump. If system fails to reach spec-
(2) Bring A/C system up to operating temperature ified vacuum, the system has a leak that must be
and pressure. This is done by allowing the engine to corrected. If system maintains the specified vacuum
run with the A/C on for 5 to 7 minutes. for 30 minutes, start the vacuum pump. Then open
(3) Open hood 5 minutes prior to leak test. This the suction and discharge valves and evacuate an ad-
will dissipate any accumulated refrigerant in the en- ditional 10 minutes.
gine compartment. (3) Close all valves. Turn off and disconnect the
(4) With the engine not running, use an R-134a vacuum pump.
Electronic Leak Detector and search for leaks. Move The system is now ready to be charged with refrig-
probe slowly along the bottom side of lines and fit- erant.
tings, because R-134a is heavier than air. Fittings,
lines, or components that appear to be oily usually CHARGING REFRIGERANT SYSTEM
indicates a refrigerant leak.
(5) To inspect the evaporator core for leaks. Set the WARNING: REVIEW WARNINGS AND CAUTIONS IN
blower at low speed and the selector in PANEL and GENERAL INFORMATION SECTION OF THIS
RECIRC mode check for leaks at CENTER panel ou- GROUP BEFORE CHARGING SYSTEM.
lets.
After the system has been tested for leaks and
DISCHARGING REFRIGERANT SYSTEM evacuated, a refrigerant charge can be injected into
the system. Refer to refrigerant capacities for proper
WARNING: REVIEW WARNINGS AND CAUTIONS IN amount of refrigerant charge.
GENERAL INFORMATION SECTION OF THIS The most accurate method of charging is to com-
GROUP BEFORE DISCHARGING SYSTEM. pletely evacuate the system. Then charge the system
using a Recovery/Recycling Station approved for
R-134a refrigrant is a hydrofluorocarbon (HFC) R-134a refrigerant. Refer to the operating instruc-
that does not contain chlorine. R-134a refrigerant Re- tions provided with the equipment for proper opera-
covery/Recycling Station that meets SAE standard tion.
J2210 must be used to discharge the refrigerant sys-
tem. Refer to the operating instructions provided CAUTION: Do not over charge refrigerant system.
with the equipment for proper operation. This will cause excessive compressor head pres-
sure and can cause noise and system failure.
EVACUATING REFRIGERANT SYSTEM
WARNING: REVIEW WARNINGS AND CAUTIONS IN REFRIGERANT CHARGE CAPACITY
GENERAL INFORMATION SECTION OF THIS The R-134a system charge capacity is 0.9 kPag (32
GROUP BEFORE EVACUATING SYSTEM. oz.) for XJ and YJ vehicles.
J AIR CONDITIONING 9
REFRIGERANT OIL
It is important to have the correct amount of oil in Add an additional 28 grams (1 fluid oz.) of
the A/C system. This will ensure proper lubrication of compressor oil to the system when a receiver-
the compressor. Too little oil will result in damage to drier, condenser or evaporator core is replaced.
the compressor. Too much oil will reduce the cooling
capacity of the system. OIL LEVEL
The oil used in the SD-709 compressor is a poly- When an A/C system is assembled at the factory,
alkylene glycol synthetic oil SP-20 PAG. This is a all components (except the compressor) are refriger-
wax-free refrigerant oil. Only refrigerant oil of the ant oil free. After the system has been charged and
same type should be used to service the system. Do operated, the oil in the compressor is dispersed
not use any other oil. The oil container should be through the system. The evaporator, condenser and
kept tightly capped until it is ready for use and then compressor will retain a significant amount of oil (re-
capped after use to prevent contamination. Refriger- fer to the Refrigerant Oil Capacities Chart).
ant oil will quickly absorb any moisture it comes in When a component is replaced, the specified
contact with. amount of refrigerant oil must be added. When the
It will not be necessary to check oil level in the compressor is replaced, the oil must be drained from
compressor or to add oil unless there has been an oil
the replaced compressor and measured. Drain all the
loss. This may be due to a rupture or leak from a
oil from the new compressor. Add back into the new
line, shaft seal, evaporator or condenser. Oil loss at a
compressor the amount of oil that was drained out of
leak point will be evident by the presence of a wet,
the old compressor.
shiny surface around the leak.