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Heating, Ventilation, and Air Conditioning

Air Conditioning System Repair Procedures

In this manual: Heating, Ventilation, and Air Conditioning
General Information — 15Maintenance — 7Engine Mechanical System — 84Engine Electrical System — 49Emission Control System — 22Fuel System — 95Clutch System — 28Manual Transmission — 21Dual Clutch Transmission (DCT) System — 47Drive Shaft and Axle — 20Suspension System — 36Steering — 23Restraints — 39Brake System — 54Body (Interior and Exterior) — 209Body Electrical System — 254Heating, Ventilation, and Air Conditioning — 56
24steps
~144min
5/5difficulty
Done 0 of 24

Refrigerant System Service Basics (R-134a)

Refrigerant Recovery: Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 for removing HFC-134a (R-134a) from air conditioning systems.In case of accidental system discharge, ventilate the work area before resuming service. For additional health and safety information, consult lubricant manufacturers.
  1. Connect the R-134a refrigerant recovery/recycling/charging system (A) to the high-pressure port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
  2. Measure the amount of refrigerant oil removed from the air conditioning system after the recovery process is complete. Be sure to install the same amount of new refrigerant oil back into the air conditioning system before charging.
System Evacuation: Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 for removing HFC-134a (R-134a) from air conditioning systems.In case of accidental system discharge, ventilate the work area before resuming service. For additional health and safety information, consult lubricant manufacturers.
  1. When the air conditioning system has been opened to the atmosphere, for example during installation or repair, it must be evacuated using an R-134a recovery/recycling/charging system. (If the system has been open for several days, the receiver/drier should be replaced, and the system must be evacuated for several hours.)
  2. Connect the R-134a refrigerant recovery/recycling/charging system (A) to the high-pressure port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.
  3. If the low pressure does not reach 93.3 kPa (700 mmHg, 27.6 inHg) after 10 minutes, there is probably a leak in the system. Partially charge the system and check it for leaks (refer to Refrigerant Leak Test).
  4. Remove the low-pressure valve from the low-pressure service port.
System Charging: Use only service equipment that is UL listed and certified to meet the requirements of SAE J2210 for removing HFC-134a (R-134a) from air conditioning systems.In case of accidental system discharge, ventilate the work area before resuming service. For additional health and safety information, consult lubricant manufacturers.
  1. Connect the R-134a refrigerant recovery/recycling/charging system (A) to the high-pressure service port (B) as shown, following the equipment manufacturer's instructions.
  2. Add the same amount of new refrigerant oil to the system as was removed during recovery. Use only the specified refrigerant oil. Charge the system with 500 ± 25 g (17.6 ± 0.88 oz) of R-134a refrigerant. Do not overcharge the system, or the compressor will be damaged.
Refrigerant Leak Test: Always perform a leak test using an electronic leak detector whenever a leak or refrigerant loss is suspected, and whenever service operations involve disconnecting or loosening fittings or connections.If a refrigerant leak is detected, perform the following steps:
  1. Check the torque at the connection fittings and, if it is too loose, tighten to the specified torque. Check for refrigerant leakage using a leak detector (A).
  2. If the leak continues even after tightening the fitting, discharge the refrigerant from the system, disconnect the fittings, and inspect the seating surfaces for damage. Always replace, even if the damage is minor.
  3. Check the compressor oil and add oil if necessary.
  4. Charge the system and recheck for refrigerant leaks. If no leaks are found, evacuate and recharge the system again.

Refrigerant System Service Basics (R-1234yf)

Refrigerant Identification
  • Do not mix HFO-1234yf (R-1234yf) in the vehicle with other refrigerants, such as R-12, R-134a, etc.
  • Use only UL-listed service equipment certified to meet SAE standards for recovery and recycling of R-1234yf from air conditioning systems. Do not use service equipment for other refrigerants, such as R-12, R-134a, etc.
  • Check which refrigerant is in the system if there is concern that the system has been tampered with in any way, and check the type and quantity of refrigerant that should be in the air conditioning system, and possible problems resulting from accidental or intentional mixing of refrigerants.
  • It is recommended to use a SAE-certified refrigerant identifier to prevent improper recovery and, as a result, further spread of contaminated refrigerant, which can potentially damage other air conditioning systems and service equipment. Contaminated refrigerant (a mixture of more than one refrigerant or non-system refrigerant) in recovery/recycling equipment may lead to potential contamination of more refrigerant.
  • Some types of electronic leak detectors (heated diode or corona discharge), as well as motors, switches, and controls in recovery and recycling machines, can generate sparks that may serve as ignition sources in the presence of refrigerants classified as flammable (A2 or A3) under ASHRAE 34 2006.
  • Mixing refrigerants in the air conditioning system may result in higher than expected system pressure, damage to the system and components, diagnostic errors, and/or other potential hazards to people and the environment.
  • In case of mixing with another refrigerant, recover the contaminated refrigerant from the air conditioning system and dispose of it in accordance with all applicable national, regional, or local regulations. Clean the interior of the air conditioning system with a specialized cleaning agent and charge with new refrigerant.
Refrigerant Recovery: Use only service equipment that is UL listed and certified to meet the requirements of SAE standards for removing HFO-1234yf (R-1234yf) from air conditioning systems.In case of accidental system discharge, ventilate the work area before resuming service. For additional health and safety information, consult lubricant manufacturers.
  1. Connect the R-1234yf refrigerant recovery/recycling/charging equipment (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.
  2. Measure the amount of refrigerant oil removed from the air conditioning system after the recovery process is complete. Be sure to install the same amount of new refrigerant oil back into the air conditioning system before charging.
System Evacuation: Use only service equipment that is UL-listed and certified to meet SAE standards for removing HFO-1234yf (R-1234yf) from the air conditioning system.In case of accidental system discharge, ventilate the work area before resuming service. For additional health and safety information, consult lubricant manufacturers.
  1. When the air conditioning system has been opened to the atmosphere, for example during installation or repair, it must be evacuated using R-1234yf refrigerant recovery/recycling/charging equipment. (If the system has been open for several days, the receiver/drier should be replaced, and the system must be evacuated for several hours.)
  2. Connect the R-1234yf refrigerant recovery/recycling/charging equipment (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.
  3. If the low pressure does not exceed 87.7 kPa (658 mmHg, 25.9 inHg) after 5 minutes, there is likely a leak in the system. Partially charge the system and check for leaks (refer to "Refrigerant Leak Check").
  4. Remove the low-pressure valve from the low-pressure service port.
System Charging: Use only service equipment that is UL listed and certified to meet the requirements of SAE standards for removing HFO-1234yf (R-1234yf) from air conditioning systems.In case of accidental system discharge, ventilate the work area before resuming service. For additional health and safety information, consult lubricant manufacturers.
  1. Connect the R-1234yf refrigerant recovery/recycling/charging equipment (A) to the high-pressure service port (B), as shown, following the equipment manufacturer's instructions.
  2. Add the same amount of new refrigerant oil to the system as was removed during recovery. Use only the specified refrigerant oil. Charge the system with 500 ± 25 g (17.6 ± 0.88 oz) of R-1234yf refrigerant. Do not overcharge the system, or the compressor will be damaged.
Refrigerant Leak Test: Always perform a leak test using an electronic leak detector whenever a leak or refrigerant loss is suspected, and whenever service operations involve disconnecting or loosening fittings or connections. If a refrigerant leak is detected, perform the following steps:
  1. Check the torque at the connection fittings and, if it is too loose, tighten to the specified torque. Check for refrigerant leakage using a leak detector (A).
  2. If the leak continues even after tightening the fitting, discharge the refrigerant from the system, disconnect the fittings, and inspect the seating surfaces for damage. Always replace, even if the damage is minor.
  3. Check the compressor oil and add oil if necessary.
  4. Charge the system and recheck for refrigerant leaks. If no leaks are found, evacuate and recharge the system again.

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