NO.6 AIR FROM VENT NOT COLD ENOUGH.

STEP	INSPECTION	ACTION
1	INSPECT DRIVE BELT • Inspect drive belt. • Is it okay?.	Yes	Go to the next step.
No	Adjust or replace drive belt, then go to Step 21.
2	INSPECT REFRIGERANT SYSTEM PEREFORMANCE • Carry out refrigerant system performance test. • Is operation normal?	Yes	Operation is normal. (Recheck malfunction symptoms.)
No	Go to the next step.
3	CHECK TO SEE WHETHER MALFUNCITION IS IN BLOWER UNIT INTAKE AND CONDENSER OR ELSEWHERE • Are refrigerant’s high-pressure and low-pressure values both high?	Yes	Go to the next step.
No	Go to Step 6.
4	INSPECT BLOWER UNIT INTAKE • Is blower unit intake clogged?	Yes	Remove obstruction, then go to Step 21.(If air does not reach evaporator within cooling unit, heat exchange does not occur and refrigerant pressure rises. Therefore, removal of obstruction is necessary.)
No	Go to the next step.
5	INSPECT CONDENSER • Inspect the condenser. • Is it okay?.	Yes	Add or subtract refrigerant to make specified amount, then go to Step 21. (Excessive amount of refrigerant.)
No	Replace the condenser, or repair and clean condenser fins, then go to Step 21.
6	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE, RECEIVER/DRIER AND REFRIGERANT LINES OR ELSEWHERE • Are refrigerant’s high-pressure and low-pressure values both low?	Yes	Go to the next step.
No	Go to Step 14.
7	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE AND RECEIVER/DRIER OR ELSEWHERE • Immediately after A/C compressor operates, does refrigerant’s high-pressure value momentarily rise to correct value, then fall and stay below it? (is there negative pressure on low-pressure side?)	Yes	Go to the next step.
No	Go to Step 10.
8	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR RECEIVER/DRIER • Turn A/C switch off and let air conditioner stop for 10 minutes. • Start engine. • Turn both A/C switch and fan switch on. • Does malfunction occur after A/C compressor turns on?	Yes	Go to the next step.
No	Start vacuum pump for 30 minutes and replace receiver/drier, then go to Step 21.(Since receiver/drier has become saturated with water, replacement is necessary.)
9	VERIFY THAT EXPANSION VALVE HEAT SENSING TUBE WITHIN A/C UNIT IS POSITIONED SECURELY AND CORRECTLY • Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?	Yes	Replace expansion valve, then go to Step 21.(since valve closes too much, replacement is necessary.)
No	Install heat-sensing tube securely in proper position, then go to Step 21.
10	INSPECT REFRIGERANT LINES • Inspect refrigerant lines. ― Is piping free of damage and cracks? ― Are piping connections free of oil grime? (Visual inspection) ― Are piping connections free of gas leakage? ― Are piping installation points on condenser free of gas leakage? ― Are piping installation points on receiver/drier free of gas leakage? ― Are piping installation points on cooling unit free of gas leakage? *Perform gas leak inspection using gas leak tester. • Ate above items okay?	Yes	Go to the next step.
No	If piping or an A/C component is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to Step 13.
11	INSPECT EVAPORATOR PIPING CONNECTIONS IN A/C UNIT FOR GAS LEAKAGE • Are piping connections for evaporator in cooling fan unit free of gas leakage?	Yes	If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that the malfunction does not occur. Add or subtract refrigerant to make specified amount, then go to Step 21.
No	• If piping is damaged or cracked, replace it. Then go to Step 21. • If there is no damage, go to next step.
12	INSPECT EVAPORATOR PIPING CONNECTIONS IN A/C UNIT FOR LOOSE • Are piping connections for evaporator in cooling unit loose?	Yes	Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that the malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.
No	If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.
13	INSPECT PIPING CONNECTIONS FOR LOOSE • Are piping connections loose?	Yes	Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that the malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.
No	If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.
14	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE, AIR MIX ACTUATOR AND COMPRESSOR OIL OR ELSEWHERE • Does refrigerant’s high-pressure value hardly increase?	Yes	Go to the next step. (Pressure hardly increases.)
No	Go to Step 17.
15	CHECK TO SEE WHETHER MALFUNCTION IS IN COMPRESSOR OIL AMOUNT AND A/C COMPRESSOR OR ELSEWHERE • When engine is racing, does high-pressure value increase?	Yes	Return to Step 3.
No	Go to the next step.
16	CHECK TO SEE WHETHER MALFUNCTION IS IN COMPRESSOR OIL AMOUNT OR A/C COMPRESSOR • After compressor oil is replenished each 10 ml {10 cc, 0.34 ft oz}, does high-pressure value increase?	Yes	Troubleshooting completed. (Explain to customer that cause was insufficient compressor oil.)
No	Replace A/C compressor, then go to Step 21. (Cause is defective A/C compressor.)
17	CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR ELSEWHERE • Is only refrigerant low-pressure value high?	Yes	Go to Step 20.
No	Go to the next step.
18	VERIFY THAT AIR MIX IS INSTALLED SECURELY AND PROPERLY • Are heater unit’s air mix rod, air mix link, air mix cranks and air mix shaft securely and properly installed?	Yes	Go to the next step.
No	Repair or install air mix rod, air mix link air mix cranks and air mix shaft securely in proper position, then go to Step 21.
19	CHECK TO SEE WHETER MALFUNCTION IS IN A/C COMPRESSOR OIL AMOUNT OR ELSEWHERE 1. Start the fan switch at 4th position. 2. Turn the A/C switch on. 3. Set to FRESH mode. 4. Set the temperature control to MAX COLD. 5. Set to VENT mode. 6. Run the engine speed at a constant 1,500rpm for 105 ml {105 cc, 3.55 ft oz}. 7. Run the engine at idle for 1 minute. 8. 1 engine speed cycles is defined as going from idle speed to 4,000rpm and back to idle speed over a period of 12 seconds. Perform 5 cycles. 9. Run the engine at idle speed for 30 seconds. 10. Remove all compressor oil from A/C compressor and verify that it is 105 ml {105 cc, 3.55 ft oz}. 11. If it is more than 105 ml {105 cc, 3.55 ft oz}, put 105 ml {105 cc, 3.55 ft oz}, back into A/C compressor. 12. Carry out above steps 1 to 10 again and verify that compressor oil is 105 ml {105 cc, 3.55 ft oz}. • Is there 105 ml {105 cc, 3.55ft oz} of compressor oil in A/C compressor?	Yes	Go to Step 21.
No	Carry out 1 to 10 of step 19 again until compressor oil is 10 5ml {105 cc, 3.55ft oz}.
20	VERIFY THAT EXPANSION VALVE HEAT SENSING TUBE WITHIN A/C UNIT IS POSITIONED SECURELY AND CORRECTLY • Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?	Yes	Replace expansion valve, then go to the next step. (Since valve opens too much, replacement is necessary.)
No	Install heat-sensing tube securely in proper position, then go to the next step.
21	CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR • Does cool air blow out? (Are results of refrigerant system performance test okay?)	Yes	Troubleshooting completed. Explain repairs to customer.
No	Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.

STEP

INSPECTION

ACTION

INSPECT DRIVE BELT

• Inspect drive belt.

• Is it okay?.

Yes

Go to the next step.

Adjust or replace drive belt, then go to Step 21.

INSPECT REFRIGERANT SYSTEM PEREFORMANCE

• Carry out refrigerant system performance test.

• Is operation normal?

Yes

Operation is normal. (Recheck malfunction symptoms.)

Go to the next step.

CHECK TO SEE WHETHER MALFUNCITION IS IN BLOWER UNIT INTAKE AND CONDENSER OR ELSEWHERE

• Are refrigerant’s high-pressure and low-pressure values both high?

Yes

Go to the next step.

Go to Step 6.

INSPECT BLOWER UNIT INTAKE

• Is blower unit intake clogged?

Yes

Remove obstruction, then go to Step 21.(If air does not reach evaporator within cooling unit, heat exchange does not occur and refrigerant pressure rises. Therefore, removal of obstruction is necessary.)

Go to the next step.

INSPECT CONDENSER

• Inspect the condenser.

• Is it okay?.

Yes

Add or subtract refrigerant to make specified amount, then go to Step 21. (Excessive amount of refrigerant.)

Replace the condenser, or repair and clean condenser fins, then go to Step 21.

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE, RECEIVER/DRIER AND REFRIGERANT LINES OR ELSEWHERE

• Are refrigerant’s high-pressure and low-pressure values both low?

Yes

Go to the next step.

Go to Step 14.

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE AND RECEIVER/DRIER OR ELSEWHERE

• Immediately after A/C compressor operates, does refrigerant’s high-pressure value momentarily rise to correct value, then fall and stay below it? (is there negative pressure on low-pressure side?)

Yes

Go to the next step.

Go to Step 10.

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR RECEIVER/DRIER

• Turn A/C switch off and let air conditioner stop for 10 minutes.

• Start engine.

• Turn both A/C switch and fan switch on.

• Does malfunction occur after A/C compressor turns on?

Yes

Go to the next step.

Start vacuum pump for 30 minutes and replace receiver/drier, then go to Step 21.(Since receiver/drier has become saturated with water, replacement is necessary.)

VERIFY THAT EXPANSION VALVE HEAT SENSING TUBE WITHIN A/C UNIT IS POSITIONED SECURELY AND CORRECTLY

• Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?

Yes

Replace expansion valve, then go to Step 21.(since valve closes too much, replacement is necessary.)

Install heat-sensing tube securely in proper position, then go to Step 21.

INSPECT REFRIGERANT LINES

• Inspect refrigerant lines.

― Is piping free of damage and cracks?

― Are piping connections free of oil grime? (Visual inspection)

― Are piping connections free of gas leakage?

― Are piping installation points on condenser free of gas leakage?

― Are piping installation points on receiver/drier free of gas leakage?

― Are piping installation points on cooling unit free of gas leakage?

*Perform gas leak inspection using gas leak tester.

• Ate above items okay?

Yes

Go to the next step.

If piping or an A/C component is damaged or cracked, replace it.

Then go to Step 21.

If there is no damage, go to Step 13.

INSPECT EVAPORATOR PIPING CONNECTIONS IN A/C UNIT FOR GAS LEAKAGE

• Are piping connections for evaporator in cooling fan unit free of gas leakage?

Yes

If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that the malfunction does not occur.

Add or subtract refrigerant to make specified amount, then go to Step 21.

• If piping is damaged or cracked, replace it. Then go to Step 21.

• If there is no damage, go to next step.

INSPECT EVAPORATOR PIPING CONNECTIONS IN A/C UNIT FOR LOOSE

• Are piping connections for evaporator in cooling unit loose?

Yes

Tighten connections to specified torque.

If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that the malfunction does not occur.

Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.

If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that malfunction does not occur.

Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.

INSPECT PIPING CONNECTIONS FOR LOOSE

• Are piping connections loose?

Yes

Tighten connections to specified torque.

If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that the malfunction does not occur.

Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.

If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 ft oz} of compressor oil and verify that malfunction does not occur.

Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE, AIR MIX ACTUATOR AND COMPRESSOR OIL OR ELSEWHERE

• Does refrigerant’s high-pressure value hardly increase?

Yes

Go to the next step.

(Pressure hardly increases.)

Go to Step 17.

CHECK TO SEE WHETHER MALFUNCTION IS IN COMPRESSOR OIL AMOUNT AND A/C COMPRESSOR OR ELSEWHERE

• When engine is racing, does high-pressure value increase?

Yes

Return to Step 3.

Go to the next step.

CHECK TO SEE WHETHER MALFUNCTION IS IN COMPRESSOR OIL AMOUNT OR A/C COMPRESSOR

• After compressor oil is replenished each 10 ml {10 cc, 0.34 ft oz}, does high-pressure value increase?

Yes

Troubleshooting completed. (Explain to customer that cause was insufficient compressor oil.)

Replace A/C compressor, then go to Step 21.

(Cause is defective A/C compressor.)

CHECK TO SEE WHETHER MALFUNCTION IS IN EXPANSION VALVE OR ELSEWHERE

• Is only refrigerant low-pressure value high?

Yes

Go to Step 20.

Go to the next step.

VERIFY THAT AIR MIX IS INSTALLED SECURELY AND PROPERLY

• Are heater unit’s air mix rod, air mix link, air mix cranks and air mix shaft securely and properly installed?

Yes

Go to the next step.

Repair or install air mix rod, air mix link air mix cranks and air mix shaft securely in proper position, then go to Step 21.

CHECK TO SEE WHETER MALFUNCTION IS IN A/C COMPRESSOR OIL AMOUNT OR ELSEWHERE

1. Start the fan switch at 4th position.

2. Turn the A/C switch on.

3. Set to FRESH mode.

4. Set the temperature control to MAX COLD.

5. Set to VENT mode.

6. Run the engine speed at a constant 1,500rpm for 105 ml {105 cc, 3.55 ft oz}.

7. Run the engine at idle for 1 minute.

8. 1 engine speed cycles is defined as going from idle speed to 4,000rpm and back to idle speed over a period of 12 seconds. Perform 5 cycles.

9. Run the engine at idle speed for 30 seconds.

10. Remove all compressor oil from A/C compressor and verify that it is 105 ml {105 cc, 3.55 ft oz}.

11. If it is more than 105 ml {105 cc, 3.55 ft oz}, put 105 ml {105 cc, 3.55 ft oz}, back into A/C compressor.

12. Carry out above steps 1 to 10 again and verify that compressor oil is 105 ml {105 cc, 3.55 ft oz}.

• Is there 105 ml {105 cc, 3.55ft oz} of compressor oil in A/C compressor?

Yes

Go to Step 21.

Carry out 1 to 10 of step 19 again until compressor oil is 10 5ml {105 cc, 3.55ft oz}.

VERIFY THAT EXPANSION VALVE HEAT SENSING TUBE WITHIN A/C UNIT IS POSITIONED SECURELY AND CORRECTLY

• Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?

Yes

Replace expansion valve, then go to the next step.

(Since valve opens too much, replacement is necessary.)

Install heat-sensing tube securely in proper position, then go to the next step.

CONFIRM THAT MALFUNCTION SYMPTOMS DO NOT RECUR AFTER REPAIR

• Does cool air blow out? (Are results of refrigerant system performance test okay?)

Yes

Troubleshooting completed.

Explain repairs to customer.

Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.

6	Air from vent not cold enough.
DESCRIPTION	• Magnetic clutch operates but A/C system malfunctions.
POSSIBLE CAUSE	• Drive belt malfunction (Step 1) • Malfunction in blower unit or condenser (Step 4, 5) • Malfunction in receiver/drier or expansion valve (valve closes too match). (Step 8, 9) • Malfunction in refrigerant lines (Step 10, 11) • Malfunction in piping connections (Step 1, 2, 13) • A/C compressor system malfunction, insufficient compressor oil. (Step 15, 16) • Compressor oil over-full, malfunction in expansion able valve or heater unit air mix link system. (Step 17—20)