Article > Tech

Air Conditioning Service is a Good Topic Any Time of Year

By Larry Carley

Many motorists don’t know is that their A/C system works year round, not just during the hot summer months.
February might not seem like the most logical month to be thinking about air conditioning parts, but what many motorists don’t know is that their A/C system works year round, not just during the hot summer months. On most late model vehicles with automatic climate control systems, the A/C system cycles on and off as needed to dehumidify air entering the passenger compartment. This helps clear the windshield and prevent the other windows from steaming over as well during cold weather.

One clue that something may be amiss with the A/C system, therefore, is poor defroster performance. If air is blowing out of the defroster ducts on top of the instrument panel but the defrosters are slow to clear the windshield, the A/C system may not be dehumidifying the air. The problem could be low refrigerant due to a leak, a weak compressor that is not developing normal system pressure, or a control problem with a switch or sensor.

A/C problems can occur any time of year, not just during the hottest days of summer — though that’s when motorists are most likely to notice poor cooling performance from an A/C system. Many will put off needed repairs as long as the weather is tolerable. But give them a few hot days of sweltering heat, and their resistance will melt like butter in the hot sun.

The DIY market for A/C parts is still there, but mostly for simple tasks such as recharging a leaky A/C system with additional refrigerant. More ambitious jobs include replacing leaky hoses or seals, or a bad compressor. Diagnosis is often the biggest challenge, especially if the cause of a no-cooling problem is not obvious. Is it the refrigeration circuit, an electrical problem or a control issue? Difficult cooling problems and repairs are best left to an A/C professional.

Anybody can still buy R134a in most areas, though various attempts have been made to restrict or ban R134a sales to non-professionals. The reason why some people would like to see a can ban is to prevent DIYers from adding refrigerant to leaky systems. Others see it as a conspiracy to force motorists to take their vehicles to a repair shop or dealership for repairs.

Adding refrigerant to an A/C system is fairly simple. First, you locate the low-pressure service port, which is typically on a hose or the accumulator toward the back of the engine compartment. You then connect a service hose and valve to a can of refrigerant. The valve is turned to puncture the top of can, which allows refrigerant to flow into the hose (this is necessary to displace air inside the hose).

The service hose is then attached to the quick-connect fitting on the low-pressure service port.
To get the refrigerant to flow into the system, the engine must be started and the A/C turned on. The compressor will then pull refrigerant through the service connection into the system. After several minutes, all of the refrigerant should have been pulled from the can into the system. At this point, the service hose can be disconnected and another can added to the system if it still needs more refrigerant.

The amount of refrigerant in an A/C system is critical for proper operation. An overcharged system will not cool efficiently, nor will a system that is low on refrigerant. Many late model A/C systems have very small refrigerant capacities (only a can or two), so one has to be very careful not to overcharge the system.

A gauge set that connects to the high- and low-pressure A/C service ports is essential for accurate charging. Some DIY A/C service kits have an inexpensive gauge that will display the high- or low-pressure side reading on a color-coded gauge. Though not as accurate as a professional gauge set or a recharging station that weighs the refrigerant as it is added to the system, a DIY gauge is certainly better than adding refrigerant until the system blows cold air (which it may or may not, depending on how much air contamination is in the system).

Adding refrigerant to an A/C system will often restore normal cooling, provided the compressor, control valves, sensors, switches and condenser fan are all working properly, too. But if the A/C system has a leak — and the leak is not found and repaired — sooner or later the new refrigerant will leak out and the system will stop blowing cold air again.
R134a contains no chlorofluorocarbons (CFCs) so it won’t harm the ozone layer as R12 did. However, R134a is a greenhouse gas that can contribute to global warming. R134a retains heat 1,300 times more than carbon dioxide, which is currently a hot environmental topic as governments look for ways to minimize CO2 emissions.

There is still considerable debate over the impact manmade CO2 and other gases are having on average global temperatures and weather. A pound or two of refrigerant leaking out of a car’s A/C system over a period of several months isn’t going to bring about the end of civilization as we know it. But the combined effects of zillions of ounces of refrigerant leaking from zillions of vehicles all over the planet could have a measurable impact on global warming.
The point here is that anyone who is buying R134a refrigerant in small cans probably has a leaky A/C system. A late model vehicle should not leak more than a few fractions of an ounce of refrigerant a year. If it can’t hold a charge from one cooling season to the next, it has a major leak that needs to be diagnosed and repaired.

Refrigerant leaks can be found one of three ways. A visual inspection of the A/C compressor and system hoses should be made to look for “wet spots” left by compressor oil that has leaked out with the refrigerant. If a system is leaking refrigerant, it will also be leaking compressor oil. The most likely places to look for leaks are at the hose and pipe connections, and the A/C compressor shaft seal.

Another method for finding leaks is to look for telltale dye stains on system hoses, the compressor and condenser. Many late model vehicles are factory-filled with refrigerant that contains colored dye. The dye is typically yellow or green, and gives off a fluorescent glow when illuminated by an ultraviolet (UV) light.

If the A/C system does not contain dye, a small dose of dye can be added to the system when it is recharged. Or, refrigerant that already contains dye can be used to recharge the system. It may take a few days of operation before the leak shows up, but sooner or later it usually will — unless the leak is in the evaporator inside the HVAC unit under the dash. Leaks here are essentially invisible because the evaporator is buried and can’t be inspected directly. For these types of leaks, an electronic leak detector is often needed to sniff out the escaping refrigerant.

Some motorists are of the mindset that it’s cheaper to keep adding refrigerant than to fix the leak. This approach may get them though the hottest days of summer, but as was explained earlier, you need A/C year round for dehumidification and defrosting. What’s more, a leak that isn’t fixed can cause bigger problems down the road — such as a possible compressor failure or internal corrosion that ruins other expensive parts such as the condenser or evaporator.

The way to permanently fix a refrigerant leak is to replace the hose, seal or other part that is leaking. The other option is to add some type of A/C sealer product to the system to plug the leak. A/C sealer products contain various ingredients that can seal small pinholes in metal tubes, the evaporator or condenser, or cause hose seals and compressor shaft seals to swell to slow down a leak.

Such products can provide an easy and cheap fix for a small leak. But if overused, too much sealer in the system may gum up the compressor or orifice tube. Professional technicians don’t like sealer products because the chemicals can plug up their refrigerant recovery and recycling equipment.

Compressors require a certain amount of PAG oil to keep their innards lubricated and turning freely. The amount of oil used in a late model A/C system isn’t much — only a few ounces in some cases — so it doesn’t take much of a leak to raise the risk of compressor failure significantly. What’s more, the type of PAG oil in the system must be the exact type specified by the vehicle manufacturer. PAG oil comes in various viscosities, and using the wrong one can also cause compressor failure.

A dose of compressor oil can be easily added to an A/C system when it is premixed with refrigerant. The problem with this approach is that the motorist has no way of knowing how much oil is in the system, and how much additional oil is needed. Too much compressor oil can also cause cooling problems by interfering with the flow of refrigerant through the condenser. It can also cause compressor failure if the compressor injects a big gulp of liquid and hydrolocks.

Another fact to keep in mind with refrigerant leaks is that leaks go both ways. As refrigerant leaks out, air and moisture seep into the system. Air displaces refrigerant, making the system work harder and harder to provide cooling. Air contamination will reduce cooling performance and can also cause compressor noise. Moisture can freeze and block the orifice tube or expansion valve, which controls the flow of refrigerant through the evaporator and it can react with the refrigerant to form acids and sludge that gum up the compressor and control valves.

The only way to get rid of air and moisture in an A/C system is to vacuum purge it with a special A/C vacuum pump. This is something else few do-it-yourselfers know anything about. If they’ve replaced a hose, a compressor or other A/C component themselves, the A/C system will be full of air and moisture. It won’t accept refrigerant very well when they attempt to recharge the system, and the A/C won’t cool well because its contaminated with air.

The correct way to complete an A/C repair after a faulty component or leaky hose has been replaced is to vacuum purge the system for 30 minutes, and to make sure it holds vacuum before any refrigerant or oil are added. If the system holds vacuum, then it can be easily recharged with the specified amount of refrigerant and oil as needed.

If an A/C system has suffered a compressor failure, or it is found to be full of black gunk when a hose or other part is replaced, it should be flushed with an approved A/C cleaning chemical to remove the contaminants. If this is not done, any junk that remains in the system may cause the orifice tube to plug, or the compressor to fail.

Some types of condensers cannot be flushed because of their design (those with parallel flow tubes or extruded tubes with very small openings). The condenser acts like a trash collector and will catch any debris that comes out of the compressor. So if it can’t be flushed, it will have to be replaced. A new orifice tube should also be installed, as well as an in-line filter following a compressor failure.
  Previous Comments
avatar   Joe Bob   star   5/8/2010   7:55 PM

I find it ironic that i can get on here at work, and read about A/C service, when my store doesn't have a working A/C, and neither does one of my delivery trucks. Next thing you know they will have a column on pay raises.

avatar   Tony   star   4/25/2010   6:35 PM

Well there are many components to complete an A/c but really the orifice tube is a main thing on it, there is no way an a/c can work even if a brand new compressor has been replaced, make sure u have the old one replace for a new one even if the price in more than $20.00 for a little orifice tube ( filter ).

avatar   Ed   star   4/9/2010   4:11 PM

Wedge, then next time your DM does a store visit, you run up to him or her, exclaiming you have found a way to cut down on that store's warranty returns dramatically! And it starts with your manager!

Your customer has zero excuses, you know why? First, you stopped them before selling the compressor and told them that they needed a drier, orifice tube/expansion valve, system flushed (And if its a vehicle with a parallel-flow condenser, an inline filter), proper amount of refrigerant and PAG/Ester oil, otherwise their warranty would be null and void. Secondly, the customer has this same warning posted three different flaps of the box in an eye-catching font and color. Thirdly, the compressor is sealed within a bag with more of the same warning. Fourthly, the compressor has a service tag wired tied to it with the warning one last time.

We honor warranties, yes, on items that truly deserve a warranty, but warranty abuse is huge and countermen seem to have this mentality that warranty abuse is limited to the scope of commercial, racing, off-road and agricultural. When in fact warranty abuse is being committed by Joe Blow because he was too lazy to do it the right way the first time, and we should feel bad for that customer, why?

avatar   Wedge Antilles   star   4/6/2010   6:54 PM

Chris is 100% correct; however that is not how the suitation usually goes. Since I work at a store where my customers have a "What can you do for me today" attitude I spend most of my summer doing compressor warranties at my store manager's instance.

avatar   Chris   star   3/6/2010   2:15 PM

Having done quite a bit of A/C work myself, I cannot stress enough that the system must be clean, clean, CLEAN. I understand if you're stuck out, without a lot of money, it's burning hot outside, and the wife is nagging you to fix the darned thing. At the very least, get your compressor, accumulator, and orifice tube/expansion valve. If you have no other way, get a can of the strong A/C flush, not the aerosol, and use the air compressor at the gas station if you have to, but FLUSH the lines! And VACUUM the lines! Rent a vacuum pump for $25 and vacuum the heck out of the system. Get everything as clean as humanly possible, and you may just wind up with a working A/C. Your counterman may just thank you for saving him a warranty claim as well.

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