Working pressures diagnostics method is an easy and cost effective way to determine major AC system problems.

AC System Diagnostics - Operating Pressures R134A

However, to perform the right measurements, the system must be in operational condition. This requires a correct level of refrigerant charge
(at least 1,5/25 PSI to run the compressor). Before the vehicle is started, the static system pressure should be read. Pressure values should
be very nearly equal on both LP and HP gauges. The actual static pressure will depend on the ambient temperature. To ensure it is on the
right level, refer to a static pressures table applicable for R134A refrigerant (N.B. not shown on this poster). A low static pressure means a
too low system charge, indicating a leak that must be found and repaired. Bear in mind, that an average AC system loses up to 50 grams/2
oz. of refrigerant per year.

HOW TO PROCEED
FOR PROPER DIAGNOSTICS,

2
FOLLOW THE STEPS BELOW
Start the engine and the AC system, SCENARIO 1 SCENARIO 2 SCENARIO 3
and then set it to produce the lowest
temperature and 70% of the possible
air blow

3
Connect gauges
to the AC loops
RECOMMENDED TOOLS

1
HP & LP service ports.
Purge the lines of the
PROPERLY CALIBRATED atmospheric air.

R134A GAUGES
Read the
values indicated
on the LP & HP
GAUGES gauges, and refer
MANIFOLD SET to the operating
pressures table
to determine possible
FILLING STATION system failure.

4
WITH GAUGES Wait until the engine
gets to its proper
working temperature Low pressure: High pressure: Low pressure: High pressure: Low pressure: High pressure:
too high Normal or too low too low Normal or too high Normal or too low Normal

Replace the valve/control icing

Improper connection of the a. Too low refrigerant charge The thermostatic pressure valve Warm air getting into the a. Possible problems with the
protection probe on the evaporator
suction and pressure lines on the b. Error on the power supply to the is defective evaporators cassette/ vehicles air recirculation
compressor reversed compressors electromagnetic a. Diagnose/replace the valve compartment mechanism
clutch The expansion valve is closed, i.e. b. Make sure the system is clean/ b. Flaps/valves in the HVAC unit
The compressor magnetic clutch c. Wrong distance between clutch blocked or clogged properly flushed Heater does not stop warming malfunctioning
does not engage - hub slips on the hub and pulley
pulley Restriction in the refrigerant line a. Dirt/impurities in the AC loop. The Evaporator freezing
between the receiver dryer and the system must be flushed.
The expansion valve is blocked in a. Diagnose/replace the valve expansion valve a. Heater valve broken
b. Make sure the system is clean/ b. Replace the valve/the compressor b. Error in the heating system control
the open position c. Replace the receiver dryer
Important remarks for operation pressures diagnostics properly flushed The compressors suction valve mechanism
The compressor's ECV valve is (MCV/ECV) is blocked and does
Air recirculation function must be disabled during the pressure defective or misses the correct not allow flow of a high refrigerant a. Improper system charge mainly
measurements set the air intake function as coming from outside the regulation volume overcharge
vehicle cabin! a. Diagnose the MCV/ECV valve a. Thermostatic probe on the
b. Improper vacuum/moisture in the
b. Replace the valve/compressor evaporator is malfunctioning
Set the air recirculation function ON only if the ambient temperature is above The compressor is malfunctioning The receiver dryer is malfunctioning system
c. Replace the compressor if b. Interior blower malfunction
30 C / 86 F and make sure that before the test is performed, the AC system or damaged clogged or saturated c. Refrigerant contaminated by
damaged
operates for 10-15 mins., lowering the cabin temperature properly. It is not improper use of agents such
c. Compressors ECV/MCV
recommended to take the pressure measurement in an ambient temperature as leak-stops, flushing agent
above 35 C / 95 F. malfunction
residues, too much UV dye
The most effective method of system troubleshooting is by pressure
measurement, and consists of two reading phases first, measurements are
taken while the engine is idling, second, measurements are taken while keeping
the engine at a constant speed of 1,500-2,000 RPM.

For vehicles equipped with spherical and automated AC systems (zonal

climatronics), the measurement should be taken by different air production
scenarios for available zones (i.e. at frontal zone, at rear zone, etc.).

HOW TO READ THE POSTER SCENARIOS: SCENARIO 4 SCENARIO 5 SCENARIO 6

PINK POINTER RED AREA

TOO HIGH WORKING PRESSURE, POSSIBLE RANGE OF CORRECT
LOW-PRESSURE SIDE WORKING PRESSURES AT GIVEN
AMBIENT TEMPERATURES,
HIGH-PRESSURE SIDE

BLACK POINTER
CORRECT WORKING
PRESSURE,
LOW-PRESSURE SIDE

BLACK POINTER
CORRECT WORKING
PRESSURE,
HIGH-PRESSURE SIDE

VALUES APPLICABLE FOR Low pressure: High pressure: Low pressure: High pressure: Improper Low & High pressure:
BLUE AREA
POSSIBLE RANGE OF CORRECT R134A ONLY PINK POINTER Normal or too high Too high Normal or too low Too low Pointers indicate same values on both gauges
WORKING PRESSURES AT GIVEN TOO LOW WORKING PRESSURE,
AMBIENT TEMPERATURES, HIGH-PRESSURE SIDE
LOW-PRESSURE SIDE

System overcharge Make sure that system is charged Too low refrigerant level a. Make sure that system is charged Compressor failure a. Determine cause of the
APPLICABLE FOR FIXED DISPLACEMENT COMPRESSOR
properly acc. to manufacturers properly acc. to manufacturers compressor failure
ABBREVIATIONS
ECV/MCV failure causing improper recommendation Expansion valve failure clogged or recommendation Electromagnetic clutch of the b. Replace the compressor
APPLICABLE FOR VARIABLE DISPLACEMENT COMPRESSOR
suction pressure blocked b. Diagnose the loop for possible compressor does not operate
Diagnose/replace the valve or replace
leakages properly
the compressor a. Error on the power supply to the
Condenser inner stoppage/ System stoppage between receiver
R134A OPERATING PRESSURES TABLE contaminations dryer and evaporator Driving belt/compressors pulley compressors electromagnetic
a. Make sure the system is cleaned/ a. Diagnose/replace the expansion clutch
valve malfunction
flushed b. Wrong distance between clutch
High-pressure side clogged High-pressure side stoppage
AMBIENT TEMP. C VARIABLE DISPLACEMENT COMPRESSOR FIXED DISPLACEMENT COMPRESSOR b. Replace the condenser hub and pulley must be adjusted
stoppage around service port and b. Dirt/impurities in the AC loop. ECV/MCV failure causing improper
R134A
in between compressor-condenser- Low ambient temperature Make sure the system is clean or suction pressure
filter a. Improper system charge mainly below 5 C / 41 F is flushed. a. Improper pulley alignment
LP (bar) HP (bar) LP (bar) HP (bar) overcharge
b. Driving belt/belt tensioner
Ambient temperature above b. Improper vacuum/moisture in the
min. max. min. max. min. max. min. max.
c. Replace the receiver dryer excessive wear
40 C / 104 F system
15.5 1.5 2.3 9.5 13.0 0.5 3.0 9.5 13.0
c. Refrigerant contaminated by
Diagnose/replace the valve or replace
21.0 1.5 2.3 12.5 17.5 0.5 3.0 12.5 17.5 improper use of agents such
the compressor
26.5 1.5 2.3 14.0 20.5 0.5 3.0 14.0 20.5
as UV dye, leak-stops, flushing
agents etc.
32.0 1.5 2.5 16.0 24.0 0.5 3.5 16.0 24.0 d. The system must be flushed.
38.8 1.5 2.5 18.5 25.5 0.5 3.5 18.5 25.5 e. Replace the receiver dryer
43.0 1.5 2.5 22.0 28.0 0.5 3.5 22.0 28.0

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Printed in the EU. January 2017