Component Tests

Air Inlet Door Actuator 

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Blend Door Actuator - DATC 

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Blend Door Actuator - EMTC 

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Defrost/Panel/Floor Mode Door Actuator 

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Evaporator Temperature Sensor 

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In-Vehicle Temperature/Humidity Sensor 

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Heater Core - Plugged 

1. 1.
   
   Check to see that the engine coolant is at the correct level.

1. 2.
   
   Start the engine and turn on the heater.

1. 3.
   
   When the engine coolant reaches operating temperature, feel the heater core inlet and outlet hose to see if they are hot.
   • If the inlet hose is not hot:
     • the thermostat is not working correctly.
   • If the outlet hose is not hot:
     • the heater core may have an air pocket.
     • the heater core may be restricted or plugged.

Heater Core - Pressure Test 

Use the Pressure Test Kit to carry out the pressure test.

1. 1.
   
   
   NOTE: Due to space limitations, a bench test may be necessary for pressure testing.

   Drain the coolant from the cooling system. Refer to Engine Cooling .

1. 2.
   
   Disconnect the heater hoses from the heater core.

1. 3.
   
   Install a short piece of heater hose, approximately 101 mm (4 in) long on each heater core tube.

1. 4.
   
   Fill the heater core and heater hoses with water and install the plug (221373) and the adapter (221374) from the Pressure Test Kit. Secure the heater hoses, plug and adapter with hose clamps.

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1. 5.
   
   Attach the pump and gauge assembly from the Pressure Test Kit to the adapter.
   • 014-R1072 Radiator Pressure Test Set

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1. 6.
   
   Close the bleed valve at the base of the gauge. Pump 138 kPa (20 psi) of air pressure into the heater core.

1. 7.
   
   Observe the pressure gauge for a minimum of 3 minutes.

1. 8.
   
   If the pressure drops, check the heater hose connections to the core tubes for leaks. If the heater hoses do not leak, remove the heater core from the vehicle and carry out the bench test.

Heater Core - Bench Test 

1. 1.
   
   Remove the heater core from the vehicle. Refer to Climate Control .

1. 2.
   
   Drain all of the coolant from the heater core.

1. 3.
   
   Connect the 101 mm (4 in) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter.

1. 4.
   
   Apply 138 kPa (20 psi) of air pressure to the heater core. Submerge the heater core in water.

1. 5.
   
   If a leak is observed, install a new heater core.

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Evaporator/Condenser Core - On-Vehicle Leak Test 

1. 1.
   
   Recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging .

1. 2.
   
   
   NOTE: DO NOT leak test an evaporator core with the suction accumulator attached to the evaporator core tubes.

   Disconnect the suspect evaporator core or condenser core from the A/C system. Refer to Climate Control .

1. 3.
   
   Use the correct adapters with a Rotunda approved A/C Service Unit to test the evaporator or condenser.
   • 219-00082 ACF-3000 33PC Adapter Kit - Revised 1st released 44pc kit.
   • 219-00083 A/C Flushing Adapter Kit 2 of 3 (Previously "Supplement A", 2nd released kit).
   • 219-00084 A/C Flushing Adapter Kit 3 of 3.

1. 4.
   
   
   NOTE: The automatic shut-off valves on some hoses do not open when connected to the fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the adapter fittings. The test is not valid if the shut-off valve does not open.

   Connect the hoses from the A/C Service Unit to the adapter fittings on the evaporator or condenser.

   • 265?37887 Ritchie R134A A/C Refrigerant Hybrid Management System

1. 5.
   
   Open both valves and start the vacuum. Allow the A/C Service Unit to vacuum for a minimum of 45 minutes after the low pressure gauge indicates 101 kPa (30 in-Hg). The 45-minute evacuation is necessary to remove any refrigerant from oil left in the evaporator or condenser. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak.

1. 6.
   
   If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves are open and the A/C Service Unit is operating, close the valves and observe the low pressure reading. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the adapter fitting connections before installing a new evaporator or condenser.

1. 7.
   
   After evacuating for 45 minutes, close the valves and stop the service unit. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark.
   • If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
   • If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
   • If a small amount of vacuum is lost, operate the vacuum pump with the valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the evaporator core or condenser core. Then recheck for loss of vacuum.
   • If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss.

1. 8.
   
   If the evaporator core or condenser core leaks, as verified by the above procedure, install a new evaporator core or condenser core. Refer to Climate Control .

AIR CONDITIONING (A/C) Compressor - External Leak Test 

1. 1.
   
   Recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging .

1. 2.
   
   Disconnect the refrigerant lines from the A/C compressor. Refer to Climate Control .

1. 3.
   
   Install the adapters from the A/C Flush Adapter Kit on the ports of the A/C compressor, using the existing retaining bolts.
   • 219-00082 ACF-3000 33PC Adapter Kit - Revised 1st released 44pc kit.
   • 219-00083 A/C Flushing Adapter Kit 2 of 3 (Previously "Supplement A", 2nd released kit).
   • 219-00084 A/C Flushing Adapter Kit 3 of 3.

1. 4.
   
   Connect the high and low pressure lines of the A/C Service Unit to the corresponding fittings on the adapter.
   • 265?37887 Ritchie R134A A/C Refrigerant Hybrid Management System

1. 5.
   
   Charge the A/C compressor following the air conditioning service unit instructions. Open the low pressure valve, the high pressure valve and set the refrigerant charge amount to 0.23 kg (8 oz).

1. 6.
   
   
   NOTE: Use a Rotunda-approved Electronic Leak Detector for R-134a refrigerant SAE Certified to J2791.

   Using the Refrigerant Leak Detector, check for leaks at the compressor shaft.

   • 023?22791 Robinair Infrared A/C Refrigerant Leak Detector w/Case

1. 7.
   
   When the leak test is complete, recover the refrigerant from the compressor.

1. 8.
   
   If an external leak is found, install a new A/C compressor. Refer to Climate Control .