Test results

Connect the climate control system to the special repressurizing equipment and check the pressure of the system

 See Test 5040OB AIR CONDITIONING SYSTEM OPERATION CHECK (PRESSURE)

Move on to Step 4

Pressure not correct

Move on to Step 1

With the engine started, the climate control system on (compressor ON button), check for leaks by moving the "nose" of the leak detector near the system pipe housings or the housing for the drier filter or the pipe joins at the condenser pack and the actual condenser.

Move on to Step 2

1. Gas leak from condenser

2. O-ring seat groove(s)

3. O-ring seals puckered

1. Replace the condenser and refill correctly

 Op. 5040A40 AIR CONDITIONING CONDENSER - R.R.

2. Replace the component where grooves have been found in the O-ring seats (drier filter or condenser or connecting pipes) and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

3. Replace the o-rings and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

Mark the point where the gas is escaping at the condenser

With the engine started, the climate control system on (compressor ON button), check for leaks by moving the "nose" of the leak detector near the system pipe housings or the housing for the drier filter or the pipe joins at the condenser pack and the actual condenser.

Move on to Step 3

1. Gas leak from condenser

2. O-ring seat groove(s)

3. O-ring seals puckered

1. Replace the condenser and refill correctly

 Op. 5040A40 AIR CONDITIONING CONDENSER - R.R.

2. Replace the component where the grooves where found in the O-ring seat (expansion valve), replace the evaporator if the grooves were located in the O-ring seat for the valve side pipes and refill correctly

3. Replace the o-rings and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

Mark the point where the gas is escaping at the condenser

With the engine started and the climate control system at the maximum speed (compressor button ON), place the temperature adjustment button in the LO position, move the probe of the leak detector near the pipe outlet connector and check for any leaks.

If there is a leak, repeat the test to make sure that there really is a leak.

With the engine switched off, move the leak detector probe to the area of the compressor shaft and the compressor rear seal.

If there is a leak, repeat the test to make sure that there really is a leak

Move on to Step 4

1. O-ring seals puckered

2. Grooves in the O-ring seats (on the compressor or the inlet/outlet pipe)

3. Leak from compressor shaft

4. Leak from compressor rear gasket

1. Replace the o-rings and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

2. Replace the compressor or inlet/outlet pipe

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

3. Replace the compressor

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

4. Replace the compressor

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

Connect the diagnostic equipment and check:

- that there are no errors at the air mixing actuators;

- that there are no faults in the outside temperature sensor;

- that there are no faults in the passenger compartment temperature sensor;

- that there are no errors at the linear sensor

Move on to Step 6

1. Error at the air mixture actuators

2. Error in the outside temperature sensor

3. Error at the passenger compartment temperature sensor

4. Error at the linear sensor

1. Move on to Step 5

2. Move on to Step 5

3. Move on to Step 5

4. Move on to Step 9

Check the continuity/insulation and visually inspect for any looseness or damage at the electrical connection contacts:

- for the air mixture actuator(s) in the case of an error at the mixture actuator;

- for the sensor if there is an error in the outside temperature sensor;

- for the climate control system control unit connector

 See E6020 AIR CONDITIONING

Move on to Step 10

1. Electrical connections loose or damaged

2. Electrical connection broken or not insulated

1. Restore the electrical connections

 See E6020 AIR CONDITIONING

2. Restore the continuity/insulation of the electrical connection

 See E6020 AIR CONDITIONING

Check that the air conditioning high and low pressure pipes are not blocked

Move on to Step 7

1. Pipe from compressor to condenser obstructed

2. Pipe from condenser to expansion valve obstructed

1. Replace the pipe from the compressor to the condenser

 Op. 5040A50 PIPE FROM AIR CONDITIONING COMPRESSOR TO CONDENSER - R+R

2. Replace the pipe from the condenser to the expansion valve

Keeping the diagnostic equipment connected, check:

- that there are no errors at the engine management node;

- through active diagnosis, that the compressor engagement relay is working correctly, making sure that, at the same time, the compressor electromagnet coupling is activated.

- that the solar sensor is working properly

 See Test 5040DC SOLAR SENSOR OPERATION CHECK

Move on to Step 10

1. Errors at the Engine Management Node

2. The relay comes on and the coupling is not activated

3. The relay comes on and the coupling is not activated

4. Solar sensor defective

1. Continue as instructed by the diagnostic equipment

2. Move on to Step 8

3. Move on to Step 9

4. Replace the solar sensor

 Op. 5010D56 SOLAR SENSOR - R.R. FOLLOWING ELECTRICAL SYSTEM CHECK

Check the continuity/insulation of the electrical circuit for the compressor engagement relay

 See E6021 COMPRESSOR ENGAGEMENT

Move on to Step 10

1. Electrical connections broken or not insulated

2. Compressor engagement relay faulty

1. Restore the continuity/insulation of the electrical connections

 See E6021 COMPRESSOR ENGAGEMENT

2. Replace the compressor engagement relay

Check the continuity/insulation of the electrical power circuit for the compressor

 See E6021 COMPRESSOR ENGAGEMENT

Move on to Step 10

1. Electrical connections broken or not insulated

2. Electromagnetic coupling faulty

1. Restore the continuity/insulation of the electrical connections

 See E6021 COMPRESSOR ENGAGEMENT

2. Replace the compressor complete with coupling

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

Check that the compressor switches on correctly

 See Test 5040BC CHECK ON CLIMATE CONTROL COMPRESSOR ACTIVATION/DEACTIVATION FROM LINEAR SENSOR

Move on to Step 11

1. Electrical connections broken

2. Linear sensor does not give go ahead

1. Check and, if necessary, restore the continuity/insulation of the electrical connection

 See E6021 COMPRESSOR ENGAGEMENT

2. Replace the linear sensor

 Op. 5040B20 AIR CONDITIONING LINEAR PRESSURE TRANSDUCER - R.R.

Check that the following errors do not persist:

- at the air mixture actuators (after the self-learning procedure, if necessary);

- at the outside temperature sensor;

- at the passenger compartment temperature sensor

End of diagnosis

1. Left air mixture actuator error

2. Right air mixture actuator error

3. Outside temperature sensor error

4. Passenger compartment temperature sensor error

1. Move on to Step 12

2. Move on to Step 12

3. Replace the outside temperature sensor

4. Replace the climate control system control unit

 Op. 5040D15 CONTROL UNIT WITH KNOBS AND BUTTONS FOR DUAL ZONE AIR CONDITIONER - R.R.

Remove the actuator and check using the control unit control that the actuator turns checking for mechanical impediments that prevent its rotation

End of diagnosis

1. The actuator does not turn

2. Kinematic components or flaps broken/stuck

1. Replace the mixture actuator

 Op. 5040D94 AIR CONDITIONING LEFT UPPER AIR DISTRIBUTION FLAP CONTROL MOTOR (DEFROST) - R.R.

and/or

 Op. 5040D96 AIR CONDITIONING RIGHT UPPER DISTRIBUTION FLAP CONTROL MOTOR (DEFROST) - R.R.

2. Replace the component that is faulty

Test results

Connect the climate control system to the special repressurizing equipment and check the pressure of the system

 See Test 5040OB AIR CONDITIONING SYSTEM OPERATION CHECK (PRESSURE)

Move on to Step 4

Pressure not correct

Move on to Step 1

With the engine started, the climate control system on (compressor ON button), check for leaks by moving the "nose" of the leak detector near the system pipe housings or the housing for the drier filter or the pipe joins at the condenser pack or the actual condenser.

Move on to Step 2

1. Gas leak from condenser

2. O-ring seat groove(s)

3. O-ring seals puckered

1. Replace the condenser and refill correctly

 Op. 5040A40 AIR CONDITIONING CONDENSER - R.R.

2. Replace the component where grooves have been found in the O-ring seats (drier filter or condenser or connecting pipes) and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

3. Replace the o-rings and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

Mark the point where the gas is escaping at the condenser

With the engine started, the climate control system on (compressor ON button), using the leak detector check for any leaks moving the leak detector probe near the expansion valve, the bend in the pipes and the pipe brazing (evaporator side) or the evaporator itself

Move on to Step 3

1. Gas leak from evaporator

2. O-ring seat groove(s)

3. O-ring seals puckered

1. Replace the evaporator and refill correctly

 Op. 5040C64 A/C EVAPORATOR - R+R

2. Replace the component where the grooves where found in the O-ring seat (expansion valve), replace the evaporator if the grooves were located in the O-ring seat for the valve side pipes and refill correctly

3. Replace the o-rings and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

Mark the point where the gas is escaping at the evaporator

With the engine started and the climate control system at the maximum speed (compressor button ON), place the temperature adjustment knob/button in the maximum cold position, move the "nose" of the leak detected near the connector to be analyzed and check for any leaks. If there is a leak, repeat the test to make sure that there really is a leak.

With the engine switched off, move the leak detector probe to the area of the compressor shaft and the compressor rear seal.

If there is a leak, repeat the test to make sure that there really is a leak

Move on to Step 4

1. O-ring seals puckered

2. Groove in the O-ring seats (on the compressor or the inlet/outlet pipe)

3. Leak from compressor shaft

4. Leak from compressor rear gasket

1. Replace the o-rings and refill correctly

 Op. 0010T84 AIR CONDITIONING SYSTEM REFRIGERANT - DEHYDRATING AND REPRESSURIZING

2. Replace the compressor or inlet/outlet pipe

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

3. Replace the compressor

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

4. Replace the compressor

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

Connect the diagnostic equipment and check that there are no errors at the linear sensor

Move on to Step 5

Error at the linear sensor

Move on to Step 8

Keeping the diagnostic equipment connected, check:

- that there are no errors at the engine management node;

- through active diagnosis, that the compressor engagement relay is working correctly, making sure that, at the same time, the compressor electromagnet coupling is activated

Move on to Step 8

1. Error at Engine Management Node

2. The relay comes on and the coupling is not activated

3. The switch comes on and the coupling is not activated

1. Proceed as instructed by the diagnostic equipment

2. Move on to Step 6

3. Move on to Step 7

Check the continuity/insulation of the electrical circuit for the compressor engagement relay

 See E6021 COMPRESSOR ENGAGEMENT

Move on to Step 8

1. Electrical connections broken or not insulated

2. Compressor engagement relay faulty

1. Restore the continuity/insulation of the electrical connections

 See E6021 COMPRESSOR ENGAGEMENT

2. Replace the compressor engagement relay

Check the continuity/insulation of the electrical power circuit (switch) for the compressor

 See E6021 COMPRESSOR ENGAGEMENT

Move on to Step 8

1. Electrical connections broken or not insulated

2. Electromagnetic coupling faulty

1. Restore the continuity/insulation of the electrical connections

 See E6021 COMPRESSOR ENGAGEMENT

2. Replace the compressor complete with coupling

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

Check that the compressor switches on correctly

 See Test 5040BC CHECK ON CLIMATE CONTROL COMPRESSOR ACTIVATION/DEACTIVATION FROM LINEAR SENSOR

Move on to Step 9

1. Electrical connections broken

2. Linear sensor does not give go ahead

1. Check and, if necessary, restore the continuity/insulation of the electrical connection

 See E6021 COMPRESSOR ENGAGEMENT

2. Replace the linear sensor

 Op. 5040A20 AIR CONDITIONING COMPRESSOR - R.R. INCLUDES CHECKING FLUID LEVEL AND TOPPING UP IF NECESSARY

Visually check the correct operation of the mixer actuator from the climate control unit temperature control knob.

Check whether the control on the control unit is interrupted by checking the electrical continuity

 See Test 5040DH SEQUENTIAL PROCEDURE FOR CHECKING MIXTURE AND DISTRIBUTION ACTUATOR OPERATION

End of diagnosis

1. Incorrect operation of actuator

2. Physical impediment to the rotation of the flap

3. Incorrect operation of kinematic components activating mixture flap

1. Replace the mixture actuator

 Op. 5040D94 AIR CONDITIONING LEFT UPPER AIR DISTRIBUTION FLAP CONTROL MOTOR (DEFROST) - R.R.

and/or

 Op. 5040D96 AIR CONDITIONING RIGHT UPPER DISTRIBUTION FLAP CONTROL MOTOR (DEFROST) - R.R.

2. If possible, restore the correct operation of the flap, otherwise replace the distributor unit or the control

3. Adjustment/replacement of mixture actuator bowden cable