Edge AWD V6-3.5L (2009)
Evaporator Core: Testing and Inspection
Climate Control System
Evaporator/Condenser Core - On-Vehicle Leak Test
1. Recover the refrigerant. Refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging See: Service and Repair/Air Conditioning
(A/C) System Recovery, Evacuation and Charging.
2. For evaporator core testing only, remove the Thermostatic Expansion Valve (TXV) from the evaporator core.
3. For condenser core testing only, disconnect the condenser-to-evaporator line spring lock coupling and the compressor-to-condenser discharge
line middle fitting.
4. For evaporator core testing only, connect the appropriate test fitting to the evaporator core TXV connection.
5. For condenser core testing only, connect the appropriate test fittings to the condenser-to-evaporator line spring lock coupling, condenser side
and the compressor-to-condenser discharge line middle fitting, condenser side.
6. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test 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 test fittings or install an adapter that will
activate the valve. The test is not valid if the shut-off valve does not open.
Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the
yellow hose to a known good vacuum pump.
7. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set
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
core or condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant
leak.
8. If the low-pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low-pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated.
Recheck the test fitting connections and gauge set connections before installing a new evaporator core or condenser core.
9. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low-pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark.
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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.
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If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
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If a small amount of vacuum is lost, operate the vacuum pump with gauge 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.
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If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for vacuum loss.
10. For evaporator core testing only, if the evaporator core does leak, as verified by the above procedure, install a new evaporator core.
11. For condenser core testing only, if the test indicates a leak, as verified by the above procedure, inspect and install new O-rings at the condenser
line fittings as necessary. Retest the system. If the test again indicates a leak, install a new condenser core.