Online Manual Jeep > Jeep Cherokee > Jeep Cherokee (XJ) > 1993 > A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES

* A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES *

 1993 Jeep Cherokee

GENERAL INFORMATION

A/C-Heater System Motorist Assurance Program

Standards For Automotive Repair

All Makes and Models

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

Motorist Assurance Program (MAP)

OVERVIEW

OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS

Heating, Ventilation and Air Conditioning

ACCUMULATORS

ACTUATORS (ELECTRICAL)

ACTUATORS (VACUUM)

AIR CONDITIONING FITTINGS

AIR CONDITIONING HOSES

AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES

AIR CONTROL DOORS

AIR DAMS (EXTERNAL)

AIR DISTRIBUTION SYSTEM

BELTS

BLEND DOORS

BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)

BLOWER MOTORS

BLOWER RESISTORS

BLOWER SWITCHES

CABIN AIR FILTERS

CIRCUIT BREAKERS

COMPRESSOR CLUTCH ASSEMBLIES

COMPRESSORS

CONDENSER AIR SEALS

CONDENSER FAN MOTORS

CONDENSERS

CONNECTORS

CONTROL CABLES

CONTROL HEADS (FUNCTION SELECTORS)

CONTROL LINKAGES

CONTROL MODULES

COOLANT

COOLING FAN BLADES

COOLING FAN CLUTCHES

COOLING FAN MOTORS

EVAPORATOR DRAIN TUBES

EVAPORATOR PRESSURE REGULATORS (EPRS)

EVAPORATORS

EXPANSION VALVES

FUNCTION SELECTORS

FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS

FUSIBLE LINKS

GASKETS

HEATER CASES

HEATER CONTROL VALVES

HEATER CORES

HEATER HOSES

HIGH PRESSURE RELIEF VALVES (HPRV)

IDLERS

IN-LINE FILTERS

METAL FITTINGS

METAL LINES

MIX AND AIR CONTROL DOORS (BLEND DOORS)

O-RINGS

ORIFICE TUBES

PILOT-OPERATED ABSOLUTES (POAS)

PLENUMS

PRESSURE CONTROL VALVES

PRESSURE SENSORS

PULLEYS

RADIATORS

RECEIVER-DRIERS

REFRIGERANT

REFRIGERANT OIL

RELAYS

SEALS

SERVICE PORTS

SPRING LOCK COUPLINGS

SUCTION THROTTLING VALVES (STVS)

SWITCHES (ELECTRICAL)

TENSIONERS

THERMISTORS AND PRESSURE SENSORS

THERMOSTATS AND HOUSINGS

VACUUM HOSES AND TUBES

VACUUM RESERVOIRS

VACUUM TUBES

VALVES IN RECEIVER (VIRS)

WATER PUMPS (ELECTRIC AUXILIARY)

WIRING HARNESSES AND CONNECTORS

MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW

The Motorist Assurance Program is the consumer outreach effort of the Automotive Maintenance and Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program is drawn from retailers, suppliers, independent repair facilities, vehicle manufacturers and industry associations.

Our organizations mission is to strengthen the relationship between the consumer and the auto repair industry. We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles-through proper, manufacturer-recommended, maintenance. We encourage participating service and repair shops (including franchisees and dealers) to adopt (1) a Pledge of Assurance to their Customers and (2) the Motorist Assurance Program Standards of Service. All participating service providers have agreed to subscribe to this Pledge and to adhere to the promulgated Standards of Service demonstrating to their customers that they are serious about customer satisfaction.

These Standards of Service require that an inspection of the vehicles (problem) system be made and the results communicated to the customer according to industry standards. Given that the industry did not have such standards, the Motorist Assurance Program successfully promulgated industry inspection communication standards in 1994-95 for the following systems: Exhaust, Brakes, ABS, Steering and Suspension, Engine Maintenance and Performance, HVAC, and Electrical Systems. Further, revisions to all of these inspection communication standards

are continually republished. In addition to these, standards for Drive Train and Transmissions have recently been promulgated. Participating shops utilize these Uniform Inspection & Communication Standards as part of the inspection process and for communicating their findings to their customers.

The Motorist Assurance Program continues to work

cooperatively and proactively with government agencies and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both regulators and industry. We maintain the belief that industry must retain control over how we conduct our business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and other government officials (and their representatives), concerned with auto repair and/or consumer protection, are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as needed.

To assure auto repair customers recourse if they were not satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other nonprofit organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in October, 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and Standards and agreed to follow the UICS in communicating the results of their inspection to their customers. To put some "teeth" in the program, an accreditation requirement for shops was initiated. The requirements are stringent, and a self-policing method has been incorporated which includes the "mystery shopping" of outlets.

We welcome you to join us as we continue our outreach... with your support, both the automotive repair industry and your customers will reap the benefits. Please visit MAP at our Internet site www. motorist.org or contact us at:

1444 I Street, NW Suite 700

Washington, DC 20005

Phone (202) 712-9042 Fax (202) 216-9646 January 1999

MAP UNIFORM INSPECTION GENERAL GUIDELINES

OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-line, engine performance and maintenance, and heating, ventilation and air conditioning, and electrical services be offered and performed under the standards and procedures specified in these sections.

Before any service is performed on a vehicle, an inspection of the appropriate system must be performed. The results of this inspection must be explained to the customer and documented on an inspection form. The condition of the vehicle and its components will indicate what services/part replacements may be "Required" or "Suggested". In addition, suggestions may be made to satisfy the requests expressed by the customer.

When a component is suggested or required to be repaired or replaced, the decision to repair or replace must be made in the customers best interest, and at his or her choice given the options available.

This section lists the various parts and conditions that indicate a required or suggested service or part replacement. Although this list is extensive, it is not fully inclusive. In addition to this list, a technician may make a suggestion. However, any suggestions must be based on substantial and informed experience,

or the vehicle manufacturers recommended service interval and must be documented.

Some conditions indicate that service or part replacement is required because the part in question is no longer providing the function for which it is intended, does not meet a vehicle manufacturers design specification or is missing.

Example:

An exhaust pipe has corroded severely and has a hole in it through which exhaust gases are leaking. Replacement of the exhaust pipe in this case is required due to functional failure.

Example:

A brake rotor has been worn to the point where it measures less than the vehicle manufacturers discard specifications. Replacement of the rotor is required because it does not meet design specifications.

Some conditions indicate that a service or part replacement is suggested because the part is close to the end of its useful life or addresses a customers need, convenience or request. If a customers vehicle has one of these conditions, the procedure may be only to suggest service.

Example:

An exhaust pipe is rusted, corroded or weak, but no leaks are present. In this case, the exhaust pipe has not failed. However, there is evidence that the pipe may need replacement in the near future. Replacement of the pipe may be suggested for the customers convenience in avoiding a future problem.

Example:

The customer desires improved ride and/or handling, but the vehicles shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customers wishes. In this case, replacement of the shocks or struts may not be sold as a requirement.

A customer, of course, has the choice of whether or not a shop will service his or her vehicle. He or she may decide not to follow some of your suggestions. When a repair is required, a MAP shop must refuse partial service on that system if, in the judgment of the service provider, proceeding with the work could create or continue an unsafe condition. When a procedure states that required or suggested repair or replacement is recommended, the customer must be informed of the generally acceptable repair/replacement options whether or not performed by the shop.

When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

The following reasons may be used for required and suggested services. These codes are shown in the "Code" column of the MAP Uniform Inspection & Communications Standards that follow:

Reasons to Require Repair or Replacement

A - Part no longer performs intended purpose

┬ - Part does not meet a design specification (regardless of

performance) ╤ - Part is missing

NOTE: When a repair is required, the shop must refuse partial

service to the system in question, if the repair creates or continues an unsafe condition.

Reasons to Suggest Repair or Replacement

1 - Part is close to the end of its useful life (just above

discard specifications, or weak; failure likely to occur soon, etc.)

2 - To address a customer need, convenience, or request (to

stiffen ride, enhance performance, eliminate noise, etc.)

3 - To comply with maintenance recommended by the vehicles

Original Equipment Manufacturer (OEM)

4 - Technicians recommendation based on substantial and

informed experience

NOTE: Suggested services are always optional. When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

HEATING, VENTILATION, AND AIR CONDITIONING

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE

OPERATION

CAUTION: Before working on any air conditioning system, be sure to review current local, state, federal, and EPA regulations regarding charging, recycling, and disposal of refrigerant.

ACCUMULATORS

ACCUMULATOR INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Beyond vehicle

manufacturers service

interval 3 Suggest replacement.

Dessicant at the end of

its useful life (saturated

with moisture) 1 . . Suggest repair or replacement.

Dessicant bag

deteriorated A (1) Require replacement.

Further inspection required.

Leaking A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Tubing connection

leaking A .. Require repair or replacement.

(1) - Inspect system to determine effects of dessicant bag deterioration.

ACTUATORS (ELECTRICAL)

ACTUATOR (ELECTRICAL) INSPECTION



Condition

Code


Procedure

Attaching hardware




broken

A

... Require

repair or replacement




of hardware.

Attaching hardware




missing


Require replacement of




hardware.

Attaching hardware not




functioning

A

Require

repair or replacement




of hardware.

Connector broken

A

Require

repair or replacement.

Connector (Weatherpack




type) leaking

A

Require

repair or replacement.

Connector melted,




affecting performance

A


(1) Require repair or




replacement.

Connector melted, not




affecting performance ..

2


(1) Suggest repair or




replacement.

Connector missing


Require replacement.

Inoperative

A

(2

) Require replacement.

Missing


Require replacement.

Noisy

2

.. Suggest

repair or replacement.

Out of adjustment

Require

repair or replacement.

Terminal broken

A

Require

repair or replacement.

Terminal burned, affecting




performance

A


(1) Require repair or




replacement.

Terminal burned, not




affecting performance

1


(1) Suggest repair or




replacement.

Terminal corroded,




affecting performance . .

A

Require

repair or replacement.

Terminal corroded, not




affecting performance

1

Suggest

repair or replacement.

Terminal loose, affecting




performance

Require

repair or replacement.

Terminal loose, not




affecting performance

1

Suggest

repair or replacement.

ACTUATORS (VACUUM)

ACTUATOR (VACUUM) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted,

affecting performance . . A (1) Require repair or

replacement. Connector melted, not

affecting performance .. 2 (1) Suggest repair or

replacement.

Connector missing C Require replacement.

Inoperative A (2) Require replacement.

Leaking (vacuum) A .. Require repair or replacement.

Linkage bent, affecting

performance A ... Require repair or replacement

of linkage. Linkage bent, not

affecting performance .. 2 ... Suggest repair or replacement

of linkage. Linkage binding, affecting

performance A ... Require repair or replacement

of linkage. Linkage binding, not

affecting performance .. 1 ... Suggest repair or replacement

of linkage.

Linkage broken A ... Require repair or replacement

of linkage. Linkage loose, affecting

performance A ... Require repair or replacement

of linkage. Linkage loose, not

affecting performance .. 1 ... Suggest repair or replacement

of linkage.

Linkage missing C Require replacement.

Linkage noisy 2 .. Suggest repair or replacement.

Missing C Require replacement.

Noisy 2 . . Suggest repair or replacement.

Out of adjustment A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

AIR CONDITIONING FITTINGS

See AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .

AIR CONDITIONING HOSES

See AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .

AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES

AIR CONDITIONING METAL LINE, HOSE AND FITTING ASSEMBLY INSPECTION
Condition Code Procedure

Require repair or replacement.


No service suggested or

required.

.. Require replacement.


Require repair or replacement of hardware.


Require replacement of hardware.


Require repair or replacement of hardware.


Suggest replacement. .... Require repair.


A Require replacement.

Abrasion damage,

affecting structural

integrity A

Abrasion damage, not

affecting structural

integrity

Application incorrect
Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not
functioning A

1

A

Clamp corroded, not
reusable

Connected incorrectly Corroded, affecting

structural integrity Corroded, not affecting

structural integrity

Cracked A

Fitting type incorrect

(such as compression

fitting) B

Flange leaking A

Insufficient clamping

force, allowing hose to

leak A

Leaking A

Melted 1

Missing C

Outer covering damaged to

the extent that the inner

fabric is visible A

Protective sleeves

damaged 2

Protective sleeves

missing C

Restricted, affecting

performance A

Routed incorrectly 2

Swollen 1

Threads damaged A

Threads stripped (threads

missing) A

Type incorrect 1

No service suggested or

required. Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Suggest repair or replacement.

Require replacement.

Require replacement.

Suggest replacement of sleeves. Require replacement of sleeves.

Require repair or replacement.

Require repair.

Suggest replacement.

Require repair or replacement.

Require replacement.

Suggest repair or replacement.

AIR CONTROL DOORS

See PLENUMS.

AIR DAMS (EXTERNAL)

AIR DAM (EXTERNAL) INSPECTION

Condition

Code

Procedure

Application incorrect,

affecting air

conditioning

system performance A

Attaching hardware

broken A

Attaching hardware
missing
C

Attaching hardware not
functioning A

Bent, affecting air

conditioning system

performance A

Blocked, affecting air

conditioning system

performance A

Broken, affecting air

conditioning system

performance A

Cracked, affecting air

conditioning system

performance A

Loose, affecting air

conditioning system

performance A

Loose, not affecting air

conditioning system

performance 2

Missing, affecting air

conditioning system

performance C

Require repair or replacement.

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair.

Suggest repair.

Require replacement.


AIR DISTRIBUTION SYSTEM

See PLENUMS.

BELTS

BELT INSPECTION

Condition Code

Alignment incorrect B

Cracked 1

Frayed 1

Missing C

Noisy 2

Plies separated A

Serpentine belt routed

incorrectly B

Tension out of

specification B

Worn beyond
adjustment range B

Procedure

(1) Further inspection

required.

Suggest replacement. Suggest replacement. Require replacement.

(2) Further inspection

required. Require replacement.

Require repair.

Require adjustment or replacement.

Require replacement.

Worn so it contacts
bottom of pulley
A

Require replacement.

  1. - Determine cause of incorrect alignment and require repair.

  2. - Determine cause of noise and suggest repair.

BLEND DOORS

See PLENUMS.

BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)

BLOWER FAN (BLOWER WHEEL OR SQUIRREL CAGE) INSPECTION


Condition

Attaching hardware
broken

Code Procedure

A ... Require repair or replacement

of hardware.

Attaching hardware
missing

Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

Application incorrect ..

Broken

Cracked

Distorted

Fins missing

Hub separated A

Inoperative A

Mounting loose A

Noisy 2

Out of balance A

of hardware. ┬ .. Require repair or replacement.

A Require replacement.

A Require replacement

A Require replacement.

Require replacement.

Require replacement.

(1) Require replacement.

Require repair or replacement.

Suggest replacement.

Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

BLOWER MOTORS

BLOWER MOTOR INSPECTION
Condition Code

Attaching hardware
broken A

Attaching hardware
missing
C

Attaching hardware not
functioning A

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted,

affecting performance .. A

Connector melted, not

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

1) Require repair or replacement.

affecting performance


Connector missing C

Current draw out of

specification B

Inoperative A

Missing C

Motor speed

insufficient 2

Noisy 2

Rotation incorrect for

application B

Terminal broken

Terminal burned, affecting

performance

Require repair or replacement.
(2) Require replacement.


Terminal burned, not

affecting performance Terminal corroded,

affecting performance . . Terminal corroded, not

affecting performance Terminal loose, affecting

performance

Terminal loose, not

affecting performance

Vibration

Wire lead conductors

exposed

Wire lead corroded

Wire lead open

Wire lead shorted

2

Suggest



A

Require Require

A


2 .

Suggest

A

Require

2 .

Suggest

Require

1 1

Suggest

A . A . A

Require Require Require Require

(1) Suggest repair or

replacement.

Require replacement.

Require replacement.

repair or replacement. Suggest replacement.

repair or replacement. repair or replacement.

(1) Require repair or replacement.

repair or replacement, repair or replacement. repair or replacement, repair or replacement.

repair or replacement. Suggest replacement.

repair or replacement. repair or replacement, repair or replacement, repair or replacement.


(1) (2)

Determine cause and correct prior to repair or replacement of part.

Check fan motor/controls. Inoperative includes intermittent operation or out of OEM specification.

BLOWER RESISTORS

BLOWER RESISTOR INSPECTION


Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Conductor exposed A Require replacement.

Require repair or replacement.

Condition

Attaching hardware
broken

Attaching hardware
missing

Connector broken

Connector melted, affecting performance

Connector melted, not affecting performance

Code

A A

Procedure

Require repair or replacement of hardware.

1) Require repair or replacement.

1) Suggest repair or replacement.

Connector missing C Require replacement.

Inoperative A (2) Require replacement.

Insulation overheated ... A Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

BLOWER SWITCHES

See SWITCHES.

CABIN AIR FILTERS

CABIN AIR FILTER INSPECTION

Condition Code Procedure

Air flow obstruction .... A Require cleaning or

replacement.

Maintenance intervals ... 3 Suggest replacement.

Missing C Require replacement.

CIRCUIT BREAKERS

See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS.

COMPRESSOR CLUTCH ASSEMBLIES

COMPRESSOR CLUTCH ASSEMBLY INSPECTION

Condition Code Procedure

Air gap incorrect B .. Require repair or replacement.

Bearing seized A .. Require replacement of bearing

or assembly. Bearing worn, affecting

performance A . . Require replacement of bearing

or assembly. Coil shows signs of

overheating 1 .... Suggest replacement of coil.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted,

affecting performance . . A

Connector melted, not

affecting performance . . 2

Connector missing C

Hub broken A

Hub cracked B

Hub loose on shaft A

Hub scored, affecting

performance A

Hub warped, affecting

performance A

Inoperative A

Noisy 2

Slips A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2
Terminal corroded,

affecting performance .. . A
Terminal corroded, not

affecting performance .. 2
Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Will not disengage A

Wire lead burned A

Wire lead conductors

exposed B

Wire lead open A

Wire lead shorted A

(1) Require repair or

replacement.

(1) Suggest repair or

replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

(2) Require repair or

replacement.

Suggest repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Require repair or replacement.

Require repair or replacement. Require repair or replacement. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

COMPRESSORS

COMPRESSOR INSPECTION

Condition

Code

Procedure


A

Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not
functioning A

Bracket bent, affecting
performance A

Bracket bent, not affecting performance

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement.

No service suggested or required.

Bracket broken, affecting

performance A Require replacement.

Bracket broken, not

affecting performance No service suggested or

required. Bracket corroded,

affecting performance .. A .. Require repair or replacement. Bracket corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting

performance A . . Require repair or replacement.

Bracket cracked, not

affecting performance .. 1 .. Suggest repair or replacement. Bracket holes elongated,

affecting performance .. A .. Require repair or replacement. Bracket holes elongated,

not affecting

performance No service suggested or

required. Bracket loose, affecting

performance A .. Require repair or replacement.

Bracket loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Bracket missing C Require replacement.

Housing broken, affecting

performance A . . Require repair or replacement.

Housing broken, not

affecting performance No service suggested or

required. Housing cracked, affecting

performance A . . Require repair or replacement.

Housing cracked, not

affecting performance .. 1 .. Suggest repair or replacement.

Inoperative A (1) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Noisy 2 (2) Suggest repair or

replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Tubing connection

leaking A . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of

OEM specification.

(2) - Compressor noise can also be caused by low oil level,

state of charge, air contamination, or type of refrigerant.

CONDENSER AIR SEALS

CONDENSER AIR SEAL INSPECTION

Condition Code Procedure

Leaking A . Require repair or replacement.

Missing C Require replacement.

CONDENSER FAN MOTORS

See COOLING FAN MOTORS.

CONDENSERS

CONDENSER INSPECTION

Condition Code Procedure

Abrasion damage, affecting

structural integrity ... A .. Require repair or replacement. Abrasion damage, not

affecting structural

integrity No service suggested or

required. Air flow obstruction,

affecting performance .. A .. Require repair or replacement. Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Bent, affecting

performance A . . Require repair or replacement.

Bent, not affecting

performance No service suggested or

required. Bracket bent, affecting

performance A . . Require repair or replacement.

Bracket bent, not

affecting performance No service suggested or

required. Bracket broken, affecting

performance A Require replacement.

Bracket broken, not

affecting performance No service suggested or

required. Bracket corroded,

affecting performance .. A .. Require repair or replacement. Bracket corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting

performance A . . Require repair or replacement.

Bracket cracked, not

affecting performance .. 1 .. Suggest repair or replacement. Bracket holes elongated,

affecting performance .. A .. Require repair or replacement. Bracket holes elongated,

not affecting

performance No service suggested or

required. Bracket loose, affecting

performance A .. Require repair or replacement.

Bracket loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Bracket missing C Require replacement.

Corroded, affecting

structural integrity ... A Require replacement.

Corroded, not affecting

structural integrity No service suggested or

required. Fitting type incorrect

(such as compression

fitting) B Require replacement.

Flange leaking A . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Restricted internally ... A .. Require repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

CONTROL CABLES

CONTROL CABLE INSPECTION


Condition

Attaching hardware
broken

Code

A

Attaching hardware
missing

Attaching hardware not
functioning A

Binding A

Bracket bent, affecting
performance A

Bracket bent, not affecting performance

Bracket broken, affecting
performance A

Bracket broken, not affecting performance

Bracket corroded,

affecting performance .. . A Bracket corroded, not

affecting performance . . 2 Bracket cracked, affecting

performance A

Bracket cracked, not

affecting performance .. . 1 Bracket holes elongated,

affecting performance ... A Bracket holes elongated,

not affecting

performance

Bracket loose, affecting

performance A

Bracket loose, not

affecting performance .. . 1

Bracket missing C

Broken A

Cracked 2

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

No service suggested or required.

Require replacement.

No service suggested or required.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

No service suggested or required.

Require repair or replacement.

Suggest repair or replacement.

Require replacement.

Require repair or replacement. Suggest repair or replacement.

Disconnected A .. Require repair or replacement.

Kinked 2 . . Suggest repair or replacement.

Melted A ( 1) Require repair or

replacement.

Missing C Require replacement.

Out of adjustment B (2) Require repair or

replacement.

Routed incorrectly 2 Suggest repair.

Seized A . . Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Follow OEM recommended adjustment procedures. Require

repair or replacement if out of specification.

CONTROL HEADS (FUNCTION SELECTORS)

CONTROL HEAD (FUNCTION SELECTOR) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted,

affecting performance . . A (1) Require repair or

replacement. Connector melted, not

affecting performance .. 2 (1) Suggest repair or

replacement.

Connector missing C Require replacement.

Contaminated 2 .... Suggest require replacement.

Leaking A . . Require repair or replacement.

Malfunctioning A (2) Require repair or

replacement. Melted, affecting

performance A (1) Require repair or

replacement. Melted, not affecting

performance No service suggested or

required.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Wire lead burned A .. Require repair or replacement.

Wire lead conductors

exposed B .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Includes inoperative, intermittent operation, or failure

to perform all functions.

CONTROL LINKAGES

CONTROL LINKAGE INSPECTION


Code

Condition

A

Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not
functioning A

Bent A

Binding A

Bracket bent, affecting
performance A

Bracket bent, not affecting performance

Bracket broken, affecting
performance A

Bracket broken, not affecting performance

Bracket corroded,

affecting performance .. . A Bracket corroded, not

affecting performance . . 2 Bracket cracked, affecting

performance A

Bracket cracked, not

affecting performance .. . 1 Bracket holes elongated,

affecting performance ... A Bracket holes elongated,

not affecting

performance

Bracket loose, affecting

performance A

Bracket loose, not

affecting performance .. . 1

Bracket missing C

Broken A

Cracked A

Disconnected A

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement. Require repair or replacement.

Require repair or replacement.

No service suggested or required.

Require replacement.

No service suggested or required.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

No service suggested or required.

Require repair or replacement.

Suggest repair or replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Missing C Require replacement.

Noisy 2 . Suggest repair or replacement.

Out of adjustment B (1) Require repair or

replacement.
Seized A . Require repair or replacement.

(1) - Follow OEM recommended adjustment procedures. Require repair or replacement if out of specification.

CONTROL MODULES

NOTE: Includes, but not limited to: IRCM, Coolant Fan Control Module (CFCM), AC Controller, Amplifier, Programmers, Control Heads, Power Modules, etc.

CONTROL MODULE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

missing C Require replacement of

hardware. Attaching hardware

threads damaged A ... Require repair or replacement

of hardware. Attaching hardware threads stripped

(threads missing) A ... Require repair or replacement

of hardware. Code set

(if applicable) A (1) Further inspection

required.

Connector broken A .. Require repair or replacement.

Connector melted,

affecting performance . . A (2) Require repair or

replacement. Connector melted, not

affecting performance .. 2 (2) Suggest repair or

replacement.

Connector missing A Require repair.

Contaminated A (3) Require repair or

replacement.

Inoperative B (4) Require repair or

replacement. Further inspection required.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (2) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead corroded A .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Refer to manufacturers diagnostic trouble code

procedure and require repair or replacement of affected component(s).

(2) - Determine cause and correct prior to repair or

replacement of part.

(3) - Determine source of contamination, such as engine coolant,

fuel, metal particles, or water. Require repair or replacement. Check for accepted cleaning procedure.

(4) - Inoperative includes intermittent operation or out of

OEM specification. Some components may be serviceable.

COOLANT

COOLANT INSPECTION

Condition Code Procedure

Acidity (pH) incorrect .. 1 Suggest correction or

replacement.

Contaminated B (1) Require replacement or

recycling. Further inspection required.

Level incorrect B (2) Require filling to

proper level.

Maintenance intervals ... 3 (3) Suggest replacement.

Mixture incorrect B Require correction or

replacement.
Type incorrect B Require replacement.

(1) - Determine source of contamination and require correction

prior to coolant replacement.

  1. - Determine source of incorrect level and suggest repair.

  2. - The system should be drained and/or flushed and

refilled with correct coolant according to OEM recommended service interval and procedures.

COOLING FAN BLADES

COOLING FAN BLADE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bent A Require replacement.

Broken A Require replacement.

Cracked A Require replacement.

Loose A . . Require repair or replacement.

Missing C Require replacement.

COOLING FAN CLUTCHES

NOTE: Some lateral movement, measured at the fan blade tip, may be normal.

COOLING FAN CLUTCH INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Bearing noisy A Require replacement.

Bearing worn A Require replacement.

Fastener loose A ... Require repair or replacement

of fastener.

Inoperative A ( 1) Require replacement.

Leaking 1 Suggest replacement.

Seized A Require replacement.

Slips (insufficient fan

speed) A Require replacement.

Thermal control

incorrect B . . Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

COOLING FAN MOTORS

COOLING FAN MOTOR INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted,

affecting performance . . A (1) Require repair or

replacement.

2

Connector melted, not affecting performance

Connector missing C

Hydraulic fan motor

leaking A

Inoperative A

Missing C

Noisy 2

Rotation incorrect for

application B

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2
Terminal corroded,

affecting performance .. . A
Terminal corroded, not

affecting performance .. 2
Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Vibration 1

Wire lead conductors

exposed B

Wire lead corroded A

Wire lead open A

Wire lead shorted A

(1) Suggest repair or

replacement.

Require replacement.

Require repair or replacement.

(2) Require replacement.

Require replacement.

Suggest replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.

Suggest repair or replacement.

Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement.

Suggest repair or replacement.
Suggest replacement.

Require repair or replacement.

.. Require repair or replacement.

.. Require repair or replacement.

Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Check fan motor/controls. Inoperative includes

intermittent operation or out of OEM specification.

EVAPORATOR DRAIN TUBES

EVAPORATOR DRAIN TUBE INSPECTION


Code

Condition

Disconnected A

Leaking A

Missing C

Restricted A

Routed incorrectly B

Procedure

Require repair.

Require replacement.

Require replacement.

Require repair or replacement.
Require repair.

EVAPORATOR PRESSURE REGULATORS (EPRS)

EVAPORATOR PRESSURE REGULATOR (EPR) INSPECTION

Condition Code

Inoperative A

Procedure

(1) Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

EVAPORATORS

EVAPORATOR INSPECTION

Condition Code Procedure

Abrasion damage, affecting

structural integrity ... A .. Require repair or replacement. Abrasion damage, not

affecting structural

integrity No service suggested or

required. Air flow obstruction,

affecting performance .. A .. Require repair or replacement. Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Bracket bent, affecting

performance A . . Require repair or replacement.

Bracket bent, not

affecting performance No service suggested or

required. Bracket broken, affecting

performance A Require replacement.

Bracket broken, not

affecting performance No service suggested or

required. Bracket corroded,

affecting performance .. A .. Require repair or replacement. Bracket corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting

performance A . . Require repair or replacement.

Bracket cracked, not

affecting performance .. 1 .. Suggest repair or replacement. Bracket holes elongated,

affecting performance .. A .. Require repair or replacement. Bracket holes elongated,

not affecting

performance No service suggested or

required. Bracket loose, affecting

performance A .. Require repair or replacement.

Bracket loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Bracket missing C Require replacement.

Corroded, affecting

structural integrity ... A Require replacement.

Corroded, not affecting

structural integrity No service suggested or

required. Evaporator foam seal

leaking A Require replacement.

Evaporator foam seal

missing C Require replacement.

Fitting type incorrect

(such as compression

fitting) B Require replacement.

Flange leaking A . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Restricted internally ... A .. Require repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

EXPANSION VALVES

EXPANSION VALVE INSPECTION


Code

Condition

Application incorrect
Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not
functioning

Corroded internally
Filter screen torn
Inoperative

Leaking

Restricted

Threads damaged

Threads stripped (threads
missing)

Procedure

Require replacement.

A ... Require repair or replacement

of hardware.

Require replacement of

hardware.

A ... Require repair or replacement

of hardware.

1 Suggest replacement.

A .. Require replacement of screen.

A (1) Require repair or

replacement.

A Require replacement.

A .. Require repair or replacement.

A .. Require repair or replacement.

A Require replacement.

(1) - Expansion valve operation may be affected by capillary tube location, corrosion, and insulation tape. Inoperative includes intermittent operation.

FUNCTION SELECTORS

See CONTROL HEADS (FUNCTION SELECTORS) .

FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS

FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION


Condition

Application incorrect

Blown

Corroded, affecting

performance

Corroded, not affecting

performance

Cracked, affecting

performance

Cracked, not affecting

performance

Code

Procedure

Require replacement.

A 2 A

A (1) Require replacement.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. (2) Require replacement.

Inoperative A

Insulation damaged,

conductors exposed A .. Require repair or replacement.

Insulation damaged,

conductors not exposed . 1 .. Suggest repair or replacement.

Missing C Require replacement.

Routed incorrectly B Require repair.

Secured incorrectly B Require repair.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Determine cause and correct prior to replacement

of part.

(2) - Inoperative includes intermittent operation.

FUSIBLE LINKS

See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS.

GASKETS

GASKET INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

HEATER CASES

See PLENUMS.

HEATER CONTROL VALVES

HEATER CONTROL VALVE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Attaching hardware not
functioning A ... Require repair or replacement

Binding 2

Coolant leak A

Disconnected A

Malfunctioning A

Missing C

Restricted A

Seized A

Vacuum leak A

of hardware.

Suggest repair or replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.
Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

(1) - Includes inoperative, intermittent operation, or failure to perform all functions.

HEATER CORES

HEATER CORE INSPECTION

Condition Code

Air flow obstruction .... A
Attaching hardware
broken A

Attaching hardware
missing

Attaching hardware not
functioning A

Connection leaking A

Corroded 1

Disconnected A

Fins damaged, affecting
performance A

Fins damaged, not affecting performance

Internal restrictions,

affecting performance ... A

Leaking A

Missing C

Procedure Require repair or replacement.

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Require repair or replacement.

No service suggested or required.

Require repair or replacement.

Require repair or replacement.

Require replacement.

HEATER HOSES

HEATER HOSE INSPECTION


Code

Condition

Application incorrect ... B

Connected incorrectly ... A

Corroded, not reusable .. 1

Cracked A

Hard (brittle) 1

Inner fabric (webbing)

damaged A

Insufficient clamping force, allowing hose to

leak A

Leaking A

Maintenance intervals ... 3

Procedure

Require replacement.

Require repair.

Suggest replacement.

Require repair or replacement.

Suggest repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Suggest replacement.

Melted 1 . . Suggest repair or replacement.

Missing C Require replacement.

Outer covering damaged .. 1 Suggest replacement.

Outer covering damaged to

the extent that the inner

fabric is visible A Require replacement.

Protective sleeves

damaged 2 . Suggest replacement of sleeves.

Protective sleeves

missing 2 . Suggest replacement of sleeves.

Restricted, affecting

performance A .. Require repair or replacement.

Restricted, not affecting

performance 2 . . Suggest repair or replacement.

Routed incorrectly 2 Suggest repair.

Safety clip missing C Require replacement.

Spongy 1 . . Suggest repair or replacement.

Stripped A Require replacement.

Surface cracks (dry-
rotted) 1 .. Suggest repair or replacement.

Swollen B Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Type incorrect 1 . . Suggest repair or replacement.

HIGH PRESSURE RELIEF VALVES (HPRV)

HIGH PRESSURE RELIEF VALVE (HPRV) INSPECTION

Condition Code Procedure

Inoperative A (1) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads
missing) A Require replacement.

(1) - Inoperative includes intermittent operation or out of
OEM specification.

IDLERS

See TENSIONERS.

IN-LINE FILTERS

IN-LINE FILTER INSPECTION

Condition Code Procedure

Connection leaking B .. Require repair or replacement.

Leaking A . . Require repair or replacement.

Restricted A Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads
missing) A Require replacement.

METAL FITTINGS

See AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .

METAL LINES

See AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .

MIX AND AIR CONTROL DOORS (BLEND DOORS)

See PLENUMS.

O-RINGS

O-RING INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

ORIFICE TUBES

ORIFICE TUBE INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Bypassing internally .... A .. Require repair or replacement.

Filter screen torn A Require replacement.

Installation incorrect .. B Require repair.

Restricted A .. Require repair or replacement.

PILOT-OPERATED ABSOLUTES (POAS)

PILOT-OPERATED ABSOLUTE (POA) INSPECTION

Condition Code Procedure

Connection damaged B .. Require repair or replacement.

Fitting damaged B . . Require repair or replacement.

Inoperative A (1) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

PLENUMS

PLENUM INSPECTION

Condition

Code

Procedure


Air control door

binding A

Air control door

broken A

Air control door

leaking A

Air control door

seized A

Attaching hardware

broken A

Attaching hardware

missing C

Attaching hardware not

functioning A

Cracked 2

Drain hole restricted ... A

Drain plugged A

Duct disconnected A

Duct leaking A

Duct missing C

Duct restricted A

Leaking A

Noisy 2

Odor 2

Restricted A

Require repair or replacement Require repair or replacement. Require repair or replacement. Require repair or replacement.

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Suggest repair or replacement.

Require repair.

Require repair.

Require repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Suggest cleaning or repair.

Suggest cleaning or repair.

Require cleaning, repair, or

replacement.

PRESSURE CONTROL VALVES

See:

  1. EVAPORATOR PRESSURE REGULATORS (EPRS)

  2. HIGH PRESSURE RELIEF VALVES (HPRV)

  3. PILOT-OPERATED ABSOLUTES (POAS)

  4. SUCTION THROTTLING VALVES (STVS)

  5. VALVES IN RECEIVER (VIRS)

PRESSURE SENSORS

See THERMISTORS AND PRESSURE SENSORS.

PULLEYS

PULLEY INSPECTION

Condition

Code

Procedure

Alignment incorrect B .. Require repair or replacement.

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning

Bearing noisy

Bearing seized

Bearing worn

Cracked

Loose

Missing

Pulley damaged, affecting
belt life

A ... Require repair or replacement

of hardware.

2 Suggest replacement.

A .. Require repair or replacement.

1 Suggest replacement.

A Require replacement.

A .. Require repair or replacement.

Require replacement.

A Require replacement.

RADIATORS

RADIATOR INSPECTION

Condition Code

Air flow obstruction .... A

Application incorrect ... B
Attaching hardware

broken A

Attaching hardware
missing

Attaching hardware not
functioning

A 1

A

A

Connection leaking . . . .
Corroded

Drain inoperative

Fins damaged, affecting

performance

Fins damaged, not

affecting performance

Internal oil cooler

A A A

leaking

Internal restrictions

Leaking

Threads damaged

Threads stripped (threads

missing)

A

Tubes damaged, affecting

performance

Tubes damaged, not

affecting performance

Procedure

. ... Require repair. Require replacement.

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Require repair or replacement.

No service suggested or required.

Require repair or replacement. Require repair or replacement. Require repair or replacement. Require repair or replacement.

Require repair or replacement. Require repair or replacement.

No service suggested or required.

RECEIVER-DRIERS

NOTE: For VIRs, see VALVES IN RECEIVER (VIRS). RECEIVER-DRIER INSPECTION


Code

Condition

Attaching hardware
broken

Attaching hardware

Procedure

A ... Require repair or replacement

of hardware.

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Contaminated, affecting

performance A Require replacement.

Dessicant bag

deteriorated A (1) Require replacement.

Further inspection required.

Dessicant at the end of its useful life (saturated

with moisture) 1

Fusible plug leaking .... A

Leaking A

Pressure relief device
leaking A

Restricted A

Sight glass no longer

transparent 2

Threads damaged A

Threads stripped (threads

missing) A

Tubing connection

leaking A

Suggest repair or replacement.

Require replacement of plug.

Require replacement.

Require replacement of pressure

relief device.

Require repair or replacement.

Suggest replacement of drier. Require repair or replacement.

Require replacement.

Require repair or replacement.

(1) - Inspect system to determine effects of dessicant bag deterioration.

REFRIGERANT

NOTE: Refrigerants include any SNAP (Significant New Alternative Policy)-approved blends.

REFRIGERANT INSPECTION

Condition

Contaminated (other than refrigerant blends)

Code

Procedure

... B Require service to remove

contamination. Different types of

refrigerants in the same

system (other than

Require repair.

Require repair.

refrigerant blends)

Overcharged

Refrigerant type

does not match

fittings and label B Require repair.

Undercharged B Require repair.

REFRIGERANT OIL

REFRIGERANT OIL INSPECTION


Code

Condition

Contaminated Overfilled

Procedure

1 .. Require repair or replacement.
Require repair.

Underfilled B Require repair.

RELAYS

RELAY INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Housing broken A Require replacement.

Housing cracked 2 Suggest replacement.

Inoperative A ( 1) Require replacement.

Melted, affecting

performance A (2) Require repair or

replacement. Melted, not affecting

performance 2 (2) Suggest repair or

replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned, affecting

performance A (2) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

(1) - Inoperative includes intermittent operation or out of

OEM specification.

(2) - Determine cause and correct prior to repair or

replacement of part.

SEALS

SEAL INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

SERVICE PORTS

SERVICE PORT INSPECTION

Condition Code Procedure

Application

does not match

refrigerant type B Require replacement.

Leaking A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Valve cap leaking A ... Require repair or replacement

of cap.

Valve cap missing C .... Require replacement of valve

cap.
Valve core sticking B .. Require repair or replacement.

SPRING LOCK COUPLINGS

SPRING LOCK COUPLING INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary.

SUCTION THROTTLING VALVES (STVS)

SUCTION THROTTLING VALVE (STV) INSPECTION

Condition Code Procedure

Connection damaged B .. Require repair or replacement.

Fitting damaged B . . Require repair or replacement.

Inoperative A (1) Require repair or

replacement.

Leaking A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

SWITCHES (ELECTRICAL)

SWITCH (ELECTRICAL) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware.

Attaching hardware not
functioning A

Binding, affecting

performance A

Binding, not affecting

performance 2

Broken A

Burned, affecting

performance A

Burned, not affecting
performance 2

Cracked, affecting

performance A

Cracked, not affecting

performance 1

Malfunctioning A

Melted, affecting
performance A

Melted, not affecting
performance 2

Missing C

Out of adjustment B

Pressure switch leaking . A

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Threads damaged A

Threads stripped (threads

missing) A

Wont return A

Worn 1

Require repair or replacement of hardware.

Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

1) Require repair or replacement.

1) Suggest repair or replacement.

Require repair or replacement.

Suggest repair or replacement.

(2) Require repair or

replacement.

(1) Require repair or

replacement.

(1) Suggest repair or

replacement.
(3) Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement.
Suggest replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Includes inoperative, intermittent operation, or failure

to perform all functions.

(3) - Missing includes high pressure cut-off switches not

installed during a retrofit from R12 to R134a.

TENSIONERS

TENSIONER INSPECTION

Condition

Code

Procedure

Alignment incorrect

Application incorrect .. .
Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not
functioning

Bearing worn

Belt tension incorrect . .

Bracket cracked

Housing cracked

Missing

Noisy

Pulley damaged, affecting

belt life

Seized

┬ .. Require repair or replacement.
Require replacement.

A ... Require repair or replacement

of hardware.

Require replacement of

hardware.

A ... Require repair or replacement

of hardware.

1 Suggest replacement.

┬ ... Require adjustment or repair.

A .. Require repair or replacement.

A .. Require repair or replacement.

Require replacement.

2 Suggest replacement.

A Require replacement.

A .. Require repair or replacement.

THERMISTORS AND PRESSURE SENSORS

NOTE: Includes, but not limited to, In-Car Temperature, Ambient Air Temperature, Sun Load Sensor, etc.

THERMISTOR AND PRESSURE SENSOR INSPECTION


Condition

Attaching hardware
broken

Code Procedure

Require repair or replacement of hardware.

Attaching hardware
missing

Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

Calibration incorrect

Connector broken

Connector (Weatherpack

type) leaking A

Connector melted,

affecting performance .. A

Require repair or replacement. Require repair or replacement.

of hardware. . . ┬ . A

Require repair or replacement.

1) Require repair or replacement.

Connector melted, not affecting performance

2 (1) Suggest repair or

replacement.

Connector missing C Require replacement.

Inoperative A (2) Require repair or

replacement.

Require replacement.

Missing

(1) Require repair or replacement.

Terminal burned, not affecting performance Terminal corroded,

affecting performance Terminal corroded, not

affecting performance

Terminal burned, affecting
performance

2 .. Suggest repair or replacement. A .. Require repair or replacement. 2 .. Suggest repair or replacement.

Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Wire lead burned A .. Require repair or replacement.

Wire lead conductors

exposed B . . Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

THERMOSTATS AND HOUSINGS

THERMOSTAT AND HOUSING INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

corroded A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Cracked A Require replacement.

Housing corroded 1 Suggest replacement of

housing.

Inoperative A (1) Require replacement.

Installation incorrect .. B .. Require repair or replacement.

Leaking A . . Require repair or replacement.

Thermostat missing C Require replacement of

thermostat.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads
missing) A .. Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM specification.

VACUUM HOSES AND TUBES

VACUUM HOSE AND TUBE INSPECTION

Condition Code Procedure

Disconnected A Require repair.

Leaking A .. Require repair or replacement.

Melted A Require repair replacement.

Missing C Require replacement.

Oil-soaked (spongy) 1 Suggest replacement.

Restricted A .. Require repair or replacement.

Routing incorrect B Require repair.

Surface cracks (dry-
rotted) 1 Suggest replacement.

VACUUM RESERVOIRS

VACUUM RESERVOIR INSPECTION


Code

Condition

Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not

functioning A

Check valve leaking

internally A

Leaking A

Missing C

Restricted A

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require replacement.

Require repair or replacement.
Require replacement.

Require repair or replacement.

VACUUM TUBES

See VACUUM HOSES AND TUBES .

VALVES IN RECEIVER (VIRS)

VALVE IN RECEIVER (VIR) INSPECTION

Condition

Application incorrect
Attaching hardware
broken

Code Procedure

Require replacement.

A ... Require repair or replacement

of hardware.

Attaching hardware
missing

C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Bracket bent, affecting

performance A . . Require repair or replacement.

Bracket bent, not

affecting performance No service suggested or

required. Bracket broken, affecting

performance A Require replacement.

Bracket broken, not

affecting performance No service suggested or

required. Bracket corroded,

affecting performance .. A .. Require repair or replacement. Bracket corroded, not

affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance A . . Require repair or replacement.

Bracket cracked, not

affecting performance Bracket holes elongated,

affecting performance Bracket holes elongated,

not affecting

performance

Bracket loose, affecting

performance A

Bracket loose, not

affecting performance .. . 1

Bracket missing C

Connection damaged B

Contaminated, affecting

performance A

Corroded internally 1

Dessicant bag

deteriorated A

Dessicant at the end of

its useful life

(saturated

with moisture) 1

Filter screen torn A

Fitting damaged B

Fusible plug leaking .... A
Inoperative
A

Leaking A

Pressure relief device
leaking A

Restricted A

Sight glass no longer

transparent 2

Threads damaged A

Threads stripped (threads

missing) A

Tubing connection

leaking A

Suggest repair or replacement. Require repair or replacement.

No service suggested or required.

Require repair or replacement.

Suggest repair or replacement.

Require replacement.

Require repair or replacement.

Require replacement. Suggest replacement.

... (1) Require replacement. Further inspection required.

Suggest repair or replacement.

Require replacement of screen.

Require repair or replacement.

Require replacement of plug.

(2) Require repair or

replacement. Require repair or replacement.

Require replacement of pressure

relief device.

Require repair or replacement.

Suggest replacement of drier. Require repair or replacement.

Require replacement.

Require repair or replacement.

(1) - Inspect system to determine effects of dessicant bag

deterioration.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

WATER PUMPS (ELECTRIC AUXILIARY)

WATER PUMP (ELECTRIC AUXILIARY) INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Require repair or replacement. Require repair or replacement.

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted,

1) Require repair or replacement.

affecting performance .. A

Connector melted, not

(1) Suggest repair or

replacement.

Require replacement.

(2) Require replacement.

Require repair or replacement.

Require replacement.

Suggest replacement.

Require repair or replacement.

affecting performance .. 2

Connector missing C

Inoperative A

Leaking A

Missing C

Noisy 2

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance Terminal corroded,

affecting performance .. Terminal corroded, not

affecting performance Terminal loose, affecting

performance

Terminal loose, not

affecting performance

Vibration

Wire lead conductors

exposed

Wire lead corroded

Wire lead open

Wire lead shorted

1) Require repair or replacement.



2 .

Suggest

repair

or

replacement.

A

Require

repair

or

replacement.

2 .

Suggest

repair

or

replacement.

Require

repair

or

replacement.

1 1

Suggest Suggest

repair or replacement. replacement.

┬ . A . A A

Require Require Require Require

repair repair repair repair

or or or or

replacement. replacement. replacement. replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Inoperative includes intermittent operation or out of

OEM specification.

WIRING HARNESSES AND CONNECTORS

WIRING HARNESS AND CONNECTOR INSPECTION

Code

Condition

Application incorrect ... B
Attaching hardware
broken A

Attaching hardware
missing
C

Attaching hardware not
functioning A

Connector broken A

Connector (Weatherpack

type) leaking A

Circuit open A

Circuit resistance

(voltage drop) out of

Procedure Require repair or replacement.

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement. Require repair or replacement.

specification A

Circuit shorted A

Connector melted,

affecting performance .. A

Connector melted, not affecting performance .. 2

Connector missing C

Diode open A

Diode shorted A

Insulation damaged,

conductors exposed A

Insulation damaged,

conductors not exposed . 1
Protective shield

(conduit) melted B

Protective shield

(conduit) missing C

Routed incorrectly B

Secured incorrectly B

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1 Voltage drop out of

specification A

Require repair or replacement. Require repair or replacement.

(1) Require repair or replacement.

(1) Suggest repair or

replacement.
Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Suggest replacement.

(1) Require replacement.

Require replacement.

Require repair.

Require repair.

Require repair or replacement.

(1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.