* 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 organization’s 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 vehicle’s (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 customer’s 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 manufacturer’s 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 manufacturer’s 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 manufacturer’s 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 customer’s need, convenience or request. If a customer’s 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 customer’s convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the vehicle’s shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customer’s 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 vehicle’s
Original Equipment Manufacturer (OEM)
4 - Technician’s 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
manufacturer’s 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.
- Determine cause of incorrect alignment and require repair.
- 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.
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
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 manufacturer’s 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.
- Determine source of incorrect level and suggest repair.
- 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:
EVAPORATOR PRESSURE REGULATORS (EPRS)
HIGH PRESSURE RELIEF VALVES (HPRV)
PILOT-OPERATED ABSOLUTES (POAS)
SUCTION THROTTLING VALVES (STVS)
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
Won’t 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.
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