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Diagnostic procedure

WARNING: This page is about a different car, the 2005 Mazda 6. However, it is still accessible from the selected car via links, so may be relevant.
NO. 9 NOISE WHILE OPERATING A/C SYSTEM DIAGNOSTIC PROCEDURE

STEP INSPECTION ACTION
1 INSPECT A/C COMPRESSOR SLIPPAGE NOISE 
  • Is there a squeaking or whirling sound (A/C compressor slippage noise)?
 Yes Go to Step 13.
No Go to next step.
2 INSPECT A/C COMPRESSOR INTERFERENCE NOISE 
  • Is there a rattling or vibrating sound (interference noise)?
 Yes Go to Step 17.
No Go to next step.
3 INSPECT MAGNETIC CLUTCH OPERATION NOISE 
  • Is there a clicking sound (magnetic clutch operation noise)?
 Yes Adjust clearance between pressure plate of magnetic clutch and A/C compressor pulley, then go to Step 18.
(See MAGNETIC CLUTCH ADJUSTMENT .)
No Condition is normal. (Recheck malfunction symptoms.)
4 INSPECT A/C COMPRESSOR NOISE TIME 
  • Is noise heard continuously for 3 s or more  after A/C compressor comes on?
 Yes Go to next step.
No Condition is normal. (Noise occurs for 2-3 s  immediately after A/C compressor turns on.)
5 INSPECT IDLE SPEED 
 Yes Go to next step.
No Follow the repair instruction described in section F, then go to Step 18.
6 INSPECT REFRIGERANT AMOUNT 
  • Inspect refrigerant amount.
  • Is it okay?
 Yes Go to Step 9.
No Go to next step.
7 INSPECT REFRIGERANT LINES 
  • Inspect refrigerant lines.
    • Is piping free of damage and cracks?
    • Are piping connections free of oil grime? (Visual inspection)
    • Are piping connections free of gas leakage?
    • Are piping installation points on condenser free of gas leakage?
    • Are piping installation points on receiver/drier free of gas leakage?
    • Are piping installation points on A/C compressor free of gas leakage?
    • Are piping installation points on A/C unit free of gas leakage
    • Perform gas leak inspection using gas leak tester.
  • Are above items okay?
 Yes Go to next step.
No If piping or A/C component(s) is damaged or cracked, replace then go to Step 18.
If there is gas leakage, repair or replace connection and replace condenser(1) , then go to Step 18.
8 INSPECT EVAPORATOR PIPING CONNECTIONS IN A/C UNIT FOR GAS LEAKAGE 
  • Are piping connections for evaporator in A/C unit free of gas leakage?
 Yes Adjust refrigerant amount to specified level, then go to Step 18.
No If piping is damaged or cracked, replace then go to Step 18.
If there is gas leakage, repair or replace connection and replace condenser(1) , then go to Step 18.
9 CHECK TO SEE WHETHER MALFUNCTION IS IN COMPRESSOR OIL OR ELSEWHERE 
  • Add 20 ml {20 cc, 0.8 fl oz}  of compressor oil.
  • Is noise heard when racing engine?
 Yes Go to next step.
No Troubleshooting completed.
Explain repair to customer.
10 CHECK TO SEE WHETHER MALFUNCTION IS IN A/C COMPRESSOR OR ELSEWHERE 
  • Drain compressor oil.
  • Is it contaminated with metal particles?
 Yes Go to next step.
No Replace A/C compressor, then go to Step 18.
11 CHECK TO SEE WHETHER MALFUNCTION IS SOMEWHERE IN A/C SYSTEM OR ELSEWHERE 
  • Is compressor oil whitish and mixed with water?
 Yes Replace entire A/C system (excluding heater), then go to Step 18.
No Go to next step.
12 INSPECT A/C COMPRESSOR OIL 
  • Is compressor oil darker than normal and contaminated with aluminum chips?
 Yes Replace A/C compressor and condenser, then go to Step 18. (Since A/C compressor may be worn and receiver/drier may be clogged, replacement of receiver/drier is necessary.)
No Condition is normal. Recheck malfunction symptoms.
13 CHECK TO SEE WHETHER MALFUNCTION IS IN A/C COMPRESSOR OR ELSEWHERE 
  • Is noise heard immediately after A/C compressor is stopped?
 Yes Replace A/C compressor, then go to Step 18. (A/C compressor discharge valve left open)
No Go to next step.
14 INSPECT DRIVE BELT 
 Yes Go to next step.
No Adjust or replace drive belt, then go to Step 18.
15 INSPECT DRIVE BELT CONDITION 
  • Is drive belt worn?
  • Does it have foreign material imbedded in it, or have oil on it?
 Yes Remove obstruction, remove oil, or replace drive belt, then go to Step 18.
No Go to next step.
16 INSPECT MAGNETIC CLUTCH 
 Yes Replace A/C compressor (excluding pressure plate, A/C compressor pulley, and stator), then go to Step 18.
No Replace magnetic clutch, then go to Step 18.
17 CHECK TO SEE WHETHER MALFUNCTION IS IN A/C COMPRESSOR OR REFRIGERANT LINES 
  • Is noise emitted from A/C compressor?
 Yes Visually inspect A/C compressor, replace appropriate parts if necessary, then go to next step.
No If noise is due to refrigerant lines, repair detached or missing clips, tighten loose bolts, then go to next step.
18 VERIFY THAT MALFUNCTION SYMPTOM OCCURS AFTER REPAIR 
  • Has A/C compressor noise stopped?
 Yes Troubleshooting completed.
Explain repairs to customer.
No Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
(1) If there is gas leakage, air enters into the A/C system. The desiccant within the receiver/drier absorbs the moisture from the air and becomes saturated. If the A/C system is used in this condition, the inside of the A/C compressor will begin to rust due to this moisture, which may cause lock up or noise to occur. Therefore, replacement of the receiver/drier is necessary.
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