Guideline for Diagnostics of the

air conditioning circuit in the vehicle

2
New generation of
fully ­automatic Bosch
air ­conditioning
service units!
u Compatible with the new regulations 2009
u Developed and manufactured by Bosch
u Very high precision during ­refrigerant filling:
accuracy +/- 10 g
u Output of monthly and annual reports on gas
­movements
u Storage of 50 documentation files which can be
­transferred via USB stick to your PC
u Display of working status, 360° all-around visibility
u Pressure gauge with large diameter, color display
and injection of UV contrast agent
u Detailed menu and display of the steps on the monitor
u Integrated database and updating via USB stick
u Heating belt and flushing functions
Change interior filter once a year of every
15 000 km!
Always remember to change the interior fil-
ter during air conditioning service. Service
is only complete with a new filter ‒ and your
customer will also perceive this.
Full benefits for the workshop...
u Additional source of turnover
u Service underscores your professionalism
in the eyes of the customer
u Simple operation for your customers
...and the car drivers
u More driving smoothness and safety
u Environmental protection
u Cost savings
 3

Overview of contents

04 Safety rules and provisions

05 Components of an air conditioner and different refrigerant circuits

06 System components of an air conditioning circuit
07 System components of an automatic air conditioning circuit
08 Two air conditioning circuits and their differences
09 Test options and reference values
10 Test options on an air conditioner
11 Reference pressure with system switched off
12 Reference pressure with system switched on
13 Reference temperature at air nozzle outlet
14 Pressure and air nozzle temperature as a function of outside temperature

15 Error diagnosis with the air conditioning service unit

16 With the system switched off: high and low pressure: below 2 bar
17 With the system switched off: high and low pressure: above 6 bar
18 With the system switched off: high and low pressure: equal to 0 bar
19 With the system switched on: low pressure low
20 With the system switched on: low pressure high
21 With the system switched on: high pressure low
22 With the system switched on: high pressure high
23 With the system switched on: high and low pressure identical
24 With the system switched on: high and low pressure low
25 With the system switched on: high and low pressure high
26 Help from ESI[tronic]

27 Diagnostics help with different fault patterns

28 Fault pattern 1: Air nozzle outlet temperature below 2°
29 Fault pattern 2: Air nozzle outlet temperature above 10°
30 Fault pattern 3: The air conditioner occasionally does not function
31 Fault pattern 4: The air conditioner does not switch on

37 ECU diagnostics relevant to the air conditioner with the KTS from Bosch
38 Check of the fault memory: Motor and air conditioner
39 Check of operating elements of the air conditioner
40 Pressure check in the refrigerant circuit
41 Check of activation of the compressor
42 Check of evaporator temperature
43 Check of interior temperature
44 Check of fan control
45 Check of position of air mixture valve
46 Check of interior ventilation system (blower)
47 Check of the solenoid clutch
4

Safety rules and provisions

Wearing of protective gloves is obligatory to prevent any liquid or steam

splashes on the skin.

Danger! Cold burns or freezing!

Wearing of protective goggles is obligatory to prevent any liquid or steam

splashes in the eyes.

Danger! Freezing of the eye fluid!

The inhalation of highly concentrated vapors, even over short periods,

must be avoided.

Danger! Unconsciousness or death!

The specifications of pressurized must be complied with! In particular,

no supply bottle (internal or external) must be filled to more than 80%
of its capacity.

Proof of performance is required prior to handling air conditioners and air conditioning service units.
The proof of performance certifies that the workshop has the technical hardware and personnel
­capable of carrying out maintenance and repair work on air conditioners.

This certification is issued for a limited period by an authorized organization, e.g. in the Bosch
­Training Centers in the framework of a training course.

How to obtain the proof of performance:

For example, by visiting an instructional course in the Bosch Service Training Center.
 5

Components of an air conditioner

and different refrigerant circuits

06 System components of an air conditioning circuit

07 System components of an automatic air conditioning circuit
08 Two air conditioning circuits and their differences
6

System components of an air conditioning circuit

Compressor Evaporator Interior filter

compacts the expanding refrigerant filters the interior air.
­refrigerant. ­lowers the temperature
at the fins and the air flow.

Solenoid clutch Interior blower

drives the guarantees circulation
­compressor. of the air flow in the pas-
senger compartment.

Evaporator sensor
or thermostat
controls the tempera-
ture development in or
at the outlet of the eva-
porator.

Ventilator Expansion valve

guarantees circula- controls the refrigerant
tion of the air flow flow.
when the vehicle is
stationary.

Condenser
controls the pressure
and the temperature in
the circuit and lique-
fies the refrigerant by
­cooling it.

Pressure switch Dryer Operating element

regulates the pressure filters moisture and impuri- permits adjustment of the
­development in the circuit. ties from the circuit. air conditioning system.

Mechanical Refrigerant in gaseous state: low pressure / low temperature

Electric Refrigerant in gaseous state: high pressure / high temperature

Coldness Refrigerant in liquid state: high pressure / high temperature

 7

System components of an automatic

air conditioning circuit

Interior
­temperature
sensor
Exterior
Heated rear
­temperature
window
sensor

Insolation
Blower
­sensor

Thermostat
Solenoid clutch
or evaporator Bedientafel mit Klima-Steuergerät of compressor
sensor

Pressure Circulating air

switch flaps motor

Motor
Mixture valve
­temperature
motor
sensor

Motor for
Supply + AVC air distribution
flap

Supply + APC ECU

Diagnosis so-
cket

All these components can be checked quickly with a diagnostics tool.

Irrespectively of whether the air conditioner is a classic model or automatic, the mechanical
! and refrigerant sections are always the same. However, there are two types of circuits.
8

Two air conditioning circuits and their differences

Traditional system with Harrison or plunging system

­expansion valve with throttle valve
(calibrated bore)

These two circuits more or less have the same method of operation.
The two components named below have different structures and are installed in different areas of the system.
The throttle valve does not regulate the flow.

How can you distinguish between them and/or recognize them?

WITH A SYSTEM WITH WITH A SYSTEM WITH

EXPANSION VALVE CALIBRATED BORE

u The filter bottle or the dryer bottle u The accumulator is installed on

is installed at the high-pressure sy- the low-pressure circuit
stem
u Thetubes on the accumulator
u The
tubes on the bottle have a have a large diameter
small diameter
 9

Test options and reference values

10 Test options on an air conditioner

11 Reference pressure with system switched off
12 Reference pressure with system switched on
13 Reference temperature at air nozzle outlet
14 Pressure and air nozzle temperature as a function of outside temperature
10

Test options on an air conditioner

Pressure check, system switched off

u Static pressure
u Engine and air conditioner switched off
u Provides an initial impression of the circuit's refrigerant filling level
u Allows you to determine the type of fault (refrigeration or electric
component)

This is always the first test that has to be carried out

! ­during troubleshooting.

Pressure check, system switched on

u Dynamic pressure
u Engine running, air conditioner switched on
u Allows you to check the different components in the refrigerant circuit

Check of temperature at air nozzle outlet

u Engine running
u Air conditioner is switched on
u Check of effect of air conditioning system

Check of interior filter

u For guaranteeing a good air flow

ECU diagnostics

u Permits the detection of faults caused by the electronics

 11

Reference pressure with system switched off

Test conditions

u Air conditioning circuit switched off for at least 5 minutes

u Engine switched off

u Air conditioning service unit connected to vehicle

u For an average outside temperature of 20 °C

LP

The pressure must be between 2 and 6 bar.

Important! The pressure values develop with the

! outside temperature, see diagram on page 14.
12

Reference pressure with system switched on

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20 °C

LP

For a compressor with variable displacement

The low pressure must be in the following range: between 1.5 and 2.5 bar
The high pressure must be in the following range: between 7 and 15 bar

For a compressor with fixed displacement

The low pressure must be in the following range: between 0.5 and 3.5 bar
The high pressure must be in the following range: between 14 and 18 bar

A compressor with variable displacement is driven continuously by the solenoid clutch.

A compressor with fixed displacement is only driven part of the time by the solenoid clutch.

Important! The pressure values develop with the

! outside temperature, see diagram on page 14.
 13

Reference temperature at the air nozzle outlet

Test conditions

u Engine running
u Air conditioning circuit in operation for at least 5 minutes
u Air conditioning service unit connected to vehicle
u For an average outside temperature of 20 °C
u Air flow directed at middle air nozzle
u Interior temperature set to minimum
u Speed of interior ventilation set to middle level
u Circulating air not activated
u Thermometer is in the middle air nozzle
u Increase temperature after 5 minutes

The temperature must be between 2° and 10 °C.

Important! The pressure values develop with the

! outside temperature, see diagram on page 14.
14

Pressure and air nozzle temperature

as a function of outside temperature

Pressure in the circuit

High pressure

Low pressure
(compressor with fixed displacement)

Low pressure
(compressor with variable displacement)

Outside air temperature

Air nozzle outlet temperature

Outside air temperature

 15

Error diagnosis with the air conditioning service unit

16 With the system switched off: high and low pressure: below 2 bar
17 With the system switched off: high and low pressure: above 6 bar
18 With the system switched off: high and low pressure: equal to 0 bar
19 With the system switched on: low pressure low
20 With the system switched on: low pressure high
21 With the system switched on: high pressure low
22 With the system switched on: high pressure high
23 With the system switched on: high and low pressure identical
24 With the system switched on: high and low pressure low
25 With the system switched on: high and low pressure high
26 Help from ESI[tronic]
16

With system switched off:

High and low pressure: below 2 bar

Test conditions

u Air conditioning circuit switched off for at least 5 minutes

u Engine switched off

u Air conditioning service unit connected to vehicle

LP

Insufficient refrigerant in the circuit. Fill with refrigerant and

The air conditioner cannot start.


perform a complete functional test.
 17

With system switched off:

High and low pressure: above 6 bar

Test conditions

u Air conditioning circuit switched off for at least 5 minutes

u Engine switched off

u Air conditioning service unit connected to vehicle

LP

Overpressure in the circuit because Check the outside temperature.

outside temperature is too high.  If it is too high, then there is no fault.

Excessive refrigerant in the refrigerant

Check the refrigerant filling level and
circuit.
 perform a complete functional test.

Important! Risk of breaking a component in the

! refrigerant circuit.
18

With system switched off:

High and low pressure: equal to 0 bar

Test conditions

u Air conditioning circuit switched off for at least 5 minutes

u Engine switched off

u Air conditioning service unit connected to vehicle

LP

Circuit completely empty. Fill with refrigerant and

The air conditioner cannot start.  perform a leak search and a complete
­functional test.
 19

With system switched on:

Low pressure low

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Check state of interior filter.

(saturated)
Poor heat exchange.  Check interior ventilation.
(malfunction)
Check state of evaporator fins. (contaminated)

Check expansion valve.

(blocked in partly closed position)
Check throttle valve.
Difficult refrigerant circulation.  (partly contaminated)
Check filter bottle.
(contaminated at outlet)
20

With system switched on:

Low pressure high

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Overpressure in the low-pressure system and Check oil level in the circuit.
insufficient coldness at the air nozzle outlet.
 (too high)

Overpressure in the low-pressure system and Check refrigerant volume.

(too high)
excessive coldness at the air nozzle outlet.
 Check function of expansion valve.
(blocked, open)

! Important! Danger to the compressor.

 21

With system switched on:

High pressure low

TEST CONDITIONS

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Underpressure in the high-pressure system

Check refrigerant volume.
and insufficient coldness at the air nozzle  (insufficient refrigerant)
outlet.

Underpressure in the high-pressure system Check the outside temperature.

and correct cold production at the air nozzle  (too low, no fault)
outlet.
22

With system switched on:

High pressure high

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Check refrigerant volume.

Overpressure in the high-pressure circuit.  (excessive refrigerant, overpressure)

Check motor ventilation system.

(not working)
Poor control of the pressure and temperature
in the high-pressure circuit.  Check function of pressure switch.
(not working)

Check function of condenser.

(contaminated)
 23

With system switched on:

High and low pressure identical

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Check tension of compressor belt.

Problem during pressure build-up.
(not sufficiently tensioned)
Check solenoid clutch.
(presence of grease)
Check solenoid clutch.
 (not in working order/no power, or ground)
Check function of compressor.
• With a compressor with variable displacement
(displacement too small)
• With a compressor with fixed displacement
(segments or the valve are not leaktight)
24

With system switched on:

High and low pressure low

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Difficult refrigerant circulation. Check refrigerant volume.

 (insufficient refrigerant)
 25

With system switched on:

High and low pressure high

Test conditions

u Engine running

u Air conditioning circuit in operation for at least 5 minutes

u Air conditioning service unit connected to vehicle

u At an average outside temperature of 20°

LP

Check refrigerant volume.

(refrigerant quantity too high)

Overpressure in the circuit.  Check motor ventilation system.

(not working)
Check function of condenser.
(contaminated)
26

Help from ESI[tronic]

u The ESI[tronic] software also contains Troubleshooting instructions for air conditioners

u These SIS Troubleshooting instructions provide a valuable insight into understanding the
method of operation of the system and help you localize the defective components
 27

Diagnostics help with different fault patterns

28 Fault pattern 1: Air nozzle outlet temperature below 2°

29 Fault pattern 2: Air nozzle outlet temperature above 10°
30 Fault pattern 3: The air conditioner occasionally does not function
31 Fault pattern 4: The air conditioner does not switch on

Certain tests and measures can be carried out with

a KTS device by monitoring the actual values and The work steps are described on the
performing actuator tests. ­respectively named pages.
28

Fault pattern 1:
Air nozzle outlet temperature below 2°

Test conditions

u Engine running
u Air conditioning circuit in operation
u Side and rear air nozzles closed
u Middle air nozzle opened
u Air flow directed at middle air nozzle
u Interior temperature set to minimum
u Speed of interior ventilation set to middle level
u Circulating air not activated
u Thermometer fitted in the middle air nozzle
u Increase temperature after 5 minutes

Check expansion valve.

(opened too wide)
Cold production too high.  Check different electric and electronic
components.
(thermostat or evaporator sensor)

Page 42
 29

Fault pattern 2:
Air nozzle outlet temperature above 10°

Test conditions

u Engine running
u Air conditioning circuit in operation
u Side and rear air nozzles closed
u Middle air nozzle opened
u Air flow directed at middle air nozzle
u Interior temperature set to minimum
u Speed of interior ventilation set to middle level
u Circulating air not activated
u Thermometer installed
u Increase temperature after 5 minutes

Carry out a complete functional test

Cold production insufficient.
 of the air conditioning system.

Carry out a complete functional test of the

Poor warm air/cold air control.  ­mechanical and electronic control system.
(check mixture valve, sensors and actuators)

Page 45
30

Fault pattern 3:
The air conditioner works sporadically

System switched off: Interruption by control.

High and low pressure NO Check refrigerant volume.
below 6 bar. (too high)

Page 40

YES

System in operation:
Low pressure correct
High pressure correct
Carry out pressure analysis.
NO
Check defective component and replace it.

YES

Temperature at inlet / outlet. Interruption by control.

NO
Filter bottle correct (replace filter bottle)

YES

Value of pressure switch, thermostat Interruption by control.

NO
or evaporator sensor correct (replace electrically / faulty sensor)

Pages 40 + 42

YES

No fault in memory for engine Interruption by control. Analyze (electronic)

NO
­management and air conditioner. malfunction and replace faulty component.

Page 40
 31

Fault pattern 4:
The air conditioner does not switch on

First step: Determine type of malfunction:

mechanical, electrical, electronic or refrigerant circuit.

Is the pressure in the refrigerant ­circuit

of the switched off air conditioner YES
­between 2 and 6 bar?

Page 40

NO

Is the pressure in the refrigerant circuit of the

NO
switched off air conditioner above 6 bar?

Page 40

NO

Is the pressure in the refrigerant circuit of the The malfunction is:

switched off air conditioner below 2 bar? electrical, electronic or mechanical.

Page 40

YES

The malfunction is in the refrigerant circuit!

Insufficient refrigerant, top up.
Continue the procedure if the A
air conditioner still does not switch on.
32

Fault pattern 4:
The air conditioner does not switch on

Are faults stored in the

YES
engine control unit?

Page 38

The malfunction is in the electronics.

Carry out the repair corresponding to the
­recorded fault and/or delete the fault code.
NO Continue the procedure if the air conditioner
still does not switch on.

Sind im Klimaanlagensteuergerät
YES
Fehler gespeichert?

Page 38

The malfunction is in the electronics.

NO
Carry out the repair corresponding to the
­recorded fault and/or delete the fault code.
Continue the procedure if the
air conditioner still does not switch on.
B
 33

Fault pattern 4:
The air conditioner does not switch on

Does the circuit closer

NO
of the air conditioner light up?

Page 39

The malfunction is electrical.

Check all fuses related to the
YES
air conditioner.
Continue the procedure if the air conditioner
still does not switch on.

Does the circuit closer

NO
of the air conditioner work correctly?

Page 39

The malfunction is mechanical.

YES Replace the switch. Continue the procedure
if the air conditioner still does not switch on.

Are faults stored in the

NO
air conditioner control unit?

Page 46

The malfunction is mechanical.

YES Check the entire ventilation:
switch, fusing, relay, blower, lines…
Carry out the repair and continue
the procedure if the air conditioner still

C does not switch on.

34

Fault pattern 4:
The air conditioner does not switch on

Start the engine, switch on the

air conditioner. NO
Does the fan work?

Page 44

The malfunction is electrical

or mechanical.
Check the entire ventilation system:
YES fusing, relay, fan, lines…
Carry out the repair and continue the
procedure if the air conditioner
still does not switch on.

Does the electric signal reach the solenoid

clutch of the compressor?
NO D
Page 47

YES

Is the current intensity correct? NO

YES

The malfunction is mechanical.

Replace the switch. Continue the procedure
if the air conditioner still does not switch on.
E
 35

Fault pattern 4:
The air conditioner does not switch on

Are continuity and internal resistance

NO
of the solenoid clutch correct?

YES

Is the chassis ground correct? NO

The malfunction is electrical.

YES Replace the defective component.
Continue the procedure if the air conditioner
still does not switch on.

Repeat the procedure from the beginning.

36

Fault pattern 4:
The air conditioner does not switch on

Is the value supplied by the thermostat

or the evaporator sensor, or the continuity, NO
correct?

Page 42

YES

Is the value supplied by the pressure switch,

NO
or the continuity, correct?

Page 40

YES

Is the value supplied by different sensors,

NO
or the continuity, correct?

Page 43

YES

Does the engine control unit allow activation

NO
of the air conditioner?

Page 43

YES
The malfunction is in the electronics.
Search for the defective component and
replace it. Continue the procedure if the
air conditioner still does not switch on.
A
 37

ECU diagnostics relevant to the air conditioner

with the KTS from Bosch

38 Check of the fault memory: Motor and air conditioner

39 Check of operating elements of the air conditioner
40 Pressure check in the refrigerant circuit
41 Check of activation of the compressor
42 Check of evaporator temperature
43 Check of interior temperature
44 Check of fan control
45 Check of position of air mixture valve
46 Check of interior ventilation system (blower)
47 Check of the solenoid clutch
38

Check of the fault memory:

Engine and air conditioner
 39

Check of operating elements of the air conditioner

40

Pressure check in refrigerant circuit

 41

Check of activation of the compressor

42

Check of evaporator temperature

 43

Check of interior temperature

44

Check of fan control

 45

Check of position of air mixture valve

46

Check of interior ventilation system

(blower)
 47

Check of the solenoid clutch

 Bosch: Skilled partner
The right to make changes of a technical nature and to alter the range on offer is reserved

for workshop business

Developments from Bosch stand for innovative progress in
­automobile manufacturing
Geared to the growing proportion of electronics in the vehicle, Bosch
offers workshops the suitable test equipment for all sizes of company
and service concepts. Sturdy, innovative, state-of-the-art automobile
technology: Computer-assisted diagnosis systems help in finding any
fault more quickly and more reliably. The modular layout using future-
oriented technologies enables broad networking and efficient use of
comprehensive information from the ESI[tronic] software. Mobility
and user-friendly user guidance support the workshop in reliable and
timesaving diagnostics.

Where to find Original Bosch Quality:

WAW 4300 D 02.2010
AA-DGP/MKT

Robert Bosch GmbH

Automotive Aftermarket
Business Unit Diagnostics
D-73201 Plochingen

www.bosch-diagnostics.com