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2004 S60 AC Overcharged?Undercharged? (RESOLVED:Clutch Gap+Overfilled) Topic is solved

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This topic is in the MVS Volvo Repair Database » AC Overcharged, Undercharged? Forget It, Jake. It's the Gap.
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mrbrian200
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Year and Model: 2006 S60 2.5T FWD
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Re: AC Overcharged?Undercharged?

Post by mrbrian200 »

Rattnalle wrote: 02 Jul 2018, 10:39 . 3 should be OK. But it really does sound like it's the issue.

And even if you do need to get to it it's doable without lowering the subframe, that's just extra work unless perhaps you have proper equipment.
Ah hah. I might be able to help here. I had this same problem when I first bought my S60: Clutch gap measures within spec, clutch initially engages then 'lets go' not to engage again until things have cooled off. Refrigerant charge was fine. I had resistance in the harness connector at the compressor.
The effect is the same as a large out of spec clutch gap: 'restricted' current through the wiring = lower magnetic flux. Once the engine/clutch coil got warm, the magnetic force decreased even more and once the clutch would cycle off it wouldn't re-engage until things cooled off.

My fix probably isn't the preferred way: I chopped off the connectors and soldered the wires together with shrink tubing over silicone sealant. Ideally you'd determine determine 'side' of the connection is responsible and replace it so as not to cause a headache should you ever need to remove the compressor for service. I decided chances are, it I ever were to need to disconnect the compressor, it would most likely be to replace it. If/when that's the case the new compressor will have a new plug. At that time I would replace the other end on engine harness.

Since then the car can achieve 'walk in freezer status' if I want it too. On a humid day I can get it so cold in there that condensation forms on the outside of all the windows and sunroof and I have to turn on the rain sensor to keep the windscreen clear. However I don't actually like it that cold. But the car can do it.

Do note, if resistance in the wiring is the source of your trouble, it might somewhere else on different vehicle- such as the relay or the coil ground wire etc-- or a bad clutch coil.

ThreeBear
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Post by ThreeBear »

UPDATE:

I have cold air!! After reading the suggestions from Jimmy57 I rechecked the clutch gap and was able to get a .6mm feeler gauge into the gap if I really wiggled it around and tried to force it in. I did the 'zip tie' version of the bread clip fix on the clutch which seems to have resolved the clutch gap issue.

HOWEVER, when I went out to test drive the car I still had HOT air blowing after a few minutes. I checked the clutch at idle with the AC on and it would only engage for maybe 1 second at a time. I checked the pressure with my cheap AC pro gauge and it was in the overfill region. I vented some of the refrigerant and took it out for a test drive and now I have cold AC. It was 95 degrees so I think I should have cold AC all the time now.

Thanks for everybody's help!!

Lessons learned: Double check your clutch gap, if it looks like a clutch gap issue it is a clutch gap issue. Don't over fill AC.


TLDR: I had a clutch gap issue and my ac was over filled. zip-tie fixed the clutch gap and bleed off some of the refrigerant.
2004 Volvo S60 2.4L NA 5-Speed Manual (~187,000miles)

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