06 XC AC Problem

Post by **IdahoBob** » 31 Jul 2016, 20:02

My '06 XC70 developed a small leak in the AC condensor. I installed a new, aftermarket (Chinese) condensor, and then took the car to the local Volvo guy. He charged the system, and it will work, as long as it's not hotter than about 80 degrees outside. The clutch would release after the compressor ran for maybe 30-45 seconds. I checked the gap (.6 mm). I'll write a post about gapping the AC clutch on the '06, since the clutch design has changed, and the bread clip and/or tie-wrap fix won't work on this newer design. I replaced the clutch, as it wouldn't hold, and the two contact faces were pretty pitted up and grooved out from the de-icer we have here in the winter. This new clutch is gapped at .3mm, and the system does the same: works fine until the outside temp gets up to about 80 degrees F, then the clutch releases. It will occasionally grab again, but release again after a few seconds. The AC guy replaced a questionable relay, and has an engine control relay on order. He says the engine relay is really hot when the AC is running. I checked the engine relay on my '04 XC70, and it gets pretty hot also when the AC is running. The two relays are different part numbers; so I can't swap them to see what the '06 does. Does anyone have any ideas on what I can check and/or suggest to the AC guy, rather than continue to throw parts at this thing? Please Advise, Happy Motoring!

Post by **MadeInJapan** » 01 Aug 2016, 20:56

I would decrease the gap even more...even .3 sounds a bit large to me. I don't think the relay has anything to do with it- they all get hot as they click on and off.

Post by **chrism** » 02 Aug 2016, 13:38

The way you describe the clutch engaging and disengaging it sounds more like it just wasn't fully charged. Also, is the radiator fan clicking on?

Post by **IdahoBob** » 02 Aug 2016, 20:00

Thanks guys...your questions led me to call the dealer, to get the spec on the gap for this model. They checked the Volvo database, and verified that it's the same as with the previous compressor (the one in the XC70's up through '04 or '05), the clutch on the compressor for the '06 gaps at .3-.5mm. Mine is .3mm... And, yes, the radiator fan is clicking on. It runs more frequently that one on my '02 & '04 XC70's. I'll ask the AC guy to verify the charge, and check the low pressure switch. If anyone else has things to check...I'm listening. Thanks!

Post by **mrbrian200** » 06 Aug 2016, 01:04

My '06 S60 AC acted about the same (didn't work on hot days, and/or only for short periods). Resistance in the pigtail connector for the clutch. Chopped out the connectors and for the time being just stripped off enough insulation to tie both ends together with a wire nut + couple cable ties to secure the wire to keep it away from the pulley. Sometime before winter I'll decide whether to track down new oe style pigtails or just solder and seal the wires together permanently. I don't see taking the compressor off often enough to worry about it all that much. If I ever need to replace the compressor I would need to find the engine harness side as chopping the connector off a new compressor would void any warranty.

I initially assumed it was likely a worn clutch/excessive gap, but I couldn't get a 0.6mm feeler in there (and from what I gather it generally isn't a problem until that gap approaches 0.8 or greater) so I looked at the electrical side which turned out to be far easier than messing with the clutch. Remove the flexible part of the charge pipe attached to the intercooler on that side to get easier access to that wiring loom....if that is your problem.

Icy cold all the time after that. Just drove cross country day before yesterday. It was 100-102F for a stretch through Missouri/eastern Kansas. AC worked awesome the whole way until I got into Colorado where I didn't need it any more.

Post by **mayorpeoria** » 06 Aug 2016, 09:43

Other items to check in my eye are both low pressure and high pressure switches, this really sounds to me like it’s not fully charged too, maybe faulty gauges? Is the a/c guy charging by using gauges or vacuuming down and putting in proper amount? even if it is 40 lbs. on the low side (not as cool interior vent temp) and it corrects the clutch disengagement it would be OK.

zjevik · Post by **zjevik** » 06 Aug 2016, 20:50

I had a similar behavior when I accidentally overcharged my AC. It was working perfectly fine until I drove it for more than 10 minutes in 90 degrees weather(South Florida). You might consider going to dealer or different AC place and recharge it again before throwing more new parts in it.

Post by **vtl** » 07 Aug 2016, 07:51

I'd say, it is OVERcharged. Or the system got too much moisture, system was not vacuumed well, and now ice blocks the flow.