1) Identify system type and specs (theory + action)
- Theory: Different refrigerants (R12, R134a, R1234yf) have different pressures, oils and service procedures. Correct refrigerant mass is specified for efficient heat transfer and compressor lubrication.
- Action: Verify refrigerant type and factory charge mass from the under‑hood label or service manual before doing anything.

2) Visual inspection and basic functional check (theory + action)
- Theory: Refrigerant loss is normally caused by leaks, failed fittings, or failed components (compressor, hoses, condenser). Charging without finding leaks is a temporary fix.
- Action: Inspect condenser (front of radiator), hoses, compressor clutch, accumulator/drier, fittings and orifice/expansion valve for oil stains, corrosion or damage. Note if compressor cycles or clutch engages when AC is switched on.

3) Leak detection and repair (theory + action)
- Theory: Refrigerant is a finite mass — recharging restores that mass but will not last if there’s a leak. Moisture entering through leaks causes acid and corrosion and reduces cooling capacity.
- Action: Pressure‑test and probe for leaks using one or more methods: electronic leak detector, UV dye and UV lamp, or pressurize with dry nitrogen and soap. Repair or replace leaking components and retest until no leaks are found.

4) Remove old refrigerant legally (theory + action)
- Theory: You must recover existing refrigerant rather than venting it. Recovery gives you a baseline of how much remained and avoids releasing greenhouse gases.
- Action: Use a certified recovery machine to evacuate and store the existing refrigerant prior to major work or component replacement.

5) Replace the desiccant/accumulator/receiver/drier and/or expansion device if service opened the system (theory + action)
- Theory: The drier/accumulator contains desiccant to remove moisture and trap debris. Once opened or after compressor failure, it is saturated with moisture/debris and must be replaced to protect the system.
- Action: Replace the receiver/drier or accumulator and, if applicable, the orifice tube/expansion valve when you open the system or replace compressor.

6) Oil handling and compressor service (theory + action)
- Theory: Refrigerant carries lubricant through the system; compressor needs correct type and quantity of oil. A failed compressor can contaminate oil with metal debris and acid, and oil must be flushed or replaced.
- Action: If replacing compressor, follow the manual for pre‑fill or oil transfer amounts, and replace contaminated oil. Do not mix incompatible oils (PAG vs mineral).

7) Evacuate the system with a vacuum pump (theory + action)
- Theory: A deep vacuum removes air and water vapor (non‑condensables). Water reacts with refrigerant and oil forming acids that destroy components. Vacuum also proves system tightness: a stable vacuum indicates no significant leaks.
- Action: Connect manifold gauges and vacuum pump, pull a vacuum (typically 500 microns or as manual specifies) and hold for a specified time (commonly 30 minutes to an hour). Monitor for vacuum rise (leak or moisture boil‑off).

8) Nitrogen pressure test after repair (optional but recommended) (theory + action)
- Theory: Pressurizing with dry nitrogen is safer for checking for leaks and for pressure testing repaired joints.
- Action: Pressurize to a safe test pressure with dry nitrogen and soap test fittings; repair any leaks and purge nitrogen before evacuation.

9) Recharge by weight while running and monitoring pressures/temperatures (theory + action)
- Theory: System performance depends on mass of refrigerant, not just static gauge pressures (which vary with ambient temperature and condenser airflow). Charging by weight ensures correct mass. During operation, the compressor maintains a pressure differential: evaporator saturation (low side) cools the cabin air by evaporating refrigerant, condenser (high side) rejects heat to ambient; correct charge balances those phases for proper cooling.
- Action, in order:
a) Connect manifold gauges and an accurate refrigerant scale to the refrigerant cylinder.
b) Evacuate manifolds then open low‑side service port. Start vehicle, set blower to max, AC to MAX, set engine speed per manual (often idle to ~1500 rpm). Allow compressor clutch to engage.
c) Add refrigerant by weight into the low‑side service hose as vapor (follow manufacturer mass). Add gradually and watch low/high pressures and evaporator outlet temperature.
d) Stop adding when specified mass is reached. If you must use pressure as guide, use pressure/temperature charts appropriate for refrigerant and ambient conditions—do not rely solely on a single pressure number.

10) Functional verification and system balancing (theory + action)
- Theory: Correct pressures, a stable compressor current, and evaporator outlet temperature confirm correct refrigeration cycle operation. Abnormal readings indicate restriction, over/under charge, poor condenser airflow, or failed compressor.
- Action: With system at steady state, record low and high pressures, compressor amp draw, and vent temperature at vent/evaporator outlet. Typical diagnostics: low suction pressure + high head pressure = undercharge or restriction; low suction and low head = undercompressing compressor; high suction = overcharge or poor condenser.

11) Explain how the repair (recharge) fixes the fault
- If the fault is low refrigerant: Replacing lost refrigerant restores the evaporator’s ability to absorb heat (evaporator saturation temperature drops), restores the proper suction pressure so the compressor can pump refrigerant effectively, and returns the cooling capacity to specification. Vacuuming beforehand removes moisture and non‑condensables that otherwise reduce heat transfer and cause corrosive damage, and replacing the drier stops future moisture contamination.
- If the fault is a leak: Charging without repairing the leak only temporarily restores cooling. Permanent repair requires finding and fixing the leak and replacing the drier; then a full evacuation and recharge restores a clean, dry refrigerant charge.
- If the fault is component failure (seized compressor, clogged orifice/expansion valve, collapsed condenser fins): Recharging alone will not help. Replacing the failed component removes the mechanical or flow restriction, then evacuating, replacing the drier, and recharging returns the refrigerant mass and proper lubrication, restoring cooling.

12) Final checks and documentation (theory + action)
- Theory: Record keeping shows what was done, how much refrigerant/oil was used and provides baseline for future diagnosis.
- Action: Note refrigerant type and weight added, pressures/temperatures, and any parts replaced. Dispose/recycle empty refrigerant cylinders and recovered refrigerant per law.

Safety and regulatory notes (concise)
- Do not vent refrigerant to atmosphere; use certified recovery equipment. Use correct PPE for refrigerant and high pressure. Follow local laws—A/C service often requires certification.

End.
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