A/C compressor cycles on and off while driving?

Tiny
WISH30
  • MEMBER
  • 1999 FORD COUGAR
  • 2.0L
  • 4 CYL
  • 2WD
  • MANUAL
  • 280,000 MILES
I had lot of problems with the system and most of them solved (for example last year when it was leaking from dryer and 5 mechanics told me it is the cabin evaporator, and I found the leak with mosquito UV lamp). Everything was okay one year since about two months ago when compressor started short cycling on lower RPMs, and the blowed air wasn't cool enough even on high RPMs. A mechanic recharged the system telling me that 50g of frayon were missing. Everything started normally again about 20 days, when the same problem appeared again. I found a leak on low pressure line (pipe-hose-pipe at one of the joints, normally again with the mosquito lamp). The hose was replaced and reassembled with a new one and the system was recharged. Now when I'm driving, I notice that compressor makes short cycling again (but blowed air is cool enough as I think), then when stand in place on idle, compressor stays turned on and air blows cold. Please help me with some further instructions. Thanks in advance.
Wednesday, August 23rd, 2023 AT 4:49 PM

33 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
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It sounds like you have a leak again, but to be sure here is how to check the pressures to help confirm the issue:

https://youtu.be/4EqdrBVb0sY?si=glgC31-t1wj7af3S

This guide can help you find the leak:

https://www.2carpros.com/articles/air-conditioner-leak-detection

Please go over these guides and get back to us.
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Thursday, August 24th, 2023 AT 12:43 PM
Tiny
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When it was leaking the short cycling was on idle, but when driving the compressor was active all the time and blowed air was not cold enough as it should be, now the situation is opposite, on iddle compressor works continously and air is cold as it should be, when driving it makes short cycles.
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Thursday, August 24th, 2023 AT 1:15 PM
Tiny
KEN L
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I see, it sounds like you have too much refrigerant in the system. Let's check the high side pressure to confirm the problem.
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Friday, August 25th, 2023 AT 11:45 AM
Tiny
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I don't have a gauge to measure that but will to it these days.
Tonight, I plan to make some electrical inspections (to be sure if the clutch connector and relay are okay).
I'm going to connect small bulb to the clutch relay power supply and lead it to the cabin (with thin wire) to be able to see if the system cuts out the power to the relay, or maybe the relay cuts out itself.
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Friday, August 25th, 2023 AT 11:50 AM
Tiny
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I quit my plan with bulbs, because I made some connection as showed on the diagram (with small dash bulbs) thinking that when relay receive power first bulb will turn on, and also the second at the same time when it is connected to ground with the closed contact of relay.
(That plan was to check if the relay is losing power from the system, or it is losing contact on switching terminals)

But in reality, something is not as I planned in theory. When I turn the ignition both bulbs turned on, and when started AC, both bulbs turned off :)

Next idea was to try with swapping horn and clutch relays and give some try of couple of days to see if problem still occurs, BUT it was also not possible in practice as in theory, the clutch just turned on and off immediately and then did not come on again. The relays are the same model, but of AC is blue color 30A and of horn is brown color 20A.

Then I turned back to the original position, so today I plan to mechanically open the clutch relay and gently clean the switching contact points and give it a try for a couple of days. If the problem still occur, will ask some AC mechanic to measure the high pressure if it is in the normal range.
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Saturday, August 26th, 2023 AT 6:34 AM
Tiny
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Yesterday I went to Ac "mechanic" and he did recharge of the system, saying the refrigerant level is okay. Tonight, I did test driving, and the compressor did the same, 10-15 seconds cycling. Any further advice?
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Wednesday, August 30th, 2023 AT 11:59 AM
Tiny
KEN L
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I am wondering if you have a compressor clutch coil going out, I liked the idea of the bulb, but I would piggyback the circuit to the compressor clutch then to the bulb then to ground. Here are the A/C and compressor wiring diagrams so you can see how the system works. This way you can see if the signal is causing it or the compressor, please let me know.
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Saturday, September 2nd, 2023 AT 12:49 PM
Tiny
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This is pretty complicated for me, but also almost impossible for our "professional mechanics".

I gave a try to the high-pressure switch and will see what will happen.

Explanation: I have done jump test, the high-pressure switch has 4 contacts, two of them are normally closed, so when the connector is removed and those contacts jumped, the clutch turns on and compressor works with both radiator fans running on normal speed, and when other two pins jumped, radiator fans start high speed.

My logical opinion was that when starting A/C the fans work normal, when rising the pressure fans should start run high with clutch still on, and when upper limit of pressure is reached, the fans should still run high, but clutch cut off. (It was just my logic, maybe is wrong)

So, I bought another high-pressure sensor and last night replaced it (normally for my financials - second use) and normally good amount of frayon sprayed out :(

In this case tomorrow or the day after tomorrow I should visit a mechanic to refill the system (because now it still blows cold but makes short cycling even on idle) and see if something will go on better or worse way. Normally I will inform you about the results. In case you have some additional opinions please let me know as soon as possible.

The removed sensor was F68H-19D594-AA 9630, the replaced is F42H-19D594-AA 9949
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Sunday, September 3rd, 2023 AT 1:10 PM
Tiny
KEN L
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I think it could be a defective high-pressure sensor. I still like the idea of splicing in a bulb to the power source to the compressor clutch. Please let me know what happens.
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Monday, September 4th, 2023 AT 11:10 AM
Tiny
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It is very bad when you live in a small city or small country where every second person is a "pro" for everything.

My father went to two places and had no result.

Yesterday at the technical station for registration of vehicles, they said it is 400g of frayon but we cannot recharge the machine shows there is leak somewhere.

Today on other tech stations the same answer, "the machine beeps saying that there is some leak, if I continue it may explode".

Tomorrow it should be taken to the first of those five mechanics who started the very long story of "reparations" last year. :(
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Tuesday, September 5th, 2023 AT 3:56 AM
Tiny
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Latest update, we left the car to the "specialist" yesterday morning, and few moments he told my father: I charged the system with paint only and going to wait some more time to find where is leaking :D (funny and sadly at the same time).
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Thursday, September 7th, 2023 AT 6:41 AM
Tiny
KEN L
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I think he used dye which is a good way to find the leak.
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Friday, September 8th, 2023 AT 4:05 PM
Tiny
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I will see, but I doubt if he even knows how to properly discharge and recharge, because here every idiot is an expert
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Friday, September 8th, 2023 AT 5:09 PM
Tiny
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The car is at home, the final answer is the same from the same "mechanic" that gave me one year ago, it leaks from somewhere, but I can't see where, probably the evaporator under the dash is leaking, but I have lot of work now, I can replace it in winter. Tragic and comedic in what miserable country we live.
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Monday, September 11th, 2023 AT 2:23 AM
Tiny
KEN L
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Car repairs can be frustrating I know, please hang in there we'll get through it together.
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Monday, September 11th, 2023 AT 12:03 PM
Tiny
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Tomorrow I'm starting with a new mechanic in the city next to mine, it is not far, just 10km, so we will see what they will concluse. Will let you know.
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Monday, September 11th, 2023 AT 12:09 PM
Tiny
KEN L
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Please do.
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Tuesday, September 12th, 2023 AT 9:50 AM
Tiny
WISH30
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Tomorrow I should go to bring the car back (now I am at work), the simple and standardised answer was: "It is probably leaking from the evaporator under the dash". So I should try to find another one more mechanic, because as I think it is impossible the evaporator to start leak just from replacing high pressure sensor. Even if it is true, why those 400grams of freon remained, didn't leak away.
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Thursday, September 14th, 2023 AT 9:42 AM
Tiny
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Today I took the car at home and tomorrow will drive it to another city near me (50km) and will left there for another inspection (if they even solve something).
In the between-time I would like to ask you if you have evaporator location or removal steps diagram, because if they tell me the same, next step must be to try to reach the evaporator and bring the car to a mechanic to be replaced.

I often think to sell the car, but now I am deeply underwater, because I bought it $1,500, and could sell it not more than $1,200 300, but in these 3 and a half years I spent over $3500 to get nothing :(
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Friday, September 15th, 2023 AT 8:33 AM
Tiny
KEN L
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Yep, that is rough, here is how to remove the evaporator. Check out the images (below). Please let us know how it goes.
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Monday, September 18th, 2023 AT 10:13 AM

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