A/C fuse pops as soon as I turn A/C on

Tiny
THUNDERMOOSE
  • MEMBER
  • 2002 CHEVROLET EXPRESS
  • 5.7L
  • V8
  • 2WD
  • AUTOMATIC
  • 200,000 MILES
As soon as I turn on the A/C using the climate control knob, the 10amp fuse in the under-the-hood fuse box pops. (Even with compressor clutch unplugged) I also tried a 20a fuse as well, it also pops immediately.

Even with the two-pin compressor clutch coil unplugged. Was the first thing I checked.

Swapped horn relay with ac relay to test if it was shorted, and the relay is good. The fuse does not pop with the ac relay removed/missing.

Can anyone share A/C wiring diagram for my vehicle listed above 1500 5.7L V8?
As well as a cooling system diagram?
This van has rear A/C as well. Both blows warm.

And what are some first things I should try? Could the diode or VCM/computer be damaged (but only affecting the A/C) (Read below) and popping the fuse?

Backstory: just bought it from a neighbor. The A/C went out on him like "a year ago" and he paid a shop to replace compressor, drier, and other stuff. He said it worked well and blew cold up until a week or two ago, but then every once in a while, it wouldn't work so he would need to go in and unplug and reinsert the compressor clutch coil wire when it stopped working. And then it would magically start working again.
He suspected the connector was just worn so he bought a replacement and removed the old one and installed a new one. Poorly I might add - the wires are just twisted together and then each is covered by heat shrink tubing that is not even shrunk yet. They easily slide down the wire and expose the splices that are a part.

Those two wires are properly secured now. But if those two wires touched. Would that of have fried something? Or would it have just immediately popped the fuse and that's it?
Could the control module/computer have that circuit fried or something?
And lastly. Could the diode be damaged and immediately popping the fuse?
Sunday, May 1st, 2022 AT 12:16 AM

14 Replies

Tiny
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Just tested both diodes in the under the hood fuse box. They both read 0.570v one direction and OL in the other. Seems they are good enough for the multi meter.

Okay, I just tested the two-pin clutch coil cable. Both pins are grounded. The van is off. Is this normal? Does not sound right.
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Sunday, May 1st, 2022 AT 12:31 PM
Tiny
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Unplugged pressure sensor on dryer, and the clutch coil still grounded on both pins. Trying to find the other pressure sensor.
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Sunday, May 1st, 2022 AT 1:18 PM
Tiny
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Okay, so, I just found the other pressure sensor dangling behind the compressor not plugged into anything. I felt around the rear of the compressor, and I didn't see a sensor?
Could this van have only one sensor?
I'm going to test of fuse still popping.
With dryer sensor unplugged and clutch coil still grounded on both pins.
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Sunday, May 1st, 2022 AT 1:50 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,700 POSTS
Hi,

The compressor clutch shouldn't have ground at both connectors. One is a ground, but the other is for power. If you check the wiring to the clutch, do they both show ground?

There should be a dark green wire and a black wire to the compressor clutch. The dark green wire receives power from the compressor clutch relay which is an open circuit until AC is requested. Pull the compressor relay and see if the fuse still fails.

I attached the wiring schematic for the circuit below, so you have a reference.

Try this and let me know what happens. Also, it does have both a high and low-pressure switch.

Take care and I'll watch for your reply.

Joe

See pics below.
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Sunday, May 1st, 2022 AT 7:40 PM
Tiny
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Hey Joe, thank you for the reply and thank you for the schematics!

So I double-checked pith pins on the clutch coil harness, both are grounded (the green and the black).

When I remove the relay, the fuse does not pop when turning the ac on. I tried swapping the relay with the identical horn relay, and it still blows. The horn works just fine with either relay.

And I spoke to the prior owner earlier. He took it to a shop a year ago to get the AC system repaired (replaced compressor), and apparently the shop did not bother to install the pressure sensor that is on the back of the compressor, and so that is why the harness connector was just dangling.

Also, more info from prior owner. A few months after the shop fixed the ac, the old owner had to keep popping the hood and wobble/reseat the clutch coil cable for the compressor to kick in. Apparently one day that trick stopped working, so he replaced the connector hoping it would fix it. But it did not. So he sold the van to me shortly later.

Any idea on what next to check?
And yes, I will see about getting that sensor and installing it ASAP so as to not damage the compressor in the event of a pressure issue.
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Sunday, May 1st, 2022 AT 7:58 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

Do me a favor. Remove the compressor relay. Recheck the green wirer with the compressor disconnected. If you still have continuity to ground, there is a short to ground between the compressor and the relay. If there isn't, we need to remove and inspect the relay box to make sure nothing is shorting there.

Let me know.

Joe
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Sunday, May 1st, 2022 AT 9:23 PM
Tiny
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Joe,

I've removed the relay and tested the clutch coil harness. Still grounded on both pins.
I've also just discovered something. The fuse is actually piping as soon as the van starts. Not when starting the ac as I thought.

I've done the following tests:
Removed diode and started: fuse pops.
Removed relay and started: does not pop.
Removed fuse and relay: does not pop.

During all of these tests - the clutch coil harness is always grounded on both pins.

To help me visualize the diagram you sent, this is a crappy diagram I drew up. The numbers on the relay socket correspond to the relay orientation (that I have it) and numbered pins.

What should I test next?
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Tuesday, May 3rd, 2022 AT 12:43 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

The fused power goes through the relay. If it doesn't fail with the relay out, then the problem is either the relay, the connector pins the relay connects to, or the wire between the relay and the compressor is shorted to ground. One of the two wires should provide power and not ground.

Trace that wire and see if you can find anything damaged. Also, if nothing is found, disconnect the battery and inspect the fuse/relay box.

Let me know what you find.

Joe
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Tuesday, May 3rd, 2022 AT 3:53 PM
Tiny
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Update:

I tried another diode and another relay from a donor Chevy Express of same year but a 3500.
The fuse was still popping, and in the process of elimination, I used a 25a fuse by accident and started the engine. No pop. Realized it. And thought it was weird. So, I started the A/C and heard a pop on the passenger side engine compartment. I got scared and unplugged that sensor and put a 10a in.

But get this. The A/C is working now. The compressor spins. I did not check the ground on the clutch harness yet though. Will do that in the am.

I plugged the pressure sensor on the accumulator back in just to test, and it's still working. So just in case, I went to the auto parts store and replaced it with a new one, and it's still working.

I am at a loss for words on this, if this whole time it was just the pressure sensor on the accumulator. I tested the harness, but never could test the sensor properly due to access.

I think that the harness to the pressure sensor was the one grounded/shorted this whole time. But now I just blew the short open so much with the higher load that it's no longer shorted (humor in that? Lol).

But now I'm worried that I won't be able to use that sensor. How can I test the harness to the sensor?
It's a two pin. It's the one on the accumulator not the one on the back of the compressor.
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Tuesday, May 3rd, 2022 AT 9:41 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

Could the loud pop have been the compressor clutch? That is the only thing that makes sense. Does the 10 amp now fail when you install it?

Let me know.

Joe
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Wednesday, May 4th, 2022 AT 6:41 PM
Tiny
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Nope, the 10a works just fine now.

Here's the series of events:

Compressor clutch unplugged and High pressure always unplugged (sensor not installed yet). Low pressure sensor, relay, diode, and a 10a fuse.
Tried it, it popped fuse.
Tried the same as above, but now with a 25a fuse. Heard a pop hear accumulator area maybe? Shut it all off.
Put a 10a back in and started. No fuse pop.
So, I plugged in the compressor and turned it back on. And it works now.
I suspect this whole time the low sensor was failing and shorting or something, and the 10a fuse was taking the blow for it. But since we ran it with a 25a fuse. The short inside the sensor blew open. This clearing the short of sorts.

I replaced the sensor just in case, but don't know how to test it. My understanding is it only kicks in when the system pressure is too high, it activates. The PCM reads that, then shuts off compressor till that sensor resets when the pressure lowers. Rinse and repeat. Is this correct? And if so. If this sensor cannot work anymore due to a wire break or something. Could the pressure just damage the compressor?
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Wednesday, May 4th, 2022 AT 11:54 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,700 POSTS
Hi,

If the pressure is too high, you'll know. The compressor will likely lock up and the belt will make noise.

Regardless, I'm glad to know you got the compressor working. Please feel free to come back anytime in the future. You are always welcome here.

Take care,

Joe
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Thursday, May 5th, 2022 AT 8:04 PM
Tiny
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Thank you again! You were a life saver.
If you don't mind me asking - what database do you pull schematics from?

It turns out my public library had AutoData that you can access from inside the library, but it's schematics are not as good as yours.
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Thursday, May 5th, 2022 AT 9:57 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
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Hi,

The schematics came from Alldata. I can't be certain, but I believe there are different levels of service. They do offer a plan for people and not just shops, so if you feel it would benefit you, check into it. I'm not sure what they charge. Or you can simply come back here, and I'll get them for you. LOL

You take good care of yourself and feel free to come back any time in the future.

Joe
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Friday, May 6th, 2022 AT 7:25 PM

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