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Thanks for all the responses guys, still battling this issue. I resistance tested the all pins on the harness which all had 0 ohms, was unsure about a voltage drop test bc I'm not getting any 12V to gray wire. A/C will occasionally start working then randomly drop out, makes me feel like its a relay but I'm still unsure if a relay is used in this system and if so where the hell is it? I see in cousincarl's post that diagram like he said doesn't show a relay in the circuit but all the color codes for the wiring is different then what I have in my truck, Kbeefy's post has a diagram that shows a relay with the same color codes that my truck has but still cannot find any relay box under the hood? I've checked all around under the hood, drivers side behind the battery and all I see is harness plug connectors no relay boxes?? Any insight or maybe ever a pic of what this relay box under the hood looks like would be a huge help. Thanks Guys!
Not an a/c expert by any means but I hooked up gauges thinking it needed to be charged and I saw roughly 40 psi on low and 160 on high side of things. Correct me if I'm wrong but jumping both high and low pressure switches should override those safety's and engage the compressor?
Not an a/c expert by any means but I hooked up gauges thinking it needed to be charged and I saw roughly 40 psi on low and 160 on high side of things. Correct me if I'm wrong but jumping both high and low pressure switches should override those safety's and engage the compressor?
40/160 should be in the range as far as refrigerant is concerned.
Originally Posted by kbeefy
The switches all feed the pcm, the pcm chooses when to excite the relay, and the relay sends batt voltage to the clutch.
Do you have a good ground to your AC clutch? I know you mentioned jumping it to the battery, was that just positive or positive and negative?
Jumping the switches will tell the PCM all is well. There could be other issues though.
Start by confirming there is ground to the clutch, and that the pigtail is good.
I believe you have the same wiring as I posted above, so there is a relay somewhere. Check the fuses I listed and then you have to find the relay.
I don't have an '02 to look at, but I probably have some of the relay holders that are referenced to take a picture of. They usually have a cover on them and might not look like what your think.
Relay box #4, that has the AC relay in it, also has relays for left and right trailer turn signals, if that helps searching at all.
There are relays in the dash as well. It would somewhat stand to reason it may be there simply because the controls are there. You may or may not get a look at what's there by removing the ashtray. It's not much of a window but it's something.
Not an a/c expert by any means but I hooked up gauges thinking it needed to be charged and I saw roughly 40 psi on low and 160 on high side of things. Correct me if I'm wrong but jumping both high and low pressure switches should override those safety's and engage the compressor?
Originally Posted by kbeefy
40/160 should be in the range as far as refrigerant is concerned.
Like kbeefy said, that sounds about right for pressures. Let me see if the manual says anything about AC system troubleshooting.
EDIT: I found the document and attached it. I am still reading through it myself to see if your symptoms are mentioned. Have you scanned for DTCs?
Alright guys finally found it and fixed it!! A/C relay is in a small relay holder between master cylinder and inner fender well on an 02'. Really appreciate all the helpful responses, here's some pics to hopefully help the next person with this issue.
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