Question about 2003 Chevrolet S-10

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Just bought 2003 S-10 4-cy manual transmission. A/c compressor will never cycle off so the evaporator coil will ice up at highway speeds. The 3 wire sensor switch in the high pressure line was replaced. The voltage reading on the signal line from this switch is 3.1 volts when the a/c is first turned on and then after it has run for about 12 minutes it reads 2.4 volts. I?m not sure about the system being charged correctly. what voltages reading should I expect that would cause the pcm to turn off the compressor? thanks don T

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You will need to replace the compressor cycling switch, this part is screwed into a bung in the low side AC line under the hood.

Posted on Jul 07, 2010

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AC works for about 300 miles then stops and blows hot air. New AC compressor and freon charge. After sitting for a while it will again blow cold.


I think you have a similar problem to mine. At highway speeds is when it happens. And it is not blazing hot? Right?
Your evaporator is freezing up - as this happens the ice surrounding it prevents the flow of air over the evaporator coils and the result is warm air coming out of the registers. If I turn off the AC for about ten minutes and let unit melt the cold air comes back. This does not occur in stop and go driving.
I combat it by either running the fan at a higher than normal setting to increase air flow over the evaporator and then turning off when it gets too cold, OR using the air control to allow warmer outside air to enter into unit at highway speeds to prevent freezing up.
Newer cars have more sophisticated sensors and controls to prevent this but some older vehicles are subject to this anomaly.
Since it works fine under normal conditions I have not messed around with the freon level in system. If you release a tad of refrigerant the low pressure switch will shut off the compressor sooner and help minimize ice buildup. Good luck.

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Won't accelerate on highway? At what speed (estimate) are you traveling before you "punch it". Is the engine a 3.4 or a 3.8? Is the check engine light on? Is it flashing?

These are a few questions I need to know to try to isolate the problem, but to put you in a ballpark of possible causes, causes could be (but not limited to):
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1 Answer

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YOU COULD HAVE FAULTY CLUTCH CYCLING PRESSURE SWITCH. YOU COULD HAVE A LOT OF MOISTURE IN THE AC SYSTEM.CHECK EVAPORATOR LINE GOING IN THE FIREWALL TO EVAPORATOR IF YOU SEE ICE ON EVAPORATOR LINE TO FIREWALL.YOU HAVE A RESTRICTION IN ORIFICE TUBE IN EVAPORATOR OR LOT OF MOISTURE FREEZING UP IN THE SYSTEM.

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1 Answer

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Did you try jumping where the Clutch relay plugs into the fuse/relay box ? Pin 87 & 30 are the compressor clutch coil power supply . If you look on the bottom of the relay you will see four set's of numbers 30 & 87 , 85 & 86 . If you take a piece of wire an jump 30 to 87 this will send B+ voltage to the clutch coil engaging the compressor . Is the PCM turning on the relay ?
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1 Answer

Seems the AC is freezing up after about 30 or 40 minutes. After it unfreezes, it will work fine for another 30 or 40 minutes. I believe that the freon levels are correct.


If you have ice accumulating on the evaporator, there should be no air blowing out the registers because the air will be stopped at the evaporator.
If this is happening, the a/c is not cycling on and off as often as it should. At 70 degrees F, it should cycle on and off about 4 times/minute. Less when hotter.

If not cycling off at all, replace the screw-in pressure switch on top of the accumulator under the hood near the fire wall on passenger side.

report results of test.

The A/C cycling switch is mounted on a Schrader valve-type fitting on the suction accumulator/driver.
  • A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem.
  • This allows the suction or low side pressure to control the operation of the A/C cycling switch.
  • The electrical switch contacts open when the suction pressure drops. The contacts close when the suction pressure rises. For specifications regarding operating pressure(s), refer to Section 412-00 .
  • When the A/C cycling switch contacts close, the A/C clutch field coil is energized.
  • When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and compressor operation stops.
  • The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing.
  • This prevents icing of the A/C evaporator core and blockage of airflow.
  • It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.

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1 Answer

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Several possible causes. Knowing the state of refrigerant charge would be helpful. Assuming it has a 'full' charge (full charge 680 Grams = 1.50 Pounds) Most common causes of AC problems:
1. Thermostatic switch (sensor) malfunction in the evaporator - allowing the evaporator to ice up. Check the vent temperature (using a cooking thermometer) to see if the temperature gets near or below freezing (32 Deg F.). If so, the thermostatic switch in the evaporator is defective. Replace it.
2. Refrigerant UNDER-charge. If the temperature does NOT get near freezing, then you need a set of AC gauges to check the compressor head pressure (High side) and the suction (Low side). High side pressure (nominal) is 229 PSI (+ - 20 psi) @ 2000 RPM. Low side (nominal) is around 20 to 40 psi. NOT common problems:
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2. Compressor inefficiency (worn out).
3. Expansion Valve
4. Clogged Condensor

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