Hi David, welcome Sounds like clogged condenser filter to me, if so the very bottom of the condenser near the outlet fitting will get cold and maybe the pipe coming out of the condenser. Confirm this? I feel your pain with Chinese competition, I'm full time selling my own products on eBay and Amazon...

You are correct, poorly insulated = warmer bulb = more flow Like many things in life too much flow is bad, too little flow is bad, there is an optimum. I just mentioned that bulb because it looks tight in your picture, hard to tell how well it's mounted and insulated. You don't want to be chasing yo...

Yeah, I forgot you have a sensing bulb. How is the bulb installed and insulated? Has to be in good thermal contact with the pipe, well insulated with black goopy stuff so it measures pipe wall temperature and not the temperature of water condensing on it or the surroundings. If the bulb or capillary...

Nice job, we are getting a clear picture of what's going on. 31F subcool, you are overcharged a bit, HS pressure of 240 psig still quite reasonable. The overcharge isn't hurting you very much. 85F at the evap outlet fitting is really your problem. TXV is way out of adjustment, it's killing your perf...

My feeling is 1/4 turn is about 2 K superheat change so ~ 4F superheat change, so yeah we have same guesstimate. Every TXV can have different bias screw pitch and spring force. Yes, Usually CCW is less superheat, more flow.

I think you are measuring in the correct place for the high side. On the low side you don't really have a choice but to measure the pressure and temperature at the same location, doesn't need to be exact same, but close. Suction hose always has big pressure drops, yours is probably very big due to l...

Nice, you should add more, but only in tiny increments (like 1 oz at a time). i think when you say discharge temp you are measuring condenser outlet, and the temperature there is showing basically zero subcooling, so it makes perfect sense. I think you're somewhere in the process of filling up the r...

PRV is on top of that compressor, they tend to never seal again after they pop the first time.

what compressor did you install? Genuine Denso or mystery Asian?

cold air shouldn't be coming out underhood, fix the foam seals or seal it up somehow. If that's jacked up, makes me think the HVAC module was removed at some point, maybe an aftermarket evaporator in there or a badly assembled HVAC module? I think I'd try troubleshooting heater core problems, maybe ...