Refrigerant: Service and Repair

REFRIGERANT

Collection and Charge


SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant










Evacuating System and Charging Refrigerant











Procedure


WARNING:
Never breathe A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat.
Remove HFC-134a (R-134a) from A/C system using certified service equipment meeting requirements of SAE J-2210 [HFC-134a (R-134a) recycling equipment] or J-2209 [HFC-134a (R-134a) recovery equipment]. Ventilate work area before resuming service if accidental system discharge occurs. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1. CHECK A/C SYSTEM

1.Check that A/C system operates normally. Refer to "Description & Inspection" Description & Inspection.
2.Check if there is a large amount of leakage of refrigerant or lubricant.

CAUTION:
Never perform the lubricant return operation if a large amount of leakage of lubricant is detected.
Is the inspection result normal?
YES- GO TO 2.
NO-1- Check for refrigerant leakage. Refer to "Inspection" Fluorescent Leak Detector.
NO-2- If using electrical leak detector (SST: J-41995). Refer to "Inspection" Electrical Leak Detector.

2. LUBRICANT RETURN OPERATION

1.Start the engine and run it as follows.
-Engine speed: Idle - 1,200 rpm
-A/C switch: ON
-Fan (blower) speed: Maximum speed set
-Set temperature: Full cold
-Intake position: Recirculation (REC)
2.Perform lubricant return operation for approximately 10 minutes.
3.Stop the engine.
- GO TO 3.

3. CHECK RECOVERY/RECYCLING RECHARGING EQUIPMENT

1.Operate recovery/recycling recharging equipment.

CAUTION:
- Follow the instructions of the manufacturer for the handling or maintenance of the equipment.
- Never fill the equipment with undesignated refrigerant.
2.Check the gauge pressure of recovery/recycling recharging equipment.
Is there pressure?
YES- GO TO 4.
NO- GO TO 5.

4. DISCHARGE REFRIGERANT INSIDE PIPES

Discharge the refrigerant from the high-pressure hose and low-pressure hose of recovery/recycling recharging equipment.
- GO TO 5.

5. CONNECT RECOVERY/RECYCLING RECHARGING EQUIPMENT

1.Remove the service valve caps from the vehicle.
2.Connect recovery/recycling recharging equipment to the service valves.
- GO TO 6.

6. DISCHARGE REFRIGERANT FROM THE VEHICLE

Operate recovery/recycling recharging equipment to discharge the refrigerant from the vehicle.
- GO TO 7.

7. REMOVE ANY REMAINING REFRIGERANT

Evacuate air for approximately 10 minutes or more to remove any remaining refrigerant integrated to the compressor oil, etc.
- GO TO 8.

8. REPLACE OR REPAIR REFRIGERANT SYSTEM PARTS

1.Replace or repair the malfunctioning part.

CAUTION:
- Always use a new O-ring for the parts that the cooler system was removed.
- Apply compressor oil to the O-rings of piping when installing the piping. However, never apply it to the threads.
2.Adjust the compressor oil amount according to the replaced parts. Refer to "Description" Description.
- GO TO 9.

9. EVACUATE AIR FROM THE REFRIGERANT SYSTEM

Evacuate air from the refrigerant system for approximately 25 minutes or more.

CAUTION:
Evacuate air for at least approximately 15 minutes or more if the parts are replaced.
- GO TO 10.

10. CHECK AIRTIGHTNESS OF REFRIGERANT SYSTEM

Check the airtightness of the refrigerant system for approximately 25 minutes or more.

CAUTION:
Check the airtightness for at least approximately 15 minutes or more if the parts are replaced.
Does the pressure decrease?
YES- GO TO 11.
NO- GO TO 8.

11. CHECK REFRIGERANT LEAKAGE

1.Connect refrigerant recovery/recycling recharging equipment or manifold gauge set (SST: J-39183).
2.Charge the refrigerant of approximately 200 g (7.05 oz) to the refrigerant system.
3.Check for refrigerant leakage. Refer to "Inspection" Fluorescent Leak Detector.
NOTE:
When using electrical leak detector (SST: J-41995). Refer to "Inspection" Electrical Leak Detector.
Is the inspection result normal?
YES- GO TO 12.
NO- Repair or replace parts according to the inspection results.

12. CHARGE REFRIGERANT

1.Connect recovery/recycling recharging equipment or manifold gauge set (SST: J-39183).
2.Evacuate air again.
3.Charge the specified amount of refrigerant to the refrigerant system.
- GO TO 13.

13. CHECK REFRIGERANT LEAKAGE

Check for refrigerant leakage again. Refer to "Inspection" Fluorescent Leak Detector.
NOTE:
When using electrical leak detector (SST: J-41995). Refer to "Inspection" Electrical Leak Detector.
Is the inspection result normal?
YES- GO TO 14.
NO- GO TO 6.

14. CHECK OPERATION

Check the A/C system for normal operation. Refer to "Inspection" Refrigeration System.
Is the inspection result normal?
YES- GO TO 15.
NO- Repair or replace parts according to the inspection results.

15. CHECK RECOVERY/RECYCLING RECHARGING EQUIPMENT

1.Disconnect recovery/recycling recharging equipment or manifold gauge set (SST: J-39183).
2.Discharge the refrigerant from the high-pressure hose and low-pressure hose of the recovery/recycling recharging equipment.
3.Install the service valve caps.
- INSPECTION END