Charging A/C System
CHARGING
For 2.0L Engine (Turbo) and 2.4L Engine vehicles, use the refrigerant recovery and recycling unit to carry out recharging. For 2.0L Engine (Non-turbo) vehicles, charge the system by following procedure.
1. With the handles turned in all the way (valve closed), install the adaptor valve to the low-pressure side of the gauge manifold.
2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the quick joint (for low-pressure) to the charging hose (blue).
4. Connect the quick joint (for low-pressure) to the low-pressure service valve.
NOTE: The low-pressure service valve should be connected to the suction hose.
CAUTION:
1. Use tools that are designed for R-134a.
2. To install the quick joint, press section A firmly against the service valve until a click is heard. When connecting, run your hand along the hose while pressing to ensure that there are no bends in the hose.
5. Close the high and low-pressure valves of the gauge manifold.
6. Install the vacuum pump adaptor to the vacuum pump.
7. Connect the vacuum pump plug to the vacuum pump adaptor.
8. Connect the charging hose (yellow) to the R-134a connection port of the vacuum pump adaptor.
9. Tighten the adaptor valve handle (valve open).
10. Open the low-pressure valve of the gauge manifold.
11. Turn the power switch of the vacuum pump to the ON position.
NOTE: Even if the vacuum pump power switch is turned ON, the vacuum pump will not operate because of the power supply connection in step (7).
12. Turn the vacuum pump adaptor switch to the R-134a side to start the vacuum pump.
CAUTION: Do not operate the A/C compressor during evacuation.
13. Evacuate to a vacuum reading of 100 kPa (29.5 in.Hg) or higher (takes approx. 10 minutes).
14. Turn the vacuum pump adaptor switch OFF and allow to stand it for 5 minutes.
CAUTION: Do not operate the compressor in the vacuum condition; damage may occur.
15. Carry out a leak test. (Good if the negative pressure does not drop.)
CAUTION: If the negative pressure (vacuum) is lost, check for loose connections. Then, repeat the evacuation procedure from step 12. If negative pressure (vacuum) is still lost, add 1 lb of refrigerant and check system using an R-134a compatible leak detector.
16. Turn the handle of the adaptor valve back all the way (valve closed), remove it from the gauge manifold and install the bulk container.
17. Open the valve of the bulk container.
18. Tighten the handle of the adaptor valve (valve open) to charge the system with refrigerant.
CAUTION: If the bulk container is inverted, liquid refrigerant may be drawn into the compressor damaging it by hydraulic lock. Keep the bulk container upright to ensure that refrigerant is charged in gas state.
19. If the refrigerant is not drawn in, turn the handle of the adaptor valve back all the way (valve closed).
20. Check for gas leaks using a leak detector.
If a gas leak is detected, re-tighten the connections, and then repeat the charging procedure from evacuation in step (12).
CAUTION: A leak detector designed for R-134a should be used.
21. Start the engine.
22. Operate the A/C and set to the lowest temperature (MAX. COOL).
23. Fix the engine speed at 1,500 rpm.
24. Tighten the handle of the adaptor valve (valve open) to charge the required volume of refrigerant.
CAUTION: If the bulk container is inverted, liquid refrigerant may be drawn into the compressor damaging it by hydraulic lock. Keep the bulk container upright to ensure that refrigerant is charged in gas state.
25. After charging with refrigerant, turn the handle of the adaptor valve back all the way (valve closed).
26. Tighten the charging valve handle (valve closed). Remove the quick joint (for low pressure) from the low-pressure service valve.
CORRECTING LOW REFRIGERANT LEVEL IN CASE THE BULK CONTAINER IS USED
1. Install the adaptor value with the handle turned all the way in (valve close) to the bulk container.
2. Connect the charging hose (blue) to the adaptor valve.
3. Connect the charging hose (blue) to the quick joint (for low-pressure).
4. Open the valve of the bulk container.
5. Turn the handle of the adaptor valve to bleed the air.
6. Install the quick joint (for low-pressure) to the low-pressure service valve.
NOTE: The low-pressure service valve should be connected to the suction hose.
7. Start the engine.
8. Operate the air conditioner and set at the lowest temperature (MAX. COOL).
9. Fix the engine speed at 1,500 rpm.
10. Tighten the handle of the adaptor valve (valve open), and replenish refrigerant checking the quantity through the sight glass.
CAUTION: If the bulk container is inverted, liquid refrigerant may be draw into the compressor damaging it by hydraulic lock. Keep the bulk container upright to ensure that refrigerant is charged in gas state.
11. After replenishing is completed, turn the handle of the adaptor valve all the way in (valve close), and remove the quick joint.
METHOD BY USING REFRIGERANT RECOVERY AND RECYCLING UNIT
Using the refrigerant recovery and recycling unit, refill the refrigerant.
NOTE:
Refer to that Refrigerant Recovery and Recycling Unit Instruction Manual for operation of the unit.
DISCHARGING SYSTEM
Use the refrigerant recovery unit to discharge refrigerant gas from the system.
NOTE: Refer to that Refrigerant Recovery and Recycling Unit Instruction Manual for operation of the unit.
REFILLING OF OIL IN THE A/C SYSTEM
Too little oil will provide inadequate compressor lubrication and cause a compressor failure. Too much oil will increase discharge air temperature.
When a compressor is installed at the factory, it contains 170 Cubic.cm (5.7 fl.oz.) <2.0L Engine (Turbo) and 2.4L Engine>
100 Cubic.cm (3.4 fl.oz.) <2.0L Engine (Non-turbo)> of refrigerant oil. While the A/C system is in operation, the oil is carried through the entire system by the refrigerant. Some of this oil will be trapped and retained in various parts of the system. When the following system components are changed, it is necessary to add oil to the system to replace the oil being removed with the component.