Repair Procedure

A. Vehicle Inspection:
- Ensure the integrity of the A/C system before proceeding with retrofit.

B. Recover R-12 using R-12 recovery/recycling/recharging equipment:
- Follow Toyota recommended procedure.

C. Install R134a service fitting adapters:
1. Remove valve cores from R-12 service fittings and discard.
2. Clean external threads of the R-12 service fittings.
3. Apply adhesive to threads (Loctite 262 or equivalent), screw on R134a adapter fittings, and tighten to 13 ft.-lb.

NOTE:
Vehicles with more than 2 service fittings will require the installation of additional adaptors. All service fluings must have R134a adaptors installed.






D. Replace compressor 0-rings (10P only):
1. Remove compressor from vehicle.
2. Install covers on hose connection ports to prevent airborne contamination.
3. Clean compressor body and service valve area using brush and compressed air.
4. Remove service valve plate.
5. Remove 0-rings from service valve plate and discard.
6. Remove extension housing if used, otherwise go to step 7.
a. Separate extension housing from service valve plate.
b. Remove and discard 0-rings.
c. Lubricate and install retrofit 0-rings into extension housing using specified PAG oil (see tables).
d. Reassemble extension housing to service valve plate.






7. Reinstall service valve plate to compressor. Torque bolts to 19 ft.lbs.
8. Reinstall compressor assembly.

E. Replace piping and hose 0-rings:
1. Disconnect suction and discharge hoses from compressor.
2. Remove and discard old 0-rings.
3. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).
4. Disconnect discharge hose from condenser.
5. Remove and discard old 0-rings.
6. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).
7. Reconnect hoses and torque to specification. (Specifications can be found in applicable manuals/guides.)

F. Replace receiver/dryer
1. Remove and discard original R-12 Receiver/Dryer.
2. Using the tables, determine the proper type and amount of PAG oil. Pour 1/2 of the specified oil into the "our" side of the Receiver/Dryer.






3. Black out the sight glass on block - joint - type receiver/dryer with black paint.

4. Lubricate and install retrofit 0-rings with specified PAG oil (see tables).






5. Install retrofit Receiver/Dryer.

G. Evacuate, charge, and leak test the system (Use manufacturer's recommended procedure).
1. Evacuate for 45 minutes.
2. Vacuum check.
3. Add compressor oil.
^ Using recovery/recycling/recharging equipment charge the system with the remaining 1/2 of the specified amount of oil from step F2.
4. Charge system with specified amount of Rl34a. (refer to tables).
5. Perform a gas leak check.

H. Confirm cooling performance of Air Conditioning system.

I. Install retrofit labels:
1. Choose R134a "USE ONLY" label for proper oil type (ND-Oil 8 or ND-Oil 9).
2. Using a ball point pen, enter the proper retrofit refrigerant and oil charges on the caution label.
3. Cross out unused type of compressor oil on caution label.
4. Affix labels in a prominent location such as radiator support, underside of hood, or suspension tower area.
5. Remove any R-12 labels.