Refrigerant: Service and Repair

REFRIGERANT

Collection and Charge


SETTING OF SERVICE TOOLS AND EQUIPMENT

Discharging Refrigerant










Evacuating System and Charging Refrigerant











Procedure


WARNING:
Never breath 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 oil.

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- Check for refrigerant leakage. Refer to "Inspection" Fluorescent 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
-Blower speed: Max. position
-Air inlet: Recirculation (REC)
-Set temperature: Full cold
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 "Maintenance of Lubricant Quantity" Maintenance of Lubricant Quantity.
- 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 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.
- END