Refrigerant: Service and Repair

AIR CONDITIONING: REFRIGERANT: REPLACEMENT

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

(a) Start up the engine.

(b) Turn the A/C switch on.

(c) Operate the cooler compressor at an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

(d) Stop the engine.

(e) Recover the refrigerant from the A/C system using a refrigerant recovery unit.

2. CHARGE WITH REFRIGERANT

(a) Perform vacuum purging using a vacuum pump.

(b) Using SST charge with refrigerant HFC-134a (R134a).





Standard:

470 to 530 g (16.6 to 18.7 oz.)

SST : 09985-20010

09985-02010

09985-02050

09985-02060

09985-02070

09985-02080

09985-02090

09985-02110

09985-02130

09985-02140

09985-02150

NOTICE:
* Do not turn the A/C on before charging with refrigerant. Doing so will cause the cooler compressor to work without refrigerant, resulting in overheating of the cooler compressor.
* Approximately 100 g (3.53 oz.) of refrigerant may need to be charged after bubbles disappear.
The refrigerant amount should be checked by quantity, not with the sight glass.

HINT
Ensure that sufficient refrigerant is available to recharge the system when using a refrigerant recovery unit. Refrigerant recovery units are not always able to recover 100 % of the refrigerant from the A/C system.

3. WARM UP COMPRESSOR

(a) Keep the A/C switch on for at least 2 minutes to warm up the compressor.

NOTICE:
Be sure to warm up the compressor when turning the A/C on after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.

4. CHECK FOR LEAKAGE OF REFRIGERANT

(a) After recharging with refrigerant gas, check for leakage of refrigerant gas using a halogen leak detector.

(b) Carry out the test as follows:

* Turn the engine switch off.

* Secure good ventilation (the gas leak detector may react to volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas).

* Repeat the test 2 or 3 times.

* Make sure that there is some refrigerant remaining in the refrigeration system.

When the compressor is off: approx. 392 to 588 kPa (4 to 6 kgf/cm2, 57 to 85 psi)

(c) Using a gas leak detector, check for leakage from the refrigerant lines.





(d) Bring the gas leak detector close to the drain hose with the detector's power off, and then turn the detector on.





HINT
* After the blower motor has stopped, let the cooling unit stand for more than 15 minutes.
* Bring the gas leak detector sensor under the drain hose.
* When bringing the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to volatile gases.
If it is not possible to avoid interference from volatile gases, the vehicle should be lifted up to allow testing.

(e) If a gas leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

(f) Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.