Heating and Air Conditioning: Service and Repair

AIR CONDITIONING: REFRIGERANT: REPLACEMENT

REPLACEMENT

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
(a) Turn the A/C switch on.
(b) Operate the A/C with the setting temperature at 25°C (77°F) and the blower level at LO for 10 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.
(c) Turn the power switch off.
(d) 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) Charge with refrigerant HFC-134a (R134a).

Standard (w/o Rear Air Conditioning System):
550 to 650 g (19.4 to 22.9 oz.)
Standard (w/ Rear Air Conditioning System):
720 to 820 g (25.4 to 28.9 oz.)
SST: 09985-20010
09985-02130
09985-02150
09985-02090
09985-02110
09985-02010
09985-02050
09985-02060
09985-02070
09985-02080
09985-02140
NOTICE:
- Do not turn the A/C on before charging with refrigerant. Doing so will cause the 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.
- Avoid using the gauge manifold set that had been used for vehicles with conventional compressor oil (ND-OIL11 or equivalent) as much as possible. This will cause compressor oil remaining in the manifold to enter the vehicle, resulting in insulation performance deterioration. A gauge manifold set that had been used 3 times or less can be reused if an appropriate one is not available.
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 an A/C system.

3. WARM UP COMPRESSOR
(a) Keep the A/C switch on for at least 2 minutes to warm up the compressor.
NOTE: 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. INSPECT FOR REFRIGERANT LEAK
(a) After recharging with refrigerant gas, inspect for a refrigerant leak using a halogen leak detector.
(b) Carry out the test under the following conditions:
- Power 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)

(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.