REFRIGERANT REPLACEMENT

PROCEDURE

RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

Start the engine.

Operate the cooler compressor under the conditions shown below:

Item	Condition	Indicator
Operating Time	3 minutes or more	-
Temperature setting	Max cool	-
Blower speed	High
Engine	Idling	-
A/C switch	On

This causes most of the compressor oil from the various components of the A/C system to collect in the A/C compressor.

Tech Tips

It is not necessary to operate the cooler compressor if the A/C does not operate because of compressor lock, etc.

Stop the engine.
Recover the refrigerant from the A/C system using a refrigerant recovery unit.

Tech Tips

Use the refrigerant recovery unit in accordance with the manufacturer's instruction manual.

CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Perform vacuum purging using a vacuum pump or appropriate equipment.

Charge the air conditioning system with refrigerant.

Refrigerant type
HFC-134a (R134a)

Text in Illustration
*a	Standard charge amount	*b	Mean value in proper range
*c	Overcharged	*d	High pressure
*e	Sub-cool system	*f	Refrigerant amount

Standard charge amount
470 to 530 g (16.6 to 18.6 oz.)

SST: 09985-20010 ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

Note

Do not turn the A/C switch on before charging the air conditioning system with refrigerant. Doing so may cause the compressor to work without refrigerant, resulting in overheating of the compressor.
The refrigerant amount should be checked by quantity (weight).
The graph above is shown for reference only.

Tech Tips

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 air conditioning system.

WARM UP ENGINE
1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.
  
  Note
  
  To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing air conditioning system lines (including the compressor).

INSPECT FOR REFRIGERANT LEAK

After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.
Carry out the test under the following conditions:
- Turn the engine switch off.
- Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.
  
  Pressure when the compressor is off: approx. 392 to 588 kPa (3.9 to 5.9 kgf/cm², 57 to 85 psi)
- Ensure good ventilation (the halogen leak detector may react to volatile gases which are not refrigerant, such as gasoline vapor and exhaust gas).
- Repeat the inspection 2 or 3 times.
Remove the front outer cowl top panel sub-assembly (See page for LHD or Click here for RHD).
Remove the front bumper assembly Click here.
Remove the radiator side deflector RH Click here.

Text in Illustration
*a	Check for leaks
*b	Halogen Leak Detector Sensor
*c	Distance between Sensor and Joint to be Checked: 10 mm or less
*d	Halogen Leak Detector Sensor Moving Speed: 25 to 50 mm/sec.

How to check for refrigerant leaks in pipe joints:

Note

Gas leaking from a joint can be dissipated by even the slightest breeze. Move the halogen leak detector sensor 360° around each joint instead of keeping it in one spot when checking.

Using a halogen leak detector, check for refrigerant leaks at the pipe joints shown in the illustration.

Text in Illustration
*a	Area to be Checked	*b	Service Valve (High)
*c	Service Valve (Low)	*d	Pipe Joint
*e	Air Conditioner Pressure Sensor Joint	*f	Cooler Expansion Valve Joint
*g	Condenser Joint (Inlet)	*h	Condenser Joint (Outlet)
*i	Compressor Joint (Inlet)	*j	Compressor Joint (Outlet)

Tech Tips

After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
Disconnect the pressure sensor connector and leave it for approximately 20 minutes.
When checking for leaks, the presence of oily dirt at a joint can indicate a leak.

Standard
There are no refrigerant leaks from the joints.

If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

Text in Illustration
*1	Drain Cooler Hose
*a	Halogen Leak Detector

Bring the halogen leak detector sensor close to the drain cooler hose with the detector turned off, and then turn the detector on.

Note

Keep water away from the halogen leak detector to prevent malfunction.

Tech Tips

After the blower motor has stopped, leave the cooling unit for more than 15 minutes.
When bringing the halogen leak detector sensor close to the drain cooler hose, make sure that the halogen 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 checking for leaks.

Standard
Refrigerant is not leaking from the drain cooler hose.

If refrigerant is leaking, check for refrigerant leaks from the No. 1 cooler evaporator sub-assembly.

Remove the blower motor with fan sub-assembly Click here.

Text in Illustration
*1	No. 1 Cooler Evaporator Sub-assembly
*a	Halogen Leak Detector

Insert the halogen leak detector sensor into the air conditioning unit assembly, bring the sensor close to the No. 1 cooler evaporator sub-assembly and check for refrigerant leaks.

Tech Tips

After the blower motor has stopped, leave the cooling unit for more than 15 minutes.

Standard
Refrigerant is not leaking from the No. 1 cooler evaporator sub-assembly.

If refrigerant is leaking, disconnect the leaking joint and visually check for the cause, such as the presence of foreign matter.

Install the blower motor with fan sub-assembly Click here.
Install the radiator side deflector RH Click here.
Install the front bumper assembly Click here.
Install the front outer cowl top panel sub-assembly (See page for LHD or Click here for RHD).