REFRIGERANT REPLACEMENT

PROCEDURE

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

   
   

   1. Turn the power switch on (READY).

   2. Turn the A/C switch on.

   3. Operate the air conditioning with a set temperature of 25°C (77°F) and the blower at low for 10 minutes to circulate the refrigerant. This causes most of the compressor oil from the various components of the air conditioning system to collect in the air conditioning compressor.

   4. Turn the power switch off.

   5. Recover the refrigerant from the air conditioning system using a refrigerant recovery unit.

2. ADD COMPRESSOR OIL

   
   

   1. When performing work on air conditioning parts, follow the oil guidelines below in order to protect the cooler compressor.

      Part and Condition		Oil Level (cc)	Work Procedure
      Compressor replacement		-100 to -120	Drain oil from new compressor
      Condenser replacement		35 to 55	Fill oil into replacement part
      Evaporator replacement		40 to 60
      A/C pipe replacement	High pressure	5 to 25
      	Low pressure
      When discharging refrigerant gas quickly		30 to 50	While applying vacuum, use manifold gauge to fill oil from low pressure side valve

3. CHARGE REFRIGERANT

   
   

   1. Perform vacuum purging using a vacuum pump or appropriate equipment.

   2. Charge the air conditioning system with refrigerant.

      Refrigerant type
      HFC-134a (R134a)

      

      Text in Illustration

      *a	Sub-cool System	*b	High Pressure
      *c	Refrigerant Amount	*d	Standard charge amount
      *e	Charge additional 100 g (3.5 oz.)	*f	Point where bubbles disappear
      *g	Mean value in proper range	*h	Overcharged

      Standard charge amount
      810 to 870 g (28.6 to 30.7 oz.)

      SST

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

      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).

      Tech Tips

      Make sure 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.

4. 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).

5. CHECK FOR LEAKAGE OF REFRIGERANT

   
   

   1. After recharging the air conditioning system with refrigerant, check for refrigerant leaks using a halogen leak detector.

   2. Carry out the test under the following conditions:

      
      

      • Power switch off.

      • Secure 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.

      • 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)).

   3. 

      Text in Illustration

      *1	Halogen Leak Detector
      *a	Check for Leak

      Using a halogen leak detector, check for refrigerant leaks from the air conditioning system.

   4. If a refrigerant leak is not detected from the drain hose, remove the blower motor control from the cooling unit. Insert the halogen leak detector sensor into the unit and check for a leak.

   5. Disconnect the pressure sensor connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure sensor and check for a leak.

      Tech Tips

      When checking for leaks, the presence of oily dirt at a joint can indicate a leak.