REFRIGERANT LINE (for TMC, TMMR Made) INSTALLATION


  1. INSTALL PIPING CLAMP (for 2AR-FE, 6AR-FSE)


    1. Remove the vinyl tape from the open ends of the suction pipe sub-assembly and No. 1 cooler refrigerant suction hose.

    2. B000MT1E03
      Text in Illustration
      *1 Piping Clamp
      *2 No. 1 Cooler Refrigerant Suction Hose
      *a Groove

      Install a new piping clamp to the No. 1 cooler refrigerant suction hose.

      Note

      Securely engage the inside step of the piping clamp in the suction hose groove.

    3. Thoroughly coat 2 new O-rings and the contact surface of the No. 1 cooler refrigerant suction hose with compressor oil (ND-OIL 8).

    4. Install the 2 O-rings to the No. 1 cooler refrigerant suction hose.

      Note

      Do not let foreign matter adhere to the O-ring or O-ring seal.

    5. B000L13E08
      Text in Illustration
      *a Large Diameter Section of Piping Clamp
      *b Alignment Mark

      Engage the suction pipe sub-assembly and No. 1 cooler refrigerant suction hose by matching the alignment marks.

      Note

      Insert them by holding the pipe, not the piping clamp.

    6. B000GXWE05
      Text in Illustration
      *a Large Diameter Section of Piping Clamp

      Securely insert the piping clamp to the point where the large diameter section of the piping clamp is covered by the suction pipe sub-assembly.

      Tech Tips


      • When inserting, make sure that a click sound is heard.

      • Check that the suction pipe is securely inserted by pulling it.

  2. INSTALL PIPING CLAMP (for 2GR-FE)


    1. Remove the vinyl tape from the open ends of the suction pipe sub-assembly and No. 1 cooler refrigerant suction hose.

    2. B000MT1E03
      Text in Illustration
      *1 Piping Clamp
      *2 No. 1 Cooler Refrigerant Suction Hose
      *a Groove

      Install a new piping clamp to the No. 1 cooler refrigerant suction hose.

      Note

      Securely engage the inside step of the piping clamp in the suction hose groove.

    3. Thoroughly coat 2 new O-rings and the contact surface of the No. 1 cooler refrigerant suction hose with compressor oil (ND-OIL 8).

    4. Install the 2 O-rings to the No. 1 cooler refrigerant suction hose.

      Note

      Do not let foreign matter adhere to the O-ring or O-ring seal.

    5. B000L13E08
      Text in Illustration
      *a Large Diameter Section of Piping Clamp
      *b Alignment Mark

      Engage the suction pipe sub-assembly and No. 1 cooler refrigerant suction hose by matching the alignment marks.

      Note

      Insert them by holding the pipe, not the piping clamp.

    6. B000GXWE05
      Text in Illustration
      *a Large Diameter Section of Piping Clamp

      Securely insert the piping clamp to the point where the large diameter section of the piping clamp is covered by the suction pipe sub-assembly.

      Tech Tips


      • When inserting, make sure that a click sound is heard.

      • Check that the suction pipe is securely inserted by pulling it.

  3. CHARGE AIR CONDITIONING SYSTEM WITH 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)
      B000JWVE14
      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
      *i +/-50 g (+/-1.76 oz) - -
      Standard charge amount
      450 to 550 g (15.9 to 19.4 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

      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.

  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. INSPECT FOR REFRIGERANT LEAK


    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:


      • 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.

    3. Remove the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).

    4. Remove the front bumper assembly Click here.

    5. Remove the radiator side deflector RH Click here.

    6. B000HJJE01
      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.

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

      B000NHME01
      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.

    8. B000MNOE01
      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.

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

    10. B000IAWE01
      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.

    11. Install the blower motor with fan sub-assembly Click here.

    12. Install the radiator side deflector RH Click here.

    13. Install the front bumper assembly Click here.

    14. Install the front outer cowl top panel sub-assembly Click here for LHD or Click here for RHD).