REFRIGERANT(for HFC-134a(R134a)) REPLACEMENT

PROCEDURE

1. RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM

   1. Start the engine.

   2. Operate the compressor under the conditions shown below:

      Item	Condition
      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.

      Tip:

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

   3. Stop the engine.

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

      Tip:

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

2. 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)

      

      *a	Standard Charge Amount	*b	Mean Value in Proper Range
      *c	Overcharged	*d	High Pressure
      *e	Sub-cool System	*f	Refrigerant Amount
      *g	+/-25 g (+/- 0.9 oz)	-	-

      Standard Charge Amount

      for 1KR-FE: 360 to 410 g (12.7 to 14.5 oz)

      for 1PP: 375 to 425 g (13.2 to 15.0 oz)

      09985-20010

      09985-02010

      09985-02050

      09985-02060

      09985-02070

      09985-02080

      09985-02090

      09985-02110

      09985-02130

      09985-02140

      09985-02150

      Note:

      • Make sure that the amount of refrigerant is within 40 g (1.41 oz) of the specified amount.

      • 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).

      Tip:

      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.

3. 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 any air conditioning system lines (including the compressor).

4. INSPECT FOR REFRIGERANT LEAK

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

   2. Carry out the test under the following conditions:

      • Turn the ignition switch off.

      • 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.

      • Measure the pressure to make sure that there is some refrigerant remaining in the air conditioning system.

        Pressure when the compressor is off: approximately 392 to 588 kPa (3.9 to 5.9 kgf/cm², 57 to 85 psi)

   3. 

      *a	Inspect for Leak
      *b	Halogen Leak Detector

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

   4. 

      *1	Drain Cooler Hose
      *a	Halogen Leak Detector

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

      Tip:

      • After the blower motor with fan sub-assembly has stopped, leave the air conditioning unit assembly for more than 15 minutes.

      • Bring the halogen leak detector sensor under the drain cooler hose.

      • When bringing the halogen leak detector 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.

   5. If a refrigerant leak is not detected from the drain cooler hose, remove the blower motor with fan sub-assembly from the air conditioning unit assembly. Insert the halogen leak detector sensor into the air conditioning unit assembly and check for a leak.

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

      Tip:

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