Air Conditioning: Refrigerant: Replacement

RECOVER REFRIGERANT FROM REFRIGERATION SYSTEM
1. Start up the engine.
2. Turn the A/C switch ON.
3. Operate the cooler compressor with an engine speed of approximately 1,000 rpm for 5 to 6 minutes to circulate the refrigerant and collect the compressor oil remaining in each component into the cooler compressor.
4. Stop the engine.
5. Recover the refrigerant from the A/C system using a refrigerant recovery unit.
  SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)

ADD COMPRESSOR OIL

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

OIL REFERENCE CHART

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
A/C pipe replacement	Low pressure	5 to 25
When discharging refrigerant gas quickly		30 to 50	While applying vacuum, use manifold gauge to fill oil from low pressure side valve

CHARGE REFRIGERANT
1. Perform vacuum purging using a vacuum pump.
2. Charge refrigerant HFC-134a (R134a).
  Standard:
  
  w/o Rear cooler
  
  600+/-50g(21.2+/-1.8oz.)
  
  w/ Rear cooler
  
  750 +/-50 g (26.5 +/-1.8 oz.)
  
  SST 07110-58060 (07117-58060, 07117-58070, 07117-58080, 07117-58090, 07117-78050, 07117-88060, 07117-88070, 07117-88080)
  
  Fig 1: Charging Refrigerant Graph
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Do not operate the cooler compressor before charging refrigerant as the cooler compressor will not work properly without any refrigerant, and will overheat.
  - Approximately 200 g (7.05 oz.) of refrigerant may need to be charged after bubbles disappear. The refrigerant amount should be checked by measuring its quantity, and not with the sight glass.
WARM UP ENGINE
1. Warm up the engine at less than 1850 rpm for 2 minutes or more after charging the refrigerant.
  NOTE: Be sure to warm up the compressor when turning the A/C switch ON after removing and installing the cooler refrigerant lines (including the compressor), to prevent damage to the compressor.
CHECK FOR LEAKAGE OF REFRIGERANT
1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.
2. Perform the operation under these conditions:
  - Stop the engine.
  - Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).
  - Repeat the test 2 or 3 times.
  - Make sure that some refrigerant remains in the refrigeration system. When compressor is off:
    approximately 392 to 588 kPa (4 to 6 kgf/cm² , 57 to 85 psi)
3. Using a halogen leak detector, check the refrigerant line for leakage.
  
  Fig 2: Checking Refrigerant Line For Leakage
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.
5. Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.