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Air Conditioning System: Charging

WARNING: This page is about a different car, the 2002 Toyota Prius. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: When handling the charging cylinder, always follow the directions given in the instruction manual.
  1. Install Charging Cylinder  :
    1. Charge the proper amount of refrigerant into the charging cylinder.
      2. WARNING: Do not open both high and low hand valves of manifold gauge set.
    2. Connect the center hose to the charging cylinder.
    3. Open the valve of charging cylinder.
    4. Press the valve core on the side of manifold gauge and expel the air inside of the center hose.
      Fig 1: Connecting Manifold Gauge Set To System & Charging Cylinder
      G01065395Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. Inspect Refrigeration System For Leaks  :
    1. Open the high pressure hand valve and charge refrigerant.
    2. When the low pressure gauge indicates 98 kPa (1 kgf/cm2, 14 psi) close the high pressure hand valve.
      3. CAUTION: Use the refrigerant recovery/recycling machine to recover the refrigerant whenever replacing parts.
      Fig 2: Identifying Gas Leak Detector
      G01065396Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a gas leak detector, check the system for leakage.

      If leak is found, repair the faulty component or connection.

    3. WARNING:
    • Never run the engine when charging the system through the high pressure side.
    • Do not open the low pressure hand valve when the system is being charged with liquid refrigerant.
  3. Charge Refrigerant Into Refrigerant System  :

    If there is no leak after refrigerant leak check, charge the proper amount of refrigerant into refrigeration system.

    1. Open the high pressure hand valve fully.
      2. NOTE: A fully charged system is indicated by the sight glass being free of any bubbles.
    2. Charge specified amount of refrigerant, then close the high pressure hand valve.
    3. Charge partially refrigeration system with refrigerant.
      1. Set vehicle in these conditions:

        MAX. switch ON.

        Blower speed control set at "HI".

        Temperature control set at "MAX. COOL".

        Air inlet control set at "RECIRC".

        Running engine at 1,500 rpm.

        Fully open doors.

        2. WARNING: Do not open the high pressure hand valve.
        Fig 3: Identifying Service Valves
        G01065397Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      2. Open the low pressure hand valve.
    4. Charge refrigerant until bubbles disappear and check the pressure on the gauge through the sight glass.
      Fig 4: Identifying Sight Glass Conditions
      G01065398Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Replenishment to be 100 7 plus or minus; 50 g after bubbles disappear.
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