Refrigerant Charging Procedure

Refrigerant Charging Procedure

PROCEDURE

CAUTION:
- While working, be sure to wear protective goggles and protective gloves.
- Air in the cycle can cause insufficient air conditioning, and water in the cycle can cause clogging in the cycle (icing) and rust. To remove this air and water content, use a vacuum pump to perform evacuation before filling with refrigerant. By making the inside of the cycle a vacuum, the water content will evaporate even at normal temperatures, and can be removed.

1. Close all valves of the manifold gauge.






2. Attach the low pressure side and high pressure side hoses to the vehicle service port.

CAUTION: Confirm that the connections are secure.






3. Connect the center manifold hose of the manifold gauge to the vacuum pump.
4. Operate the vacuum pump and open the low pressure and high pressure side valves. Next, open the center manifold hose valve, and begin evacuation.

CAUTION: Make sure to perform evacuation using a vacuum pump.






5. Perform evacuation for 5 minutes or more, and when the low pressure gauge needle reaches -100.0 kPa (-750 mmHg, -29.5 inHg) or higher, close the center manifold hose valve, and stop the vacuum pump.
6. Leave alone for 5 to 10 minutes after closing the low pressure side and high pressure side valves, and check whether there is any change in the low pressure gauge needle indication. If the needle position changes, this indicates a leak. Check the pipe and hose connections, and repair the location with the problem. In this case, repeat again from step 1).
7. If there is no leakage, continue evacuation for additional 20 to 30 minutes.
8. Close all valves and stop the vacuum pump.
9. Follow the can tap operation manual, install to the refrigerant can.






10. Disconnect the center manifold hose from the vacuum pump, and connect the hose to the tap valve.
11. When a 13.6 kg (30 lb) refrigerant container is used, measure the amount of refrigerant with a refrigerant charging scale, and connect with the center manifold hose.






12. Open the valve on the HFC-134a source.
13. Loosen the center manifold hose connection on the manifold gauge for a few seconds (if there is a purge valve on the manifold gauge, push this instead) to allow the air in the center manifold hose to be bled by the refrigerant pressure.






14. Open the high pressure side and low pressure side valves of the manifold gauge to fill with refrigerant.

CAUTION: When filling with the engine running, do not open the high pressure side valve. Always fill from the low pressure side.






15. When the gauge needle reaches approximately 200 kPa (1,500 mmHg, 59.1 inHg), close all valves.
16. Using a leak tester, check for refrigerant leaks in the system.
17. After checking that there are no refrigerant leaks, fill with refrigerant up to the specified amount.
18. If the HFC-134a supply container becomes empty, close all valves, and close the can tap valve to replace the empty container. After replacing with a new HFC-134a supply container, perform air purge, and resume the filling operation.
19. If the refrigerant filling efficiency drops, close all valves.
20. Check that both the low pressure and high pressure valves are closed. Start the engine with the A/C switch OFF.
21. To prevent damage to the compressor, push the A/C switch ON-OFF quickly a few times.
22. Set up the vehicle to the following status:

CAUTION: When filling with the engine running, do not open the high pressure side valve. Always fill from the low pressure side valve.

- A/C switch ON
- Engine running at 1,500 rpm
- Blower speed setting to "HI"
- Temperature setting to "MAX COOL"
- Air inlet setting to "RECIRC"
- Window open

23. Open the low pressure side valve and fill with refrigerant up to the specified amount.
24. After filling with refrigerant, close all valves and disconnect the hose from the service port.
25. Attach the cap to the service port.