Repair Procedures

Refrigerant System Service Basics

• Because the electric compressor uses high voltage, POE oil with high volume resistivity must be used.
• Do not use the same air conditioning recovery/charging station used for conventional belt-driven compressors.

If PAG oil is mixed with the system's POE oil, dielectric breakdown may occur due to reduced volume resistance, and the compressor may not operate.

Refrigerant Recovery: Use only UL-listed service equipment certified to meet SAE J2210 requirements when removing HFC-134a (R-134a) from the air conditioning system.If the system is accidentally discharged, ventilate the work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1. 1
   Connect R-134a refrigerant recovery/recycling/charging equipment (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions. [Without Heat Pump]

   

   [With Heat Pump]

   

   

2. 2
   Measure the amount of refrigerant oil removed from the air conditioning system after the recovery process is complete. Be sure to add the same amount of new refrigerant oil back into the air conditioning system before charging.

System Evacuation: Use only UL-listed service equipment certified to meet SAE J2210 requirements when removing HFC-134a (R-134a) from the air conditioning system.If the system is accidentally discharged, ventilate the work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1. 1
   When the A/C system has been opened to the atmosphere, for example during installation or repair, it must be evacuated using an R-134a refrigerant recovery/recycling/recharging system. (If the system has been open for several days, the receiver/drier should be replaced and the system must be evacuated for several hours.)
2. 2
   Connect the R-134a Refrigerant Recovery/Recycling/Charging System (A) to the high-pressure service port (B) and the low-pressure service port (C) as shown, following the equipment manufacturer's instructions.

   

3. 3
   If the pressure does not exceed 93.3 kPa (700 mmHg, 27.6 inHg) after 10 minutes, there may be a leak in the system. Partially charge the system and check for leaks (refer to Leak Test).
4. 4
   Remove the low-pressure valve from the low-pressure service port.

System Charging: Use only UL-listed service equipment certified to meet SAE J2210 requirements when removing HFC-134a (R-134a) from the air conditioning system.If the system is accidentally discharged, ventilate the work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.

1. 1
   Connect the R-134a refrigerant recovery/recycling/recharging system (A) to the high pressure service port (B), as shown, in accordance with the equipment manufacturer's instructions.

   

2. 2
   Add the same amount of new refrigerant oil to the system as was removed during recovery. Use only the specified refrigerant oil. Charge the system with R-134a refrigerant. Do not overcharge the system, as this may damage the compressor. Specified amount: Without Heat Pump: 550 ± 25 g (19.4 ± 0.88 oz); With Heat Pump: 900 ± 25 g (31.7 ± 0.88 oz)

Refrigerant Leak Test: Always check for leaks with an electronic leak detector when a refrigerant leak is suspected and when performing service operations that involve disassembly, loosening, or connection of fittings.If a refrigerant leak is detected, perform the following steps:

1. 1
   Check the tightening torque of the connection fittings and, if loose, tighten to the specified torque. Using a leak detector (A), check for refrigerant gas leakage.
2. 2
   If the leak continues even after the fitting has been tightened, discharge the refrigerant from the system, disconnect the fittings, and inspect their sealing surfaces for damage. Always replace even if the damage is minor.
3. 3
   Check the compressor oil and add oil if necessary.
4. 4
   Charge the system and recheck for refrigerant leaks. If no leaks are found, evacuate and recharge the system again.