Refrigerant Leakage Repair

Air Conditioning System

Refrigerant Leakage Repair

Notice: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

Precautions for Replacement or Repair of Air Conditioning Parts

There are certain procedures, practices and precautions that should be followed when servicing air conditioning systems:
- Keep your work area clean.
- Always wear safety goggles and protective gloves when working on refrigerant systems.
- Beware of the danger of carbon monoxide fumes caused by running the engine.
- Beware of discharged refrigerant in enclosed or improperly ventilated garages.
- Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system.
- When discharging and recovering the refrigerant, do not allow refrigerant to discharge too fast; it will draw compressor oil out of the system.
- Keep moisture and contaminants out of the system. When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately. Never remove the caps or plugs until the lines or parts are reconnected or installed.
- When disconnecting or reconnecting the lines, use two wrenches to support the line fitting to prevent from twisting or other damage.
- Always install new O-rings whenever a connection is disassembled.
- Before connecting any hoses or lines, apply new specified compressor oil to the O -rings.
- When removing and replacing any parts which require discharging the refrigerant circuit, the operations described must be performed in the following sequence:
- Use the J 39500-A (ACR4: HFC-134a Refrigerant Recovery / Recycling / Recharging System) or equivalent to discharge and recover the refrigerant.
- Remove and replace the defective part.
- After evacuation, charge the air conditioning system and check for leaks.

Refrigerant Leakage Repair (Refrigerant Pipe Connection)

When connecting a dismounted refrigerant pipe, always install using a brand new O-ring. Use a backup wrench when removing or connecting a pipe to prevent the joint from being distorted or damaged.







Legend
(1) Backup Wrench
(2) Torque Wrench


When connecting the refrigerant pipe at the block joint, fit the protruding part of the joint firmly into the connection hole of the unit, and fasten using a bolt.







Legend
(1) Block Joint


Apply compressor oil to the O-ring before connecting.
The type of compressor oil to be used varies with the compressor type. Make use of a compressor oil that matches the type of compressor in use.







Legend
(1) Oil Application Area
(2) O-ring

Ensure to fit the O-ring firmly into the groove of the refrigerant pipe.







Legend
(1) O-ring

Insert the pipe into the union. Tighten the nut as much as possible using your hand. Next, tighten the nut to the specified torque.







Legend
(1) Nut
(2) Union

Refrigerant Pipe Joint Leakage

1. Check the torque of the connection parts of the refrigerant pipe. If they are loose, tighten to the specified torque.
- Use a backup wrench to prevent distortion or damage of the pipe.
- Do not tighten excessively.

2. Check the refrigerant pipe connection parts for leakage.
3. When a leakage is found, recover the refrigerant from the air conditioning system.
4. Check the O-ring and replace if necessary.
- Do not reuse O-rings. Make sure to replace them with new ones.
- Always apply a layer of compressor oil to the new O-ring before connecting them.

5. Tighten the refrigerant pipe connection parts to the specified torque.
- Use a backup wrench to prevent distortion or damage of the pipe.

6. Perform vacuuming, replenish the refrigerant, and check the air conditioning system.

Leakage From Hose

When there is refrigerant leakage from the inlet or outlet hose of the compressor, replace the entire hose. Do not attempt to cut or connect the hose.

1. Locate the point of refrigerant leakage.
2. Recover the refrigerant.
3. Remove the hose ASM.
- Upon disconnecting the hose, ensure to cover the joint with a cap to prevent foreign substances from entering the air conditioning cycle.

4. Install a new hose ASM to the compressor.
- Tighten the hose connection parts to the specified torque.

5. Perform vacuuming, replenish the refrigerant, and check the air conditioning system.

Leakage From Compressor

When there is compressor oil leakage from the shaft seal or shell of the compressor, replace the compressor ASM.