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Home >> Mazda >> 2002 >> Tribute LX, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 32 (Manual A/C-Heater Systems - HVAC) >> System Tests >> Refrigerant Charging >> Charging New R-134a Refrigerant

Charging New R-134a Refrigerant

WARNING: This page is about a different car, the 2002 Mazda MPV. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the manifold gauge set.
  2. Connect the tap pin side of the charging hose to the air purge valve of the manifold gauge.
  3. Connect the vacuum pump hose to the center joint of the manifold gauge.
  4. Connect the vacuum pump hose to the vacuum pump.
  5. Connect the charging hose to the refrigerant tank.
  6. Place the refrigerant tank on the scale.
    Fig 1: Connecting Manifold Gauge Set For Charging
    G01197629Courtesy of MAZDA MOTORS CORP.
  7. Open all the valves of the manifold gauge.
    CAUTION: Close the manifold gauge valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will back flow into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.
    Fig 2: Charging With New R-134a Refrigerant
    G01197630Courtesy of MAZDA MOTORS CORP.
  8. Start the vacuum pump and let it operate for 15 minutes  .
  9. Verify that high- and low-pressure side readings of the manifold gauge are at -101 kPa (-760 mm Hg, -29.9 in Hg)  . Close each valve of the manifold gauge.
    Fig 3: Closing Manifold Gauge Valves
    G01197631Courtesy of MAZDA MOTORS CORP.
  10. Stop the vacuum pump and wait for 5 minutes  .
  11. Inspect the high- and low-pressure side readings of the manifold gauge.
    • If the reading has changed, inspect for leakage and then repeat from Step  7 .
    • If the reading has not changed, go to next step.
  12. Open the valve of the refrigerant tank.
  13. Weigh the refrigerant tank to charge the suitable amount of refrigerant.

    Regular Amount Of Refrigerant (Approximate Quantity) 

    Twin A/C: 850 g (30.0 oz) 

    Single A/C: 650 g (22.9 oz) 

    WARNING:
    • If the refrigerant system is charged with a large amount of refrigerant when checking for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage.
    • If charging the system with refrigerant by service cans or refrigerant tank, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans or refrigerant tank will increase and they could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
  14. Open the low-pressure side valve of the manifold gauge.
    Fig 4: Opening Manifold Gauge Low-Pressure Side Valve
    G01197632Courtesy of MAZDA MOTORS CORP.
  15. When the high-pressure side reading increases to 98 kPa (1.0 kgf/cm 2  , 14 psi)  , close the low-pressure side valve of the manifold gauge.
    Fig 5: Closing Manifold Gauge Valves
    G01197633Courtesy of MAZDA MOTORS CORP.
  16. Inspect for leakage from the cooler pipe/hose connections using a gas leak tester.
    • If there is no leakage, go to Step  18 .
    • If leakage is found at a loose joint, tighten the joint, go to next step.
  17. Inspect for leakage again.
    • If there is no leakage after tightening the joint, go to next step.
    • If there is still a leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from Step  7 .
    WARNING: If charging the system with refrigerant by service cans or refrigerant tank, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans or refrigerant tank will increase and they could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
  18. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of refrigerant tank has decreased 400 g (14.1 oz)  from the amount in Step  13 .
    Fig 6: Charging With Refrigerant Through Low-Pressure Side Valve
    G01197634Courtesy of MAZDA MOTORS CORP.
  19. Close the low-pressure side valve of the manifold gauge.
    WARNING: If charging the system with refrigerant by service cans or refrigerant tank, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans or refrigerant tank will increase and they could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
  20. Start the engine and actuate the A/C compressor.
    Fig 7: Closing Manifold Gauge Valves
    G01197635Courtesy of MAZDA MOTORS CORP.
  21. Open the low-pressure side valve of the manifold gauge and charge with refrigerant until the weight of the refrigerant tank has decreased 850 g (30.0 oz) (Twin A/C), 650 g (22.9 oz) (Single A/C)  from the amount in Step  13 .
  22. Close the low-pressure side valve of the manifold gauge and the valve of the refrigerant tank.
  23. Stop the engine and A/C compressor.
  24. Inspect for leakage using a gas leak tester.
    • If there is no leakage, go to Step  26 .
    • If leakage is found at a loose joint, tighten the joint, then go to next step.
    Fig 8: Charging With Refrigerant Through Low-Pressure Side Valve
    G01197636Courtesy of MAZDA MOTORS CORP.
  25. Inspect for leakage again.
    • If there is still leakage after tightening the joint, go to next step.
    • If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from Step  7 .
  26. Remove the manifold gauge set.
  27. Install the caps to the charging valves.
    Fig 9: Installing Charging Valve Caps
    G01197637Courtesy of MAZDA MOTORS CORP.
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