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On-Vehicle Inspection

WARNING: This page is about a different car, the 2003 Lexus IS 300. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT REFRIGERANT VOLUME 

    Observe the sight glass on the liquid tube.

    Test conditions:

    • Running engine at 1,500 RPM
    • Blower speed control switch at "HI" position
    • A/C switch ON
    • Temperature control dial at "COOL" position
    • Fully open the doors
    Fig 1: Identifying Sight Glass On Liquid Tube
    G01314324Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    Fig 2: Symptoms Remedy Chart
    G01314325Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET 

    This is a method in which the trouble is located by using a manifold gauge set. Read the manifold gauge pressure when these conditions are established.

    Test conditions:

    • Temperature at the air inlet with the switch set at RECIRC is 30 - 35 °C (86 - 95 °F)
    • Engine running at 2,000 RPM
    • Blower speed control switch at "HI" position
    • Temperature control dial on "COOL" position

    HINT:

    It should be noted that the gauge indications may vary slightly due to ambient temperature conditions.

    1. Normally functioning refrigeration system.

      Gauge reading: 

      Low pressure side: 

      0.15 - 0.25 MPa (1.5 - 2.5 kgf/cm 2  ) 

      High pressure side: 

      1.37 - 1.57 MPa (14 - 15 kgf/cm 2  ) 

      Fig 3: Identifying Refrigerant Pressure
      G01314326Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Moisture present in refrigeration system.
      Fig 4: Identifying Moisture Present In Refrigeration System
      G01314327Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 5: Symptoms Remedy Chart
      G01314328Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Insufficient cooling
      Fig 6: Identifying Insufficient Cooling
      G01314329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 7: Symptoms Remedy Chart
      G01314330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Poor circulation of refrigerant
      Fig 8: Identifying Poor Circulation Of Refrigerant
      G01314331Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 9: Symptoms Remedy Chart
      G01314332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Refrigerant does not circulate
      Fig 10: Identifying Refrigerant Does Not Circulate Problem
      G01314333Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 11: Symptoms Remedy Chart
      G01314334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    6. Refrigerant overcharged or insufficient cooling of condenser
      Fig 12: Identifying Refrigerant Overcharged Or Insufficient Cooling Of Condenser
      G01314335Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 13: Symptoms Remedy Chart
      G01314336Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    7. Air present in refrigeration system
      Fig 14: Identifying Air Present In Refrigeration System
      G01314337Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 15: Symptoms Remedy Chart
      G01314338Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    8. Expansion valve improperly
      Fig 16: Identifying Expansion Valve Improperly Installed
      G01314339Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 17: Symptoms Remedy Chart
      G01314340Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Defective compression compressor
      Fig 18: Identifying Defective Compressor
      G01314341Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      Fig 19: Symptoms Remedy Chart
      G01314342Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT IDLE-UP SPEED 
    1. Warm up engine.
    2. Inspect idle-up speed when the these conditions are established.

      Test conditions:

      • Blower speed control switch at "HI" position
      • Temperature control dial at "COOL" position
      • A/C switch ON
      • Put gear shift in neutral
    Fig 20: Magnetic Clutch Ideal Speed Condition
    G01314343Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

    If idle speed is not as specified, check the idle control system.

  4. INSPECT FOR LEAKAGE OF REFRIGERANT 
    1. Perform in these conditions.
      • Stop engine
      • Secure good ventilation (If the gas leak detector may not react volatile gases which are not refrigerant, such as evaporated gasoline and exhaust gas)
      • Repeat the test 2 or 3 times
      • Make sure that there is some refrigerant remaining in the refrigeration system.

        When compressor is OFF: approx. 392 - 588 kPa (4 - 6 kgf.cm2 , 57 - 85 psi)

    2. Bring the gas leak detector close to the drain hose before performing the test.

      HINT:

      • After the blower motor has stopped, leave the cooling for more than 15 minutes.
      • Expose the gas leak detector sensor under the drain hose.
      • When bring the gas leak detector close to the drain hose, make sure that the gas leak detector does not react to the volatile gases.

        If such reaction is unavoidable, the vehicle must be lifted up.

    3. If gas leak is not detected on the drain hose, remove the blower resistor from the cooling unit. Then insert the gas leak detector sensor into the unit and perform the test.
    4. Disconnect the connector and leave the pressure switch for approx. 20 minutes. Then bring the gas leak detector close to the pressure switch and perform the test.
    5. Bring the gas leak detector close to the refrigerant lines.
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