Operation Procedure for Refrigerant Charge: Charge

WARNING: This page is about a different car, the 2011 Suzuki SX4. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: There is a risk of personal injury or health problems if the A/C system is charged with refrigerant incorrectly or if refrigerant containers are improperly handled. Be sure to take the following precautions to reduce the risk of injury or health problems.

Be sure to perform the refrigerant charge operation with the engine stopped. Charge the high-pressure side first and then the low-pressure side. If you do not, the refrigerant may flow backward and cause the hose or refrigerant container to burst.
Install the tap valve carefully following the instructions on the refrigerant container to prevent contact with the refrigerant.
Be sure to empty the refrigerant container before discarding it to prevent possible health problems and other dangerous consequences.
Never expose the refrigerant container to a heat higher than 40 °C (104 °F). Liquid refrigerant will turn into a toxic gas.

NOTE: Failure to take proper precautions when charging the A/C system can result in charging the system with the incorrect amount of refrigerant and can lead to poor system operation or damage to system components.

Since the A/C system has no sight glass, first recover refrigerant and evacuate the system, and then fill the system with the specified amount of refrigerant.
Charge the system only when the compressor is not hot to assure that you have used the correct amount of refrigerant.
Be sure to check the pressure gauges before and during charging to assure that there is the correct amount of refrigerant in the system.
Do not turn the refrigerant container upside down during charging. Doing so will cause liquid refrigerant to enter the compressor and damage it.

NOTE: The air conditioning system contains HFC-134a (R-134a).
Described here is a method to charge the air conditioning system with refrigerant from the refrigerant service container.
When charging refrigerant recovered by using the refrigerant and recycling equipment (when recycling refrigerant), follow the procedure described in the equipment manufacturer's instruction manual.

The initial charge of the A/C system is performed through the high pressure side with the engine stopped. And next, this method must be followed by charging from the low pressure side with the engine running.

Check if hoses are routed properly after evacuating the system.
Connect low charging hose (1) and high charging hose (2) of the manifold gauge set (3) in position. Then, open refrigerant container valve (4) to purge the charging line.
Open the high pressure side valve (5) and charge refrigerant to system.
After a while, open the low pressure side valve (6) and close the high pressure side valve.
WARNING: If the high-pressure side valve is not closed securely, the refrigerant may flow backwards and cause the hose or refrigerant container to burst, possibly resulting in a personal injury. Be sure to close the high-pressure side valve securely.
Start engine and keep engine speed at 1500 r/min, and then operate A/C system.
Charge A/C system with refrigerant in vapor state. At this time, refrigerant container should be held upright.

Fig 1: Connecting Low Charging Hose And High Charging Hose Of Manifold Gauge Set
Courtesy of SUZUKI OF AMERICA CORP.
When refrigerant container (1) is emptied, use the following procedure to replace it with a new refrigerant container.
1. Close low pressure valve.
2. Replace empty container with a refrigerant container which has been charged with refrigerant. When using refrigerant container tap valve (2), use the following procedure for replacement.
  1. Retract needle (3) and remove refrigerant container tap valve by loosening its plate nut (4).
  2. Install the refrigerant container tap valve to a new refrigerant container.
    
    Fig 2: Identifying Needle And Plate Nut
    Courtesy of SUZUKI OF AMERICA CORP.
3. Purge any air existing in center charging hose.
  When using refrigerant container tap valve, use the following procedure to purge air.
  1. Once fully tighten refrigerant container tap valve (1), and then loosen (open) plate nut (2) slightly.
  2. Open low pressure side valve (3) of manifold gauge set (4) a little.
  3. As soon as refrigerant comes out with a "hiss" through a clearance between refrigerant container and tap valve, tighten plate nut as well as low pressure side valve.
  4. Turn handle of tap valve clockwise so that its needle is screwed into the new container to make a hole for refrigerant flow.
    
    Fig 3: Identifying Low Pressure Side Valve Of Manifold Gauge Set
    Courtesy of SUZUKI OF AMERICA CORP.

After the system has been charged with specified amount of refrigerant or when low pressure gauge (1) and high pressure gauge (2) have indicated the following specified value, close low pressure side valve (3) on manifold gauge set (4).

Specified amount of refrigerant

430 ± 20 g (15.2 ± 0.7 oz))

Low side and high side pressure example (CVT model)

HIGH PRESSURE GAUGE SPECIFICATIONS

Gauges should read as follows when ambient temperature is 30 °C (86 °F).
Pressure on high pressure gauge	1220 - 1550 kPa 12.4 - 15.8 kgf/cm² 176.9 - 224.8 psi
Pressure on low pressure gauge	240 - 350 kPa 2.4 - 3.6 kgf/cm² 34.8 - 50.8 psi

Low side and high side pressure example (M/T model)

LOW SIDE AND HIGH SIDE PRESSURE SPECIFICATIONS

Gauges should read as follows when ambient temperature is 30 °C (86 °F).
Pressure on high pressure gauge	1200 - 1820 kPa 12.2 - 18.6 kgf/cm² 174.0 - 264.0 psi
Pressure on low pressure gauge	250 - 350 kPa 2.5 - 3.6 kgf/cm² 36.3 - 50.8 psi

Fig 4: Checking Low Side And High Side Pressure

Courtesy of SUZUKI OF AMERICA CORP.