Toyota Corolla 1970-1987 Repair Guide

Air Conditioning


Regular maintenance for the air conditioning system includes periodic checks of the drive belt tension. In addition, the system should be operated for at least five minutes every month (yes, in the winter too!). This ensures an adequate supply of lubricant to the bearings and also helps to prevent the seals and hoses from drying out. To do this comfortably in the winter, turn the air conditioning ON, the temperature control lever to WARM or HI and turn on the blower to the highest setting. This will engage the compressor, circulating lubricating oils within the system, but preventing the discharge of cold air. The system should also be checked for proper refrigerant charge using the refrigerant level check procedure located later in this section.

Before touching your A/C system, check with your local authorities. In many areas it is illegal for you to service the system unless you are a certified A/C system technician. Also, it may be impossible to purchase the necessary refrigerant unless you are certified


Because of the inherent dangers involved with working on air conditioning systems and R-12 refrigerant, the following safety precautions must be strictly adhered to in order to service the system safely.

  1. Avoid contact with a charged refrigeration system, even when working on another part of the air conditioning system or vehicle. If a heavy tool comes into contact with a section of tubing or a heat exchanger, it can easily cause the relatively soft material to rupture.
  3. When it is necessary to apply force to a fitting which contains refrigerant, as when checking that all system couplings are securely tightened, be sure to use a wrench on both parts of the fitting involved whenever possible. This will avoid putting torque on refrigerant tubing. (It is advisable, when possible, to use tube or line wrenches when tightening flare nut fittings.)

R-12 refrigerant is a chlorofluorocarbon which, when released into the atmosphere, can contribute to the depletion of the ozone layer in the upper atmosphere. Ozone filters out harmful radiation from the sun

  1. Do not attempt to discharge the system by merely loosening a fitting, or removing the service valve caps and cracking these valves. Precise control is possible only when using the service gauges and a proper A/C refrigerant recovery station. Wear protective gloves when connecting or disconnecting service gauge hoses.

Be sure to consult the laws in your area before servicing the air conditioning system. In some states, it is illegal to perform repairs involving refrigerant unless the work is performed by a certified technician

  1. Discharge the system only in a well ventilated area, as high concentrations of the gas which might accidentally escape can exclude oxygen and act as an anesthetic. When leak testing or soldering, this is particularly important, as toxic gas is formed when R-12 contacts any flame.
  3. Never start a system without first verifying that both service valves are properly installed, and that all fittings throughout the system are snugly connected.
  5. Avoid applying heat to any refrigerant line or storage vessel. Charging may be aided by using water heated to less than 125°F (1°C) to warm the refrigerant container. Never allow a refrigerant storage container to sit out in the sun, or near any other source of heat, such as a radiator.
  7. Always wear goggles to protect your eyes when working on a system. If refrigerant contacts the eyes, it is advisable in all cases to see a physician as soon as possible.
  9. Frostbite from liquid refrigerant should be treated by first gradually warming the area with cool water, and then gently applying petroleum jelly. A physician should be consulted.
  11. Always keep refrigerant drum fittings capped when not in use. If the container is equipped with a safety cap to protect the valve, make sure the cap is in place when the can is not being used. Avoid sudden shock to the drum, which might occur from dropping it, or from banging a heavy tool against it. Never carry a drum in the passenger compartment of a car.
  13. Always completely discharge the system into a suitable recovery unit before painting the vehicle (if the paint is to be baked on), or before welding anywhere near refrigerant lines.
  15. When servicing the system, minimize the time that any refrigerant line or fitting is open to the air in order to prevent moisture or dirt from entering the system. Contaminants such as moisture or dirt can damage internal system components. Always replace O-rings on lines or fittings which are disconnected. Prior to installation coat, but do not soak, replacement O-rings with suitable compressor oil.


It is recommended, and possibly required by law, that a qualified technician perform the following services

The most important aspect of air conditioning service is the maintenance of a pure and adequate charge of refrigerant in the system. A refrigeration system cannot function properly if a significant percentage of the charge is lost. Leaks are common because the severe vibration encountered underhood in an automobile can cause cracking or loosening of the air conditioning fittings; allowing, the extreme operating pressures of the system to force refrigerant out.

The problem can be understood by considering what happens to a common A/C system when it is operated with a continuous leak. Because the expansion valve regulates the flow of refrigerant to the evaporator, the level of refrigerant located there is fairly constant. The receiver/drier stores any excess of refrigerant, and so a loss will first appear there as a reduction in the level of liquid. As this level nears the bottom of the vessel, some refrigerant vapor bubbles will begin to appear in the stream of liquid supplied to the expansion valve. This vapor decreases the capacity of the expansion valve very little as the valve opens to compensate for its presence. As the quantity of liquid in the condenser decreases, the operating pressure will drop there and throughout the high side of the system. As the R-12 continues to be expelled, the pressure available to force the liquid through the expansion valve will continue to decrease, and, eventually, the valve's orifice will prove to be too much of a restriction for adequate flow even with the needle fully withdrawn.

At this point, low side pressure will start to drop, and severe reduction in cooling capacity, marked by freeze-up of the evaporator coil, will result. Eventually, the operating pressure of the evaporator will be lower than the pressure of the atmosphere surrounding it, and air will be drawn into the system wherever there are leaks in the low side.

Because all atmospheric air contains at least some moisture, water will enter the system and mix with the R-12 and the oil. Trace amounts of moisture will cause sludging of the oil, and corrosion of the system. Saturation and clogging of the filter/drier, and freezing of the expansion valve orifice will eventually result. As air fills the system to a greater and greater extent, it will interfere more and more with the normal flows of refrigerant and heat.

From this description, you may conclude that much of the repairman's time will be spent detecting leaks, repairing them, and then restoring the purity and quantity of the refrigerant charge. A list of general rules should be followed in addition to all safety precautions:

  1. Keep all tools as clean and dry as possible.
  3. Thoroughly purge the service gauges/hoses of air and moisture before connecting them to the system. Keep them capped when not in use.
  5. Thoroughly clean any refrigerant fitting before disconnecting it, in order to minimize the entrance of dirt into the system.
  7. Plan any operation that requires opening the system beforehand, in order to minimize the length of time it will be exposed to open air. Cap or seal the open ends to minimize the entrance of foreign material.
  9. When adding oil, pour it through an extremely clean and dry tube or funnel. Keep the oil capped whenever possible. Do not use oil that has not been kept tightly sealed.
  11. Use only R-12 refrigerant. Purchase refrigerant intended for use only in automatic air conditioning systems. Avoid the use of R-12 that may be packaged for other purposes, such as cleaning, or powering a horn, as it is impure.
  13. Completely evacuate any system that has been opened to replace a component, or that has leaked sufficiently to draw in moisture and air. This requires evacuating air and moisture with a good vacuum pump for at least one hour. If a system has been open for a considerable length of time it may be advisable to evacuate the system for up to 12 hours (overnight).
  15. Use a wrench on both halves of a fitting that is to be disconnected, so as to avoid placing torque on any of the refrigerant lines.
  17. When overhauling a compressor, pour some of the oil into a clean glass and inspect it. If there is evidence of dirt or metal particles, or both, flush all refrigerant components with clean refrigerant before evacuating and recharging the system. In addition, if metal particles are present, the compressor should be replaced.
  19. Schrader valves may leak only when under full operating pressure. Therefore, if leakage is suspected but cannot be located, operate the system with a full charge of refrigerant and look for leaks from all Schrader valves. Replace any faulty valves.

Additional Preventive Maintenance Checks

In order to prevent heater core freeze-up during A/C operation, it is necessary to maintain permanent type antifreeze protection of +15°F, or lower. A reading of -15°F is ideal since this protection also supplies sufficient corrosion inhibitors for the protection of the engine cooling system.

The same antifreeze should not be used longer than the manufacturer specifies


For efficient operation of an air conditioned car's cooling system, the radiator cap should have a holding pressure which meets manufacturer's specifications. A cap which fails to hold these pressures should be replaced.


Any obstruction of or damage to the condenser configuration will restrict the air flow which is essential to its efficient operation. It is therefore a good rule to keep this unit clean and in proper physical shape.

Bug screens are regarded as obstructions


Usually a single molded drain tube expels the condensation, which accumulates on the bottom of the evaporator housing, into the engine compartment. If this tube is obstructed, the air conditioning performance can be restricted and condensation buildup can spill over onto the vehicle's floor.


Test Gauges

Most of the service work performed in air conditioning requires the use of a set of two gauges, one for the high (head) pressure side of the system, the other for the low (suction) side.

The low side gauge records both pressure and vacuum. Vacuum readings are usually calibrated from 0 to 30 inches and the pressure graduations read from 0 to no less than 60 psi (414kPa).

The high side gauge measures pressure from 0 to at least 600 psi (4140kPa).

Both gauges are threaded into a manifold that contains two hand shut-off valves. Proper manipulation of these valves and the use of the attached test hoses allow the user to perform the following services:

  1. Test high and low side pressures.
  3. Remove air, moisture, and contaminated refrigerant.

The manifold valves are designed so they have no direct effect on gauge readings, but serve only to provide for the flow or cut-off of refrigerant through the manifold. During all testing and hook-up operations, the valves are kept in a closed position to avoid disturbing the refrigeration system. The valves are opened only to purge the system of refrigerant or to charge it.

Usually, when purging the system, the center hose is attached to a recovery station at the lower end, and both valves are cracked open slightly. This allows refrigerant pressure to force the entire contents of the system out through the center hose and into a suitable recovery station. During charging, the valve on the high side of the manifold is closed, and the valve on the low side is cracked open. Under these conditions, the low pressure in the evaporator will draw refrigerant from the relatively warm refrigerant storage container into the system.

Service Valves

For the user to diagnose an air conditioning system, he or she must gain "entrance'' to the system in order to observe the pressures. There are two types of terminals for this purpose, the hand shut off type and the familiar Schrader valve.

The Schrader valve is similar to a tire valve stem and the process of connecting the test hoses is the same as threading a hand pump outlet hose to a bicycle tire. As the test hose is threaded to the service port the valve core is depressed, allowing the refrigerant to enter the test hose outlet. Removal of the test hose automatically closes the system.

Extreme caution must be observed when removing test hoses from the Schrader valves as some refrigerant will normally escape, usually under high pressure. (Observe safety precautions.)

Using the Manifold Gauges

The following is a common guide to correct gauge usage.

  1. Wear goggles or a face shield during all testing operations.
  3. Remove caps from high and low side service ports. Make sure both gauge valves are closed.
  5. Connect low side test hose to the low side service valve (usually this valve is on the line between the evaporator outlet and the compressor).
  7. Attach high side test hose to the high side service valve (usually this valve is located on the line that leads to the condenser).
  9. Start engine and allow for warm-up. All testing and charging of the system should be done after engine and system have reached normal operation temperatures (unless the recovery/charging station's manufacturer instructs otherwise).
  11. Adjust air conditioner controls to maximum cold.
  13. Observe gauge readings. When the gauges are not being used it is a good idea to:
    1. Keep both valves in the closed position.
    3. Attach both ends of the high and low service hoses to the manifold, if extra outlets are present on the manifold, or plug them if not. Also, keep the center charging hose attached to an empty refrigerant can. This extra precaution will reduce the possibility of moisture entering the gauges. If air and moisture have gotten into the gauges, purge the hoses by supplying refrigerant under pressure to the center hose with both gauge valves open and all openings unplugged.



R-12 refrigerant is a chlorofluorocarbon which, when released into the atmosphere, can contribute to the depletion of the ozone layer in the upper atmosphere. Ozone filters out harmful radiation from the sun

The easiest and often most important check for the air conditioning system consists of a visual inspection of the system components. Visually inspect the air conditioning system for refrigerant leaks, damaged compressor clutch, compressor drive belt tension and condition, plugged evaporator drain tube, blocked condenser fins, disconnected or broken wires, blown fuses, corroded connections and poor insulation.

A refrigerant leak will usually appear as an oily residue at the leakage point in the system. The oily residue soon picks up dust or dirt particles from the surrounding air and appears greasy. Through time, this will build up and appear to be a heavy dirt impregnated grease. Most leaks are caused by damaged or missing O-ring seals at the component connections, damaged charging valve cores or missing service gauge port caps.

For a thorough visual and operational inspection, check the following:

  1. Check the surface of the radiator and condenser for dirt, leaves or other material which might block air flow.
  3. Check for kinks in hoses and lines. Check the system for leaks.
  5. Make sure the drive belt is under the proper tension. When the air conditioning is operating, make sure the drive belt is free of noise or slippage.
  7. Make sure the blower motor operates at all appropriate positions, then check for distribution of the air from all outlets with the blower on HIGH.

Keep in mind that under conditions of high humidity, air discharged from the A/C vents may not feel as cold as expected, even if the system is working properly. This is because the vaporized moisture in humid air retains heat more effectively than does dry air, making the humid air more difficult to cool

  1. Make sure the air passage selection lever is operating correctly. Start the engine and warm it to normal operating temperature, then make sure the hot/cold selection lever is operating correctly.


See Figure 1