Refrigerant System Leaks

REFRIGERANT SYSTEM LEAKS

WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage and serious or fatal injury.

Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service.

NOTE: If the A/C refrigerant system charge is empty or low, a leak in the A/C system is likely. Visually inspect all A/C lines, fittings and components for an oily residue. Oil residue can be an indicator of an A/C system leak location.

NOTE: The only way to correctly determine if the refrigerant system is fully charged with R-134a is to completely evacuate and recharge the A/C system.

Connect a suitable manifold gauge set and determine if the static A/C system pressure is above or below 345 kPa (50 psi). If less than 345 kPa (50 psi), proceed to SYSTEM EMPTY. If greater than 345 kPa (50 psi), go to SYSTEM LOW.

SYSTEM EMPTY

1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately -88 kPa (- 26 in. Hg) or greater vacuum). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to STEP 2.

2. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system and proceed to STEP 1 of the System Low procedure.

SYSTEM LOW

3. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.

4. Operate the heating-A/C system with the engine at idle under the following conditions for at least 5 minutes.
- Doors or windows open
- Transmission in Park or Neutral with the parking brake set (depending on application)
- A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged

CAUTION: A leak detector only designed for R-12 refrigerant will not detect leaks in an R-134a refrigerant system.

5. Shut the vehicle Off and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only DaimlerChrysler approved refrigerant dye.