Refrigerant System Leaks

DIAGNOSIS AND TESTING - 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 possible 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 system refrigerant charge is empty or low, a leak in the A/C system is likely. When searching for a refrigerant leak in the A/C system, use an electronic leak detector and refrigerant leak detection dye with an Ultra Violet (UV) light that is designed for R-134a refrigerant. It is important to use only high-quality refrigerant leak detection equipment to properly locate refrigerant system leaks, such as the equipment listed in the team PSE Service Equipment Catalog. Use only Chrysler approved R-134a leak detection dye, available through Mopar(R).

1. Visually inspect all A/C lines, A/C fittings and A/C components under the hood for an oily residue. Oil residue can be an indicator of a leak location.
2. Connect a high-quality manifold gauge set or refrigerant recovery machine to the A/C system and determine if the static A/C system pressure is above or below 345 kPa (50 psi) Refrigerant System Recovery. If static A/C system pressure is less than 345 kPa (50 psi), proceed to SYSTEM EMPTY. If static A/C system pressure is 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 -8 kPa (-26 in. Hg) or greater vacuum) for at least 30 minutes Refrigerant System Evacuate.

CAUTION: Use only Chrysler LLC approved R-134a leak detection dye. It is important to use only high-quality refrigerant leak detection equipment. Small leaks may not be found using low-budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.

2. Prepare an R-134a dye injector with a Chrysler approved R-134a leak detection dye.
3. Prepare the vehicle specific amount of R-134a refrigerant [1][2]Capacity Specifications.

NOTE: Anytime an R-134a leak detection dye has been added to the refrigerant system, a label indicating that dye has been added should be placed on the vehicle in plain view, for other technicians.

4. Dispense the leak detection dye and the correct amount of R-134a refrigerant into the evacuated refrigerant system . Refrigerant System Evacuate
5. Proceed to LEAK TEST.

SYSTEM LOW

CAUTION: Use only Chrysler LLC approved R-134a leak detection dye. It is important to use only high-quality refrigerant leak detection equipment. Small leaks may not be found using low-budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.

1. Prepare an R-134a dye injector with a Chrysler approved R-134a leak detection dye.

NOTE: Anytime an R-134a leak detection dye has been added to the refrigerant system, a label indicating that dye has been added should be placed on the vehicle in plain view, for other technicians.

2. Dispense the leak detection dye and 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system . Refrigerant System Evacuate
3. Proceed to LEAK TEST.

LEAK TEST

1. Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
2. Operate the heating and A/C system with the engine at idle under the following conditions for at least 15 minutes.
- Doors or windows open
- Transmission in Park or Neutral with the parking brake set (depending on transmission application)
- Front A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C compressor engaged
- If equipped, rear A/C and heater controls set to full cool and high blower.

3. Shut the vehicle off and wait at least 5 minutes.

CAUTION: Use it is important to use only a high-quality Ultra Violet (UV) light when searching for a leak in the refrigerant system. Small leaks may not be found using budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.

4. Begin searching for leaks using a high quality UV light to detect the fluorescent R-134a leak detection dye. Inspect all connections, plumbing fittings, brazed joints, hoses, hose crimps, service ports, compressor housing, pressure relief valve and A/C condenser for dye. Inspect the evaporator drain tube and condensate for presence of dye, which indicates a leak from the A/C evaporator.

WARNING: Use extreme care when working around a running engine. Keep hands and fingers clear of the radiator fan, accessory drive belt and all other moving components. Keep away when wearing loose clothing, jewelry or long hair that is not properly secured. Underhood components may become hot to the touch. Be careful not to come into contact with hot engine, A/C and engine cooling system components. Failure to follow these instructions may result in serious or fatal injury.

CAUTION: Use only an electronic leak detector designed for R-134a refrigerant. It is important to use only high-quality refrigerant leak detection equipment. Small leaks may not be found using budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.

5. If a leak is not found with the R-134a detection dye, use a high-quality electronic R-134a leak detector and insert it into the evaporator drain tube, and into the instrument panel air outlets, to check for evaporator leaks. Check the evaporator tubes at the A/C expansion valve, for leaks not visible behind the valve. Check around the front of the A/C compressor, for compressor shaft seal leaks. Check between the A/C condenser and radiator for condenser leaks not previously visible.