General Checking
CHECKING FOR A/C LEAKSAvoid breathing A/C refrigerant and lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service.
WARNING: GOOD VENTILATION IS NECESSARY IN THE AREA WHERE A/C LEAK TESTING IS TO BE DONE. IF THE SURROUNDING AIR IS CONTAMINATED WITH REFRIGERANT GAS, THE LEAK DETECTOR WILL INDICATE THIS GAS ALL THE TIME. ODORS FROM OTHER CHEMICALS SUCH AS ANTIFREEZE, DIESEL FUEL, DISC BRAKE CLEANER, OR OTHER CLEANING SOLVENTS CAN CAUSE THE SAME CONCERN. A FAN, EVEN IN A WELL-VENTILATED AREA, IS VERY HELPFUL IN REMOVING SMALL TRACES OF AIRBORNE CONTAMINATION THAT MIGHT AFFECT THE LEAK DETECTOR.
Attach the Rotunda R-134a Service Center 176-00001 or equivalent to the system. Leave both manifold gauge valves at the maximum open position. Both gauges should show approximately 413-551 kPa (60-80 psi) at 24°C (75°F) with engine not running.
LEAK DETECTOR, ELECTRONIC
Check all system connections, the compressor head gasket and shaft seal for leaks, using a good leak detector. Use Rotunda R-134a Automatic Calibration Halogen Leak Detector 023-R1003 or equivalent. Pass the leak detector along the underside of all points being checked. Refrigerant is heavier than air and will show most readily in those locations.
Operate leak detector according to manufacturer's directions.
NOTE
^ Some vehicles may have signs of refrigerant oil at the spring lock couplers. This may be caused from the assembly process which applies oil to the fittings before installation to aid in assembly. When a spring lock coupler is suspected of leaking, always wipe the fitting clean and verify the leak with Rotunda R-134a Automatic Calibration Halogen Leak Detector 023-R1003 and Fluorescent Tracer Dye 164-R3704 and Tracer Dye Injector 164-R3711.
^ All new systems contain detection dye. Leaks may be detected using ultra-violet light 164-R0721.
LEAK TRACER DYE
NOTE: R-134a fluorescent tracer dye is incorporated into the A/C system at assembly. If it is necessary to add dye, use Rotunda Dye Injector 164-R2610. A/C systems require 7.39 ml (0.25 oz) of Rotunda Fluoro-Lite/P Fluorescent Tracer Dye 164-R3712.
1. Close valve on dye injector.
NOTE: Periodically lubricate dye injector reservoir valve stem with refrigerant oil.
2. Connect hose end of dye injector to system low pressure gauge port valve and tighten it securely.
3. Close both valves on gauge manifold set and connect center hose to a charging cylinder. Leave center hose loose at the gauge manifold connection. Close valve on charging cylinder.
NOTE: If the system pressure is above 414 kPa (60 psi), there is no need to add refrigerant to the system for this operation.
4. Connect gauge manifold low pressure hose to dye injector, leaving connection at the gauge manifold loose.
5. Open injector valve to allow A/C system pressure to purge air from the dye injector reservoir and the low pressure hose to the gauge manifold. Tighten hose connection at gauge manifold gauge set. Close valve on the dye injector.
6. Remove reservoir cap from the top of dye injector and fill reservoir with 7.39 ml (0.25 oz) of Rotunda Fluoro-Lite/P Fluorescent Tracer Dye 164-R3712.
7. Replace reservoir cap. Tighten securely.
8. Open valve on charging cylinder, then open the manifold gauge low pressure valve. Open valve on the dye injector for 5 to 10 seconds to allow the dye to be forced into A/C system. Close dye injector valve. Close manifold gauge low pressure valve and valve on the charging cylinder.
9. Start engine and operate the A/C system at MAX to stabilize system (approximately 10-15 minutes).
10. Engine OFF.
11. Disconnect all hoses slowly to dissipate any residual refrigerant pressure that may be present.
12. Start engine and operate the A/C system to thoroughly mix the tracer dye with the system's compressor oil.
13. Continue to operate the A/C system in order to allow the tracer dye to circulate through the system and penetrate the leak(s). The time needed for the leak to appear will depend on the type of system and size of the leak.
14. Check for leak(s) with Rotunda UV Lamp 164-R0721 or equivalent. Scan all components, fittings and lines of the system. The exact location of the leak(s) can be pinpointed by the bright yellow-green glow of the tracer dye. Since more than one leak may exist in the system, always inspect each component.
NOTE: Fluoro-Lite/P Fluorescent Tracer Dye 164-R3712 combines and circulates with both the compressor oil and the refrigerant. For the tracer dye to show leakage in an A/C system, the compressor oil must flow throughout the system you are checking. As the refrigerant escapes, it will leave a trace of compressor oil with the dye at the point of leakage.
15. After the leak is repaired, the traces of fluorescent dye can be removed from the previously leaking areas by using any general-purpose oil solvent.
NOTE: The best leak detection results will be achieved in conditions of low ambient light. In areas that cannot be reached by the UV lamp, use a mechanic's mirror or use a non-fluorescent shop towel. Wipe the suspected leak area and then check the towel with the UV lamp for a trace of the fluorescent dye. If no leak is found, return the vehicle to the customer with instructions to bring it back at a later date to allow time for the fluorescent material to collect around the leak site.
16. Verify the repair to ensure that the leaks have been successfully repaired and all fittings are tight. Steps 12, 13, and 14 can be repeated without adding more tracer dye (unless the dye has been removed during the servicing). While Rotunda Fluoro-Lite/P Fluorescent Tracer Dye 164-R3712 can safely remain in the A/C system indefinitely without harm to components, its fluorescent lifespan is roughly 500 hours of A/C system use, after which time another infusion of dye would be required.
17. Write the dye installation date on a label (labels are included with the dye) and apply it to the engine compartment in an area where it will be seen easily by a future technician. Labeling the vehicle will tell others that dye has already been installed.