Refrigerant Leak Diagnosis
Whenever a refrigerant leak is suspected in the system or a service operation performed which results in disturbing lines or connections, it is advisable to test for leaks.CAUTION: R-134A SERVICE EQUIPMENT OR VEHICLE A/C SYSTEMS SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134A HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE. ADDITIONAL HEALTH AND SAFETY INFORMATION MAY BE OBTAINED FROM REFRIGERANT AND LUBRICANT MANUFACTURERS.
Saturn vehicles are equipped with refrigerant dye in the air conditioning system. This dye is installed in the receiver-dehydrator unit. The dye is distributed throughout the system as the vehicle is run during validation at the factory.
The preferred procedure of diagnosing a leaking refrigerant system follows:
1. Obtain service tool J42220 black light with specially tinted goggles.
IMPORTANT: A small amount of residue at various joints in the system may not be an actual leak that needs repair.
2. Point the black light at the refrigerant plumbing joints illustrated and inside the blower motor housing as illustrated in the Electronic Leak Detector procedure.
3. Observe any areas that have an excessive collection of glowing (yellow to green) refrigerant/oil residue.
4. Any area that shows excessive residue should be repaired. If the area has some residue and you suspect it may be leaking, use of an electronic leak detector is required.
5. Follow the electronic leak testing of fittings and connections .
6. After the repair is done, check refrigerant charged A/C system with an electronic leak detector to verify there are no more leaks.
7. Clean any refrigerant dye on components with brake and choke cleaner, Saturn Part No. 21007432.
8. If any refrigerant dye contacts an exterior paint surface, remove it by performing the following steps:
a. Carefully wash affected surfaces according to the Saturn Owner's Handbook to remove any dirt and to ensure that paint is not scratched during dye removal.
b. Mix water and isopropyl alcohol to obtain 50/50 mixture. Soak a soft 100 percent cotton cloth towel with the solution and wet down affected areas to remove dye.
c. After dye has been removed, wash affected areas and inspect to make sure that the dye has been removed.