Leak Testing

Leak Testing

Refrigerant Leak Testing

Tools Required

* J 39400-A Halogen Leak Detector
* J 41447R 134a A/C Tracer Dye-Box of 24
* J 42220 Universal 12V Leak Detection Lamp
* J 46297 A/C Dye Injector Kit
* J 46297-12Replacement Dye Cartridges

Important: Saturn vehicles are now manufactured with fluorescent dye installed directly into the A/C system.

The preferred method of leak testing is with the use of fluorescent dye. J 41447 is the only fluorescent dye approved by Saturn.

The fluorescent dye mixes and flows with the PAG oil throughout the refrigerant system.

Verifying some passive leaks may require using the J 39400-A, even though the A/C system contains fluorescent dye.

The only time that adding additional fluorescent dye is required is after flushing the A/C system.

Fluorescent Leak Detector

Fluorescent dye will assist in locating any leaks in the A/C system.

Important: PAG oil is water soluble.

* Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
* Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp.
Use the leak detection lamp in the following areas:

- All fittings or connections that use seal washers or O-rings
- All of the A/C components
- The A/C compressor shaft seal
- The A/C hoses and pressure switches
- The HVAC module drain tube, if the evaporator core is suspected of leaking
- The service port sealing caps
The sealing cap is the primary seal for the service ports.

* Follow the instructions supplied with the J 42220.
* To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Clean any refrigerant dye on components with brake and choke cleaner, Saturn P/N 21007432.
* If any refrigerant dye contacts an exterior paint surface, remove it by performing the following steps:

- 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.
- Mix water and isopropyl alcohol to obtain 50/50 mixture. Soak a soft 100 percent cotton cloth towel with the solution and wet down the affected areas to remove dye.
- After dye has been removed, wash affected areas and inspect to make sure that the dye has been removed.

Fluorescent Dye Injection

Important: J 41447 is the only A/C leak detection dye approved by Saturn.

* Not all of the fluorescent dyes are compatible with PAG oil.
Some types of dye decrease the oil viscosity or may chemically react with the oil.
* R-134a leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.

Important: Do NOT overcharge the A/C system with dye. This may cause reliability problems. Use only one 7.39 ml (0.25 oz) charge bottle of J 41447.

* With the A/C system charged, add J 41447 to the A/C system using J 46297. Follow the instructions provided with J 46297.
* To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Clean any refrigerant dye on components with brake and choke cleaner, Saturn P/N 21007432.
* The dye injection package contains a notice sticker. Complete the leak detection information and place the sticker near the charge label.

Halogen Leak Detector

Caution: Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result.

Ensure that the vehicle has at least 0.41 kg (0.9 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.

Important: Halogen leak detectors are sensitive to the following items:

* Windshield washing solutions

* Many solvents and cleaners

* Some adhesives used in the vehicle

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Important: Follow a continuous path in order to ensure that you will not miss any possible leaks. Test all areas of the system for leaks.

Follow the instructions supplied with the J 39400-A.