A/C Leak Detection (B07-025)

LEAK DYE APPLICATION CHART

Not all models allow leak dye. Use this chart to determine if it can be used.

USING THE R-134A A/C LEAK DETECTION KIT

1. Before adding any leak-detection dye, check if there is dye in the system now.
   • Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system.
   • Dye may have been added even though no label is present. To confirm this, do the following:
     • Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap.
     • Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will have a bright yellow fluorescent glow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system.
   • If there is no dye in the system, go to step 2.
   • If there is dye in the system, go to step  5. Do not add more dye. 
2. Add the dye.
   NOTE: Air and moisture must be evacuated from the hose assembly if it is being used for the first time, or if it has been stored with the control valve open. If the air and moisture have been evacuated, go to step 3; otherwise, do the following:
   1. Assemble the injection hose as shown in the diagram using the EMPTY Tracer-Stick® capsule and the purge fitting.
   2. Connect the service valve fitting to the low side hose of the A/C recovery and charging station.
   3. Following the manufacturer's instructions for your recovery and charging station, evacuate the hose assembly for about 3 minutes. 
   4. When evacuation is complete, disconnect the hose assembly from the A/C recovery and charging station.
   5. Remove the service valve fitting and the empty dye capsule from the set, and store them for future use.
3. Connect the hose assembly and the Tracer-Stick® dye capsule:
   1. For best results, the Tracer-Stick® should be connected so that the embossed arrow points toward the refrigerant flow.
   2. Do not remove both caps at the same time.
   3. Replace the cap the arrow points away from with the service valve fitting.
   4. Remove the cap the arrow points toward and connect the stick to the hose.
4. Connect the A/C service equipment:
   1. Connect the hose assembly with the Tracer-Stick® to the vehicle's low-side service port and to the refrigerant source.
   2. The flow through the Tracer-Stick® will be controlled by the valves at the refrigerant source.
   3. Inject the dye by operating the A/C on high and allowing a small amount of refrigerant through the stick until it is cleared of all dye (liquid refrigerant works best).
   NOTE:

   • The Tracer-Stick® has a flow restrictor to allow for liquid refrigerant to be used without concern.
   • If you have recovered refrigerant to weigh as part of your diagnostics, or if there is a low charge, it is more
   • efficient to recharge the system using normal procedures before installing the hose assembly. Dye can then be added using about 0.05 lb (0.02 kg)  of refrigerant.
   • You do not need to connect the service equipment's high-side hose to the vehicle to install the dye. If the high-side hose is connected, make sure its coupler valve is closed before proceeding.
   • Do not use the A/C recovery and charging station to recover or evacuate the A/C system when a full dye capsule is attached. The dye will be drawn into the service equipment instead of being added to the vehicle's A/C system.
5. Inspect the A/C system for leaks.
   1. Run the A/C system for 5 to 10 minutes  to circulate the dye through the system. Large leaks will be seen immediately as a fluorescent yellow glow.
   2. Smaller leaks may require at least 90 minutes  of vehicle operation before they become visible.
      NOTE:

      • Based on the case, you may return the vehicle to the client. Be sure to schedule a return visit 24 to 48 hours  later to ensure the dye has circulated through the system.
      • Turn the ECON button OFF before running the A/C system (If equipped).
   3. Stop the vehicle's engine, and inspect the system for leaks using the OPTI-PRO™ UV Plus flashlight and fluorescence-enhancing glasses from the kit. Low ambient light conditions (a dark work area) will aid in locating the leak.
      NOTE: Not all UV lamps work well with all types of fluorescent dye. Use only the lamp provided in the kit to inspect for leaks.
   4. Inspect the entire system. Be sure to check these locations:
      • damaged and corroded areas
      • fittings
      • hose-to-line couplings
      • refrigerant controls
      • service ports
      • brazed or welded areas
      • areas near attachment points
   5. Check for evaporator leaks from the evaporator drain tube area using the ultraviolet lamp and glasses.
   6. After repairing a leak, remove any fluorescent residue using the GLO-AWAY dye cleaner from the kit and hot water. Follow the instructions on the bottle.

USING THE R-1234YF A/C LEAK DETECTION KIT

1. Before adding any leak-detection dye, check if there is dye in the system now.
   • Check for a label in the engine compartment indicating that fluorescent leak-detection dye has been added to the system.
   • Dye may have been added even though no label is present. To confirm this, do the following:
     • Put on the fluorescence-enhancing glasses, and remove the low-side service port sealing cap.
     • Direct the ultraviolet lamp into the valve stem area. If dye has been previously added, the lubricant traces will glow bright yellow. You may need to press the port's valve stem briefly to release some lubricant and dye from the system.
   • If there is no dye in the system, go to step 2.
   • If there is dye in the system, go to step  13. Do not add more dye. 
2. Unscrew the handle on the EZ-Ject injector completely, and screw in the Mini-EZ dye cartridge.
3. Holding the cartridge vertically, remove the cap and screw the cartridge firmly to the coupler.
4. Insert the adapter/purge fitting into the coupler.
5. Turn the handle to push forward the plunger until a small amount of dye exits the assembly.
6. Remove the adapter/purge fitting.
7. Clean any excess dye from the coupler.
8. The R-1234yf coupler is now purged, ready for use, and will be full of dye.
   NOTE: If the dye charge is lost, repeat steps  2 through  7.
9. Connect the coupler to the service port on the vehicle.
10. Turn the plunger clockwise to inject the dye.
11. Use one 0.25 oz (7.4 ml) Mini-EZ dye cartridge for one vehicle.
12. Disconnect the coupler from the service port, and wipe both clean.
13. Start the engine, and run the A/C system on maximum for 5 to 10 minutes  to circulate the dye.
14. Turn the ignition to OFF.
15. Inspect for possible leaks with the OPTI-PRO Plus flashlight. Leaks will glow bright yellow. The fluorescence will be brightest under low-light conditions.
    1. Inspect the entire system. Be sure to check these locations:
       • damaged and corroded areas
       • fittings
       • hose-to-line couplings
       • refrigerant controls
       • service ports
       • brazed or welded areas
       • areas near attachment points
    2. Check for evaporator leaks from the evaporator drain tube area using the ultraviolet lamp and glasses.
16. Residual dye could give a false leak indication. Run the A/C system 5 to 10 minutes  and inspect with the ultraviolet light. If there is no visible glow, all leaks have been repaired.
17. To find smaller leaks, run the A/C system for a minimum of 90 minutes  and inspect it again.
    NOTE:

    • Based on the case, you may return the vehicle to the client. Be sure to schedule a return visit 24 to 48 hours  later to ensure the dye has circulated through the system.
    • Turn the ECON button OFF before running the A/C system (If equipped).
18. After the leaks are repaired, clean the residual dye (from the leak sites) with a cloth and GLO-AWAY Dye Cleaner. Check with the lamp to make sure all dye residue is removed.