Refrigerant Leak Check

Special Tools Required 

• Leak detector YGK-H-10PM
• Leak detector HLD-100
• Leak detector TIFZX-1, or commercially available
• OPTIMAX Jr. A/C Leak Detection Kit (TRP124893) These tools are available through the Honda Tool and Equipment Program; call 888-424-6857

Leak Detector Usage Tips (Refer to the Operator's Manual for complete operating instructions):

• Position the vehicle in a wind-free work area. This will aid in detecting small leaks.
• When using the leak detector for the first time, allow it to warm up for 2 minutes with the probe in a clean atmosphere. This lets the temperature sensor in the detector stabilize.
• The calibration check should be done in the "Search 2" mode. Once that is done, the other check modes do not need calibrating.
• When leak checking through the HVAC module drain hose, avoid drawing water into the probe. Water can damage the internal pump and sensor.
• Avoid creasing the flexible probe extension. Creases can restrict air flow and give false readings.
• Because the detector recalibrates itself for ambient gases, it may be necessary to move the detector away from the leak to clear the sensor. Once the sensor has cleared, recheck the suspected leak.
• When removing the clear probe tip, be careful not to lose the flow ball.
• R-134a is heavier than air; always check below and to the sides of all potential leak sources.
• Halogen leak detectors are sensitive to chemicals: windshield washing solutions, solvents/cleaners, and some vehicle adhesives. Keep these chemicals out of the area when doing leak detection.

Fluorescent Dye Usage Tips:

• Use only Tracer-Stick single dose fluorescent dye capsules from Tracerline®. Other dyes contain solvents that may contaminate the refrigerant oil, leading to component failure.
• Adding excessive amounts of dye can damage the compressor.
• PAG oil is water soluble, so 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.
• After checking and repairing leaks, thoroughly clean any residual dye from the areas where leaks were found. Use GLO-AWAY dye cleaner, from Tracerline®, and hot water to remove the dye (follow the instructions on the bottle). Residual dye stains can cause misdiagnosis of any future A/C system leaks.
• If any refrigerant dye contacts an exterior paint surface, remove it by doing this:

• Carefully wash the affected surfaces to remove any dirt, and to prevent paint scratching.
• Mix water and isopropyl alcohol in a 50/50 mixture. Soak a soft 100 percent cotton towel with the water/alcohol mixture, and place the cloth on the affected areas to remove the dye.
• After removing the dye with the water/alcohol-soaked cloth, carefully wash the affected areas, and check that there is no remaining dye.

1. Connect an R-134a refrigerant recovery/recycling/charging station (A) to the high-pressure service port (B) and the low-pressure service port (C), as shown, following the equipment manufacturer's instructions.
   Fig 1: Connect R-134a Refrigerant Recovery/Recycling/Charging Station To High-Pressure Service Port

   Courtesy of AMERICAN HONDA MOTOR CO., INC.
2. Recover refrigerant from the A/C system (see REFRIGERANT RECOVERY ), and evacuate the system (see SYSTEM EVACUATION ). If the system achieves a vacuum of approximately -93.3 kPa (-700 mmHg, -27.6 in.Hg) in 15 minutes, and holds the vacuum for 15 minutes, then the system does not have a leak at this time. If the system cannot achieve or hold a vacuum, continue the refrigerant leak check.
3. Open the high pressure valve to charge the system to the specified capacity. Select the appropriate units of measure for your refrigerant charging station.

   Refrigerant Capacity: 

   550 to 600 g 

   0.55 to 0.60 kg 

   1.2 to 1.3 lbs 

   19.4 to 21.2 oz 

4. With the engine OFF, use a halogen leak detector first to detect the leak source. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test the following areas of the system for leaks:
   DIAGNOSTIC PROCEDURE CHART
   
   

   Possible Leak Area	Diagnostic Procedure with the Leak Detector	Notes
   Service Ports	Check the service ports with the detector. If the detector "sniffs" leak, use fluorescent dye to confirm it.	When capping the service ports, ensure that the seals on the port caps are in place, and that the caps are tight. The caps are used as the final seals in the system.
   Condenser	If the detector "sniffs" a leak, use fluorescent dye to confirm it.	Check for joints or connections coated with oily dust. Check for damaged and corroded areas. Check all fittings, couplings, brazed/welded areas and areas around attachment points. Move the probe slowly (1 inch/second or less), and keep it within 1/4 inch of the component being checked. This maximizes the chance of detecting a leak. If you detect a leak, blow compressed air over the area, then recheck for leaks. For large leaks, clearing the area with compressed air may help you pinpoint the leak source.
   A/C Lines (Low pressure side)	Wiggle the hose when checking crimped metal ends on rubber hoses. If the detector "sniffs" a leak, use fluorescent dye to confirm it.	Check all fittings, couplings, pressure switches, brazed/welded areas, and areas around attachment points on A/C lines and components. Check for damaged and corroded areas. Move the probe slowly (1 inch/second or less), and keep it within 1/4 inch of the component being checked. This maximizes the chance of detecting a leak.

5. Close the quick coupler valves, then disconnect the quick couplers from the vehicle service ports.
6. Attach the universal connect set, from the Optimax Jr. Leak Detection Kit, to the service valve fitting. Close the control valve (the black knob on the connect set).
7. Attach the charging station low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the charging station vacuum pump, then close the quick coupler valve.
8. Detach the universal connect set, and install a Tracer-Stick® dye capsule between the connect set and the service valve fitting (see the manufacturer's instructions for more detail).
9. Attach the quick coupler on the universal connect set to the low pressure service port on the vehicle. Open the charging station low pressure hose quick coupler valve, but do not open the control valve.
10. Start the engine, and set the A/C system to MAX A/C. Open the control valve to let refrigerant and the dye enter the A/C system through the low pressure service port. Close the control valve when the Tracer-Stick® dye capsule is empty.
11. Run the engine and A/C system for 15 minutes to thoroughly circulate the dye. Then shut the engine off, and inspect the following areas of the system for leaks:
    NOTE:

    • Check for leaks in a dark work area, and use the UV light and the special glasses from the leak check kit. Other UV lights may not work well with the Tracer-Stick® dye.
    • Small leaks may take up to 1 week of vehicle operation (with normal A/C use) to become visible.
    DIAGNOSTIC PROCEDURE CHART
    
    

    Possible Leak Area	Diagnostic Procedure with Fluorescent Dye
    Service Ports	If a leak is found, replace the schrader valve on the service port.
    A/C Lines	Use a permanent marker pen to circle the leak area. If a leak is found, remove and replace the A/C line (see A/C LINE REPLACEMENT ).
    Condenser	If a leak is found, remove the condenser (see A/C CONDENSER REPLACEMENT ). Determine whether leak is in the condenser or the receiver/dryer. Use a permanent marker pen to circle the leak area. Replace either the receiver/dryer (see RECEIVER/DRYER DESICCANT REPLACEMENT ), or the condenser (see A/C CONDENSER REPLACEMENT ), depending upon which is leaking.
    A/C Compressor	Check for leaks at all of the compressor joints, the clutch center, the compressor front housing bolts, and the scroll bolts on the back of the compressor. If a leak is found, use a permanent marker pen to circle the leak area. If the compressor relief valve appears to be leaking, determine whether the leak is coming from the relief valve, or the joint between the compressor casing and the valve. If the leak is from the relief valve, check the A/C system pressures, and refer to the pressure test table in the A/C system test (see A/C SYSTEM TEST ). If the leak is from the casing/valve joint, replace the A/C compressor relief valve (see A/C COMPRESSOR RELIEF VALVE REPLACEMENT ). If the leak is coming from the suction hose and/or discharge hose fittings on the compressor, clean the A/C fittings and replace the suction/discharge fitting O-rings. For all other compressor leaks, remove and replace the A/C compressor (see A/C CONDENSER REPLACEMENT ).
    Evaporator	Start checking for evaporator leaks by illuminating the evaporator drain tube area. If a leak is found, remove the evaporator core (see BLOWER UNIT COMPONENT REPLACEMENT ). Determine whether leak is from evaporator or expansion valve. Use permanent marker pen to circle leak area. Replace the expansion valve (see EXPANSION VALVE REPLACEMENT ), or the evaporator core (see BLOWER UNIT COMPONENT REPLACEMENT ), depending upon which is leaking.