A/C Leak Detection (A07-030)

A/C LEAK DETECTION

TECHNICAL SERVICE BULLETIN

AFFECTED VEHICLES

ALL

REVISION SUMMARY

Under LEAK DYE APPLICATION CHART, model application was updated.

LEAK DETECTION TYPES

There are several A/C leak detection tools available.

• Refrigerant Gas Leak Detector
• Ultrasonic Leak Detector
• Leak Dye

• R-134a A/C Leak Detection Kit (P/N TRP124893A)
• R-1234yf A/C Leak Detection Kit (P/N TRP1234YFA)

REFRIGERANT GAS LEAK DETECTOR

A refrigerant leak detector can sense refrigerant gas leaking from the A/C system.

• It is a good alternative if the vehicle cannot accept leak dye.
• The system must be pressurized to use this type of leak detector.

ULTRASONIC LEAK DETECTOR

An ultrasonic leak detector listens for leaks in the A/C system.

• It is a good alternative if the vehicle cannot accept leak dye.
• The system must under vacuum to use this type of leak detector.

LEAK DYE

Dye is injected into the A/C system. System leaks are visible with an ultraviolet light.

R-134A A/C LEAK DETECTION KIT

The R-134a A/C Leak Detection Kit (P/N TRP124893A) is a required special tool. The kit is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector may not find.

When searching for leaks, always begin by using an electronic leak detector. Refer to service bulletin 18-073, Bosch ROBLD020 Dual Mode Refrigerant Gas Leak Detector  , for tips on using this tool, then follow up with the R-134a Kit.

This detection kit complements but does not replace the electronic leak detector.

R-134a A/C Leak Detection Kit (P/N TRP124893A) includes these items: 

• TPOPUVP OPTI-PRO™ UV Plus, rechargeable violet light LED leak detection flashlight (battery included)
• TRPTP3860P12 - (6) R-134a/PAG TRACER-STICK® Cartridges
• TRPTP19 - GLO-AWAY™ PLUS Fluorescent Dye Cleaner
• TRPTP9940 - Fluorescence-Enhancing Glasses
• TRPTP22 - (1) purge capsule (empty)
• TRPTP20 - R-134a hose with adapter/coupler/fitting
• TRPTP14 - USB charger (not pictured)

R-1234YF A/C LEAK DETECTION KIT

The R-1234yf A/C Leak Detection Kit (P/N TRP1234YFA) is a required special tool. It is used to add small amounts of dye to A/C systems to help locate smaller leaks that an electronic leak detector might not find.

When searching for leaks, always begin by using an electronic leak detector. Refer to service bulletin 18-073 BOSCH ROBLD020 DUAL MODE REFRIGERANT GAS LEAK DETECTOR , for tips on using this tool, then follow up with the R-1234yf A/C Leak Detection Kit.

This detection kit complements but does not replace the electronic leak detector.

R-1234yf A/C Leak Detection Kit (P/N TRP1234YFA) includes these items: 

• TPOPUVP OPTI-PRO™ UV Plus, rechargeable violet light LED leak detection flashlight (battery included)
• TRPTP1108P12 - (3) R-1234yf Low Density POE Mini-EZ™ Dye Cartridges
• TRPTP9845 - EZ-Ject™ injector assembly
• TRPTP10 - R-1234yf hose/coupler with purge fitting
• TRPTP9940 - Fluorescence-enhancing glasses
• TRPTP19 - Glo-Away™ plus fluorescent dye cleaner
• TRPTP21 - Green carrying case
• TRPTP14 - USB charger (not pictured)

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.