Dye Solution Leak Testing Procedures

WARNING: This page does not describe the selected car, but rather 125 other vehicles, including the 2003 Dodge Ram Van, 2002 Saturn Vue, 2002 Saturn SL2, 2002 Saturn SL1, and 2002 Saturn SL. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Dye-charged refrigerant cans are available to be used as internal leak detectors. Use of this type of solution may void some manufacturers warranties. Be sure to check with A/C system manufacturer concerning use of dye-charged leak detectors. Dyes which work in R-12 systems will not work in R-134a systems.

The following procedure is for introducing a dye solution, not dye-charged refrigerant, into A/C system.

Connect manifold gauge set to A/C system in a normal manner. Remove center hose from manifold gauge set and replace it with a short piece (6" long) of 1/4" tubing using two 1/4" flare nuts. Connect a container of dye solution to tubing.
Connect one end of gauge set center hose to dye solution container. Connect a container of refrigerant to other end of hose. Operate engine at idle. Set A/C system for maximum cooling. Slowly open low-side hand valve to allow dye solution to enter system.
Charge system to at least 50 percent capacity. Operate system for 15 minutes and then shut off both A/C system and engine. Check all connections for signs of colored dye solution. Check vehicle again 24 hours later. If leaks are found, repair as necessary.