A/C Refrigerant Leak Check: Check

Courtesy of HONDA, U.S.A., INC.

• Air conditioning refrigerant or lubricant vapor can irritate your eyes, nose, or throat.
• Be careful when connecting service equipment.
• Do not breathe refrigerant or vapor.
• Do not operate the leak detector near flammable vapors. Its sensor operates at high temperatures, and could ignite the vapors, resulting in personal injury and/or damage to the equipment.

NOTE: 

• If accidental system discharge occurs, ventilate work area before resuming service.
• Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers.
• Check the system for leaks using an R-134a refrigerant leak detector with an accuracy of 14 g (0.49 oz) per year or better.

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 A/C 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 evaporator 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 % 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. R134a A/C Automatic Recovery, Recycle, Recharge Machine - Connect

  1. Connect an R134a A/C automatic recovery, recycle, recharge machine to the high-pressure service port and the low-pressure service port, following the equipment manufacturer's instructions.

• 2. A/C Refrigerant - Recover

  1. Recover the refrigerant from the A/C system

  2. Measure the amount of refrigerant oil removed from the A/C system after the recovery process is completed. Be sure to put the same amount of new refrigerant oil back into the A/C system before charging.

• 3. A/C System - Evacuate
  • 1. Evacuate the system . The vacuum pump should run for a minimum of 30 minutes to eliminate all moisture from the system. When the suction gauge reads -93.3 kPa (-700 mmHg, -27.55 inHg) for at least 30 minutes, close all valves, and turn off the vacuum pump.
  • 2. If the suction gauge dose not reach approximately -93.3 kPa (-700 mmHg, -27.55 inHg) in 15 minutes, there is probably a large leak in the system. Partially charge the system, and check for leaks.
• 4. A/C Refrigerant - Charge

  1. Open high pressure valve to charge the system to the specified capacity, then close the supply valve, and disconnect the charging station fittings.

  Select the appropriate units of measure for your refrigerant charging station.

  Refrigerant Capacity:

  385 to 435 g

  13.6 to 15.4 oz

  0.385 to 0.435 kg

  0.849 to 0.959 lbs

• 5. A/C Refrigerant - Leak Check

  1. 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:

  Possible Leak Area	Diagnostic Procedure with the Leak Detector	Notes
  Service ports	Check the service ports with caps installed If the detector "sniffs" a 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
  A/C 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 in/second or less), and keep it within 1/4 in 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, cleaning the area with compressed air may help you pinpoint the leak source
  Evaporator	Check at the evaporator drain hose Check at the passenger's side vent and turn the blower on at low speed

  Possible Leak Area	Diagnostic Procedure with the Leak Detector	Notes
  A/C lines	Wiggle the rubber hoses when checking crimped metal ends 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 in/second or less), and keep it within 1/4 in of the component being checked. This maximizes the chance of detecting a leak

  2. Close the quick coupler valves, then disconnect the quick couplers from the vehicle service ports

  3. 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)

  4. Attach the charging machine low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the charging machine vacuum pump, then close the quick coupler valve

  5. 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)

  6. Attach the quick coupler on the universal connect set to the low pressure service port on the vehicle. Open the charging machine low pressure hose quick coupler valve, but do not open the control valve

  7. Start the engine, and set the A/C system to maximum cooling. 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

  8. 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.

  Possible Leak Area	Diagnostic Procedure with Fluorescent Dye
  Service ports	If a leak is found, replace the cap/O-ring seal or A/C line as needed
  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
  A/C condenser	If a leak is found, remove the A/C condenser Determine whether leak is in the A/C condenser or the dryer desiccant Use a permanent marker pen to circle the leak area Replace either the dryer desiccant or the A/C condenser , depending upon which is leaking

  Possible Leak Area	Diagnostic Procedure with Fluorescent Dye
  A/C compressor	Check for leaks at all of the A/C compressor joints, the clutch center, the A/C compressor front housing bolts, and the scroll bolts on the back of the A/C compressor If a leak is found, use a permanent marker pen to circle the leak area If the A/C compressor relief valve appears to be leaking, determine whether the leak is coming from the relief valve, or the joint between the A/C 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 . If the leak is from the casing/valve joint, replace the A/C compressor relief valve If the leak is coming from the suction hose and/or discharge hose fittings on the A/C compressor, clean the A/C fittings and replace the suction/discharge fitting O-rings For all other A/C compressor leaks, remove and replace the A/C compressor
  Evaporator	Start checking for evaporator leaks by illuminating the evaporator drain tube area If a leak is found, remove the evaporator core Determine whether leak is from evaporator or expansion valve Use a permanent marker pen to circle leak area Replace the expansion valve or the evaporator core , depending upon which is leaking