Leak Test

Leak Check

Inspection of refrigerant leak
Refrigerant leak may cause an adverse effect not only on the performance and durability of each component of the
air-conditioner, but also on the global atmosphere.
Therefore, it is most important to repair refrigerant leak when there is any leak found.




Inspection flow of refrigerant leak

Inspection steps
Check the components of the air conditioner to see if there occurs any refrigerant leak along the flow of refrigerant.


NOTE:
- To avoid an error in the detection of refrigerant leak, make sure there is no refrigerant vapor or cigarette smoke around the vehicle before conducting the inspection.
Also, select a location where the refrigerant vapor will not be blown off by wind.
- Inspection should be conducted chiefly on the pipe connections and sections where a marked oil contamination is found.
When refrigerant is leaking, oil inside is also leaking at The same time.
- It is not possible to visually check the leak from inside the cooling unit. Follow the method below when checking.
Remove the drain hose or resistor of the cooling unit, and insert a leak detector to see if there occurs any

High pressure side
1. Discharger section of compressor
2. Inlet/outlet section of condenser
3. Inlet/outlet section of receiver driver
4. Inlet section of cooling unit

Low pressure side
1. Outlet section of cooling unit
2. Intake section of compressor

Major checking points of refrigerant leak Compressor
- Pipe connection
- Sealing section of shaft
- Mating section of cylinder

Condenser
- Pipe connection
- Welds of condenser body

Receiver drier
- Pipe connection
- Attaching section of pressure switch
- Section around the sight glass

Evaporator unit (cooling unit)
- Pipe connection
- Connections of expansion valve
- Brazed sections of evaporator

NOTE:
- The evaporator and expansion valve are contained in the case. Remove the drain hose or the resistor of the cooling unit and insert a leak detector when checking for any leak.

Flexible hose
- Pipe connection
- Caulking section of the hose
- Hose (cracks, pinholes, flaws)

Pipe
- Pipe connection
- Pipe (cracks, flaws)

Charge Valve

NOTE: The charge valve, which is used to connect the gauge manifold, is normally provided with a resin cap. When the valve inside gets deteriorated, refrigerant will leak out

Leak at Refrigerant Line Connections
1. Check the torque on the refrigerant line fitting and, if too loose, tighten to the specified torque.
- Use two wrenches to prevent twisting and damage to the line.
- Do not over tighten.
2. Perform a leak test on the refrigerant line fitting.
3. If the leak is still present, discharge and recover the refrigerant from the system.
4. Replace the O-rings.
- O-rings cannot be reused. Always replace with new ones.
- Be sure to apply the specified compressor oil to the new 0-rings.
5. Retighten the refrigerant line fitting to the specified torque.
- Use two wrenches to prevent twisting and damage to the line.
6. Evacuate, charge and retest the system.

Leaks In The Hose
If the compressor inlet or outlet hose is leaking, the entire hose must be replaced. The refrigerant hose must not be cut or spliced for repair.
1. Locate the leak.
2. Discharge and recover the refrigerant.
3. Remove the hose assembly.
- Cap the open connections at once.
4. Connect the new hose assembly.
- Use two wrenches to prevent twisting or damage to the hose fitting.
- Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.

Compressor Leaks
If leaks are located around the compressor shaft seal or shell, replace or repair the compressor.