Refrigerant System Leaks

DIAGNOSIS AND TESTING - REFRIGERANT SYSTEM LEAKS

WARNING: R-134a service equipment or vehicle A/C system should not be pressure tested or leak tested with compressed air. Mixture of air and R-134a can be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing property damage and possible serious or fatal injury.
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge an R-134a system. If accidental system discharge occurs, ventilate work area before resuming service.

WARNING: Use extreme care when working around a running engine. Keep hands and fingers clear of the radiator fan, accessory drive belt and all other moving components. Keep away when wearing loose clothing, jewelry or long hair that is not properly secured. Underhood components may become hot to the touch. Be careful not to come into contact with hot engine, A/C and engine cooling system components. Failure to follow these instructions may result in serious or fatal injury.

CAUTION: The use of an A/C recycling/charging station for purposes of determining the actual charge level of an A/C system is not recommend. Service recycling/charging stations do not reflect the correct amount of refrigerant charge in the A/C system after a single "reclaim" cycle. Tests have shown that it can take two or more "reclaim" cycles to remove all of the refrigerant charge, depending on the equipment being used. Always conduct the A/C Performance Test as outlined to determine actual charge level A/C Performance.

NOTE: Always conduct the A/C Performance Test as outlined prior to searching for an A/C refrigerant leak A/C Performance.

A refrigerant leak in the A/C system is the most common cause of automotive A/C systems not blowing cold air.

The A/C system in this vehicle comes equipped from the factory with fluorescent refrigerant leak detection dye installed in the refrigerant system.

When searching for a refrigerant leak in the A/C system, use an Ultra Violet (UV) light and an electronic leak detector that is designed for R-134a refrigerant. It is important to use only high-quality refrigerant leak detection equipment to properly locate refrigerant system leaks, such as the equipment listed in the team PSE Service Equipment Catalog. When the use of additional leak detection dye is required, use only Chrysler LLC approved refrigerant leak detection dye, available through Mopar(R).

LEAK TEST

CAUTION: Use it is important to use only a high-quality Ultra Violet (UV) light when searching for a leak in the refrigerant system. Small leaks may not be found using budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.

NOTE: Always conduct the A/C Performance Test as outlined prior to searching for an A/C refrigerant leak A/C Performance.

1. Begin searching for refrigerant leaks using a high quality UV light to detect the fluorescent refrigerant leak detection dye.
- Inspect all connections, plumbing fittings, brazed joints, hoses, hose crimps, service ports, compressor housing, pressure relief valve and A/C condenser for dye
- Inspect the evaporator drain tube and condensate for presence of dye, which indicates a leak from the A/C evaporator
- If equipped with rear A/C, inspect the underbody refrigerant lines, fittings, rear evaporator drain tube and condensate for presence of dye, which indicates a leak from the rear evaporator
- If no leaks are found using a UV light, proceed to 2.

2. If a leak is not found with the leak detection dye, operate the heating and A/C system with the engine at idle under the following conditions for at least 15 minutes, then proceed to 3.
- Doors or windows open
- Transmission in Park or Neutral with the parking brake set (depending on transmission application)
- A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C compressor engaged (If the A/C compressor does not engage, go to LOW OR EMPTY REFRIGERANT SYSTEM )
- If equipped with rear A/C, set rear controls to full cool and high blower

3. Shut the vehicle off and wait at least 5 minutes.

CAUTION: Use only an electronic leak detector designed for R-134a refrigerant. It is important to use only high-quality refrigerant leak detection equipment. Small leaks may not be found using budget equipment. Failure to follow these instructions may result in an incomplete diagnosis and possible remaining refrigerant leaks.

4. Use a high-quality electronic R-134a leak detector and insert it into the evaporator drain tube and the instrument panel air outlets, to check for evaporator leaks. Check the evaporator tubes at the A/C expansion valve, for leaks not visible behind the expansion valve. Check around the front of the A/C compressor, for compressor shaft seal leaks. Check between the A/C condenser and radiator for condenser leaks not previously visible.
5. If equipped with rear A/C, insert the leak detector into the rear evaporator drain tube and rear air outlets. Check the underbody A/C lines and fittings, evaporator tubes and rear A/C expansion valve.

LOW OR EMPTY REFRIGERANT SYSTEM

NOTE: This procedure should only be done after an A/C Performance Test has been conducted and a refrigerant system leak has NOT been found using the factory installed leak detection dye.

Do the following if the A/C compressor will not engage and a refrigerant leak in the A/C system is suspected. but cannot be found using the factory installed leak detection dye.

1. Recover, evacuate and recharge the refrigerant system Refrigerant System Charge.
2. Operate the heating and A/C system with the engine at idle under the following conditions for at least 15 minutes.
- Doors or windows open
- Transmission in Park or Neutral with the parking brake set (depending on transmission application)
- A/C and heater controls set to outside air, full cool, panel mode, high blower and A/C compressor engaged
- If equipped with rear A/C, set rear controls to full cool and high blower

3. Shut the vehicle off and return to LEAK TEST.