Non-Trouble Code Procedures
Refrigerant System Tests Checking For A/C LeaksNOTE: Good ventilation is necessary in the area where a/c leak testing is to be performed. If the surrounding air is contaminated with refrigerant gas, the leak detector will indicate this gas all the time. Odors from other chemicals such as antifreeze, diesel fuel, disc brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well ventilated area, is very helpful in removing small traces of contamination from the air that might affect the leak detector.
Leak Detector, Electronic
1. Attach Rotunda R-134a Manifold Gauge Set 176-00032 or equivalent, to the service gauge port valves.
2. Leave both manifold gauge set valves closed. Both gauges should indicate approximately 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine OFF.
3. If a leak is found in the refrigerant system, recover the refrigerant and service the system.
A/C Compressor
External Leak Test - On Vehicle
1. Key ON, engine running.
2. Turn the A/C system on.
3. Using Rotunda R-134a Electronic Halogen Leak Detector 161-00010 or equivalent, check the A/C compressor for leaks.
4. Check the A/C compressor front and rear seals, the center housing seal, the shaft seal, the low and high-pressure line seals, and around the A/C compressor cylinder bolt heads for leakage.
5. After checking the compressor for leaks, turn the A/C system off.
6. Key OFF.
7. If an external leak is found at the:
^ Thermo protection switch seal, high- or low-pressure line seals, shaft seal, or rear cover seal, service the seal on the A/C compressor.
^ Front seal of the A/C compressor body or the center housing assembly, install a new A/C compressor.
^ Cylinder bolt head, remove the cylinder bolt and inspect the underside of the cylinder bolt head along with the sealing surface the cylinder bolt contacts. If the cylinder bolt is damaged, replace it. If damage is found to the A/C compressor case, replace the A/C compressor. If a new bolt is installed and the A/C compressor still leaks, replace the A/C compressor.
8. Retest the A/C compressor if it was serviced.
Leak Test - On Bench
1. Recover the A/C system refrigerant following the recommended service procedure. Refrigerant Recovery
2. Remove the manifold attaching bolt and remove the manifold from the rear head of the compressor. Install Pressure Test Plate T94P-19623-E on the rear head of the compressor using the existing manifold attaching bolt.
3. If very little or no pressure is indicated, charge the refrigerant system.
4. Leak test the refrigerant system using Rotunda R-134a Electronic Halogen Leak Detector 161-00010 or equivalent.
3. Connect the low- and high-pressure lines of a Rotunda R-134a Manifold Gauge Set 176-00032 or equivalent, to the pressure test plate fittings.
4. Attach the center of the manifold gauge set to a refrigerant container standing in an upright position.
5. Rotate the compressor shaft ten complete revolutions with the clutch hub to distribute oil within the compressor.
6. Open the low-pressure gauge valve, the high-pressure gauge valve, and the valve on the refrigerant container to allow the refrigerant vapor to flow into the compressor.
7. Use Rotunda R-134a Electronic Halogen Leak Detector 161-00010 or equivalent, to check for leaks at the compressor shaft and the compressor center seal.
8. If a shaft leak is found, install a new shaft seal. If an external leak is found at the center joint of the compressor, install a new compressor assembly.
9. Leak test, evacuate, and charge the A/C system following the recommended procedures. Observe all safety precautions.