A/C Refrigerant Leak Check
Special Tools Required
Image Description/Tool Number
11328487.png R134a A/C Automatic Recover/Recycle/Recharge Machine ROB48920T, commercially available
14149284.png Dual Mode Refrigerant Gas Leak Detector ROBLD020*
13793835.png Infrared Refrigerant Leak Detector ROB22791*
3717548.png OPTIMAX Jr. A/C Leak Detection Kit TRP124893*
*These tools are available through the Honda Tool and Equipment Program; call 888-424-6857.
Compressed air mixed with the R-134a forms a combustible vapor.
The vapor can burn or explode causing serious injury.
Never use compressed air to pressure test R-134a service equipment or vehicle air conditioning systems.
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.

NOTE:
If accidental system discharge occurs, ventilate the 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:
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Carefully wash the affected surfaces to remove any dirt, and to prevent paint scratching.
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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.
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After removing the dye with the water/alcohol-soaked cloth, carefully wash the affected areas, and check that there is no remaining dye.

5. A/C Refrigerant - Leak Check
1.
With the engine OFF, use a 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
  
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.
If a leak could not be found with the detector, do the following: 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 A/C recover/recycle/recharge machine low pressure hose quick coupler to the service valve fitting, and open the quick coupler valve. Evacuate the connect set using the A/C recover/recycle/recharge 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. Attach the A/C recover/recycle/recharge machine low side pressure hose to the service valve fitting. Open the A/C recover/recycle/recharge 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 Infrared Leak Detector or 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
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