For 1990-2009 cars

Test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the lines or the connections. Leaks are commonly found at the refrigerant fittings or at the connections. Leaks are commonly caused by the following problems:

• | Improper torque

• | Damaged O-ring seals

• | Dirt or lint on the O-ring seals

### Liquid Leak Detectors

Use a liquid leak detector solution on locations such as fittings. Apply the solution to the area in question with the swab that is supplied with the solution. Look for bubbles to appear. This will indicate the existence and location of any leak.

For areas where this is not practical, such as sections of the evaporator and the condenser, an electronic leak detector is more useful.

### Electronic Leak Detectors

Follow the manufacturer's instructions for calibration, operation, and maintenance of an electronic leak detector. Battery condition is especially important to the accuracy of a portable model. Set the detector to R-134a before beginning the test.

Important: Electronic leak detectors are sensitive to windshield washing solutions, solvents and cleaners, and certain vehicle adhesives.

Surfaces must be clean to prevent false readings. Make sure that all surfaces are dry to prevent damage to the detector.

### General Testing Instructions

• | Follow the entire path of the refrigerant system.

• | Completely circle each joint at 25-50 mm (1-2 in) per second.

• | Hold the probe tip within 6 mm (0.25 in) of the surface.

• | Do not block the air intake.

The audible tone changes from 1-2 clicks per second into a solid alarm if there is a leak. Adjust the balance control to maintain 1-2 clicks per second.

Test all of the following areas, even after 1 leak has been confirmed:

• | Evaporator inlet and outlet

• | Receiver-drier inlet and outlet

• | Condenser inlet and outlet

• | Brazed and welded areas

• | Damaged areas

• | Hose couplings

• | Compressor rear head

• | All fittings and joints

### Testing Service Ports/Access Valves

The sealing cap is the primary seal for the service ports. This cap contains a special leak-free O-ring. Make sure that this cap is not missing or loose. Always use the correct cap.

### Testing the Evaporator Core

Leaks in the evaporator core are difficult to find. Test the evaporator core using the following procedure:

1. Run the blower fan at speed setting 4 for at least 15 minutes.
2. Turn the blower to the OFF position.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to Blower Motor Resistor Replacement .
5. Insert the leak detector probe as close as possible to the evaporator core. The detector will indicate a leak with a solid alarm.
6. Use a flashlight to search for refrigerant oil in the core surface.

### Testing the Compressor Shaft Seal

1. Blow shop air behind and in front of the compressor clutch/pulley for at least 15 seconds.
2. Wait 1-2 minutes.
3. Probe the area in front of the pulley. If the detector emits a solid alarm, there is a leak.