AutoZone | Repair Guides | Heating, Ventilation, & Air Conditioning | Maintenance | Leak Testing | AutoZone.com

Search suggestions

    My Vehicles

    Add a Vehicle

    Find a Store

    Select Store

    SAVE 20% + GET A $10 GIFT CARD ON ONLINE SHIP TO HOME ORDERS OVER $100.

    Use Code: 20STACK10

    See Details

    2006 Mercury Monterey

    Leak Testing

    Print

    Electronic Leak Testing




    CAUTION
    Good ventilation is necessary in the area where electronic A/C leak testing is to be carried out. 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. Using a fan to ventilate the area to be tested before proceeding with the leak detection procedure is helpful in removing small traces of contamination from the air, but the fan should be turned off during actual testing.


    NOTE
    The system pressure should be between 60-80 psi (413-551 kPa) at 75°F (24°C) with the engine off.

    1. Leak test the refrigerant system using the Refrigerant Leak Detector 216-00001 or equivalent. Follow the instructions included with the leak detector for handling and operation techniques.

      Click image to see an enlarged view

      Fig. Leak testing the A/C system

    2.  
    3. If a leak is found, recover the refrigerant, as outlined in this section
    4.  
    5. Repair the system.
    6.  
    7. Test the system for normal operation.
    8.  

    Fluorescent Dye Leak Detection



    Fluorescent Dye Injection - Using A Dye Injector Loop Kit

    Specific to:

    Ford Freestar 2004-2006

    Mercury Monterey 2004-2006


    NOTE
    Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.


    NOTE
    Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses.


    NOTE
    Refrigerant system pressure should be between 60-80 psi (413-551 kPa) at 75°F (24°C).

    1. Verify that the valves on the deluxe injector loop kit are closed.

      Click image to see an enlarged view

      Fig. Verify that the valves on the deluxe injector loop kit are closed

    2.  
    3. Fill the deluxe injector loop kit reservoir with 0.25 oz (7 ml) of fluorescent dye.

      Click image to see an enlarged view

      Fig. Fill the deluxe injector loop kit reservoir with 0.25 oz. of fluorescent dye

    4.  
    5. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves.
      WARNING
      Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine.

    6.  
    7. Start the engine.
    8.  
    9. Open the high-pressure service valve.

      Click image to see an enlarged view

      Fig. Open the high-pressure service valve

    10.  
    11. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system.

      Click image to see an enlarged view

      Fig. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system

    12.  
    13. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system.
      NOTE
      Close the valves on the deluxe injector loop kit while the A/C compressor is operating.

    14.  
    15. Close the valves on the deluxe injector loop kit.
      NOTE
      Leave all valves on the special tool closed when not in use.

    16.  
    17. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle.
    18.  

    Fluorescent Dye Injection - Using An A/C Refrigerant Center And Dye Injector

    Specific to:

    Ford Freestar 2004-2006

    Mercury Monterey 2004-2006


    NOTE
    Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.


    NOTE
    Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers instructions on evacuation of any non-condensable gasses from the hoses.


    NOTE
    Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation.


    NOTE
    Refrigerant system pressure should be between 60-80 psi (413-551 kPa) at 75°F (24°C) with the engine off.

    1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves.
    2.  
    3. Verify that the valves on the fluorescent dye injector are closed.

      Click image to see an enlarged view

      Fig. Verify that the valves on the fluorescent dye injector are closed

    4.  
    5. Fill the fluorescent dye injector reservoir with 0.25 oz (7 ml) of fluorescent dye.

      Click image to see an enlarged view

      Fig. Fill the fluorescent dye injector reservoir with 0.25 oz. of fluorescent dye

    6.  
    7. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or manifold gauge set.
    8.  
    9. Open all valves and inject the fluorescent dye into the refrigerant system.
    10.  
    11. When fluorescent dye injection is complete, close all valves.
    12.  
    13. Recover the refrigerant from the R-134a fluorescent dye injector.
    14.  
    15. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set.
    16.  

    Fluorescent Dye Leak Detection - Using A Uv Lamp

    Specific to:

    Ford Freestar 2004-2006

    Mercury Monterey 2004-2006


    NOTE
    Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line and fitting in the refrigerant system for a leak.

    1. Check for leaks using a Rotunda-approved UV lamp.
    2.  
    3. Inspect all components, lines and fittings of the refrigerant system.

      Click image to see an enlarged view

      Fig. Using a Rotunda-approved UV lamp, inspect all components, lines and fittings of the refrigerant system

    4.  
    5. If a leak is found, recover the refrigerant, as outlined in this section.
    6.  
    7. Repair the refrigerant system leak(s).
    8.  
    9. Evacuate and charge the refrigerant system, as outlined in this section.
    10.  
    11. After the leak(s) is/are repaired, remove any traces of fluorescent dye with a general purpose oil solvent.
    12.  
    13. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda-approved UV lamp.
    14.  

     
    AutoZone Logo