Avenger, Sebring Coupe, Stratus Coupe, 1999-2006

Testing The System

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Leak Testing




CAUTION
Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.


CAUTION
R-134A service equipment or vehicle A/C should not be pressure or leak tested with compressed air. Mixture of air and R-134A can be combustible at elevated pressures and can be explosive.


CAUTION
Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may be irritating to the eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge R-134A system. If accidental system discharge occurs, ventilate work area before resuming service.

Refer to the precautions at the beginning of this section.

If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a. This is accomplished by performing a system Charge Level-Check or Fill. If while performing this test A/C liquid line pressure is less than 345 kPa (50 psi) proceed to Empty Refrigerant System Leak Test. If liquid line pressure is greater than 345 kPa (50 psi) proceed to low refrigerant level leak test. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. A review of the fittings, lines and components for oily residue is an indication of the leak location. To detect a leak in the refrigerant system, perform one of the following procedures as indicated by the symptoms.


CAUTION
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, personal injury or death. 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 R-134a system. If accidental system discharge occurs, ventilate work area before resuming service.

If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a by performing a Refrigerant System Charge Level test or by completely evacuating and recharging the A/C system. Follow instructions on Manufactures R-134a refrigerant recovery/recycling/charging station to perform charge level test. If the A/C liquid line pressure is found to be less than 345 kPa (50 psi) proceed to the System Empty procedure below. If liquid line pressure is found to be greater than 345 kPa (50 psi), proceed to the System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. Inspect the fittings, lines and components for oily residue to indicate a leak location.


CAUTION
The R-134a service equipment and the vehicle A/C system should never be pressure tested or leak tested with compressed air. A 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, personal injury or death.


CAUTION
Avoid breathing the A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, and throat. Use only the approved service equipment meeting SAE requirements to discharge the R-134a system. If an accidental system discharge occurs, ventilate the work area before resuming service.

If the A/C system is not cooling properly, determine if the refrigerant system is fully charged with R-134a by performing a Refrigerant System Charge Level test or by completely evacuating and recharging the A/C system. Follow the instructions on the manufacture-s R-134a refrigerant recovery/recycling/charging station to perform a charge level test. If the A/C liquid line pressure is found to be less than 50 psi (345 kPa), proceed to the System Empty procedure below. If the liquid line pressure is found to be greater than 50 psi (345 kPa), proceed to the System Low procedure. If the refrigerant system is empty or low in refrigerant charge, a leak at any line fitting or component seal is likely. Inspect the fittings, lines, and components for oily residue to indicate a leak location.

System Empty

Evacuate the refrigerant system to the lowest degree of vacuum possible (approx. 28 in Hg.) Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed with this procedure:

  1. Prepare a.284 Kg. (10 oz.) refrigerant charge to be injected into the system.
  2.  
  3. Connect and dispense 10 ounces (0.284 Kg) of refrigerant into the evacuated refrigerant system.
  4.  
  5. Proceed to Step 2 of Low Refrigerant Level Leak Test.
  6.  

  1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately 28 in Hg.) (refer to the Evacuating the System section of this manual). Determine if the system holds a vacuum for 15 minutes. If vacuum is held, a leak is probably not present. If system will not maintain vacuum level, proceed to next step.
  2.  
  3. Prepare and dispense 0.284 kilograms (10 ounces) of R-134a refrigerant into the evacuated refrigerant system (refer to Charging the System section of this manual) then proceed to the System Low procedure.
  4.  

  1. Evacuate the refrigerant system to the lowest degree of vacuum possible (approximately 28 in. Hg.). Refer to Evacuating the System.
  2.  
  3. Determine if the system holds a vacuum for 15 minutes.
    1. If a vacuum is held, a leak is probably not present.
    2.  
    3. If the system will not maintain vacuum level, proceed to the next step.
    4.  

  4.  
  5. Prepare and dispense 10 ounces (0.284 kilograms) of R-134a refrigerant into the evacuated refrigerant system. Refer to Charging the System.
  6.  
  7. Proceed to the System Low procedure.
  8.  

System Low
  1. Determine if there is any refrigerant (R-134A) in the system.
    NOTE
    Position the vehicle in a wind-free work area. This will aid in detecting small leaks.

  2.  
  3. Run the engine for five minutes to bring the system up to operating temperature and pressure.
  4.  
  5. Set the transaxle in Park or Neutral
  6.  
  7. Engine idling at 700 rpm
  8.  
  9. A/C controls set in 100 percent outside air
  10.  
  11. Blower switch in the high A/C position
  12.  
  13. A/C in the ON position
  14.  
  15. Open all windows
    NOTE
    A leak detector designed for R-12 refrigerant (only) will not detect leaks in a R-134A refrigerant system.

  16.  
  17. Shut off the vehicle and wait 2 to 7 minutes.
  18.  
  19. Use an electronic leak detector that is designed to detect R-134A type refrigerant and search for leaks.
    1. Fittings, lines, or components that appear to be oily usually indicate a refrigerant leak. To inspect the evaporator core for leaks, insert the leak detector probe into the drain tube opening or a heat duct
      NOTE
      An R-134a dye is available to aid in leak detection. Use only Chrysler approved refrigerant dye.

    2.  

  20.  
  21. If a thorough leak check has been completed without indication of a leak, proceed to System Charge Level.
  22.  

  1. Position the vehicle in a wind free work area. This will aid in detecting small leaks.
  2.  
  3. Operate the heating-A/C system with the engine at idle under the following conditions for at least five minutes.
    1. Doors or windows open
    2.  
    3. Transaxle in Park or Neutral with the parking brake set (depending on application)
    4.  
    5. A/C-heater controls set to outside air, full cool, panel mode, high blower and with A/C compressor engaged.
      WARNING
      A leak detector only designed for R-12 refrigerant will not detect leaks in a R-134a refrigerant system.

    6.  

  4.  
  5. Shut the vehicle OFF and wait 2-7 minutes. Then use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet. A dye for R-134a is available to aid in leak detection. Use only Daimler Chrysler® approved refrigerant dye.
  6.  

  1. Position the vehicle in a wind free work area. This will aid in detecting small leaks.
  2.  
  3. Operate the heating-A/C system with the engine at idle under the following conditions for at least five minutes:
    1. The doors or windows should be open.
    2.  
    3. The transaxle should be in Park or Neutral with the parking brake set.
    4.  
    5. The A/C-heater controls should be set to outside air, full cool, panel mode, high blower, with the A/C compressor engaged.
      WARNING
      A leak detector that is designed for R-12 refrigerant only, will not detect leaks in a R-134a refrigerant system.

    6.  

  4.  
  5. Shut the vehicle OFF and wait 2-7 minutes. Then, use an electronic leak detector that is designed to detect R-134a refrigerant and search for leaks. Fittings, lines or components that appear to be oily usually indicate a refrigerant leak.
  6.  
  7. To inspect the A/C evaporator for leaks, insert the leak detector probe into the drain tube opening or an air outlet.
  8.  
  9. A dye for R-134a is available to aid in leak detection. Use only Daimler Chrysler® approved refrigerant dye.
  10.  

 
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