Continental 2000-2002

Leak Testing

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  1. Use either an ultraviolet (UV) or an electronic leak detector to check for leaks at all refrigerant lines, connections, and components.
  2.  

Electronic Leak Detection




CAUTION
Read and follow all of the Warnings, Cautions and Notes in the Precautions at the beginning of this section before continuing.


NOTE
This procedure requires the use of H10PM Refrigerant Leak Detector with Battery, 216-00001 or equivalent.


WARNING
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. 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.


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. Follow the instructions included with the leak detector for handling and operation techniques.
  2.  
  3. If a leak is found, discharge and 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 Detection

NOTE
This procedure requires the use of the following special tools, or their equivalents. R-134a Refrigerant Service Center 023-00153, 120 Watt UV Spot Lamp 164-R0721, R-134a Fluorescent Dye Injector 164-R0775, High Intensity UV Lamp - 12 volt, R-134a Leak Detection Dye 164-R6060, R-134A Manifold Gauge Set 176-R032A, Deluxe Injector Loop Kit 219-00069.


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 the special tool.
  2.  
  3. 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 outline 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 the special tool.
  14.  

Fluorescent Dye Injection - Using A Dye Injector Loop Kit

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 24°C.

  1. Verify that the valves on the special tool are closed.

    Click image to see an enlarged view

    Fig. Make sure the valves on the special tool are closed

  2.  
  3. Fill the special tool reservoir with 0.25 oz. (7 ml) of fluorescent dye.

    Click image to see an enlarged view

    Fig. Fill the special tool reservoir with 0.25 oz. (7 ml) of fluorescent dye

  4.  
  5. Install the special tool 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 special tool valves and inject the fluorescent dye into the refrigerant system.

    Click image to see an enlarged view

    Fig. Open the special tool valves and inject the fluorescent dye into the refrigerant system

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

  14.  
  15. Close the valves on the special tool.
    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 special tool from the vehicle.
  18.  

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

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. Install an R-134a A/C refrigerant service center or a manifold and gauge set.
  2.  
  3. Verify that the valves on the special tool are closed.

    Click image to see an enlarged view

    Fig. Make sure the valves on the special tool are closed

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

    Click image to see an enlarged view

    Fig. Fill the special tool reservoir with 0.25 oz. (7 ml) of fluorescent dye

  6.  
  7. Install the special tool 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.  

 
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