Fluorescent Dye Injection - Using a Dye Injector Loop Kit

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

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 413-551 kPa (60-80 psi) at 24 °C.

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

Fig 1: Identifying Valves On Deluxe Injector Loop Kit
Courtesy of FORD MOTOR CO.
Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz.) of fluorescent dye.

Fig 2: Filling Deluxe Injector Loop Kit Reservoir
Courtesy of FORD MOTOR CO.
Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves.

CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine.

Start the engine.
Open the high-pressure service valve.

Fig 3: Opening High-Pressure Service Valve
Courtesy of FORD MOTOR CO.
Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system.

Fig 4: Injecting Fluorescent Dye Into Refrigerant System
Courtesy of FORD MOTOR CO.
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.

Fig 5: Closing High-Pressure Service Valve
Courtesy of FORD MOTOR CO.

NOTE: Close the valves on the deluxe injector loop kit while the A/C compressor is operating.

Fig 6: Closing Valves On Deluxe Injector Loop Kit

Courtesy of FORD MOTOR CO.

Close the valves on the deluxe injector loop kit.

NOTE: Leave all valves on the special tool closed when not in use.

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