Fluorescent Dye Leak Testing Procedures

WARNING: This page does not describe the selected car, but rather 125 other vehicles, including the 2003 Dodge Ram Van, 2002 Saturn Vue, 2002 Saturn SL2, 2002 Saturn SL1, and 2002 Saturn SL. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Even though refrigerant dye is non-toxic and water soluble, wearing rubber gloves will prevent hands from glowing when under Ultraviolet (UV) Black light. Wash hands frequently and thoroughly, using a dye cleaner or soap and water before entering vehicle, or touching other underhood components. Refrigerant dye will transfer from hands to anything touched. Refrigerant dye is suspended in refrigerant oil. Refrigerant oil will stain paint it comes into contact with and be highlighted by refrigerant dye. Use R-134a Leak Dye Cleaner (J43872) to clean area around fittings and leak areas.

CAUTION: Fluorescent dye, when mixed with PAG oil, remains detectable in A/C system for 2 years. DO NOT exceed specified quantity of refrigerant oil in system. Use only 0.25 ounce of refrigerant oil charge.

NOTE: Fluorescent leak detection method is intended to be used in conjunction with an electronic leak detection method, to pinpoint smaller leaks. Fluorescent dye takes time to work. Depending on leak rate, dye could take up to 7 days to become visible after installation into A/C system.

NOTE: After refrigerant dye is installed into A/C system, complete refrigerant leak detection notice sticker (supplied with dye package) and place next to underhood charge label.

Start engine and allow to idle. Turn A/C system on and controls to maximum cold position. Ensure compressor clutch is engaged. If compressor clutch stays engaged at idle, low side refrigerant pressure is sufficient to check for a leak. If necessary, charge A/C system so compressor clutch will operate.

NOTE: A/C refrigerant system does not have to be evacuated and/or opened to install leak detection dye when using tracer dye injector.

If A/C system is charged, install fluorescent leak detection dye using R-134a A/C tracer dye injector. Follow dye injector manufacturer instructions. If A/C system is discharged, add dye to replacement component with specified amount of refrigerant oil.
After installing dye, clean low side fitting to remove any residue, using fluorescent dye cleaner or general purpose oil solvent. Observe and record ambient air temperature and humidity. Place thermometer in center A/C outlet duct.
Start engine. Turn A/C system on and controls to maximum cold position. Increase engine speed to 1500 RPM. After about 5 minutes, record outlet temperature displayed on center A/C outlet duct thermometer. If outlet temperature is at least 20°F (11°C) colder than ambient temperature, A/C system is operating properly.
Turn engine off. Check for refrigerant leaks using an electronic leak detector. See ELECTRONIC LEAK TESTING PROCEDURE . Perform repairs as necessary. If no leaks are found, go to next step.
Using Leak Detection Lamp Kit (J42220) UV lamp and Yellow glasses, slowly pan A/C system with UV lamp directed toward all possible leak areas. When a leak is found, fluorescent dye, when viewed through Yellow glasses and highlighted with UV lamp, will glow Light Green or Yellow/Green.
Leak detection dye mixes with refrigerant PAG oil. Therefore, extremely small leaks may be pressure, temperature or vibration sensitive and may not be active during a 5 minute test. It may be necessary to request vehicle be returned for further testing in 3 to 5 days. Because detection dye and PAG oil are water soluble, vehicles driven in rain, through sprinkler puddles, etc., may experience leak detection problems.
Perform repairs as necessary. Clean A/C system components, especially repaired area, using a Leak Dye Cleaner (J43872) or water until dye can no longer be detected. Start engine and allow to idle. Operate A/C system at maximum cold settings for 5 minutes and recheck for leaks.