Pinpoint Test AJ: Refrigerant Leak Detection

WARNING: This page is about a different car, the 2023 Ford Bronco. However, it is still accessible from the selected car via links, so may be relevant.

Possible Sources
- O-ring and Fitting Leaks
- System Leaks
- Condenser Leaks
- Evaporator Leaks
- Compressors
- A/C Line Leaks

AJ1 CHECK FOR LEAKS USING THE FLUORESCENT DYE LEAK DETECTION

NOTE: Proper Air Conditioning (A/C) system diagnosis on a vehicle's compressor is dependent on correct refrigerant system charge and tested in ambient temperatures above 21.1°C (70°F).

Carry out the fluorescent dye leak detection. REFER to: Fluorescent Dye Leak Detection .

Is the presence of a leak found using the fluorescent dye leak detection?

Yes	Repair any leaks found using Fluorescent Dye Leak Detection . After the leak(s) is repaired, remove any traces of fluorescent dye with a dye cleaner. REFER to: Climate Control Tools and Equipment .

GO to AJ2

AJ2 CHECK THE A/C (AIR CONDITIONING) SYSTEM PRESSURE

NOTE: Static refrigerant pressure, under perfect conditions, should approximately reflect ambient air temperature. Do not rely upon the static refrigerant pressure alone to determine if the system is properly charged. Refer to the current Ford Web Based Technical Training courses for basic HVAC system refrigerant operation.
- Ignition OFF.
- Connect a manifold gauge set.
- With a manifold gauge set connected, check for A/C system pressure.
Is the A/C system pressure between 413-551 kPa (60-80 psi) at 24 Degrees C/ 75.2 Degrees F?

Yes GO to AJ3

No GO to AJ4

AJ3 CHECK FOR LEAKS USING THE ELECTRONIC LEAK DETECTION

NOTE: Proper Air Conditioning (A/C) system diagnosis on a vehicle's compressor is dependent on correct refrigerant system charge and tested in ambient temperatures above 21.1°C (70°F).

Carry out the electronic leak detection. REFER to: Electronic Leak Detection .

Leak test the refrigerant system using the probe by slowly following the path of the refrigerant circuit checking each component and connection. Refer to the Leak Detection Reference Tab. Follow the instructions included with the Electronic Leak Detector for handling and operation techniques.

Is the presence of a leak found using the electronic leak detection?

Yes	Repair any leaks found using Electronic Leak Detection . After the leak(s) is repaired, remove any traces of fluorescent dye with a dye cleaner. REFER to: Climate Control Tools and Equipment .

GO to AJ4

AJ4 CHECK FOR LEAKS USING THE EVACUATION AND VACUUM TEST

NOTE: In an Electric or Hybrid vehicle with a battery chiller, it may be necessary to activate the battery chiller(s) to open the solenoid(s) to allow vacuum and gas to pass through to chiller for leak testing. Refer to vehicle-specific procedure for refrigerant reclaim and charging to see if solenoid(s) activation is necessary. Follow the Service Article procedure to perform activation if needed.

Recover the refrigerant and evacuate the A/C system. REFER to: Air Conditioning (A/C) System Recovery, Evacuation and Charging .

Turn off the vacuum pump.

Observe the low-pressure gauge for 45 minutes to confirm whether or not a leak exists under vacuum.

Did the low pressure gauge maintain 99.4 kPA (29.5 in-Hg) for 45 minutes(?

Yes	Charge the A/C system and perform the refrigerant system test. REFER to: Refrigerant System Tests - 2.3L EcoBoost (199kW/270PS) . REFER to: Refrigerant System Tests - 2.7L EcoBoost (238kW/324PS) .

GO to AJ5

AJ5 CHECK FOR LEAKS USING THE A/C SYSTEM LEAK TEST USING FORMING GAS

Carry out the A/C system leak test using forming gas. REFER to: Air Conditioning (A/C) System Leak Test Using Forming Gas .

Was a leak found using the A/C system leak test using forming gas?

Yes	Repair any leaks found using Air Conditioning (A/C) System Leak Test Using Forming Gas . After the leak(s) is repaired, remove any traces of fluorescent dye with a dye cleaner. REFER to: Climate Control Tools and Equipment .

GO to AJ6

AJ6 CHECK FOR LEAKS IN THE EVAPORATOR CORE
- Carry out the evaporator core leak check. REFER to: Evaporator Core Leak Check .
Did the low pressure gauge maintain 29.In HG for the 30 minutes in the evaporator core?

Yes GO to AJ7

No INSTALL a new evaporator core. REFER to: Evaporator .

AJ7 CHECK FOR LEAKS IN THE CONDENSER CORE
- Carry out the condenser core leak check. REFER to: Condenser Core Leak Check .
Did the low pressure gauge maintain 29.In HG for the 30 minutes in the condenser core?

Yes REPAIR the concern found in the refrigerant system tests chart.

No INSTALL a new condenser core. REFER to: Condenser .

AJ8 CHECK FOR LEAKS IN THE A/C COMPRESSOR

Carry out the A/C compressor leak detection. REFER to: Air Conditioning (A/C) Compressor Leak Detection .

Was a leak detected in the A/C compressor?

Yes	INSTALL a new A/C compressor. REFER to: Air Conditioning (A/C) Compressor - 2.3L EcoBoost (199kW/270PS) . REFER to: Air Conditioning (A/C) Compressor - 2.7L EcoBoost (238kW/324PS) .

No	Follow the Service Article for reassembly of the A/C System. CHECK OASIS for any applicable service articles: TSB, GSB, SSM or FSA.