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TSB 24-009-02

AC System Leak Detection

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Date: Oct. 28, 2002

Models: 1994-2003 (BR/BE, DR) Ram Pickup Truck

1995 - 2003 (AS) Ram Van/Wagon
1995 - 2003 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
1998 - 2003 (DN) Durango
2002 - 2003 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1996 - 2000 (GS) Chrysler Voyager (international Markets)
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2003 (JR) Sebring Sedan/Stratus Sodan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2003 (KJ) Uiberty/Cherokee (international Markets)
1993 - 2003 (LH) Concorde/intropidNision/LHSINew Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2003 (PL) Neon
2002            (PG) PT Cruiser (international Markets)
1997 - 2002 (PR) Prowler
2001 - 2003 (PT) PT Cruiser
2001 - 2003 (RG) Chrysler Voyager (international Markets)
2001 - 2003 (RS) Town & Country/Caravan/Voyager
1995 - 2002 (SR) Viper
2001 - 2003 (ST) Sebring Coupe/Stratus Coupe
1997 - 2003 (TJ) Wrangler
2001- 2003 (WG) Grand Cherokee (international Markets)
1999 - 2003 (WJ) Grand Cherokee
1997 - 2001 (XJ) Cherokee
2003             (ZB) Viper
1995 - 1998 (ZG) Grand Cherokee (international Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagonear

NOTE: THIS BULLETIN APPLIES TO VEHICLES USING R-134A REFRIGERANT IN THE A/C SYSTEM.

Overview:
This bulletin Involves installing a new panel vent door assembly.

Symptom/Condition:
Customers may indicate that there is a lack of air coming from the panel vents or that air is bleeding to the floor vents in the panel mode.

Equipment Required:
BG-750 PSE: 12 Volt UV Lamp (or equivalent)
BG-734 PSE: R-134a Dye Injector (or equivalent)
BG-795 PSE: Brite-Outs Fluorescent Dye Cleaner (or equivalence)
BG-71224 PSE: R-134a Stay-Brite Fluorescent Leak Dye (or equivalence)

Discussion: 

Vehicles from the factory no longer have leak detection dye in the A/C system. To determine the source of R-134a leak:

1.   Add dye to the system. Using BSL-734R-134a Dye injector (or equivalent) add 7.39ml (0.25 oz.) of BSL-712 leak tracer dye through the A/C system low pressure service port.

NOTE: THE DYE INJECTOR HOLDS EXACTLY 7.39 ml (0.25 oz.) OF LEAK TRACER DYE.

2.   Clean dye from surfaces. Any spilled dye should be cleaned from surfaces using BG-795 Fluorescent Dye Cleaner (or equivalent).

NOTE: ANY DYE ON THE EXTERIOR OF THE A/C COMPONENTS MAY LATER BE DIAGNOSED AS A LEAK.

3.   Operate the system. This will thoroughly mix the dye with the system lubricant. The operating time needed for the dye/lubricant to penetrate the leak(s) will depend on the size of the leak. A very small leak could lake hours or days of system operation to appear.

4.    Check for leaks. Using a BF-750 12 volt UV Lamp (or equivalent), scan all lines, fittings, and components. The exact location of the leak(s) will be pinpointed by a bright yellow/green glow of dye. When checking for evaporator leak(s) shine the UV light at the evaporator drain hole to check for traces of dye. If traces of dye appear -at the drain hole, check the evaporator and connections when the unit is removed from the vehicle. Verify leak location.

5.    Install Identification sticker. Place one of the dye 10 stickers (included with dye) in a prominent location showing that the vehicle has a fluorescent dye in the A/C system that can be used to detect future leaks. The dye will not affect the operation or durability of the A/C system.

Policy:    Information Only


Thanks to David Lovell for supplying this TSB information

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This page was edited on: May 3, 2004