REFRIGERANT LINES
ATC-167
C
D
E
F
G
H
I
K
L
M
A
B
ATC
2005 Pathfinder
CAUTION:
●
Replace the O-rings on the rear expansion valve and the rear high- and low-pressure A/C pipes
with new ones, then apply compressor oil to them for installation.
●
After charging refrigerant, check for leaks.
Checking for Refrigerant Leaks
EJS002YK
Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant
leakage, damage, and corrosion. Any A/C lubricant leakage may indicate an area of refrigerant leakage. Allow
extra inspection time in these areas when using either an electronic refrigerant leak detector (J-41995) or fluo-
rescent dye leak detector (J-42220).
If any dye is observed using a fluorescent dye leak detector (J-42220), confirm the leak using a electronic
refrigerant leak detector (J-41995). It is possible that the dye is from a prior leak that was repaired and not
properly cleaned.
When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all
system components and connections.
When searching for refrigerant leaks using an electronic refrigerant leak detector (J-41995), move the probe
along the suspected leak area at 25 - 50 mm (1 - 2 in) per second and no further than 6 mm (1/4 in) from the
component.
CAUTION:
Moving the electronic refrigerant leak detector probe slower and closer to the suspected leak area will
improve the chances of finding a leak.
Checking System for Leaks Using the Fluorescent Dye Leak Detector
EJS002YL
1.
Check the A/C system for leaks using the fluorescent dye leak detector and safety goggles (J-42220) in a
low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye
will appear as a bright green/yellow area at the point of leakage. Fluorescent dye observed at the evapo-
rator drain opening indicates an evaporator core assembly leak (tubes, core or expansion valve).
2.
If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or
cloth, then inspect the shop rag or cloth with the fluorescent dye leak detector (J-42220) for dye residue.
3.
After the leak is repaired, remove any residual dye using refrigerant dye cleaner (J-43872) to prevent
future misdiagnosis.
4.
Perform a system performance check and then verify the leak repair using a electronic refrigerant leak
detector (J-41995).
NOTE:
●
Other gases in the work area or substances on the A/C components, for example, anti-freeze, wind-
shield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the sur-
faces to be checked are clean.
●
Clean with a dry cloth or blow off with shop air.
●
Do not allow the sensor tip of the electronic refrigerant leak detector (J-41995) to contact with any sub-
stance. This can also cause false readings and may damage the detector.
Dye Injection
EJS002YM
NOTE:
This procedure is only necessary when recharging the system or when the compressor has seized and must
be replaced.
1.
Check the A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.52 kg/cm
2
, 50 psi).
2.
Pour one bottle 7.4 cc (1/4 ounce) of the HFC-134a (R-134a) fluorescent leak detection dye (J-41447) into
the HFC-134a (R-134a) refrigerant dye injector (J-41459).
CAUTION:
If repairing the A/C system or replacing a component, pour the HFC-134a (R-134a) fluorescent leak
detection dye (J-41447) directly into the open system connection and proceed with the service
procedures.
3.
Connect the refrigerant dye injector (J-41459) to the low-pressure service valve.
4.
Start the engine and switch the A/C system ON.
5.
When the A/C system is operating (compressor running), inject one bottle 7.4 cc (1/4 ounce) of HFC-134a
(R-134a) fluorescent leak detection dye (J-41447) through the low-pressure service valve using HFC-
134a (R-134a) refrigerant dye injector (J-41459). Refer to the manufacturer's operating instructions.