Explorer 4WD V8-4.6L VIN W (2002)
Evaporator Core: Testing and Inspection
On-Vehicle Vacuum Leak Detection W/Manifold Gauge Set
NOTE:
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If an evaporator core leak is suspected, the evaporator core must be vacuum leak-tested before it is removed from the vehicle.
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Carry out periodic inspection of the manifold gauge set, hoses and vacuum pump by setting a maintenance schedule. Make sure that there are no
leaks in the equipment.
1. Discharge and recover the refrigerant.
2. Connect the red and blue hoses from the manifold gauge set to the low-pressure and high-pressure service gauge valve ports.
3. Connect the yellow hose to a vacuum pump.
4. Open both manifold gauge set valves and start the vacuum pump.
5. Allow the vacuum pump to operate for a minimum of 45 minutes after the low-pressure gauge indicates 101 kPa (30 in-Hg).
NOTE: The 45-minute evacuation is necessary to remove any refrigerant from the PAG oil left in the system. If the refrigerant is not completely
removed from the PAG oil, outgassing will degrade the vacuum and appear as a refrigerant system leak.
6. If the low-pressure gauge reading does not reach 101 kPa (30 in-Hg) when the manifold gauge set valves are open and the vacuum pump is
operating, close the manifold gauge set valves and observe the low-pressure gauge. If the vacuum decreases rapidly to zero, a large leak is
indicated. Recheck the manifold gauge set, the vacuum pump, and the service gauge port valve connections.
7. After evacuating for 45 minutes, close the manifold gauge set valves, turn off the vacuum pump, and observe the low-pressure gauge reading; it
should remain at 101 kPa (30 in-Hg).
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If the low-pressure gauge vacuum reading decreases 34 kPa (10 in-Hg) or more in 10 minutes a refrigerant system leak is indicated.
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If a very small leak is suspected wait 30 minutes and observe the low-pressure gauge reading.
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If a small amount of vacuum is lost open the manifold gauge set valves and operate the vacuum pump for an additional 30 minutes to remove
any remaining refrigerant from the PAG oil in the refrigerant system. Recheck for a loss of vacuum.
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If a very small leak is suspected allow the system to set overnight with vacuum applied and check for vacuum loss.
8. If it has been determined that a leak is present, divide the refrigerant system in half to assist in determining where to start and isolate the leak.
Continue to subtract components being leak tested until the leak has been identified.
