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Fluorescent Dye Injection - Using a Dye Injector Loop Kit

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet black light. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.
NOTE: Before using the R-134a Fluorescent Dye Injector for the first time, refer to the equipment manufacturer's instructions on evacuation of non-condensable gasses from the hoses.
NOTE: Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24°C (75°F) with the engine off and cool.
  1. Verify that the valves on the Deluxe Injector Loop Kit are closed.
    2. Fig 1: Identifying Valves On Fluorescent Dye/Lubricant Injector
    G04611374Courtesy of FORD MOTOR CO.
  2. Fill the Deluxe Injector Loop Kit reservoir with 7 ml (0.25 oz.) of fluorescent dye.
    3. Fig 2: Identifying Deluxe Injector Loop Kit Reservoir
    G03902307Courtesy of FORD MOTOR CO.
  3. Install the Deluxe Injector Loop Kit between the high-pressure and low-pressure service gauge port valves.
    4. CAUTION: Make sure all tools and hoses are clear of the engine cooling fan and drive belt before starting the engine. Failure to keep tools and hoses clear from the engine cooling fan and drive belt will result in damage to the tools and/or vehicle.
  4. With the A/C off, start the engine. Allow engine speed to stabilize below 1,000 RPM.
  5. Open the high-pressure service valve.
    6. Fig 3: Identifying High-Pressure Service Valve
    G03890023Courtesy of FORD MOTOR CO.
    NOTE: To prevent pressure spike/liquid slug, crack the Deluxe Injector Kit valves and slowly open to inject the fluorescent dye into the refrigerant system.
  6. Open the Deluxe Injector Loop Kit valves and inject the fluorescent dye into the refrigerant system.
    7. Fig 4: Locating Valves On Deluxe Injector Loop Kit
    G03890024Courtesy of FORD MOTOR CO.
  7. Close the high-pressure service valve to allow the pressure inside the Deluxe Injector Loop Kit to equalize with the suction side of the refrigerant system.
    8. Fig 5: Identifying High-Pressure Service Valve
    G03890023Courtesy of FORD MOTOR CO.
    NOTE: Close the valves on the Deluxe Injector Loop Kit while the A/C compressor is operating.
  8. Close the valves on the Deluxe Injector Loop Kit.
    9. Fig 6: Locating Valves On Deluxe Injector Loop Kit
    G03890024Courtesy of FORD MOTOR CO.
    NOTE: Leave all valves on the special tool closed when not in use.
  9. Disconnect the high-pressure and low-pressure service valves and remove the Deluxe Injector Loop Kit from the vehicle.
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