Technical product information
Topic
Market area
Brand
Transaction No.
Level
Status
Release date

HVAC refrigerant leakage - Diagnosis guidelines
Bentley: worldwide (2WBE)
Bentley
2069806/1
EH
Approval

New customer code
Object of complaint
air conditioning -> heating, cooling -> automatic A/C mode
air conditioning -> heating, cooling -> manual A/C mode
air conditioning -> cooling

Complaint type
Position
functionality -> cannot be activated
functionality -> without function / defect
component / consumables

New workshop code
Object of complaint

Complaint type

Position

air conditioning -> cooling -> evaporator leaks -> leaking
front
air conditioning -> cooling -> evaporator leaks -> leaking connection front

Vehicle data
All Models
Sales types
Type MY

Brand Designation Engine code Gearbox code Final drive code

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Documents
Document name
master.xml
hvacword.doc

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Technical product information
HVAC refrigerant leakage - Diagnosis guidelines

Transaction No.: 2069806/1

Customer statement / workshop findings
Customer statement:
HVAC not cooling
Or
HVAC cooling less than expected
Workshop findings:
HVAC refrigerant leakage confirmed
CAUTION
DO NOT UNDER ANY CIRCUMSTANCES INSTALL TRACER ADDITIVES INTO THE HVAC SYSTEM

Before conducting any work on the HVAC system the operative MUST refer to the following within Rep.Gr 87
•

Refrigeration system - Safety and general information

Technical background
It has been observed that some HVAC components have been incorrectly diagnosed and replaced
After the components were returned for inspection no faults were found
This TPI relates to HVAC components being incorrectly diagnosed and replaced, in some cases the leak could have been cured by only
replacing O-rings
CAUTION
The leaks in these scenarios were repaired after component replacement however as the parts were not at fault the actual fix of the leak would
have been resolved by replacing O-rings only

NOTICE
IMPORTANT NOTICE: Before proceeding the operative should check to confirm there are no VIN applicable HVAC/refrigerant leak related
TPI’s for example TPI 2069806/Workshop diagnosis based on the customer complaint could be as follows:
•

HVAC is not cooling or the HVAC is not effective due to leakage of the refrigerant

•

Refrigerant recovered from the system shows a low volume or no refrigerant at all

•

Leakage is suspected from the compressor as no other leakage source was found

NOTICE
please refer to the examples shown below (Figures 1,2 and 3) of leaks found on a HVAC compressor

INTERNAL

Figure 1

Figure 2

INTERNAL

Figure 3
CAUTION
CAUTION: In the event the HVAC sniffer tool traces a HVAC leak from any of the outlets (Figure 4)

INTERNAL

Figure 4
Or
A complaint is received that refrigerant is evident within the cabin the operative MUST first ensure that a leak is not evident within the plenum
chamber or around the centre console (Figures 5 and 6) as refrigerant could be leaking into the plenum chamber/cabin and recirculated back
into the cabin as this could lead to misdiagnosis and/or incorrect part replacement

Figure 5

INTERNAL

Figure 6
In the event that leakage is suspected from the thermal expansion valve (TXV) the thermal expansion valve can be replaced
when the HVAC unit is fitted within the car
•

The operative must first refer to the attached flow chart before proceeding with any diagnosis or parts replacement

•

Before conducting any work on the HVAC system the operative MUST refer to the following within Rep.Gr 87

•

Refrigeration system - Safety and general information

•

Refrigerant oil - Special instructions

•

Refrigeration system - To discharge and charge

IMPORTANT TIP: When a HVAC line/connection has been opened the operative MUST always cap/bung the applicable port using a suitable
cap/bung

NOTICE
The operative must always change the receiver drier if the air conditioning compressor has failed
CAUTION
In the event the evaporator or compressor is suspected to be at fault the operative must raise a Technical DISS query before conducting any
further work ensuring the following is attached:
•

Photograph and video of the r efrigerant quantity and the actual leakage location

Or
In the event the evaporator or compressor is not suspected as being at fault and the issue can be successfully diagnosed and repaired, please
raise a non technical DISS query stating the issue which was evident and how the issue was resolved

Production change
Measure
Refer to the Technical background section

Warranty accounting instructions
Due to the numerous scenarios please refer to the warranty accounting instructions with Elsa pro

NOTICE
All HVAC related claims will be checked by the Warranty team, any claims which are not deemed as applicable will be cancelled
– In the event that parts are replaced parts without the required attachments or the parts are found to be not at fault warranty claims will be
liable for rejection

INTERNAL

Parts information
Refer to the ETKA parts catalogue

INTERNAL

Take photographs/videos to
showing a reduction or /no HVAC
Refrigerant

Confirm leakage source by HVAC
sniffer tool or leak detection
spray/Soapy water

Leakage Suspected at Evaporator
as not found in other part

Leakage

Other than Evaporator

Source

Replace affected part
Confirm Evaporator Leakage
Raise a Technical DISS Query requesting permission to
replace the evaporator

Yes

Replace Evaporator

INTERNAL

Leakage
present on
Evaporator

No

Do not Replace
Evaporator, continue
with further diagnosis