T-SB-0058-23

Rev1

August 21, 2023

Page 8 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Air Conditioning Leak Detection Dye and Injection Tool Use (continued)
2. Identify the compressor oil and refrigerant
system type by looking at the under-hood
air conditioning label for the compressor oil
and refrigerant type the vehicle is using
and select the corresponding dye injector
tool brass coupler.

Figure 1.

1
c

3. Prepare the dye injection tool with the dye
cartridge by removing the large cap from
the first cartridge.

2
c

1

Compressor Oil

2

Refrigerant Type and System Charge Amount

Figure 2.
1
c

2
c

4. Completely unscrew the handle on the
injector and screw the dye cartridge into it.
NOTE
When screwing on the dye cartridge to the
injector handle, make sure the piston rod
remains in the fully unscrewed position.

1

Large Cap

2

Dye Injection Tool

© 2025 Toyota Motor Sales, USA

T-SB-0058-23

Rev1

August 21, 2023

Page 9 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Air Conditioning Leak Detection Dye and Injection Tool Use (continued)
5. Remove the purge fitting from the brass
coupler and hold the cartridge vertically
with the small cap on top.

Figure 3.
3
c
1
c

6. Remove the cap and screw the cartridge
firmly to the brass coupler.

2
c

7. Insert the purge fitting into the
brass coupler.
8. AFTER the purge fitting is installed,
continue holding the dye injection tool in
the vertical position to avoid dye form
leaking out until the purge process
is complete.

1

Purge Fitting

2

Brass Coupler

3

Hold Cartridge Vertically

9. Turn the handle to advance the plunger
until it stops, passing all the dye out of
the cartridge.
10. Remove the purge fitting from the
brass coupler.
11. Completely unscrew the handle on the
injector and unscrew the first empty
cartridge from the brass coupler
and dispose.
12. Install the second cartridge onto the
brass coupler.

© 2025 Toyota Motor Sales, USA

T-SB-0058-23

Rev1

August 21, 2023

Page 10 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Air Conditioning Leak Detection Dye and Injection Tool Use (continued)
13. Install the purge fitting to the brass coupler
and turn the handle to advance the plunger
until a small amount of fluorescent dye
exits the purge fitting.

Figure 4.
1
c

1

Fluorescent Dye

14. Remove the purge fitting. The injection tool
assembly is now purged and ready for use.
15. Connect the brass coupler to the low side
service port.

Figure 5.

NOTE
Wrap the coupler connection with a shop rag
as a small amount of dye may spray out due
to refrigerant pressure.

2
c

1
c

1

Brass Coupler

2

Low Side Service Port

© 2025 Toyota Motor Sales, USA

T-SB-0058-23

Rev1

August 21, 2023

Page 11 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Air Conditioning Leak Detection Dye and Injection Tool Use (continued)
16. Turn the plunger clockwise to inject all the
dye into the vehicle.

Figure 6.

1
c

1

Turn Clockwise

17. Disconnect the brass coupler from the service port and wipe both clean.
NOTE
Wrap the coupler connection with a shop rag as a small amount of dye may spray out due to
refrigerant pressure.

18. Start the engine, turn the air conditioning switch ON, set the temperature to MAX COOL, and
run the compressor for 10 minutes to circulate the dye through the system.
19. Turn OFF the air conditioning and engine.
Put on UV glasses and check for
refrigerant leaks along the air conditioning
system components while shining the
UV light.

Figure 7.

1
c

HINT
 Areas where there are refrigerant leaks
will glow in a bright yellow green.
 For smaller leaks, operate the air
conditioning system over the next 24 to
48 hours and reinspect periodically.

1

UV Lamp

20. AFTER the leaks are repaired, use the GLO-AWAY, dye cleaner, and UV flashlight to clean
the area and ensure NO dye remains.

© 2025 Toyota Motor Sales, USA

T-SB-0058-23

Rev1

August 21, 2023

Page 12 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Air Conditioning Leak Detection Dye and Injection Tool Use (continued)
Figure 8. Refrigerant Line

C

A
c

C
B

C

A
A

2

3
4

A
B

1

B

D

5

D

A

A

A
A

B

When leaking occurs around “A” refer to the Inspect the Pipe Fitting Areas of the Expansion Valve and
Evaporator subsection.
When leaking occurs around “B” refer to the Inspect the Condenser and Pipe Fitting Area subsection.

C

When leaking occurs around “C” refer to the Inspect the Compressor and Pipe Fitting Area subsection.

D

When leaking occurs around “D” refer to the Inspect Other Joint Areas subsection.

1

Condenser

2

Compressor

3

Evaporator

4

Expansion Valve

5

Rear Air Conditioner

A

© 2025 Toyota Motor Sales, USA

T-SB-0058-23

Rev1

August 21, 2023

Page 13 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections
Inspect the Pipe Fitting Areas of the Expansion Valve and Evaporator
NOTICE
 Do NOT reuse the O-rings once they are removed.
 As there may be a malfunction in multiple components, make sure to complete ALL steps and
replace ALL parts in which defects are found.
 If no malfunction is found in ANY related parts, a temporary leak may have occurred due to
foreign matter on an O-ring, deformation, etc.

1. Remove the pipes from the
expansion valve.

Figure 9.

NOTICE
 Wipe off the joint area with a clean cloth
BEFORE disassembly.
 Slowly remove the pipes straight to
prevent the sealing face from being
damaged and foreign materials from
dropping off.

2. Inspect the ENTIRE O-ring surfaces
making sure they are free from defects,
such as damage (cuts, dents, or crushed
areas), foreign material adhesion, or twists.
If there are ANY defects, clean or replace
the part. Refer to the O-ring Abnormalities
subsection for judgement criteria.

2

1

Pipe

2

Expansion Valve

Figure 10.

1

NOTICE
 Inspect the O-ring surfaces in a
well-lit area.
 When it is difficult to inspect the
surface conditions due to oil adhesion,
degrease the surface (such as by
wiping it with a clean white cloth). Make
sure NOT to lose any foreign material
that was adhering to the surface that
may indicate the source of the leak.

1

© 2025 Toyota Motor Sales, USA

O-ring

1

T-SB-0058-23

Rev1

August 21, 2023

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect the Pipe Fitting Areas of the Expansion Valve and Evaporator (continued)

3. Remove the O-rings and inspect the entire
pipe surfaces making sure they are free
from defects, such as foreign material
adhesion, damage, or corrosion. If there
are ANY defects, clean or replace the part.
Refer to the Sealing Surface Abnormalities
(O-ring Attachment Area) subsection for
judgment criteria.

Figure 11.

1

NOTICE
When removing the O-rings, use soft
tools (such as a toothpick) to avoid
damaging the sealing face or the O-ring.
1

4. Inspect the ENTIRE sealing surfaces of the
expansion valve (pipe side) making sure
they are free from defects, such as foreign
material adhesion, damage, or corrosion. If
there are ANY defects, clean or replace the
part. Refer to the Sealing Surface
Abnormalities (Part Joint Area) subsection
for judgment criteria.

Sealing Surface

Figure 12.

1

NOTICE
When it is difficult to check the surface
conditions due to oil adhesion, degrease
the surface (such as by wiping it with a
clean white cloth). Make sure NOT to lose
any foreign material that was adhering to
the surface that may indicate the source
of the leak.

1

© 2025 Toyota Motor Sales, USA

Sealing Surface

Page 14 of 25

T-SB-0058-23

Rev1

August 21, 2023

Page 15 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect the Pipe Fitting Areas of the Expansion Valve and Evaporator (continued)

5. Remove the expansion valve from
the evaporator.

Figure 13.
1

NOTICE
 Slowly remove the pipes straight to
prevent the sealing face from being
damaged and foreign materials from
dropping off.
 If the expansion valve is difficult to
remove, gently move it up and down
and right to left for removal.

6. Inspect the ENTIRE sealing surfaces of the
expansion valve (evaporator side) making
sure they are free from defects, such as
foreign material adhesion, damage, or
corrosion. If there are ANY defects, clean
or replace the part. Refer to the Sealing
Surface Abnormalities (Part Joint Area)
subsection for judgment criteria.

1

Evaporator

2

Expansion Valve

Figure 14.

NOTICE
When it is difficult to inspect the surface
conditions due to oil adhesion, degrease
the surface (such as by wiping it with a
clean white cloth). Make sure NOT to lose
any foreign material that was adhering to
the surface that may indicate the source
of the leak.

1

1

© 2025 Toyota Motor Sales, USA

Sealing Surfaces