2

T-SB-0058-23

Rev1

August 21, 2023

Page 16 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)

7. Inspect the ENTIRE O-ring surfaces of the
evaporator 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.

Figure 15.

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.

8. Inspect the ENTIRE evaporator surface by
remove the O-rings 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.

1

O-rings

Figure 16.

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

© 2025 Toyota Motor Sales, USA

Sealing Surfaces

T-SB-0058-23

Rev1

August 21, 2023

Page 17 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect the Condenser and Pipe Fitting Area
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 the 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 discharge and liquid pipes
from the condenser.

Figure 17.

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.

1
2

1

Discharge Side

2

Liquid Side

Figure 18.

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-rings

T-SB-0058-23

Rev1

August 21, 2023

Page 18 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect the Condenser and Pipe Fitting Area (continued)

3. Inspect the ENTIRE pipe surfaces by
removing the O-rings 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 19.

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 surface of the
condenser making sure it is 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 Surfaces

Figure 20.

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

© 2025 Toyota Motor Sales, USA

Sealing Surfaces

T-SB-0058-23

Rev1

August 21, 2023

Page 19 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect the Compressor and Pipe Fitting Area
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 and
replace ALL the 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 discharge and suction pipes
from the compressor.

Figure 21.
1

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

Discharge Side

2

Suction Side

Figure 22.

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

T-SB-0058-23

Rev1

August 21, 2023

Page 20 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect the Compressor and Pipe Fitting Area (continued)

3. Inspect the entire pipe surfaces by
removing the O-rings 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
judgement criteria.

Figure 23.

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 surface of the
compressor making sure it is 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 24.

1

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

© 2025 Toyota Motor Sales, USA

Sealing Surfaces

T-SB-0058-23

Rev1

August 21, 2023

Page 21 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect Other Joint Areas
NOTICE
 Do NOT reuse the O-rings once they are removed.
 Make sure to inspect all the related parts and replace all the parts where 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. Inspect the ENTIRE O-ring surface of the
pipe or part 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.

Figure 25.

1

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.

1

© 2025 Toyota Motor Sales, USA

O-ring

T-SB-0058-23

Rev1

August 21, 2023

Page 22 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
HVAC O-ring Joint Inspections (continued)
Inspect Other Joint Areas (continued)

2. Inspect the ENTIRE sealing surfaces of the
pipe or part by removing the O-rings
making sure they are free from defects,
such as foreign material adhesion,
damage, or corrosion. If there are ANY
defects, clean or replace the pipe or part.
Refer to the Sealing Surface Abnormalities
(O-ring Attachment Area) subsection for
judgement criteria.

Figure 26.

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

1

1

© 2025 Toyota Motor Sales, USA

Sealing Surfaces

T-SB-0058-23

Rev1

August 21, 2023

Page 23 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Judgement Criteria
O-ring Abnormalities
Table 2.

There are NO cuts, dents, crushed areas, foreign materials, or twists.
OK CONDITION

CUT

DENT / CRUSHED
AREA

Metal Fragment

Resin Fragment

FOREIGN MATERIAL

TWIST

© 2025 Toyota Motor Sales, USA

Lint

Hair

T-SB-0058-23

Rev1

August 21, 2023

Page 24 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Judgement Criteria (continued)
Sealing Surface Abnormalities (O-ring Attachment Area)
Table 3.

Processing evidence in circumferential direction is NOT a cause of leakage.
OK CONDITION

Metal Fragment

Resin Fragment

Lint

Hair

FOREIGN MATERIAL

DAMAGE

White and Yellow Materials Adhered
(Corrosion Product)
CORROSION

© 2025 Toyota Motor Sales, USA

Damage (Scratches) in Axial
Direction and Discoloration (Black)

T-SB-0058-23

Rev1

August 21, 2023

Page 25 of 25

Air Conditioning Leak Detection Dye and O-ring Joint Inspections
Judgement Criteria (continued)
Sealing Surface Abnormalities (Part Joint Area)
Table 4.

Processing evidence in circumferential direction is NOT a cause of leakage.

OK CONDITION

Metal Fragment

Resin Fragment

Lint

FOREIGN MATERIAL

DAMAGE

Uneven Discoloration (Black) on Sealing Surface

CORROSION

© 2025 Toyota Motor Sales, USA

Hair