Fails Leak Test; Will Not Inject Oil Or Dye - Bosch ACS 653 Repair Instruction

ACS 653, ACS 663 Service Manual

Fails Leak Test

NOTE: To ensure an accurate leak test, it
is imperative that a thorough recovery and
evacuation of the system be performed. During
the recovery process, cold spots can develop
in an automotive system. Pockets of refrigerant
in desiccant and in system oil will continue
to vaporize as the A/C system temperature
equalizes toward ambient. As this occurs, A/C
system pressure will increase, which may be
interpreted by the unit as a leak. This will vary
somewhat with ambient temperature conditions.
1. Verify the service hoses are properly
attached to the unit (valves open) without
any restrictions.
2. If vacuum can not be maintained, using
Service Leak Check in the service menu,
pressurize the unit and use a leak detector
to check all hoses, fittings, and components
for leaks. Repair as needed.
3. Check the PAG (S2), POE (S14) dye
(S15), high- (S6) and low-side (S7) charge,
Identifier (S17 - for ACS 663-RI only -) and
vacuum (S9) solenoids for bleed-through.
Repair as needed.
NOTE: A leaking high- (S6) or low-side (S7)
charge solenoid may be identified by an internal
pressure rise above zero. A leaking vacuum
(S9) or PAG (S2) or POE (S14) or dye (S15) or
Identifier (S17 - for ACS 663-RI only -) solenoid
would not normally rise above zero.
4. Verify the low-side pressure transducer is
functioning properly. Enter service menu
and verify low-side inlet transducer reading.
• Compare the low-side transducer reading
shown in the service menu with the
reading on the low-side panel gauge. The
readings should match, assuming the
low-side panel gauge is accurate.
• If the low-side inlet transducer is reading
pressure while the system is in a vacuum,
replace the transducer. Verify the
replacement transducer reads zero at
atmosphere by plugging it into the wiring
harness prior to installation.
• If replacing the transducer doesn't correct
the reading, replace control board.
Robert Bosch GmbH
Diagnostics and Testing

Will Not Inject Oil or Dye

1. Verify the oil and dye injection bottles
are securely attached and contains an
appropriate amount of oil or dye.
2. Verify a vacuum has been pulled on the
system.
3. Verify the high-side service hose is properly
attached to the unit without any restrictions
and coupler valve is open.
4. Open service menu and go into Output test
to activate the PAG (S2) or POE (S14) or
dye (S15) solenoids.
5. Verify power to the oil/dye inject solenoids
(S2, S14, S15).
6. Verify the solenoid coil is opening the
solenoid properly.
• With the system pulled into a vacuum,
remove the oil/dye bottle, place a finger
over the end of the oil/dye inject tube
and activate the oil/dye inject solenoid.
Suction should be felt at the oil/dye inject
tube.
• If no suction is felt, the oil inject solenoid
may not be receiving power. Check the
continuity of the wiring between solenoid
and power board. Repair as needed.
• If the wiring is correct and no power is
being applied to the solenoid, replace
the power board.
7. Verify operation of the oil/dye inject check
valves. Replace as needed.
55
SP00D00624 2021-04-08