2023-2026 Toyota Models AC Leak Detection TSB

Introduction

Toyota has released Technical Service Bulletin (TSB) T-SB-0058-23 Rev1, dated August 21, 2023, to provide detailed instructions for identifying and repairing air conditioning (AC) refrigerant leaks across a wide range of its 2023-2026 models. This bulletin focuses on using a specialized dye injection tool kit and conducting thorough O-ring joint inspections to pinpoint the exact location of leaks. This TSB is crucial for maintaining optimal AC performance and preventing further system damage.

Revision History

This bulletin, T-SB-0058-23 Rev1, was updated on June 13, 2025. The revision included updates to the applicability list, incorporating various 2017-2026 model year vehicles such as the Prius Prime, Sienna, Crown, Yaris, Raize, Venza HV, 86, 4Runner, Avanza, bZ4X, Camry, Corolla, Highlander, Hiace, Land Cruiser, Mirai, RAV4, and Tundra. Additionally, the Introduction, Parts Information, Required Tools & Equipment, and Air Conditioning Leak Detection Dye and Injection Tool Use sections were updated. Any previously printed versions of this bulletin should be discarded to ensure technicians are using the most current procedures.

Symptoms of an AC Refrigerant Leak

Owners of affected Toyota vehicles, including the Toyota Camry, might notice a decrease in the effectiveness of their air conditioning system. Common symptoms of an AC refrigerant leak include the AC blowing warm air, the system running constantly without cooling, or unusual noises coming from the AC compressor. These symptoms indicate a potential loss of refrigerant, which can lead to reduced comfort and potential damage to AC components if not addressed promptly.

Important Warnings for Technicians and Owners

This TSB includes several critical warnings to ensure safety and proper procedure:

• UV Light Safety: Do NOT look directly into the UV flashlight and ALWAYS wear UV protection glasses.
• Tool Connection Safety: Wear safety glasses when connecting/disconnecting the dye injection tool from the air conditioning service port.
• System Operation: Do NOT operate the air conditioning system while the dye injection tool is connected to the AC system.
• Evacuated Systems: Do NOT connect the dye injection tool to a system that is evacuated.
• Refrigerant Requirement: The air conditioning system MUST contain enough refrigerant to operate the compressor and circulate the dye to find leaks.
• Dye Mixing: Do NOT mix ND-11 and ND-12 dyes. ALWAYS use the dye cartridge with the designated injector tool brass coupler.
• Dye Disposal: Dispose of ANY dye in accordance with all local, state, and federal regulations.
• O-ring Reuse: Do NOT reuse the O-rings once they are removed.
• Component Replacement: As there may be a malfunction in multiple components, make sure to complete ALL steps and replace ALL parts in which defects are found.
• Temporary Leaks: 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.
• Disassembly Preparation: Wipe off the joint area with a clean cloth BEFORE disassembly. Slowly remove pipes straight to prevent sealing face damage and foreign material drop-off.
• O-ring Removal: When removing O-rings, use soft tools (such as a toothpick) to avoid damaging the sealing face or the O-ring.
• Surface Inspection: Make sure NOT to lose any foreign material that was adhering to the surface that may indicate the source of the leak.
• Compressor Oil Compatibility: ND-8 compressor oil is NOT compatible with ND-12 oil systems.

Required Tools and Parts

Technicians performing these inspections and repairs will utilize specific tools and parts, including:

• Dye Cartridges: ND-11 A/C Dye Cartridges (Part Number: 00289-DYE11) and ND-12 A/C Dye Cartridges (Part Number: 00289-DYE12). These are for Denso AC systems only and are available through ZEP Products via the TCMC (Toyota Complete Maintenance Care) Program website via Dealer Daily. Each part number contains two dye cartridges.
• Brass Couplers:
  • R-134a / Brass Coupler (for ND-11): 09870-10010-Y
  • R-1234yf / Brass Coupler (for ND-11): 09870-20010-Y
  • R-134a / Brass Coupler (for ND-12): 09870-10010-B
  • R-1234yf / Brass Coupler (for ND-12): 09870-20010-B
• Injector Handle: 09870-TP9845
• Ultraviolet (UV) Flashlight: 09870-TPOPUVP
• Flashlight Charger: 09870-0TP14
• GLO-AWAY + Dye Cleaner: 09870-0TP19
• Yellow Glasses: 09870-TP9940
• Case: 09870-CASE
• A/C Machines: R1234YF A/C Machine and R134A A/C Machine.

Replacement components for the dye injection tool kit can be ordered by calling Approved Dealer Equipment (ADE) at 1-800-368-6787 (USA) or 01-55-50103041 (Mexico).

Warranty Information

This service bulletin notes that warranty information is "Not Applicable to Warranty" for both USA and Mexico markets. This means that the procedures outlined are for diagnostic and repair guidance, and the cost of repairs may not be covered under standard warranty, depending on the specific circumstances of the AC leak.

Air Conditioning Leak Detection Procedure

To accurately locate AC refrigerant leaks, technicians follow a precise dye injection procedure. Two dye cartridges are required per vehicle service. The first cartridge is completely purged through the brass coupler to ensure no contaminants like moisture or air are introduced. The second cartridge is then injected into the AC system.

1. Identify System Type: The technician first identifies the compressor oil and refrigerant system type (R-134a or R-1234yf) by checking the under-hood AC label. This determines the correct dye injector tool brass coupler to use.
2. Prepare Dye Injection Tool: The dye injection tool is prepared by removing the large cap from the first dye cartridge. The handle on the injector is completely unscrewed, and the dye cartridge is screwed into it, ensuring the piston rod remains fully unscrewed.
3. Purge First Cartridge: The purge fitting is removed from the brass coupler. The cartridge is held vertically with the small cap on top, then the cap is removed, and the cartridge is screwed firmly to the brass coupler. The purge fitting is reinserted. While holding the tool vertically, the plunger is advanced until all dye is passed out of the cartridge, completing the purge process. The purge fitting is then removed, and the first empty cartridge is unscrewed and disposed of.
4. Install Second Cartridge: The second dye cartridge is installed onto the brass coupler.
5. Final Purge: The purge fitting is installed to the brass coupler, and the handle is turned to advance the plunger until a small amount of fluorescent dye exits the purge fitting, indicating the tool is fully purged and ready for use.
6. Connect to AC System: The brass coupler is connected to the low-side service port. A shop rag should be wrapped around the connection as a small amount of dye may spray out due to refrigerant pressure.
7. Inject Dye: The plunger is turned clockwise to inject all the dye into the vehicle's AC system.
8. Circulate Dye: After disconnecting the brass coupler and wiping it clean, the engine is started, the AC switch is turned ON, the temperature is set to MAX COOL, and the compressor is run for 10 minutes to circulate the dye throughout the system.
9. Inspect for Leaks: The AC and engine are turned OFF. Wearing UV glasses, the technician uses a UV flashlight to check for refrigerant leaks along all AC system components. Areas with leaks will glow a bright yellow-green. For smaller leaks, the AC system may need to operate for 24 to 48 hours before re-inspection.
10. Clean Up: After repairs, GLO-AWAY dye cleaner and a UV flashlight are used to clean the area and ensure no dye remains.

AC Component Inspection Areas

Figure 8 in the TSB illustrates the refrigerant line and identifies key inspection areas: 'A' for the Expansion Valve and Evaporator, 'B' for the Condenser, 'C' for the Compressor, and 'D' for Other Joint Areas. Each area requires specific inspection steps.

Expansion Valve and Evaporator Inspection

This inspection focuses on the pipe fitting areas of the expansion valve and evaporator. Technicians remove the pipes from the expansion valve, carefully wiping the joint area clean before disassembly. The O-rings are removed using soft tools like a toothpick to prevent damage. Both the O-rings and the pipe surfaces are inspected for defects such as cuts, dents, crushed areas, foreign material adhesion, or corrosion. The sealing surfaces of the expansion valve (pipe side) and the evaporator are also thoroughly examined. If any defects are found, the parts are cleaned or replaced. It is critical not to lose any foreign material found, as it may indicate the source of the leak.

Condenser and Pipe Fitting Area Inspection

For the condenser, the discharge and liquid pipes are removed. Similar to other components, the joint area is cleaned, and O-rings are removed carefully. The O-ring surfaces and pipe surfaces are inspected for any defects, foreign material, or corrosion. The sealing surfaces of the condenser are also checked for abnormalities. Any defective parts are cleaned or replaced.

Compressor and Pipe Fitting Area Inspection

The discharge and suction pipes are removed from the compressor. The O-ring surfaces and pipe surfaces are inspected for damage, foreign material adhesion, or twists. The sealing surface of the compressor is also examined for defects. If issues are found, the parts are cleaned or replaced.

Other Joint Areas Inspection

Finally, any other joints within the AC system are inspected. This involves examining the O-ring surfaces of the pipes or parts and their corresponding sealing surfaces for defects, foreign material, or corrosion. As with all other areas, defective components are either cleaned or replaced.

Judgment Criteria for O-rings and Sealing Surfaces

Technicians use specific criteria to determine if O-rings and sealing surfaces are acceptable or require attention.

O-ring Abnormalities

An O-ring is considered in "OK CONDITION" if there are NO cuts, dents, crushed areas, foreign materials, or twists. Abnormalities include:

• CUT: Visible cuts on the O-ring surface.
• DENT / CRUSHED AREA: Indentations or flattened sections on the O-ring.
• FOREIGN MATERIAL: Presence of metal fragments, resin fragments, lint, or hair on the O-ring.
• TWIST: The O-ring is twisted or deformed from its original shape.

Sealing Surface Abnormalities (O-ring Attachment Area)

For the O-ring attachment area, "OK CONDITION" means that processing evidence in the circumferential direction is NOT a cause of leakage. Abnormalities include:

• FOREIGN MATERIAL: Metal fragments, resin fragments, lint, or hair on the sealing surface.
• DAMAGE: Physical damage to the sealing surface.
• CORROSION: White and yellow materials adhered (corrosion product), scratches in the axial direction, or black discoloration.

Sealing Surface Abnormalities (Part Joint Area)

For the part joint area, "OK CONDITION" also means that processing evidence in the circumferential direction is NOT a cause of leakage. Abnormalities include:

• FOREIGN MATERIAL: Metal fragments, resin fragments, lint, or hair on the joint surface.
• DAMAGE: Physical damage to the joint surface.
• CORROSION: Uneven discoloration (black) on the sealing surface.

Owner Action

If you experience symptoms of an AC refrigerant leak, such as your Toyota Camry AC blowing warm air, it is recommended to have your vehicle inspected by a qualified technician. While this TSB provides repair guidance, it is not a recall, and warranty coverage for the repair may vary. Prompt diagnosis and repair can prevent further damage to your AC system.

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NHTSA ID: T-SB-0058-23