Service bulletin LI83.30-P-077763

A bulletin is a manufacturer's communication to its dealers, as NHTSA indexes it. The summary is NHTSA's. The document is the manufacturer's: read it at NHTSA. A bulletin is not a recall, and listing a model year does not mean every vehicle of it is concerned.

NHTSA's summary

Complaint Customer concern of Air Conditioning not cooling. *NOTE - Use of tracer DYE for leak checks is not approved. Only approved leak check procedures as per WIS are approved. Cause Possible refrigerant leak. Remedy Perform the following measures : *Important* - Photo documentation requirement is no longer in effect as of 10/1/2025. Remedy 1: Replace Evaporator (Only applies to vehicles produced PRIOR to April 15, 2022 and has NOT had the evaporator replaced previously) 1. Ensure that the rest of the AC system has been thoroughly checked for leaks with forming gas as per WIS before condemning the evaporator. 2. If no other leaks are found, replace the evaporator Note - *If the evaporator housing has been opened or the evaporator or housing has been tampered with, the claim will be debited. Remedy 2: (Applies to all vehicles produced on or AFTER April 15, 2022 up to August 1, 2025) 1. Ensure that the entire AC system has been thoroughly checked for leaks with forming gas as per WIS . 2. If no leaks were found AND the system came in with no cooling/low charge, OR the evaporator is suspected of leaking: 3. Replace ONLY the expansion valve bracket, seals, and bolts as supplied in kit A 167 832 47 00, in accordance with the procedure outlined in WIS document AR83.30-P-5520ME. 4. IF THE PRODUCTION DATE IS BETWEEN JUNE 1, 2023 AND JULY 1, 2024, REPLACE THE DRYER AS WELL. (NOT THE CONDENSER) 5. After, charge the system and perform a few drive cycles. 6. Recheck the vehicle for leaks. 7. If no leaks are found, the vehicle can be released. 8. If a minor leak is detected that is less than 50ppm, then perform the following steps: • If a leak is detected, fill the system with forming gas • Close all doors and windows for 10 minutes. • Vehicle off with no blower activation. • Open the driver's door and measure ppm detection as soon as the door is open and the sniffer goes into the vehicle. • If no leaks are measured, fill the system and release. Remedy 3: (Only applies to vehicles produced AFTER August 1, 2025) Ensure that the entire AC system has been thoroughly checked for leaks with forming gas as per WIS . If no leaks are found or the expansion valve has been found to be leaking, remove the expansion valve and check the bracket. If the bracket is bent, replace the expansion valve bracket, seals, and bolts as supplied in kit A 167 832 47 00. In the warranty submission, include photos of both sides of the bracket and a side profile so it can be seen that the bracket is bent. If the bracket is NOT bent or leaks from other locations are found, then open a TIPS case with the following: 1. Initial Quick Test 2. Create a short video of the actual pressures via AC machine, showing the engine running, and hold a copy of the VIN/RO in view as well. 3. OBS recording of XENTRY AC actual values of compressor request to be on and current value. (Instructions in Attachments) 4. Video recording of the leak being found via sniffer at the R/F AC drain after removing the under dash panel if the evaporator is suspected. (see attached videos) 5. If the evaporator is found to be leaking via sniffer, another video needs to be uploaded (or a continuation if only making the video after checks), showing the expansion valve being checked for leaks. 6. If no leaks are found with the sniffer at the expansion valve, spray soapy water mix on the expansion valve and check for leaks. Upload a video showing the spray test and VIN. 7. Provide photos of both sides of the bracket and a side profile so it can be seen that the bracket is not bent. 8. Open a TIPS case in the HV/LV inbox labeled "167 AC leak after April 1, 2025" with all attachments. NOTE: (Applies to all 167's) • Please see the list of WIS documents for forming gas leak check and recharging of the system. • Review PCTT 9/25 for forming gas best practices. • Review PCTT 5/25 for bracket removal best practices. See attachment for further instructions.

The document

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Components

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