FORD MUSTANG 2003 Workshop Manual

system discharge pressures.
zThe dual- function pressure switch is mounted on a Schrader valve- type fitting on the high
pressure side of the A/C manifold and tube.
z It is not necessary to discharge the refrigerant system to remove the dual- function pressure
switch.
z A valve depressor, located inside the threaded end of the dual- function pressure switch,
presses on the Schrader valve stem.
z This allows the dual- function pressure switch to monitor the compressor discharge pressure.
z When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C
compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. For specifications regarding operating pressure(s), refer to Section 412 - 00 .
The dual- function pressure switch has a second set of electrical contacts used for high- speed cooling
fan control.
zWhen the compressor discharge pressure rises, the contacts close and engage the high speed
fan control. When the pressure drops, the contacts open and the high speed fan control is
disengaged.
Refrigerant Containment Switch (3.8L)
The refrigerant containment switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
zThe refrigerant containment switch is mounted on a Schrader- type valve fitting on the high
pressure side of the compressor manifold and tube assembly.
z A valve depressor, located inside the threaded end of the refrigerant containment switch,
presses on the Schrader valve stem.
z This allows the refrigerant containment switch to monitor the A/C compressor discharge
pressure.
z When the A/C compressor discharge pressure rises, the switch contacts open, disengaging the
A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. For additional information regarding operating pressure(s), refer to Section 412 -
00 .
z It is not necessary to discharge the refrigerant system to remove the refrigerant containment
switch.
Spring Lock Coupling Item Part Number Description
1 — Plastic indicator ring (part of 19D690) Klj . 8 ba
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The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular
cage.
zWhen the coupling is connected together, the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
z The garter spring and cage then prevent the flared end of the female fitting from pulling out of
the cage.
z Three O- ring seals are used to seal between the two halves of the A/C condenser core
couplings. All other couplings have two O- ring seals.
z Use only the O- ring seals listed in the Ford Master Parts Catalog for the spring lock coupling.
z A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to
indicate, during vehicle assembly, that the coupling is connected. Once the coupling is
connected, the indicator ring is no longer necessary but will remain captive by the coupling near
the cage opening.
z The indicator ring may also be used during repair operations to indicate connection of the
coupling.
z An A/C tube lock coupling clip (19E746) may be used to secure the coupling but is not required.
Service Gauge Port Valves
The high- pressure service gauge port valve is located on the A/C manifold and tube.
The low pressure service gauge port valve is located on the suction accumulator. 2 — Female fitting (part of 19860)
3 19E746 A/C tube lock coupling clip
4 19E576 A/C tube lock coupling spring
5 — Cage (part of 19D690)
6 — O-
ring seals (part of 19D690) 7 — Male fitting (part of 19835)
Item Part
Number Description
1 19D702 A/C charging valve cap
2 19D701 Low pressure service gauge port valve (part of
19C836)
3 19D701 Schrader-
type valve 4 — O-
ring seal (part of 19D701) 5 19D701 High pressure service gauge port valve (part of Klj . 9 ba
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The fitting is an integral part of the refrigeration line or component.
zSpecial couplings are required for both the high side and low side service gauge ports.
z A new Schrader- type valve core can be installed if the seal leaks.
z Always install the A/C charging valve cap (19D702) on the service gauge port valves after
repairing the refrigerant system. 19D734)
6 19D702 A/C charging valve cap Klj . 10 ba
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DIAGNOSIS AND TESTING
Air Conditioning
Refer to
Section 412 - 00 .
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
3.8L
Removal and Installation CAUTION: If installing a new air conditioning compressor due to an internal failure of the
old unit, you must carry out the following procedures to remove contamination from the air
conditioning system.
zIf A/C flushing equipment is available, carry out the flushing of the air conditioning
system prior to installing a new air conditioning compressor. For additional information,
refer to Section 412 - 00 .
z If A/C flushing equipment is not available, carry out filtering of the air conditioning
system after a new air conditioning compressor has been installed. For additional
information, refer to Section 412 - 00 .
z Install a new evaporator core orifice (19D990), as directed by the A/C flushing or filtering
procedure.
z Install a new suction accumulator (19C836), as directed by the A/C flushing or filtering
procedure.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C compressor
or damage to the suction accumulator.
1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Disconnect the battery. For additional information, refer to Section 414 - 01
3. Unlatch the air breather.
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
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4. Disconnect the mass airflow (MAF) sensor electrical connector.
5. Remove the air cleaner outlet tube (9B659).
1. Loosen the clamp.
2. Disconnect the crankcase ventilation tube (6758).
3. Remove the air cleaner outlet tube assembly.
6. Remove the drive belt (8620) from the A/C compressor pulley.
7. Disconnect the electrical compressor clutch connector.
8. Remove the bolt and disconnect the A/C manifold and tube (19D734). zDiscard the O- ring seals. Klj . 2 ba
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9. Remove the bolts and the A/C compressor.
10. To install, reverse the removal procedure. zInstall new O- ring seals lubricated in clean PAG oil.
z If filtering of the refrigerant system is not to be performed, lubricate the refrigerant system
with the correct amount of clean PAG oil. For additional information, refer to Section 412 -
00 .
11. If filtering of the air conditioning system is not to be performed, evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 3 ba
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Klj . 4 ba
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
4.6L
Removal and Installation CAUTION: If installing a new air conditioning compressor due to an internal failure of the
old unit, you must carry out the following procedures to remove contamination from the air
conditioning system.
zIf A/C flushing equipment is available, carry out the flushing of the air conditioning
system prior to installing a new air conditioning compressor. For additional information,
refer to Section 412 - 00 .
z If A/C flushing equipment is not available, carry out filtering of the air conditioning
system after a new air conditioning compressor has been installed. For additional
information, refer to Section 412 - 00 .
z Install a new evaporator core orifice (19D990), as directed by the A/C flushing or filtering
procedure.
z Install a new suction accumulator (19C836), as directed by the A/C flushing or filtering
procedure.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C compressor
or damage to the suction accumulator.
1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Remove the drive belt from the A/C compressor pulley.
3. Raise the vehicle. For additional information, refer to Section 100 - 02 .
4. Disconnect the A/C compressor electrical connector. SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
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5. Remove the bolt and detach the manifold and tube assembly.
6. Remove the compressor.
1. Remove the bolts.
2. Remove the compressor.
7. To install, reverse the removal procedure. zInstall new O- ring seals lubricated in clean PAG oil.
z If filtering of the refrigerant system is not to be performed, lubricate the refrigerant system
with the correct amount of clean PAG oil. For additional information, refer to Section 412 -
00 .
8. If filtering of the refrigerant system is not to be performed, evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 2 ba
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