lock FORD MUSTANG 2003 Workshop Manual

GENERAL PROCEDURES
Heater Hose Coupling
Disconnect
CAUTION: Do not attempt to install a new bushing, spacer or O- rings in the heater hose
coupling; damage to the heater hose coupling can result. If the heater hose coupling is the
cause of a coolant leak, the affected heater hose must be replaced as an assembly.
1. WARNING: The engine must be off, fully cool and the cooling system fully
depressurized before attempting to disconnect any heater water hoses. Failure to comply
with this warning can result in serious injury or burns from hot liquid escaping out of the
engine cooling system.
Depressurize the engine cooling system.
2. Push the heater hose toward the tube to fully expose the locking tabs.
3. NOTE: When compressing the white coupling retainer with the special tool, the special tool
must be perpendicular to and on the highest point of the coupling.
NOTE: If the heater hose coupling is accessible, the retainer tabs can be compressed by hand
to disconnect the heater hose.
Push the special tool over the coupling retainer windows to compress the retainer locking tabs.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Remover, Heater Hose Inlet
Tube
412-
042 (T85T-18539- AH) Disconnect Tool, Heater Hose
412-
127
Material Item Specification
MERPOL®
—
ESE-
M99B144- B Klj . 1 ba
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GENERAL PROCEDURES
Manifold Gauge Set Connection
1. Turn both valves on the R- 134a Manifold Gauge Set clockwise to close the low- and high-
pressure hoses to the center manifold and center hose.
2. Remove the A/C charging valve cap (19D702) from the low- pressure service gauge port valve.
3. Remove the A/C charging valve cap from the high- pressure service gauge port valve.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a Manifold Gauge Set
176- R032A or equivalent Klj . 1 ba
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z
A one- piece lip- type seal (installed from the front of the A/C compressor) is used to seal it at the
shaft opening in the assembly.
z Five double- acting pistons operate within the cylinder assembly. The pistons are actuated by a
swashplate that converts the rotating action of the shaft to a reciprocating force.
z Reed- type discharge valves are located between the cylinder assembly and the head at each
end of the A/C compressor.
z The A/C compressor uses PAG oil, or equivalent. This oil contains special additives required for
the A/C compressor.
z The A/C compressor oil from vehicles equipped with an FS- 10 A/C compressor may have some
dark colored streaking while maintaining a normal oil viscosity. This is normal for the A/C
compressor and is caused by break- in wear of the piston rings.
The magnetic A/C clutch has the following characteristics: zIt drives the compressor shaft.
z When the battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch plate and
hub assembly is drawn toward the A/C clutch pulley.
z The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together
as one unit, causing the compressor shaft to rotate.
z When (B+) is removed from the A/C clutch field coil, springs in the clutch plate and hub
assembly move the clutch plate away from the A/C clutch pulley. A/C Compressor Pressure Relief Valve Item Part Number Description
1 19D798 A/C clutch field coil
2 19D784 A/C clutch pulley
3 N805338-S2 Pulley snap ring
4 19D648 A/C clutch hub spacer
5 19D786 Disk and hub assembly
6 N805332-S2 A/C clutch bolt Klj . 3 ba
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The suction accumulator (19C836) is mounted to the A/C accumulator bracket (19D606) to the right of
the vehicle centerline. The inlet tube of the suction accumulator attaches directly to the A/C evaporator
core outlet tube and the outlet tube attaches to the A/C manifold and tube.
After entering the inlet of the suction accumulator, the heavier oil-
laden refrigerant contacts an
internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the
canister.
zA small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated
heavier liquid refrigerant and oil mixture to reenter the compressor suction line at a controlled
rate.
z As the heavier mixture passes through the small diameter liquid bleed hole, it has a second
chance to vaporize and recirculate through the A/C compressor without causing compressor
damage due to slugging.
z A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out
refrigerant system contaminant particles.
z A desiccant bag is mounted inside the canister to absorb any moisture which may be in the
refrigerant system.
z A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A
long- travel Schrader- type valve stem core is installed in the fitting so that the A/C cycling switch
can be removed without discharging the A/C system.
A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader- type valve fitting on the top of the suction
accumulator.
zA valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
z This allows the suction pressure inside the suction accumulator to control the operation of the
A/C cycling switch.
z The electrical switch contacts open when the suction pressure drops. The contacts close when
the suction pressure rises. For specifications regarding operating pressure(s), refer to Section 412 - 00 .
z The A/C cycling switch will control the A/C evaporator core pressure at a point where the
plate/fin surface temperature will be maintained slightly above freezing.
z This prevents icing of the A/C evaporator core and blockage of air flow.
z It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Dual- Function Pressure Switch (4.6L)
The dual- function pressure switch is used to interrupt A/C compressor operation in the event of high Klj . 7 ba
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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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10. Turn the tool handle clockwise to expand the tool tip inside the shaft seal.
11. Pull the seal from the A/C compressor.
Installation 1. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other
foreign materials to enter the A/C compressor.
Clean the A/C compressor nose area.
2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent.
3. Position the shaft seal and the special tool over the A/C compressor shaft. Klj . 4 ba
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REMOVAL AND INSTALLATION
Suction Accumulator
Removal and Installation
1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Disconnect the A/C cycling switch electrical connector.
3. Remove the cycling switch.
4. Disconnect the suction line spring lock coupling. zDiscard the O- ring seals.
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. Disconnect the refrigerant containment switch (RCS) electrical connector.
6. Remove the RCS.
7. Remove the nut and disconnect A/C fitting.
zDiscard the O- ring seal.
8. Disconnect the spring lock coupling. zDiscard the O- ring seals. Klj . 2 ba
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REMOVAL AND INSTALLATION
Compressor Manifold and Tube Assembly —
4.6L
Removal and Installation
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Disconnect the suction line spring lock coupling. zDiscard the O- ring seals.
3. Remove the A/C muffler bracket nut.
4. Disconnect the spring lock coupling. zDiscard the O- ring seals.
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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