Compressor FORD KUGA 2011 1.G Repair Manual

SECTION 412-01 Climate Control
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
412-01-3
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 412-01-4
Climate Control (Component Location) ........................................................................\
......
412-01-10
Climate Control (Overview) ........................................................................\
........................
412-01-10
Pollen filter ........................................................................\
..................................................
412-01-10
Heat exchanger ........................................................................\
..........................................
412-01-10
Evaporator assembly ........................................................................\
..................................
412-01-10
Blower motor ........................................................................\
..............................................
412-01-11
Fault Memory Interrogation without diagnostics unit - vehicles with automatic temperature
control ........................................................................\
.......................................................
412-01-11
Switch over from Celsius to Fahrenheit ........................................................................\
......
412-01-12
Climate Control (System Operation and Component Description) .....................................
412-01-12
System Diagram ........................................................................\
.........................................
412-01-19
System Operation ........................................................................\
.......................................
412-01-19
Climate control housing ........................................................................\
..........................
412-01-22
Climate control ........................................................................\
........................................
412-01-24
Component Description ........................................................................\
..............................
412-01-24
Air conditioning compressor ........................................................................\
...................
412-01-24
Pollen filter ........................................................................\
..............................................
412-01-24
Control assembly, climate control - vehicles with manual temperature control ..............
412-01-25
Control assembly, climate control - vehicles with automatic temperature control ...........
412-01-25
Control assembly, climate control - vehicles with DVD navigation system with a touch
screen........................................................................\
................................................... 412-01-25
Climate control module - vehicles with DVD navigation system with a touch screen.....
412-01-25
Sun sensor - vehicles with automatic temperature control .............................................
412-01-26
In-vehicle temperature sensor ........................................................................\
................
412-01-26
Ambient temperature sensor ........................................................................\
..................
412-01-26
Blower motor ........................................................................\
...........................................
412-01-26
Blower control module - vehicles equipped with automatic temperature control ............
REMOVAL AND INSTALLATION 412-01-28
(34 626 4)
Air Conditioning (A/C) Compressor — 2.5L Duratec (147kW/200PS) - VI5 ....
412-01-29
Air Conditioning (A/C) Compressor to Condenser Discharge Line .....................................
412-01-30
Air Conditioning (A/C) Compressor to Condenser Discharge Line — 2.5L Duratec
(147kW/200PS) - VI5 ........................................................................\
................................
412-01-31
Condenser ........................................................................\
..................................................
412-01-35
Clutch and Clutch Field Coil........................................................................\
.......................
412-01-36
Pollen Filter — RHD........................................................................\
...................................
412-01-37
(34

374 0)
Blower Motor — RHD ........................................................................\
.............
412-01-40
(34 382 0)
Blower Motor Resistor — Vehicles With: Manual Temperature Control, RHD .
412-01-41
(34 382 0)
Blower Motor Resistor — Vehicles With: Dual Automatic Temperature
Control ........................................................................\
..................................
412-01- 1
Climate Control
412-01- 1
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PAGE 1 OF 2 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

412-01-42
Heater Core and Evaporator Core Housing .......................................................................
412-01-45
(34 364 0)
Heater Core — RHD ........................................................................\
...............
412-01-53
Suction Accumulator ........................................................................\
...................................
412-01-56
Suction Accumulator to Air Conditioning (A/C) Compressor Line ......................................
412-01-57
Suction Accumulator to Air Conditioning (A/C) Compressor Line — 2.5L Duratec
(147kW/200PS) - VI5 ........................................................................\
................................
412-01-58
Low-Pressure Cutoff Switch ........................................................................\
.......................
412-01-59
High-Pressure Cutoff Switch ........................................................................\
.......................
412-01-60
Evaporator ........................................................................\
..................................................
412-01-62
Evaporator Outlet Line ........................................................................\
................................
412-01-65
Evaporator Core Orifice ........................................................................\
..............................
412-01-68
Condenser to Evaporator Line........................................................................\
....................
412-01-71
(34 300 0)
Climate Control Assembly — Vehicles With: Manual Temperature Control ....
412-01-72
(34 300 0)
Climate Control Assembly — Vehicles With: Automatic Temperature Control .
412-01-73
(34 485 4)
Footwell Air Discharge Temperature Sensor ..................................................
412-01-74
Center Register Air Discharge Temperature Sensor ..........................................................
412-01-75
In-Vehicle Temperature Sensor ........................................................................\
..................
412-01-76
(34 676 0)
Ambient Air Temperature Sensor ...................................................................
412-01-77
(34 665 0)
Sunload Sensor ........................................................................\
......................
412-01-78
(34 591 0)
Footwell Vent/Duct Blend Door Actuator — RHD ...........................................
412-01-79
(34 606 0)
Air Inlet Blend Door Actuator ........................................................................\
..
412-01-80
(34 608 0)
Driver Side Temperature Blend Door Actuator ...............................................
412-01-81
(34 608 0)
Passenger Side Temperature Blend Door Actuator .......................................
412-01-82
(34 591 0)
Defrost Vent/Register Blend Door Actuator — RHD ......................................
412-01-2
Climate Control
412-01- 2
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A/C compressor
Description
Visteon VS16
A/C compressor (vehicles with 2.0L Duratorq-TDCi (DW 10) engines)
Zexel KC88
A/C compressor (vehicles with 2.5L Duratec-ST (VI5) engine)
G1158274en2008.50 Kuga8/2011
412-01- 3
Climate Control
412-01- 3
SPECIFICATIONS
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Climate control
32
1
4
5
6
789
E97591
Description
Item
Condenser
1
Air conditioning compressor
2
High pressure filling connection
3
Refrigerant drier
4Description
Item
Dual pressure switch
5
Low pressure filling connection
6
Low pressure limiting switch
7
Evaporator Core Orifice Tube
8
Evaporator assembly
9
G1034943en2008.50 Kuga8/2011
412-01- 7
Climate Control
412-01- 7
DESCRIPTION AND OPERATION
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Air conditioning system - vehicles with manual temperature control
18
6
7
3
9
2
5
4
E97576
HS-CAN
MS-CAN
Description
Item
Air conditioning compressor
1
Climate control system control assemblyRefer to Component Description: Control
assembly, climate control - vehicles with
manualtemperaturecontrol(page24)
2
Genetic electronic module (GEM).
3Description
Item
Ambient air temperature sensorRefer to Component Description:
Ambienttemperaturesensor(page26)
4
instrument cluster
5
High pressure limiting switch
6
Dual pressure switch
7
G1034947en2008.50 Kuga8/2011
412-01- 17
Climate Control
412-01- 17
DESCRIPTION AND OPERATION
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Description
Item
Powertrain control module (PCM)
8Description
Item
9 Air conditioning clutch relay
Air conditioning system - vehicles with automatic temperature control
18
6
7
3
9
5
2
4
E97577
HS-CAN
MS-CAN
MS-CAN
Description
Item
Air conditioning compressor
1
Climate control system control assemblyRefer to Component Description: Control
assembly, climate control - vehicles with
automatictemperaturecontrol(page25)
2Description
Item
Genetic electronic module (GEM).
3
Ambient air temperature sensorRefer to Component Description:
Ambienttemperaturesensor(page26)
4
instrument cluster
5
G1034947en2008.50 Kuga8/2011
412-01- 18
Climate Control
412-01- 18
DESCRIPTION AND OPERATION
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1
2
3
5
4
67
8
9
10
11
E100819
Description
Item
Condenser
1
Air conditioning compressor
2
Suction accumulator
3
Evaporator assembly
4
Blower motor
5Description
Item
Evaporator Core Orifice Tube
6
Cooling fans.
7
High - pressure (liquid and warm)
8
Low - pressure (liquid and cool)
9
Low pressure (gaseous and cold)
10
High pressure (gaseous and hot)
11
The engine driven refrigerant compressor (2) sucks
in gaseous refrigerant from the suction accumulator
and compresses it. The temperature of the
refrigerant rises to a value between 70 °C and 110
°C. It passes to the condenser (1) under high
pressure.
At this point heat is drawn from the refrigerant by
the air being forced past the cooling fins. Because
of this heat loss, the refrigerant liquefies and leaves
the condenser.
A fixed orifice tube (6), which separates the
refrigerant at high pressure from that at low
pressure, is located between the condenser and
the evaporator (5). This fixed orifice tube slows
down the flow of the refrigerant from the compressor, so that pressure builds up in the
condenser.
After passing through the fixed orifice tube the
liquid refrigerant expands in the circuit to the
evaporator, where it becomes gaseous. This
causes heat to be extracted from the air coming
into the vehicle. The air cools down, and excess
moisture contained in it is condensed and is
drained off. The refrigerant coming from the
evaporator flows into the refrigerant accumulator
and is again sucked in by the refrigerant
compressor.
The system is protected by a high-pressure limiting
switch, in order to prevent damage by excessive
pressure (e.g. because of overfilling with
refrigerant). If the pressure exceeds the maximum
G1034947en2008.50 Kuga8/2011
412-01-
23
Climate Control
412-01- 23
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permitted, the high-pressure switch turns off the
refrigerant compressor.
The compressor on-off cycle is controlled by the
dual pressure switch depending on the pressure
in the refrigerant accumulator. The dual pressure
switch turns the refrigerant compressor off
permanently if the pressure falls below a permitted
value (e.g. if there is a leak).
Component Description
Air conditioning compressor
E100826
The special feature of a compressor with variable
swash plate is that the stroke of the pistons can
be varied by means of the variable swash plate.
The swash plate is mounted on a slide rail in the
axial direction.
The piston stroke and thus the delivery rate are
determined by means of the variable obliqueness
of the swash plate.
The obliqueness of the swash plate is dependent
upon the chamber pressure and thus on the
pressure conditions at the top and bottom of the
piston. This is supported by springs in front of and
behind the swash plate.
The chamber pressure is determined by the high
and low pressure applied to the control valve and
by a calibrated orifice bore. If the low pressure is
relatively high, the control valve is opened and the
chamber pressure is reduced.
If the low pressure is relatively low, the control
valve is closed and the chamber pressure is
increased. The force due to the chamber pressure
exerted on the piston bottom, is higher than the
sum of the force due to the low pressure on the
piston top and the spring force.
Pollen filter
E97720
The fresh air flowing into the vehicle through the
air inlet housing passes through a pollen filter which
is located on the left-hand side of the climate
control housing (LHD and RHD) and removes
pollen and dust particles measuring 0.003 mm or
more.
Control assembly, climate control -
vehicles with manual temperature control
E97721
In vehicles with manual temperature control, the
heating and air conditioning are operated using
three rotary switches. The air distribution flaps are
actuated via the air distribution flap/temperature
control flap actuating unit, which is connected via
a rod to the control assembly for the climate
control. The temperature control flap is also
actuated via the air distribution flap/temperature
control flap actuating unit, which is connected via
a cable to the control assembly. In addition, the
operating switch for recirculated air mode and the
on/off switch for the air conditioning are located on
the control assembly.
G1034947en2008.50 Kuga8/2011
412-01-24
Climate Control
412-01- 24
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Air Conditioning (A/C) Compressor — 2.5L Duratec(147kW/200PS) - VI5(34 626 4)
Materials
Specification
Name
WSH-M1C231-B /
6U7J-M1C231-AA
Compressor Oil - Air
Conditioning
Removal
NOTE:
Removal steps in this procedure may
contain installation details. 1.
Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
2. Refer to: Air Conditioning (A/C) Compressor
Belt (303-05 Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
3. CAUTION: Make sure that all openings are sealed.
2. Torque: 20Nm
3. Torque: 25Nm
E112667
1
2
3
2
33
Installation
1.To install, reverse the removal procedure.
2. Coat the O-ring seals on the refrigerant lines.
Material: Compressor Oil - Air Conditioning
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
G1158270en2008.50 Kuga8/2011
412-01- 28
Climate Control
412-01- 28
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Air Conditioning (A/C) Compressor to Condenser Discharge Line
MaterialsSpecification
Name
WSH-M1C231-B /
6U7J-M1C231-AA
Compressor Oil - Air
Conditioning
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
2. CAUTION: Make sure that all openings are sealed. Use new blanking caps.
Torque: 8Nm
E101235
3.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E98183
5. CAUTION: Make sure that all openings are sealed. Use new blanking caps.
Torque: 20Nm
E101236
Installation
1.To install, reverse the removal procedure.
2. Coat the O-ring seals on the refrigerant lines.
Material: Compressor Oil - Air Conditioning
(WSH-M1C231-B / 6U7J-M1C231-AA)
refrigerant oil
G1068631en2008.50 Kuga8/2011
412-01- 29
Climate Control
412-01- 29
REMOVAL AND INSTALLATION
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