climate control FORD MUSTANG 2003 Owner's Manual

GENERAL PROCEDURES
Air Conditioning Line (Peanut) Fitting
Disconnect
1. CAUTION: Support the female fitting with a wrench to prevent the tubes from
twisting.
Remove the nut from the peanut fitting.
2. Pull the peanut fitting apart.
3. CAUTION: Do not use metal tools to remove the O- ring seal. They can cause axial
scratches across the O- ring seal groove, resulting in refrigerant leaks.
Remove the O- ring seal with a non- metallic tool.
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GENERAL PROCEDURES
Refrigerant System Tests
1. Connect the R- 134a Manifold Gauge Set. For additional information, refer to Manifold Gauge Set Connection in this section.
2. Adjust the climate controls for maximum cooling. zStart the engine.
z Select MAX A/C operation.
z Set the blower motor speed to maximum.
3. Stabilize the in- vehicle temperature at 21- 27°C (70-80°F).
4. NOTE: When the ambient temperatures exceed 38°C (100°F), do not run the engine above
normal idle speed.
Maintain the engine speed at 1,500 rpm.
5. Determine the compressor discharge (high) pressure. 1. Record the ambient temperature.
2. Record the discharge (high) pressure.
3.NOTE: In ambient temperatures between 38- 43°C (100-110°F), the system performance
pressures will be the same as those for ambient temperatures shown on the chart in the
32- 38°C (90- 100°F) range.
The system performance is acceptable when the pressure reading falls between the
upper and lower limits shown.
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
42003 Mustang Workshop Manual
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GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment
1. Check the A/C clutch air gap at three equally- spaced places between the A/C clutch hub (2884)
and the A/C clutch pulley (2E884).
2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. For additional information, refer to Section 412 - 03 .
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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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GENERAL PROCEDURES
Electronic Leak Detection
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to
be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will
indicate this gas all the time. Odors from other chemicals such as anti- freeze, diesel fuel, disc
brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-
ventilated area, is very helpful in removing small traces of contamination from the air that
might affect the leak detector.
1. NOTE: The system pressure should be between 413- 551 kPa (60-80 psi) at 24°C (75°F) with
the engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
z Repair the system.
z Test the system for normal operation.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
H10PM Refrigerant Leak
Detector With Battery
216-
00001 or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Tracer Dye Leak Detection
NOTE:
Ford Motor Company vehicles are produced with a permanent leak tracer dye incorporated into
the A/C system. The location of leaks can be pinpointed by the bright yellow- green glow of the tracer
dye. Since more than one leak can exist, always inspect each component.
1. Check for leaks using a 120 Watt UV spot lamp. zScan all components, fittings and lines of the A/C system.
2. After the leak is repaired, remove any traces of tracer dye with a general purpose oil solvent.
3. Verify the repair by operating the system for a short time and inspect with the UV spot lamp.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
120 Watt 110 Volt UV Lamp
20°C
164-
R0721 or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Flushing
WARNING: Use extreme care and observe all safety and service precautions related to the
use of refrigerants.
WARNING: Due to refrigerant hazards, always wear safety goggles and non- penetrable
gloves when working on or flushing A/C systems.
CAUTION: An A/C refrigerant analyzer must be used before the recovery of any vehicle's
A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the
vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated
A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the
equipment manufacturer's procedures and instructions.
CAUTION: Suction accumulator/drier, muffler, hoses, thermal expansion valve, and fixed
orifice tube should be removed when flushing the A/C system. Internal plumbing of these
devices makes it impossible to correctly remove any residual- flushing agent. Except for the
hoses, these components are typically discarded after A/C system contamination. Hoses can
normally be reused unless they are clogged with foreign material. The 3.785 liters (1 gallon) of
A/C Systems Flushing Solvent F4AZ-19579- A and FL1-A filter used in A/C Flush and Purge
Machine 219- 00022 are intended for use on one vehicle only. They may be used to flush both
the A/C condenser core and the A/C evaporator core on an individual vehicle, but under no
circumstances should they be used on more than one vehicle.
1. NOTE: Prior to using the A/C Flush and Purge Machine 219- 00022 for the first time, review the
operating instructions.
NOTE: Only the A/C Flush and Purge Machine kit 219- 00023, which includes A/C Flush and
Purge Machine 219- 00022, A/C Flush and Purge Fitting Kit 219- 00024, and the Ford Part
number F4AZ-19579- A A/C Systems Flushing Solvent, is approved for use on Ford vehicles. No
other flushing device or solvent is approved for flushing heat exchangers. Use of any other
flusher or solvent may cause damage to the A/C system and the flushing unit.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
A/C Flush and Purge Machine
219-
00022 (part of 219- 00023)
or equivalent A/C Flush and Purge Fitting Kit
219-
00024 (part of 219- 00023)
or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and
Charging
Refrigerant System Recovery
NOTE:
Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant
system recovery, evacuation, and charging may be accomplished using a separate recovery station,
vacuum pump, charging cylinder, and manifold gauge set.
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing in this section.
2. NOTE: Some R- 134a service centers require the use of an A/C manifold gauge set. For
additional information, refer to Manifold Gauge Set Connection in this section.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a A/C Refrigerant Center
176- 00002 or equivalent R-
134a A/C Refrigerant Center
023- 00153 or equivalent R-
134a Manifold Gauge Set
176- R032A or equivalent 1.2 CFM Vacuum Pump
023-
00162 or equivalent 4.0 CFM Vacuum Pump
023-
00163 or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Refrigerant System Filtering Following Air Conditioning
(A/C) Component Installation
1. Install the new A/C compressor. For additional information, refer to Section 412 - 03 .
2. Install the new suction accumulator/drier. For additional information, refer to Section 412 - 03 .
3. Install the new A/C evaporator core orifice. For additional information, refer to Section 412 - 03 .
4. Orient the filter inlet toward the A/C condenser core.
5. NOTE: The pancake filter is not permanently installed and will be removed at the end of this
procedure.
Temporarily install the pancake filter between the A/C condenser core and the condenser to
evaporator tube. 1. Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating.
2. Make the connections using the A/C Test Fitting Set.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Set, A/C Fittings
412-
DS028 (014- 00333, D93L-
19703- B) or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Refrigerant Oil Adding
CAUTION: During normal A/C operation, oil is circulated through the system with the
refrigerant, and a small amount is retained in each component. If certain components of the
system are removed for new installation, some of the refrigerant oil will go with the component.
To maintain the original total oil charge, it is necessary to compensate for the oil lost by adding
oil to the system with the new part.
1. NOTE: Service A/C compressors are shipped without compressor oil.
Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring
device. zIf the amount of oil drained from the old A/C compressor is between 85- 142 ml (3-5
ounces), pour the same amount plus 30 ml (1 ounce) of clean PAG Refrigerant
Compressor Oil (R-134a Systems) F7AZ-19589- DA (Motorcraft YN-12-C) WSH M1C231-
B or equivalent into the new A/C compressor.
z If the amount of oil that was removed from the old A/C compressor is greater than 142 ml
(5 ounces), pour the same amount drained of clean PAG Refrigerant Compressor Oil (R-
134a Systems) or equivalent into the new A/C compressor.
z If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3
ounces), pour 85 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R- 134a
Systems) or equivalent into the new A/C compressor.
2. For the suction accumulator/drier, drill one 13 mm (0.52 in) hole in the suction accumulator/drier cylinder and drain the oil into a calibrated container.
zAdd a quantity of new oil to match that drained from the old suction accumulator/drier
plus 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R- 134a Systems) or
equivalent.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent to the suction accumulator/drier inlet tube.
4. For the A/C condenser core, add 30 ml (1 ounce) of clean PAG Refrigerant Compressor Oil (R- 134a Systems) or equivalent to the A/C condenser core or the suction accumulator/drier inlet
tube.
5. Add 60 ml (2 ounces) of clean PAG Refrigerant Compressor Oil (R- 134a Systems) or equivalent
to the suction accumulator/drier inlet tube when carrying out each of the following repairs:
zinstallation of a new A/C evaporator core orifice
z installation of a new A/C compressor pressure relief valve (19D644)
z installation of a new refrigerant line
z repair of an O- ring seal leak
z repair of a charge port leak
6. Installation of new components that do not require discharge of refrigerant and resulting oil loss, such as the A/C cycling switch and the A/C pressure transducer, do not require additional oil.
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