FORD MUSTANG 2003 Workshop Manual

Assembly
1. To assemble, reverse the disassembly procedure. Klj . 4 ba
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SPECIFICATIONS
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricant
PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-
DA (MC YN-12-
C) WSH-
M1C231-
B
Torque Specifications Description Nm lb-
ft lb-
in A/C compressor mounting bolts 25 18 —
A/C manifold retaining bolt 20 15 —
3.8L engine A/C compressor mounting bracket bolts 47 35 —
3.8L engine A/C compressor mounting bracket nut 25 18 —
A/C compressor clutch retaining bolt 13 10 —
Suction accumulator/drier clamp screw 8 — 71
Coolant bottle bolts 10 — 89
Peanut fittings 8 — 71
Radiator bracket bolts 9 — 81
Condenser core bracket bolts 5 — 44
A/C muffler bracket nut 25 18 — Klj . 1 ba
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Klj . 2 ba
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DESCRIPTION AND OPERATION
Air Conditioning
The A/C refrigerant system is a clutch cycling orifice tube type. The system components are:
zA/C compressor (19703)
z A/C clutch (2884)
z A/C condenser core (19712)
z A/C evaporator core (19860)
z suction accumulator (19C836)
z connecting refrigerant lines
The refrigeration system operation is controlled by the:
zA/C evaporator core orifice (19D990).
z A/C cycling switch (19E561).
z A/C compressor pressure relief valve (19D644).
z Refrigerant containment switch (3.8L) (19D594).
z Dual- function pressure switch (4.6L) (19D594).
The refrigerant system incorporates an A/C compressor controlled by an A/C cycling switch.
The A/C cycling switch senses A/C evaporator core pressure to control A/C compressor operation.
An A/C compressor pressure relief valve is installed in the A/C manifold and tube (19D734) to protect
the refrigerant system against excessively high refrigerant pressures.
An evaporator core orifice is installed in the A/C evaporator core inlet tube to meter the liquid
refrigerant into the A/C evaporator core.
A refrigerant containment switch is installed on 3.8L vehicles to cut- off A/C compressor operation in
the event of abnormally high refrigerant system pressure.
A dual- function pressure switch is used on 4.6L vehicles for cooling fan control, and to cut- off A/C
compressor operation in the event of abnormally high refrigerant system pressure. Refrigeration System Components SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Klj . 1 ba
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A/C Compressor and Clutch Assembly
NOTE:
Internal A/C compressor components are not serviced separately. The FS- 10 A/C compressor
is serviced only as an assembly. The A/C clutch pulley, A/C clutch field coil (19D798) and the shaft
seal are serviceable.
The FS- 10 A/C compressor has the following characteristics:
z A ten- cylinder swashplate design utilizing the tangential design mount. Item Part Number Description
1 19E561 A/C cycling switch
2 19D701 A/C charge port valve (low side)
3 19D594 Refrigerant containment switch (3.8L vehicles)
3 19D594 Dual-
function pressure switch (4.6L vehicles) 4 19D734 A/C manifold and tube
5 19D644 A/C compressor pressure relief valve
6 19703 A/C compressor
7 19D701 A/C charge port valve (high side)
8 19712 A/C condenser core
9 19835 Condenser to evaporator tube
10 19C836 Suction accumulator
11 — A/C evaporator core (part of 19850 assembly) Klj . 2 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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An A/C compressor pressure relief valve is incorporated into the compressor A/C manifold and tube to:
zrelieve unusually high refrigerant system discharge pressure buildups. For specifications
regarding operating pressure(s), refer to Section 412 - 00 .
z prevent damage to the A/C compressor and other system components.
z avoid total refrigerant loss by closing after the excessive pressure has been relieved.
A/C Condenser Core
The A/C condenser core has the following characteristics:
zIt is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator
(8005).
z It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat
and by condensing gas to liquid refrigerant as it is cooled.
Refrigerant Lines
The condenser to evaporator tube (19835) contains the high pressure liquid refrigerant upstream of the
evaporator core orifice.
The A/C manifold and tube (19D734) is attached to the A/C compressor, is sealed with O- ring seals,
and has the following features:
zThe upstream side contains low pressure refrigerant gas.
z The downstream side contains high pressure refrigerant gas and a fitting used to mount a
serviceable high pressure A/C charge port valve.
z The downstream side also contains a fitting used to mount the refrigerant containment switch
(3.8L) or dual- function pressure switch (4.6L). A long- travel Schrader-type valve stem core is
installed in the fitting so that the switch can be removed without discharging the A/C system. Klj . 4 ba
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A/C Evaporator Core
NOTE:
The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
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.
The A/C evaporator core is the plate/fin type with a unique refrigerant flow path.
zA mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C
evaporator core inlet tube and moves out of the A/C evaporator core through the A/C
evaporator core outlet tube.
z This flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core.
Evaporator Core Orifice
NOTE: The evaporator core orifice is an integral part of the condenser to evaporator line and should
be installed as an assembly with the line.
NOTE: A new evaporator core orifice should be installed whenever a new A/C compressor is installed.
The evaporator core orifice has the following characteristics:
zIt is located in the A/C condenser to evaporator line.
z It has filter screens located on the inlet and outlet ends of the tube body.
z The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the evaporator
core orifice.
z O-ring seals on the evaporator core orifice prevent the high- pressure liquid refrigerant from
bypassing the evaporator core orifice. Klj . 5 ba
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z
Adjustment or repair cannot be made to the evaporator core orifice assembly. A new evaporator
core orifice must be installed as a unit.
Suction Accumulator
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.
In addition to the preceding condition, a new suction accumulator should be installed if one of the
following conditions exist:
zThe suction accumulator is perforated.
z The refrigerant system has been opened to the atmosphere for a period of time longer than
required to make a minor repair.
z There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines
or the refrigerant oil is thick and dark. Item Part Number Description
1 19E561 A/C cycling switch
2 — O-
ring seal (part of 19C836) 3 19D701 Low pressure service gauge port valve
4 — Inlet from A/C evaporator core (part of 19C836)
5 — Outlet to A/C compressor (part of 19C836)
6 — Anti-
siphon hole (part of 19C836) 7 — Desiccant bag (part of 19C836)
8 — Oil return orifice filter (part of 19C836)
9 — Vapor return tube (part of 19C836)
10 — Suction accumulator dome (part of 19C836) Klj . 6 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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