oil FORD MUSTANG 2003 Workshop Manual

6. Correctly oil match the system. For additional information, refer to
Refrigerant Oil Adding in this
section.
7. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
8. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to
make adjustments.
9. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select MAX A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly.
Make sure the A/C system is operating correctly.
10. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C
system operating.
11. Stop the engine.
12. Recover the refrigerant from the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
13. Remove the fittings, flexible hoses and pancake filter from between the and the condenser to evaporator tube.
14. Discard the pancake filter. It can be used one time only.
15. Reconnect the condenser to evaporator tube to the A/C condenser core.
16. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Klj . 2 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.
SECTION 412-
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GENERAL PROCEDURES
Inspection and Assembly Requirements —
Following an A/C
Compressor Failure
CAUTION: To prevent refrigerant system contamination and possible failure of the new
A/C compressor, carry out the following procedures.
1. NOTE: A dirty A/C evaporator core orifice or a condenser to evaporator tube containing black
refrigerant oil and particles indicates that the A/C compressor has failed and a new A/C
compressor must be installed.
Remove and discard the A/C evaporator core orifice. For additional information, refer to Section 412 - 03 .
2. Remove the A/C compressor. For additional information, refer to Section 412 - 03 .
z Drain the residual refrigerant oil from the A/C compressor and measure the volume for
correct system oil matching. For additional information, refer to Refrigerant Oil Adding in
this section.
3. NOTE: The suction accumulator/drier and A/C evaporator core orifice cannot be cleaned and a
new A/C evaporator core orifice must be installed.
Remove the suction accumulator/drier. For additional information, refer to Section 412 - 03 .
z Drain the residual refrigerant oil from the suction accumulator/drier and measure the
volume for correct oil system matching. For additional information, refer to Refrigerant Oil Adding in this section.
4. NOTE: System flushing is the preferred method of cleaning. However, if flushing equipment is
not available, carry out system filtering.
Carry out an A/C system flushing or filtering procedure:
zIf A/C system flushing equipment is available, clean the A/C evaporator core and the A/C
condenser core by flushing. For additional information, refer to Flushing in this section.
z If A/C system flushing equipment is not available, carry out a system filtering procedure.
For additional information, refer to Refrigerant Oil Adding After A/C Component
Replacement in this section.
5. Install a new A/C compressor. For additional information, refer to Section 412 - 03 .
6. Install the new suction accumulator/drier. For additional information, refer to Section 412 - 03 .
7. Install the new A/C evaporator core orifice. For additional information, refer to Section 412 - 03 .
8. Correctly oil match the system. For additional information, refer to Refrigerant Oil Adding in this
section.
9. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
SECTION 412-
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GENERAL PROCEDURES
Contaminated Refrigerant Handling
1. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant
into your recovery/recycling equipment.
Recover the contaminated refrigerant using suitable recovery- only equipment designed for
capturing and storing contaminated refrigerant.
zThis equipment must only be used to recover contaminated refrigerant to prevent the
spread to other vehicles.
z If this equipment is not available, contact an A/C repair facility in your area with the
correct equipment to carry out this repair.
2. Determine and correct the cause of the customer's initial concern.
3. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured
for correct oil system matching. For additional information, refer to Refrigerant Oil Adding in this
section.
The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be
installed.
Remove the suction accumulator/drier. For additional information, refer to Section 412 - 03 .
4. Clean the A/C evaporator core and the A/C condenser core by flushing. For additional information, refer to Air Conditioning (A/C) System Flushing in this section.
5. Install the new suction accumulator/drier. For additional information, refer to Section 412 - 03 .
6. Correctly oil match the system. For additional information, refer to Refrigerant Oil Adding in this
section.
7. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
8. Dispose of contaminated refrigerant according to all federal, state and local regulations.
SECTION 412-
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SPECIFICATIONS
SECTION 412-
02: Heating and Ventilation 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricant
MERPOL® ESE-
M99B144-
B PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-
DA (Motorcraft
YN- 12-C) WSH-
M1C231- B
Torque Specifications Description Nm lb-
in Interior evaporator core housing bracket nut and bolts 8 71 Klj . 1 ba
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REMOVAL AND INSTALLATION
Evaporator Core Housing
Removal
NOTE:
The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
1. Disconnect the battery ground cable.
2. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
3. Drain the cooling system. For additional information, refer to Section 303 - 03A or
Section 303 -
03B .
4. Remove the instrument panel. For additional information, refer to Section 501 - 12 .
5. Disconnect the heater hose couplings from the heater core. For additional information, refer to Section 412 - 00 .
6. Disconnect the vacuum connector. SECTION 412-
02: Heating and Ventilation 2003 Mustang Workshop Manual Material
Item Specification
PAG Compressor Oil (R-134a
Systems)
F7AZ- 19589- DA (Motorcraft
YN- 12-C) WSH-
M1C231-
B MERPOL®
NA ESE-
M99B144-
B Klj . 1 ba
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12. Remove the interior evaporator core housing bolts.
13. Remove the evaporator core housing.
Installation 1. To install, reverse the removal procedure. zLubricate the coolant hoses with coolant hose lubricant or plain water only, if needed.
z Install new O- ring seals lubricated with PAG oil. Klj . 3 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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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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