AC system FORD MUSTANG 2003 Workshop 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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Connect
1. Clean all dirt or foreign material from the fittings.
2. CAUTION: Use only the new O- ring seals. The use of any O-ring seals other than
those specified in the Ford Master Parts Catalog may result in intermittent leakage
during vehicle operation.
Install the O- ring seal.
z Lubricate the O- ring seal with PAG Refrigerant Compressor Oil (R- 134a Systems) F7AZ-
19589- DA (Motorcraft YN-12- C) or equivalent meeting Ford specification WSH-M1C231-
B.
3. Lubricate the inside of the fittings with PAG Refrigerant Compressor Oil (R- 134a Systems)
F7AZ- 19589- DA (Motorcraft YN-12- C) or equivalent meeting Ford specification WSH-M1C231-
B.
4. NOTE: When correctly assembled, the male and female fittings should be flush.
Assemble the male and female fittings together. Klj . 2 ba
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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
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6. Determine the compressor suction (low) pressure.
1. Record the ambient temperature.
2. Record the suction (low) 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.
7. Determine the A/C clutch ON time. 1. Record the ambient temperature.
2. Record the A/C clutch ON time in seconds.
3.NOTE: When the ambient temperature is above 26°C (80°F), the A/C clutch may not
cycle.
The system performance is acceptable when the recorded time falls between the upper
and lower limits shown.
8. Determine the A/C clutch OFF time. 1. Record the ambient temperature.
2. Record the A/C clutch OFF time in seconds.
3.NOTE: When the ambient temperature is above 26°C (80°F), the A/C clutch may not
cycle. Klj . 2 ba
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The system performance is acceptable when the recorded time falls between the upper
and lower limits shown.
9. Determine the total A/C clutch cycle time. 1. Record the ambient temperature.
2. Record the time the A/C clutch is engaged plus the time it is disengaged (time ON plus time OFF).
3. NOTE: When the ambient temperature is above 26°C (80°F), the A/C clutch may not
cycle.
The system performance is acceptable when the recorded time falls between the upper
and lower limits shown.
10. Determine the A/C clutch cycle rate per minute. 1. Record the ambient temperature.
2. Record the number of A/C clutch cycles occurring in one minute.
3.NOTE: When the ambient temperature is above 26°C (80°F), the A/C clutch may not
cycle.
The system performance is acceptable when the recorded number of cycles falls
between the upper and lower limits shown.
11. Determine the center A/C register discharge temperature. 1. Record the ambient temperature. Klj . 3 ba
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2. Record the center A/C register discharge temperature.
3.
NOTE: In ambient temperatures between 38- 43°C (100-110°F), the A/C register
discharge temperatures 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 center A/C register discharge
temperature falls between the upper and lower limits shown. Klj . 4 ba
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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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