AC system FORD MUSTANG 2003 Workshop Manual

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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Ford Motor Company has approved a procedure to provide technicians with a non-
CFC method
of flushing contaminated A/C system heat exchangers, A/C evaporator core, and A/C
condenser core. The procedure allows the specific components to be cleaned and flushed while
installed in their normal in- vehicle location. The types of contamination flushed include particle
matter that results from A/C compressor or desiccant failure within the suction accumulator/drier
and gummy residue that can form when refrigerant oil is overheated during A/C compressor
seizure. The flushing process is a two- step procedure that involves the use of an A/C Flush and
Purge Machine 219- 00022 to:
z Circulate the flushing solvent through the heat exchanger in the reverse direction of
normal refrigerant flow (back- flushing). Particulate matter picked up during flushing is
filtered from the returning solvent before the solvent is returned to the reservoir for
continued circulation.
z Remove the flushing solvent from the heat exchanger. In this step of the procedure,
pressurized air 621- 862 kPa (90-125 psi) is used to push and evaporate any remaining
flush solvent from the heat exchanger.
2. Discharge the A/C system. Observe all safety precautions. For additional information, refer to the procedure in this section.
3. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
4. Connect the A/C Flush and Purge Machine 219- 00022 and A/C Flush and Purge Fitting Kit 219-
00024 to the heat exchanger to be flushed. Do not flush through the A/C evaporator core orifice,
mufflers or hoses. Internal plumbing and material make- up of these components make it
impossible to correctly remove foreign material or residual flushing solvent.
5. Use 3.785 liters (one gallon) of A/C Systems Flushing Solvent part number F4AZ-19579- A to
flush the heat exchanger for a minimum of 15 minutes. The flush solvent may be used for one
or both heat exchangers in the A/C system. However, the flush solvent is intended for one
vehicle only. The filter used on the flushing unit is also intended for use on one vehicle only.
6. Flush the component for a minimum of 15 minutes.
7. Apply 621- 862 kPa (90-125 psi) pressurized air to the component for a minimum of 30 minutes.
The 30- minute purge time is required to force and evaporate all residual solvent from the A/C
system component. Failure to successfully remove all residual solvent within the component
can result in system damage when reconnected and operated. Dispose of the used flush
solvent and filter in accordance with local, state and federal emissions.
8. NOTE: A/C system filtering as described in this section is optional if system flushing is carried
out. However, the filter kit use is recommended after flushing if the A/C system contamination is
extensive.
Install a new A/C evaporator core orifice in any vehicle being serviced for A/C compressor or
desiccant failure.
9. Install new refrigerant hoses if clogged with foreign material.
10. Reconnect the heat exchanger being serviced.
11. Add additional refrigerant oil as required. For additional information, refer to the procedure in this section.
12. Evacuate, leak test and charge the A/C system. For additional information, refer to the procedure in this section.
13. Check the system for normal operation. Klj . 2 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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Connect an R-
134a A/C service center to the low- and high-pressure service gauge port valves.
3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer.
4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the vacuum does not decrease, disconnect the
refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes.
7. Carry out the required repairs.
Refrigerant System Evacuation
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. Connect an R- 134a service center to the low- and high-pressure service gauge port valves.
2. Evacuate the system until the low- pressure gauge reads at least 99.4 kPa (29.5 in- Hg) of
vacuum and as close to 101.1 kPa (30 in- Hg) as possible. Continue to operate the vacuum
pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low- pressure gauge for five minutes to make sure that
the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service
the leak, and evacuate the system again.
Refrigerant System Charging
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. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. For additional information, refer to Refrigerant Oil Adding in this section.
2. Charge the system with the specified amounts of refrigerant oil and refrigerant.
3. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to
be drawn into the system. Continue to add refrigerant into the system until the specified weight
of R- 134a has been added. Close the charging cylinder valve and allow the system to pull any
remaining refrigerant from the hose. When the low- pressure drops to approximately 207 kPa
(30 psi), close the charging hose valve. Klj . 2 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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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.
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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.
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GENERAL PROCEDURES
Refrigerant Identification Testing
1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior to recovering or charging the refrigerant system.
Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the
sample for testing.
2. The diagnostic tool will display one of the following: zIf the purity level of R- 134a or R-12 is 98% or greater by weight, the green "PASS" light
emitting diode (LED) will light. The weight concentrations of R- 134a, R-12, R-22,
hydrocarbons, and air will be displayed on the digital display.
z If refrigerants R-134a or R- 12 do not meet the 98% purity levels, the red "FAIL" LED will
light and a horn will sound alerting the user of potential hazards. The weight
concentrations of R-134a, R- 12, R-22, and hydrocarbons will be displayed on the digital
display.
z If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting
the user of potential hazards. The weight concentrations of R- 134a, R-12, R-22, and
hydrocarbons will also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R- 134a or R-12 content is
98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant
sample content because air is not considered a contaminant, although air can affect A/C system
performance. When the diagnostic tool has determined that a refrigerant source is pure (R- 134a
or R- 12 is 98% or greater by weight) and air concentration levels are 2% or greater by weight,
the diagnostic tool will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated.
5. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant
into R- 134a or R- 12 recovery/recycling equipment.
Recover any contaminated refrigerant using suitable recovery- only equipment designed for
capturing and storing contaminated refrigerant. For additional information, refer to
Contaminated Refrigerant Handling in this section.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Refrigerant Identifier with Air-
Radicator
198-
00003 or equivalent Klj . 1 ba
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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.
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