AC system FORD MUSTANG 2003 Workshop Manual

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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system discharge pressures.
zThe dual- function pressure switch is mounted on a Schrader valve- type fitting on the high
pressure side of the A/C manifold and tube.
z It is not necessary to discharge the refrigerant system to remove the dual- function pressure
switch.
z A valve depressor, located inside the threaded end of the dual- function pressure switch,
presses on the Schrader valve stem.
z This allows the dual- function pressure switch to monitor the compressor discharge pressure.
z When the compressor discharge pressure rises, the switch contacts open, disengaging the A/C
compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. For specifications regarding operating pressure(s), refer to Section 412 - 00 .
The dual- function pressure switch has a second set of electrical contacts used for high- speed cooling
fan control.
zWhen the compressor discharge pressure rises, the contacts close and engage the high speed
fan control. When the pressure drops, the contacts open and the high speed fan control is
disengaged.
Refrigerant Containment Switch (3.8L)
The refrigerant containment switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
zThe refrigerant containment switch is mounted on a Schrader- type valve fitting on the high
pressure side of the compressor manifold and tube assembly.
z A valve depressor, located inside the threaded end of the refrigerant containment switch,
presses on the Schrader valve stem.
z This allows the refrigerant containment switch to monitor the A/C compressor discharge
pressure.
z When the A/C compressor discharge pressure rises, the switch contacts open, disengaging the
A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C
compressor. For additional information regarding operating pressure(s), refer to Section 412 -
00 .
z It is not necessary to discharge the refrigerant system to remove the refrigerant containment
switch.
Spring Lock Coupling Item Part Number Description
1 — Plastic indicator ring (part of 19D690) Klj . 8 ba
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The fitting is an integral part of the refrigeration line or component.
zSpecial couplings are required for both the high side and low side service gauge ports.
z A new Schrader- type valve core can be installed if the seal leaks.
z Always install the A/C charging valve cap (19D702) on the service gauge port valves after
repairing the refrigerant system. 19D734)
6 19D702 A/C charging valve cap Klj . 10 ba
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
3.8L
Removal and Installation CAUTION: If installing a new air conditioning compressor due to an internal failure of the
old unit, you must carry out the following procedures to remove contamination from the air
conditioning system.
zIf A/C flushing equipment is available, carry out the flushing of the air conditioning
system prior to installing a new air conditioning compressor. For additional information,
refer to Section 412 - 00 .
z If A/C flushing equipment is not available, carry out filtering of the air conditioning
system after a new air conditioning compressor has been installed. For additional
information, refer to Section 412 - 00 .
z Install a new evaporator core orifice (19D990), as directed by the A/C flushing or filtering
procedure.
z Install a new suction accumulator (19C836), as directed by the A/C flushing or filtering
procedure.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C compressor
or damage to the suction accumulator.
1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Disconnect the battery. For additional information, refer to Section 414 - 01
3. Unlatch the air breather.
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
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9. Remove the bolts and the A/C compressor.
10. To install, reverse the removal procedure. zInstall new O- ring seals lubricated in clean PAG oil.
z If filtering of the refrigerant system is not to be performed, lubricate the refrigerant system
with the correct amount of clean PAG oil. For additional information, refer to Section 412 -
00 .
11. If filtering of the air conditioning system is not to be performed, evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 3 ba
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
4.6L
Removal and Installation CAUTION: If installing a new air conditioning compressor due to an internal failure of the
old unit, you must carry out the following procedures to remove contamination from the air
conditioning system.
zIf A/C flushing equipment is available, carry out the flushing of the air conditioning
system prior to installing a new air conditioning compressor. For additional information,
refer to Section 412 - 00 .
z If A/C flushing equipment is not available, carry out filtering of the air conditioning
system after a new air conditioning compressor has been installed. For additional
information, refer to Section 412 - 00 .
z Install a new evaporator core orifice (19D990), as directed by the A/C flushing or filtering
procedure.
z Install a new suction accumulator (19C836), as directed by the A/C flushing or filtering
procedure.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C compressor
or damage to the suction accumulator.
1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Remove the drive belt from the A/C compressor pulley.
3. Raise the vehicle. For additional information, refer to Section 100 - 02 .
4. Disconnect the A/C compressor electrical connector. SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
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5. Remove the bolt and detach the manifold and tube assembly.
6. Remove the compressor.
1. Remove the bolts.
2. Remove the compressor.
7. To install, reverse the removal procedure. zInstall new O- ring seals lubricated in clean PAG oil.
z If filtering of the refrigerant system is not to be performed, lubricate the refrigerant system
with the correct amount of clean PAG oil. For additional information, refer to Section 412 -
00 .
8. If filtering of the refrigerant system is not to be performed, evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 2 ba
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Removal
1. Remove the A/C compressor (19703). For additional information, refer to Air Conditioning (A/C) Compressor — 3.8L or
Air Conditioning (A/C) Compressor — 4.6L in this section.
2. Remove the bolt. 1. Hold the A/C disc and hub assembly (19D786) with the special tool.
2. Remove the bolt.
3. Remove the A/C disc and hub assembly and spacer (19D648). 1. Thread an 8 x 1.25 mm (0.05 in) bolt into the A/C disc and hub assembly to force it from the compressor shaft.
2. Lift the A/C disc and hub assembly and spacer from the compressor shaft.
4. Using the special tool, remove the shaft seal felt from the nose of the A/C compressor.
5. Clean the compressor nose area. Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (MC YN-12- C) WSH-
M1C231-
B Klj . 2 ba
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10. Turn the tool handle clockwise to expand the tool tip inside the shaft seal.
11. Pull the seal from the A/C compressor.
Installation 1. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other
foreign materials to enter the A/C compressor.
Clean the A/C compressor nose area.
2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent.
3. Position the shaft seal and the special tool over the A/C compressor shaft. Klj . 4 ba
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