HVAC Systems - General Servicing Ford Explorer Sport Trac I

HANDLING/SAFETY PRECAUTIONS

1. Always work in a well-ventilated, clean area. Refrigerant is colorless and invisible as a gas. Refrigerant is heavier than oxygen and will displace oxygen in a confined area. Avoid breathing refrigerant vapors. Exposure may irritate eyes, nose and throat.
2. Always wear eye protection when working around A/C system and refrigerant. The A/C systems high pressure can cause severe injury to eyes and skin if a hose were to burst. If necessary, wear rubber gloves or other protective clothing.
3. Refrigerant evaporates quickly when exposed to atmosphere, freezing anything it contacts. If liquid refrigerant contacts eyes or skin (frostbite), DO NOT rub eyes or skin. Immediately flush affected area with cool water for 15 minutes and consult a doctor or hospital.
4. Never use R-134a in combination with compressed air for leak testing. Pressurized R-134a in the presence of oxygen (air concentrations greater than 60 percent by volume) may form a combustible mixture. DO NOT introduce compressed air into R-134a containers (full or empty), A/C system components, or service equipment.
5. DO NOT expose A/C system components to high temperatures (steam cleaning for example), as excessive heat will cause refrigerant system pressure to increase. Never expose refrigerant directly to open flame. If refrigerant needs to be warmed, place bottom of refrigerant tank in warm water. Water temperature must not exceed 125°F (52°C). CAUTION: When R-134a is exposed to an open flame, drawn into engine, or detected with a Halide (propane) leak tester, a poisonous gas is formed. Keep work areas well ventilated.
6. Use care when handling refrigerant containers. DO NOT drop, strike, puncture, or incinerate containers. Use DOT 4BW or DOT 4BA approved refrigerant containers.
7. Never overfill refrigerant containers. The safe filling level of a refrigerant container MUST NOT exceed 60 percent of the containers gross weight rating. Store refrigerant containers at temperatures less than 125°F (52°C).
8. R-134a refrigerant is sold and stored in 30 or 50-pound Light Blue containers, while Freon (R-12) is stored in White colored containers.
9. Refrigerant R-12 and R-134a must never be mixed, as they and their desiccants and lubricants are not compatible. If the refrigerants are mixed, system cross-contamination or A/C system component failure may occur. Always use separate servicing and refrigerant recovery/recycling equipment.
10. Read and follow equipment manufacturers instructions for all service equipment to be used. The Material Safety Data Sheet (MSDS), provided by refrigerant manufacturer/supplier, contains valuable information regarding the safe handling of refrigerants.

IDENTIFYING R-134a SYSTEMS & COMPONENTS

To prevent refrigerant cross-contamination, use following methods to identify R-134a based systems and components.

Fittings & "O" Rings

All R-134a based A/C systems use 1/2" x 16 ACME threaded fittings (identifiable by square threads) and quick-connect service ports. (Scheme 1)

Scheme 1

Underhood A/C Specification Labels

Most R-134a based systems will be identified through the use of underhood labels with R-134a refrigerant clearly printed on labels. (Scheme 2) The underhood label used on Ford Motor Co. vehicles is Yellow. (Scheme 3) Most manufacturers will identify refrigerant type with labels affixed to compressor. Before servicing an A/C system, always determine which refrigerant is being used.

Scheme 2

Scheme 3

REFRIGERANT OILS

Refrigerant R-12 based systems use mineral oil, while R-134a systems use synthetic Polyalkylene Glycol (PAG) oils. Using a mineral oil based lubricant with R-134a will result in A/C compressor failure due to lack of proper lubrication.

Note. PAG oil absorbs moisture very rapidly, 2.3-5.6 percent by weight as compared to a mineral oil absorption rate of 0.005 percent by weight.

Note. Use ONLY the specified oil for the appropriate system or A/C compressor. Always check the underhood A/C specification label or A/C compressor label before adding refrigerant oil to A/C system.

SCHRADER-TYPE VALVES

Note. Although similar in construction and operation to a tire valve, NEVER replace a Schrader-type valve with a tire valve.

Schrader valve is similar in construction and operation to a tire valve. (Scheme 4) When a test gauge hose is attached (hose has built-in valve core depressor), Schrader stem is pushed inward to the open position and allows system pressure to reach the gauge.

If test hose being used does not have a built-in core depressor, an adapter must be used. Never attach hoses or adapters to a Schrader valve unless it is first connected to manifold gauge set.

Schrader Service Valve (Compressor Location Shown). Scheme 4

SPECIAL VALVE CONNECTORS

On some General Motors models, thread size on high-side service valve (3/8" x 24 threads) is different from thread size on low-side service valve (7/16" x 20 threads). Special adapters are required to make this connection. (Scheme 5) These adapters are available in 45-degree and 90-degree angles in addition to straight-fixed and flexible adapters.

Flexible High Side Adapter. Scheme 5

R-134a SERVICE VALVES/PORTS

All vehicles with R-134a refrigerant use quick-disconnect service valves/ports. All R-134a systems use quick-disconnect fittings with sealing caps that thread into inside of service port instead of onto outside of service port.

The high side uses a large service port and the low side uses a small service port. (Scheme 1) The R-134a service ports have internal metric threads to help prevent the accidental connection of R-12 servicing equipment.

There are 2 types of quick-disconnect service couplings which can be used on R-134a systems. One type of service coupling depresses service port valve when connection is made. The other type connects onto service port but will not depress service port valve until a knob is rotated. (Scheme 6)

Scheme 6

SERVICE VALVE LOCATIONS

For service valve locations, see SERVICE VALVE LOCATIONS (CARS) or SERVICE VALVE LOCATIONS (TRUCKS & VANS) table.

SERVICE VALVE LOCATIONS (CARS)

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SERVICE VALVE LOCATIONS (TRUCKS & VANS)

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SERVICE EQUIPMENT

Because R-134a is not interchangeable with R-12, separate sets of hoses, gauges and recovery/recycling equipment are required to service vehicles. This is necessary to avoid cross-contamination and damaging system.

All equipment used to service systems using R-134a must meet SAE standard J2210. The service hoses on the manifold gauge set must have manual (turn wheel) or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into the atmosphere.

For identification purposes, R-134a service hoses must have a Black stripe along their length and be clearly labeled SAE J2196/134a. The low pressure test hose is Blue, with a Black stripe. The high-side test hose is Red, with a Black stripe. The center test hose is Yellow, or White, with a Black stripe.

Note. Refrigerant R-12 service hoses will only be labeled SAE J2196.

All R-134a manifold gauge sets can be identified by one or all of the following

1. Labeled FOR USE WITH R-134a on set.
2. Labeled HFC-134 or R-134a on gauge face.
3. Light Blue color on gauge face. In addition, pressure/temperature scales on R-134a gauge sets are different from R-12 manifold gauge sets.

MANIFOLD GAUGE SET

A manifold gauge set is used to determine the systems high-side and low-side pressures, correct refrigerant charge and operating efficiency. High (discharge) and low (suction) pressures must be compared to determine system operation. Manifold gauge sets for the 2 refrigerant types are basically the same except for fittings at ends of hoses. Fittings are different to ensure connection only to appropriate refrigerant system.

Service hoses on gauge set should have a manual turn wheel or automatic back-flow valves at service port connector ends. This will prevent refrigerant from being released into the atmosphere.

1. Low-Side Gauge & Hose Low-side gauge, which may have a Blue identifying feature, is used to measure low-side (suction) pressure. Low-side gauge is also called a compound gauge because it can measure pressure and vacuum. Pressure scale ranges from 0-150 psi; vacuum scale ranges from 0-30 in. Hg. Low-side hose is Blue, with a Black stripe.
2. High-Side Gauge & Hose High-side gauge, which may have a Red identifying feature, is used to measure high-side (discharge) pressure. Gauge scale ranges from 0-500 psi. High-side hose is Red, with a Black stripe.
3. Center Manifold Hose Center manifold hose is either Yellow or White with a Black stripe. Center hose is used to recover, evacuate and charge refrigerant system. When low-side or high-side pressure valves are opened, refrigerant will escape through the charge hose.

CONNECTING GAUGE SET

Note. R-134a quick disconnect service couplings are connected in the same sequence as Schrader-type service valves.

1. Put on safety goggles and cover vehicles fender. Slowly remove protective caps from Schrader valves to check for leaky valves. CAUTION: Ensure hand valves on manifold gauge set and the hose-end shutoff valves are closed before attaching test hoses to Schrader valves.
2. Ensure service hoses are equipped with valve core depressor to match Schrader valve. If not, install special adapters for this purpose. If the high-side service hose connector will not fit on high-side Schrader valve, a special adapter must be used. See «SPECIAL VALVE CONNECTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__special-valve-connectors) .
3. Ensure both manifold gauge set hand valves are closed. Connect low-side service hose to low-side (suction) service valve and finger tighten connections. Connect high-side service hose to high-side (discharge) service valve and finger-tighten connections.

Note. After test gauges are installed, test hoses must be purged of all air before proceeding with testing.

STABILIZING A/C SYSTEM

1. Once manifold gauge set is attached to system and test hoses have been purged, the system is ready for testing. Place all test hoses, gauge set and other equipment away from all moving parts of engine.
2. Start engine and turn A/C controls to maximum cooling position (full cold or MAX A/C). Set blower on high speed. Open doors and/or windows. Operate system for 5-10 minutes. System should now be stabilized and ready for test readings.

PRESSURE-TEMPERATURE RELATIONSHIP

A refrigerant, when confined in an enclosed space, increases in pressure as the temperature increases. Conversely, if the temperature is lowered, the pressure also decreases.

Depending on temperature, a corresponding pressure will exist in such an enclosed space. For example, at 70°F (21.1°C) a gauge will indicate about 71.0 psi (5.0 kg/cm 2 ). The R-134a PRESSURE-TEMPERATURE RELATIONSHIP table shows this relationship.

R-134a PRESSURE-TEMPERATURE RELATIONSHIP

PRESSURE GAUGE READINGS

The pressure gauge readings shown represent an expansion valve type system using a Nippondenso 10-cylinder compressor. (Scheme 54)- (Scheme 62). Gauge indications will vary depending on system configuration and compressor application.

Temperature and humidity, as well as other factors, affect pressure gauge readings. Compared to R-12 systems, pressure readings on R-134a systems are generally lower for low side pressure and higher for high side pressure. Pressure gauge readings should be used only as a guide.

Note. For additional information, see the latest MITCHELL® AUTOMOTIVE AIR CONDITIONING BASIC SERVICE & TRAINING MANUAL.

Normally Functioning R-134a A/C System. Scheme 54

Some Moisture In R-134a System. Scheme 55

Low R-134a Charge. Scheme 56

Poor R-134a Refrigerant Circulation. Scheme 57

No R-134a Refrigerant Circulation. Scheme 58

Insufficient Cooling Of Condenser Or R-134a Refrigerant Overcharge. Scheme 59

Air In R-134a System. Scheme 60

Expansion Valve Improperly Mounted Or Heat Sensing Tube Defective (Opening Too Wide). Scheme 61

Compressor Malfunction. Scheme 62

DAIMLERCHRYSLER CORP.

Refrigerant System Service Equipment

When servicing air conditioning system, a R-134a refrigerant recovery/recycling/charging station meeting SAE Standard J2210 must be used. Refer to operating instructions supplied by equipment manufacturer for proper care and use of this equipment. A manifold gauge set may be needed with some recovery/recycling/charging equipment. The service hoses on gauge set being used should have manual (turn wheel), or automatic back-flow valves at service port connector ends. This will prevent refrigerant from being released into atmosphere.

Manifold Gauge Set Connections

The manifold gauge set connects as follows

1. Low pressure hose (Blue with Black stripe) attaches to suction service port.
2. High pressure hose (Red with Black stripe) attaches to discharge service port.
3. Center manifold hose (Yellow or White with Black stripe) is used to recover, evacuate and charge refrigerant system. When low or high pressure valves on manifold gauge set are opened, refrigerant in system will escape through this hose.

Refrigerant Recovery

A R-134a refrigerant recovery/recycling/charging station meeting SAE Standard J2210 must be used to recover refrigerant from an R-134a refrigerant system. Refer to operating instructions supplied by equipment manufacturer for proper care and use of this equipment.

Refrigerant System Evacuate

If refrigerant system has been open to atmosphere, it must be evacuated before system can be charged. If moisture and air enters system and becomes mixed with refrigerant, compressor head pressure will increase to greater than acceptable operating levels. This will reduce the performance of air conditioner and damage compressor. Evacuating refrigerant system will remove air and boil moisture out of system at near room temperature.

To evacuate refrigerant system, use the following procedure

1. Connect a R-134a refrigerant recovery/recycling/charging station and a manifold gauge set to refrigerant system of vehicle.
2. Recover refrigerant.
3. Open low and high side valves and start charging station vacuum pump. When suction gauge reads 26 in. Hg. (88 kPa) vacuum or greater, close all valves and turn off vacuum pump. If refrigerant system fails to reach specified vacuum, system has a leak that must be corrected. If refrigerant system maintains specified vacuum for 5 minutes, restart vacuum pump, open suction and discharge valves and evacuate system for an additional 10 minutes.
4. Close all valves and turn off charging station vacuum pump.
5. Refrigerant system is now ready to be charged with R-134a refrigerant. See «REFRIGERANT SYSTEM CHARGE»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__refrigerant-system-charge) .

Refrigerant System Charge

After refrigerant system has been tested for leaks and evacuated, a refrigerant charge can be injected into system. For system capacity, see SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article. A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge refrigerant system with R-134a refrigerant. Refer to operating instructions supplied by equipment manufacturer for proper care and use of this equipment.

FORD MOTOR CO.

Note. Ford Motor Company recommends use of an A/C service center to carry out recovery, evacuation and charging of 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.

Refrigerant System Recovery

1. Prior to recovering refrigerant system, verify purity of refrigerant using Refrigerant Identifier/Air-Radicator (198-00003) or equivalent. Refer to operating instructions supplied by equipment manufacturer for proper care and use of this equipment.
2. Connect an R-134a A/C service center to low and high pressure service gauge port valves.
3. Recover refrigerant from system following operating instructions provided by equipment manufacturer.
4. Once service center has recovered vehicle A/C system refrigerant, close service center inlet valve (if equipped). Then turn off power supply.
5. Allow vehicle A/C system to remain closed for about 2 minutes. Observe system vacuum level as shown on gauge. If vacuum does not decrease, disconnect refrigerant center hose(s).
6. If system vacuum does decrease, repeat steps 2 - 5 until vacuum level remains stable for 2 minutes.
7. Carry out required repairs.

Refrigerant System Evacuation

1. Connect an R-134a service center to low and high pressure service gauge port valves.
2. Evacuate system until low pressure gauge reads at least 29.5 in. Hg (99.4 kPa) of vacuum and as close to 30 in. Hg (101.1 kPa) as possible. Continue to operate vacuum pump for a minimum of 45 minutes.
3. Turn off vacuum pump. Observe low pressure gauge for 5 minutes to ensure system vacuum is held. If vacuum is not held for 5 minutes, leak test system, repair leak and evacuate system again.

Refrigerant System Charging

1. Correctly oil match system to verify correct amount of refrigerant oil is present in system. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
2. Charge system with specified amounts of refrigerant oil and refrigerant. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
3. When no more refrigerant is being drawn into system, start engine and select MAX A/C operation. Adjust blower motor speed to maximum and allow remaining refrigerant to be drawn into system. Continue to add refrigerant into system until specified weight of R-134a has been added. Close charging cylinder valve and allow system to pull any remaining refrigerant from hose. When low pressure drops to about 30 psi (207 kPa), close charging hose valve.

GENERAL MOTORS

Note. Tools Required: ACR 2000 Air Conditioning Service Center (J-43600).

The ACR 2000 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen containing function controls and displays prompts that lead technician through recover, recycle, evacuate and recharge operations.

R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank to maintain a constant 12-15 lbs (5.45-6.82 kg ) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify technician if there are foreign gases present in A/C system. If foreign gases are present, ACR 2000 will not recover refrigerant from A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

For operation and setup instruction of ACR 2000, refer to manufactures manual. Always recharge A/C system with proper amount of R-134a. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.

If oil was removed from A/C system during recovery process or due to component replacement, oil must be replenished. For proper quantities of oil to add to A/C refrigerant system, see SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.

JEEP

For recovery, evacuation and recharging procedures, see DAIMLERCHRYSLER CORP.

A/C SYSTEM FILTERING (FOCUS)

1. An A/C kit has been released to provide the necessary equipment and information to perform mandatory A/C system filtering procedure.
2. Reclaim refrigerant. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
3. To determine if A/C compressor has failed and must be replaced, remove A/C evaporator core orifice and condenser to evaporator tube, if necessary. Look for a dirty A/C evaporator core orifice or a condenser to evaporator tube containing black refrigerant oil and particles.
4. Cap all open refrigerant lines and components to prevent entry of dirt and moisture. Remove damaged A/C compressor. See COMPRESSOR under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
5. Install NEW A/C compressor. A/C clutch may have to be transferred to NEW A/C compressor.
6. Remove suction accumulator.
7. Add clean refrigerant oil to NEW suction accumulator. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
8. Install suction accumulator.
9. Get correct repair kit for vehicle be repaired. Filter kit with "SPN" suffix "A" is used on vehicles with a nylon lined evaporator to compressor suction line.
10. Remove a length of evaporator to compressor suction line to accommodate suction filter and install filter using clamps provided with kit. (Scheme 63) Ensure filter is correctly oriented for refrigerator system flow. Check label on filter. On filter for nylon lined evaporator to compressor suction line, install "O" rings (2 on each filter tube ensuring they are properly seated in grooves on tube). Tighten clamps securely.
11. Install a NEW A/C evaporator core orifice.
12. Install a pancake filter in condenser to evaporator tube between A/C condenser core and A/C evaporator core orifice. (Scheme 64) Ensure filter inlet is toward A/C condenser core. Connections can be made using A/C Test Fitting Set and flexible refrigerant hose of 2500 psi (17200 kPa) burst rating. Individual fittings are also available.
13. Evacuate, charge and leak test system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
14. Check all refrigerant system hoses, lines and positioning of newly installed filters to ensure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments.
15. Provide adequate air flow to front of vehicle (with a fan, if necessary) and set selector valve at MAX A/C. Set blower motor on HIGH and temperature control at full cool. Start engine and let it idle briefly. Ensure A/C system is operating correctly.
16. Gradually increase engine speed to 1200 RPM by running it at lower RPM for short periods (first at 800 RPM, then at 1000 RPM). Set engine at 1200 RPM and run it for an hour with A/C system operating.
17. Stop engine.
18. Reclaim refrigerant. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
19. Allow engine to cool sufficiently to remove fittings, flexible hoses and pancake filter from condenser to evaporator tube.
20. Discard pancake filter. (Scheme 64) It can be used one time only.
21. Reconnect condenser to evaporator tube back into system.
22. Evacuate, charge and leak test system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
23. Check operation of A/C system in all modes.

Scheme 63

Scheme 64

A/C SYSTEM FILTERING (VILLAGER)

1. Install replacement A/C compressor. See COMPRESSOR under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
2. Install replacement suction accumulator/drier. See ACCUMULATOR-DRIER under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
3. Install replacement A/C evaporator core orifice. See FIXED ORIFICE TUBES under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
4. Orient filter inlet toward A/C condenser core.
5. Temporarily install pancake filter between A/C condenser core and condenser to evaporator tube. (Scheme 64) Use flexible refrigerant hose of 2500 psi (17,238 kPa) burst rating. Make connections using test fitting set.
6. Permanently install suction filter in evaporator to compressor suction line close to A/C compressor. (Scheme 63) Remove a length of suction hose (close to compressor end) to accommodate suction filter. Install 2 "O" ring seals on each end of suction filter. Install suction filter in evaporator to compressor suction line with arrow pointing in direction of refrigerant flow. Install clamps.
7. Properly oil match system. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
8. Evacuate and charge the system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
9. Check all refrigerant system hoses, lines and position of newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments.
10. Provide adequate airflow to front of vehicle (with a fan, if necessary). Select MAX A/C operation and set blower motor speed to maximum. Start engine and let it idle briefly. Make sure A/C system is operating properly.
11. Gradually increase engine speed to 1200 RPM by running it at lower RPM for short periods (first at 800 RPM, then at 1000 RPM). Set engine at 1200 RPM and run it for one hour with A/C system operating.
12. Stop engine.
13. Recover refrigerant from system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
14. Remove fittings, flexible hoses and pancake filter from between A/C condenser core and condenser to evaporator tube.
15. Discard pancake filter. (Scheme 64) It can be used one time only.
16. Reconnect condenser to evaporator tube to A/C condenser core.
17. Evacuate and charge system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.

A/C SYSTEM FILTERING (EXCEPT FOCUS & VILLAGER)

1. Orient filter inlet toward A/C condenser core.
2. Temporarily install pancake filter between A/C condenser core and condenser to evaporator tube. (Scheme 64) Use flexible refrigerant hose of 2500 psi (17,238 kPa) burst rating. Make connections using A/C test fitting set.
3. Lubricate refrigerant system with correct amount of clean PAG oil. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
4. Evacuate and charge refrigerant system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
5. Check all refrigerant system hoses, lines and position of newly installed filters to ensure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments.
6. Provide adequate airflow to front of vehicle (with a fan, if necessary). Select A/C operation and set blower motor speed to maximum. Start engine and let it idle briefly. Ensure A/C system is operating correctly.
7. Gradually increase engine speed to 1200 RPM by running it at lower RPM for short periods (first at 800 RPM, then at 1000 RPM). Set engine at 1200 RPM and run it for one hour with A/C system operating.
8. Stop engine.
9. Recover refrigerant. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
10. Remove fittings, flexible hoses and pancake filter from between condenser and condenser to evaporator tube.
11. Discard pancake filter. It can be used one time only.
12. Reconnect condenser to evaporator tube to A/C condenser core.
13. Evacuate, charge and leak-test refrigerant system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.

Information is not available from manufacturer.

Note. Prior to using A/C Flush/Purge Machine (219-00022) for the first time, review operating instructions.

Note. Only A/C Flush/Purge Machine Kit (219-00023), which includes A/C Flush/Purge Machine (219-00022), A/C Flush/Purge Fitting Kit (219-00024) and A/C Systems Flushing Solvent Part No. F4AZ-19579-A, 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 A/C system and flushing unit. 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 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 suction accumulator and gummy residue that can form when refrigerant oil is overheated during A/C compressor seizure. The flushing process is a 2-step procedure that involves the use of an A/C flush/purge machine to: Circulate flushing solvent through heat exchanger in reverse direction of normal refrigerant flow (back-flushing). Particulate matter picked up during flushing is filtered from returning solvent before solvent is returned to reservoir for continued circulation. Remove flushing solvent from heat exchanger. In this step of procedure, pressurized air 90-125 psi is used to push and evaporate any remaining flush solvent from heat exchanger.

1. Recover refrigerant. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.
2. Disconnect refrigerant lines from heat exchanger(s) to be flushed.
3. Connect A/C flush/purge machine fitting kit and A/C flush/purge machine to heat exchanger to be flushed. DO NOT flush through 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.
4. Flush heat exchanger for a minimum of 15 minutes.
5. Apply 90-125 psi pressurized air to component for a minimum of 30 minutes. The 30-minute purge time is required to force and evaporate all residual solvent from A/C system component. Failure to successfully remove all residual solvent within component can result in system damage when reconnected and operated. Dispose of used flush solvent and filter in accordance with local, state and federal regulations.
6. Install a NEW A/C evaporator core orifice in any vehicle being serviced for an internal A/C compressor or desiccant failure.
7. Install NEW refrigerant hoses if clogged with foreign material.
8. Install a NEW suction accumulator in any vehicle being serviced for an internal A/C compressor or desiccant failure.
9. Reconnect heat exchanger being serviced.
10. If a NEW A/C compressor is not to be installed, lubricate refrigerant system with correct amount of clean PAG oil. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
11. If a NEW A/C compressor is not to be installed, evacuate, leak test and charge A/C system. See «FORD MOTOR CO.»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__ford-motor-co) under RECOVERY/EVACUATION & RECHARGING.

Note. Tools Required: ACR 2000 Air Conditioning Service Center (J-43600) Flush Adapter Kit (J-45268) Leak Detection Dye (J-41447) Leak Detection Dye Injector (J-41459) Universal 12 Volt Leak Detection Lamp (J-42220)

1. Flushing is intended to remove contaminated PAG oil, desiccant (following a desiccant bag failure), overcharge of PAG oil and refrigerant contamination.
2. Recover refrigerant. See «GENERAL MOTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__general-motors) under REFRIGERANT RECOVERY/EVACUATION & RECHARGING.
3. Remove orifice tube. See ORIFICE under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
4. Connect A/C lines with orifice tube removed.
5. Remove A/C compressor. See COMPRESSOR under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
6. Install flush adapter to A/C compressor hose assembly.
7. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: Service filter with AC Delco Part No. GF 470, before each flush. Connect flush filter to suction port of flush adapter. Connect Blue hose from ACR 2000 to flush filter adapter. Connect Red hose from ACR 2000 to flush adapter.
8. Reverse flow refrigerant flushing is recommended for desiccant bag failure only. Perform the following procedure and replace accumulator when flush is complete: Service filter with AC Delco Part No. GF 470, before each flush. Connect flush filter to discharge port of flush adapter. Connect Blue hose from ACR 2000 to flush filter adapter. Connect Red hose from ACR 2000 to suction port of flush adapter.
9. Flush A/C system. Follow instructions supplied with ACR 2000. Close valve on external refrigerant tank, before starting flush process.
10. Remove flush adapter from A/C compressor hose assembly.
11. Remove A/C compressor drain plug. See COMPRESSOR under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
12. Install A/C compressor drain plug.
13. If replacing A/C compressor after flushing system, perform the following: Determine if NEW service compressor is shipped with PAG oil. If service compressor is shipped with PAG oil, DO NOT DRAIN NEW PAG oil from compressor. Deduct amount of PAG oil shipped with service compressor from specified amount of PAG oil. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article. Add calculated amount to compressor, as needed. If service compressor is shipped dry, no calculation is required. Add total system capacity of PAG oil to compressor. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
14. Install A/C compressor. See COMPRESSOR under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
15. Inspect orifice tube for debris. Clean or replace as needed.
16. Install orifice tube. See ORIFICE under REMOVAL & INSTALLATION in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
17. Evacuate and recharge A/C system. See «GENERAL MOTORS»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__general-motors) under REFRIGERANT RECOVERY/EVACUATION & RECHARGING.
18. Add total system capacity of PAG oil to A/C system. See SPECIFICATIONS in appropriate MANUAL A/C HEATER SYSTEMS or AUTOMATIC A/C HEATER SYSTEMS article.
19. Add one bottle of leak detection dye using leak detection dye injector.
20. Leak test fittings using universal 12 volt leak detection lamp.

Information is not available from manufacturer.

LEAK TESTING

Bubble Solution Detector

This is a solution applied externally at suspected leak points. Leaking refrigerant will cause detector to form bubbles and foam. A soap and water solution also works well.

Dye Solution

This is a colored solution that may be introduced into A/C system. Dye will show up and color components at leak points. Some manufacturers offer refrigerant containing a Red dye. This dye-containing refrigerant is installed by normal charging procedures. Other dye solutions are visible with a Black light only.

Fluorescent Leak Detection

Note. All 2002 model year GM passenger vehicles have a fluorescent leak detection tracer dye added to the A/C system. An underhood A/C charge label (when available) will have CONTAINS REFRIGERANT DYE on the label. Not all vehicles with the dye will have the new A/C charge label.

Note. Ford Motor Co. vehicles with A/C system fluorescent leak detection tracer dye will have a Green "X" on the accumulator.

One of the most effective ways to detect a leak in an A/C system is with fluorescent leak detention tracer dye. If fluorescent dye has been added during vehicle production, additional refrigerant dye for leak detection is not required. Dye added to A/C system during production will remain unless removed during a flushing process. Dye mixes with refrigerant oil, not refrigerant. On Ford vehicles, dye is visible using a 120 watt UV spot light. On GM vehicles, dye is visible using Yellow glasses and a High Intensity Black Light (J28428-E).

Electronic Leak Detector

This instrument will draw in any leaking refrigerant through a test probe and then sound an audible signal or create a flashing light if refrigerant is found. It is the most sensitive of the leak detectors used. Leak detectors are sensitive to windshield washing solutions, many solvents and cleaners and some adhesives. Ensure surfaces near test areas are clean and dry to prevent false signal or detector damage. Liquids ingested into detector will damage detector. (Scheme 65)

Electronic Leak Detector. Scheme 65

PREPARATION FOR LEAK TESTING

Connect manifold gauge set to A/C system. Ensure low-side and high-side gauge set valves are closed. Check system pressure. Pressure should be at least 50 psi (3.5 kg/cm 2 ). If system is empty, evacuate A/C system and apply 28 in. Hg of vacuum. If system holds vacuum for 15 minutes, there most likely are no leaks present. If low, add just enough refrigerant (about 10 ounces) to bring system to 50 psi (3.5 kg/cm 2 ).

Ensure all joints, connections and fittings are free of oil dirt and other contaminants. Using a refrigerant leak detector, check all refrigerant line connections for leaks. Check condenser and compressor seal area.

Start engine and allow to idle. Operate A/C system for about 5 minutes. Set A/C controls to outside air and high blower speed. Turn A/C on and open vehicle windows. Turn engine off and wait 2-7 minutes. Refrigerant is heavier than air. Always check for leaks at bottom of refrigerant lines and components. Refrigerant oil will leak with refrigerant. Visually check all connections and compressor clutch area for oil stains. If compressor shaft seal is leaking, a fresh oil streak will normally be seen on underside of hood, above compressor clutch.

Always perform leak testing after A/C service. Move refrigerant leak detector slowly to check for leaks, as leaks will not be detected if leak testing is performed too quickly.

BUBBLE DETECTOR LEAK TESTING PROCEDURE

This leak detection method is recommended when it is impossible or difficult to determine the exact location of the leak using other methods. Although commercial bubble detectors are more effective, household soap solutions may be used.

Using dauber that comes with commercial soap solution, apply solution to all joints, connections, fittings or controls where a leak might be suspected. If high-suds household solutions are used, apply with a small brush. Wherever bubbles form, leaks are present and must be repaired. Check entire system, as there may be more than one leak.

ELECTRONIC LEAK TESTING PROCEDURE

Note. Some electronic leak detectors will function on only R-12 systems or on only R-134a systems and some will function on both R-12 and R-134a systems. Familiarize yourself with tester being used and know what type of system you are leak testing.

Electronic leak detectors should be used in well ventilated areas. Avoid using around explosive gases. Always follow manufacturers instructions for specific tester being used. If none are available, proceed as follows

1. Turn all controls and detector sensitivity knob to OFF position or zero setting. Connect leak detector to an approved source of power. Turn switch to ON position and allow unit to warm up for about 5 minutes.
2. Check operation of tester by positioning probe in a reference source where refrigerant is known to be present in small amounts. Adjust controls and sensitivity knob until detector reacts properly. Move probe away from refrigerant source and reaction should stop. If reaction continues, adjust sensitivity knob to a lower setting.
3. When tester reacts properly, leak test A/C system by moving probe under all components, fittings and connections. Keep probe moving. To check evaporator, insert probe into drain tube opening or a heater duct. DO NOT allow probe to contact refrigerant or refrigerant oil. When leaks are found, repair as necessary. Keep in mind, there may be more than one leak.

DYE SOLUTION LEAK TESTING PROCEDURES

The following procedure is for introducing a dye solution, not dye-charged refrigerant, into A/C system.

1. Connect manifold gauge set to A/C system in a normal manner. Remove center hose from manifold gauge set and replace it with a short piece (6" long) of 1/4" tubing using two 1/4" flare nuts. Connect a container of dye solution to tubing.
2. Connect one end of gauge set center hose to dye solution container. Connect a container of refrigerant to other end of hose. Operate engine at idle. Set A/C system for maximum cooling. Slowly open low-side hand valve to allow dye solution to enter system.
3. Charge system to at least 50 percent capacity. Operate system for 15 minutes and then shut off both A/C system and engine. Check all connections for signs of colored dye solution. Check vehicle again 24 hours later. If leaks are found, repair as necessary.

FLUORESCENT DYE LEAK TESTING PROCEDURES

Note. Fluorescent leak detection method is intended to be used in conjunction with an electronic leak detection method, to pinpoint smaller leaks. Fluorescent dye takes time to work. Depending on leak rate, dye could take up to 7 days to become visible after installation into A/C system.

Note. After refrigerant dye is installed into A/C system, complete refrigerant leak detection notice sticker (supplied with dye package) and place next to underhood charge label.

1. Start engine and allow to idle. Turn A/C system on and controls to maximum cold position. Ensure compressor clutch is engaged. If compressor clutch stays engaged at idle, low side refrigerant pressure is sufficient to check for a leak. If necessary, charge A/C system so compressor clutch will operate.
2. If A/C system is charged, install fluorescent leak detection dye using R-134a A/C tracer dye injector. Follow dye injector manufacturer instructions. If A/C system is discharged, add dye to replacement component with specified amount of refrigerant oil.
3. After installing dye, clean low side fitting to remove any residue, using fluorescent dye cleaner or general purpose oil solvent. Observe and record ambient air temperature and humidity. Place thermometer in center A/C outlet duct.
4. Start engine. Turn A/C system on and controls to maximum cold position. Increase engine speed to 1500 RPM. After about 5 minutes, record outlet temperature displayed on center A/C outlet duct thermometer. If outlet temperature is at least 20°F (11°C) colder than ambient temperature, A/C system is operating properly.
5. Turn engine off. Check for refrigerant leaks using an electronic leak detector. See «ELECTRONIC LEAK TESTING PROCEDURE»(/ford/explorer-sport-trac/i-2000-2005/remont/general-servicing-all-makes/#hvac-systems-general-servicing__electronic-leak-testing-procedure) . Perform repairs as necessary. If no leaks are found, go to next step.
6. Using Leak Detection Lamp Kit (J42220) UV lamp and Yellow glasses, slowly pan A/C system with UV lamp directed toward all possible leak areas. When a leak is found, fluorescent dye, when viewed through Yellow glasses and highlighted with UV lamp, will glow Light Green or Yellow/Green.
7. Leak detection dye mixes with refrigerant PAG oil. Therefore, extremely small leaks may be pressure, temperature or vibration sensitive and may not be active during a 5 minute test. It may be necessary to request vehicle be returned for further testing in 3 to 5 days. Because detection dye and PAG oil are water soluble, vehicles driven in rain, through sprinkler puddles, etc., may experience leak detection problems.
8. Perform repairs as necessary. Clean A/C system components, especially repaired area, using a Leak Dye Cleaner (J43872) or water until dye can no longer be detected. Start engine and allow to idle. Operate A/C system at maximum cold settings for 5 minutes and recheck for leaks.

See also:
• SERVICE VALVE LOCATIONS (CARS)
• SPECIAL VALVE CONNECTORS
• REFRIGERANT SYSTEM CHARGE
• DAIMLERCHRYSLER CORP.
• FORD MOTOR CO.
• GENERAL MOTORS
• ELECTRONIC LEAK TESTING PROCEDURE