Climate Control System - General Information Ford Explorer Sport Trac I

GENERAL SPECIFICATION

GENERAL SPECIFICATION

TORQUE SPECIFICATIONS

Torque Specifications

The manual climate control system heats and/or cools the vehicle depending on the function selector switch position and the temperature selected.

1. The function selector switch position determines heating or cooling and air distribution.
2. The temperature control setting determines the air temperature.
3. The heater blower motor switch (18578) varies the blower motor speed.

Principles Of Operation

There are four main principles involved with the basic theory of operation

1. Heat Transfer
2. Latent Heat Of Vaporization
3. Relative Humidity
4. Effects Of Pressure

Heat Transfer

If two substances of different temperature are placed near each other, the heat in the warmer substance will transfer to the colder substance.

Latent Heat Of Vaporization

When a liquid boils (converts to gas) it absorbs heat without raising the temperature of the resulting gas. When the gas condenses (converts back to a liquid), it gives off heat without lowering the temperature of the resulting liquid.

Relative Humidity

The amount of moisture (water vapor content) that the air can hold is directly related to the air temperature. The more heat there is in the air, the more moisture the air can hold. The lower the moisture content in the air, the more comfortable you feel. Removing the moisture from the air lowers its relative humidity and improves personal comfort.

Effects Of Pressure On Boiling Or Condensation

As the pressure is increased on a liquid, the temperature at which the liquid boils (converts to gas) also increases. Conversely, when the pressure on a liquid is reduced, its boiling point is also reduced. When in the gas state, an increase in pressure causes an increase in temperature, while a decrease in pressure will decrease the temperature of the gas.

Compressor Anti-Slugging Strategy

Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate damage to the A/C compressor, compressor anti-slugging strategy (CASS) is utilized.

CASS is initiated only under specific conditions

1. The ignition is off for more than 8 hours.
2. The ambient temperature is above -4°C (25°F).
3. Battery voltage is above 8.5 volts during engine cranking.

When these conditions are present, the powertrain control module (PCM) will activate the A/C control relay prior to cranking of the engine. The A/C control relay engages the A/C compressor for approximately 4-15 A/C compressor revolutions or a maximum of two seconds (depending upon vehicle application), allowing the liquid refrigerant to be pushed from the A/C compressor. CASS is initiated by the PCM regardless of the function selector switch position.

The Refrigerant Cycle

During stabilized conditions (air conditioning system shutdown), the refrigerant is in a vaporized state and pressures are equal throughout the system.

When the A/C compressor (19703) is in operation it increases pressure on the refrigerant vapor, raising its temperature. The high-pressure and high-temperature vapor is then released into the top of the A/C condenser core (19712).

The A/C condenser core, being close to ambient temperature, causes the refrigerant vapor to condense into a liquid when heat is removed from the refrigerant by ambient air passing over the fins and tubing. The now liquid refrigerant, still at high pressure, exits from the bottom of the A/C condenser core and enters the inlet side of the A/C evaporator core orifice (19D990).

The A/C evaporator core orifice is the restriction in the refrigerant system that creates the high pressure buildup in the A/C evaporator core (19860) and separates the high and low pressure sides of the A/C system. As the liquid refrigerant leaves this restriction, its pressure and boiling point are reduced.

The liquid refrigerant is now at its lowest pressure and temperature. As it passes through the A/C evaporator core, it absorbs heat from the passenger compartment air flow passing over the plate/fin sections of the A/C evaporator core. This addition of heat causes the refrigerant to boil (convert to gas). The now cooler passenger compartment air can no longer support the same humidity level of the warmer air and this excess moisture condenses on the exterior of the evaporator coils and fins and drains outside the vehicle.

The suction accumulator (19C836) is designed to remove moisture from the refrigerant and to prevent any liquid refrigerant that may not have been vaporized in the A/C evaporator core from reaching the A/C compressor. The A/C compressor is designed to pump refrigerant vapor only, as liquid refrigerant will not compress and can damage the A/C compressor.

The refrigerant cycle is now repeated with the A/C compressor again increasing the pressure and temperature of the refrigerant.

The A/C cycling switch (19E561) interrupts compressor operation before the external temperature of the A/C evaporator core gets low enough to cause the condensed water vapor (excess humidity) to turn to ice. It does this by monitoring low side line pressure. It is known that a refrigerant pressure of approximately 210 kPa (30 psi) will yield an operating temperature of 0°C (32°F). The A/C cycling switch controls system operation in an effort to maintain this temperature.

The high side line pressure is also monitored so that A/C compressor operation can be interrupted if system pressure becomes too high.

The A/C compressor pressure relief valve (19D644) will open and vent refrigerant to relieve unusually high system pressure.

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When MAX A/C is selected

1. The air inlet door vacuum control motor is at full vacuum, closing off outside air and admitting only recirculated air.
2. The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at full vacuum preventing the flow of hot coolant to the heater core. Blended air temperature is not available.
4. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.
6. The center console blower motor (if equipped) is enabled.

Scheme 74

When A/C is selected

1. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at no vacuum allowing the flow of hot coolant to the heater core. Blended air temperature is available.
4. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.
6. The center console blower motor (if equipped) is enabled.

Scheme 75

When PANEL is selected

1. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum control motor is at no vacuum, directing airflow to the instrument panel A/C registers. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at no vacuum allowing the flow of hot coolant to the heater core. Blended air temperature is available.
4. The temperature can be adjusted to heat the air, but the air cannot be cooled below the outside temperature.
5. The A/C compressor will not operate.
6. The blower motor is on.
7. The center console blower motor (if equipped) is enabled.

Scheme 76

When OFF is selected

1. The air inlet door vacuum control motor is at full vacuum, closing off outside air from entering the passenger compartment.
2. The panel/floor door vacuum control motor is at full vacuum and the panel/defrost door vacuum control motor is at no vacuum, closing off airflow to the defrost duct, side window demisters, the floor duct, and the instrument panel A/C registers. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at full vacuum preventing the flow of hot coolant to the heater core.
4. The A/C compressor will not operate.
5. The blower motor is off.
6. The center console blower motor (if equipped) is disabled.

Scheme 77

When PANEL/FLOOR is selected

1. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. The panel/defrost door vacuum control motor is at full vacuum and the panel/floor door vacuum control motor is at partial vacuum, directing airflow to the floor duct and the instrument panel A/C registers. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at no vacuum allowing the flow of hot coolant to the heater core. Blended air temperature is available.
4. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.
6. The center console blower motor (if equipped) is enabled.

Scheme 78

When FLOOR is selected

1. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. The panel/floor door vacuum control motor is at full vacuum and the panel/defrost door vacuum control motor is at no vacuum, directing airflow to the floor duct. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at no vacuum allowing the flow of hot coolant to the heater core. Blended air temperature is available.
4. The temperature can be adjusted to heat the air, but the air cannot be cooled below the outside temperature.
5. The A/C compressor will not operate.
6. The blower motor is on.
7. The center console blower motor (if equipped) is enabled.

Scheme 79

When FLOOR/DEFROST is selected

1. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. The panel/floor door vacuum control motor is at partial vacuum and the panel/defrost door vacuum control motor is at no vacuum, directing airflow to the floor duct, the defroster duct, and the side window demisters. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at no vacuum allowing the flow of hot coolant to the heater core. Blended air temperature is available.
4. The temperature can be adjusted to heat or cool the air below the outside temperature.
5. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
6. The blower motor is on.
7. The center console blower motor (if equipped) is enabled.

Scheme 80

When DEFROST is selected

1. The air inlet door vacuum control motor is at no vacuum, admitting only outside air into the passenger compartment.
2. The panel/floor door and panel/defrost door vacuum control motors are at no vacuum, directing airflow to the defroster duct and the side window demisters. A small amount of airflow from the side window demisters will be present.
3. The heater control valve is at no vacuum allowing the flow of hot coolant to the heater core. Blended air temperature is available.
4. The temperature can be adjusted to heat or cool the air below the outside temperature.
5. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
6. The blower motor is on.
7. The center console blower motor (if equipped) is enabled.

Scheme 81

For Explorer Sport wiring diagrams see AIR CONDITIONING in SYSTEM WIRING DIAGRAMS article. For Explorer Sport Trac wiring diagrams see AIR CONDITIONING in system wiring diagrams article.

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Inspection & Verification

1. Verify the customer's concern by operating the climate control system to duplicate the condition.
2. Inspect to determine if one of the following mechanical or electrical concerns apply: A leak in the vacuum control circuit may occur during acceleration (slow leak), may exist at all times (large leak), and may exist only when specific functions are selected (indicating a leak in that portion of the circuit). The vacuum hoses used in the passenger compartment control circuit are constructed from PVC plastic material. The vacuum hoses used in the engine compartment are constructed of Hytrel®. Because of the materials used, never pinch the vacuum hoses off during diagnosis to locate a leak. A wood golf tee can be used as a plug when it is necessary to plug one end of the vacuum hose for leak test purposes.
3. If the inspection reveals obvious concern(s) that can be readily identified, repair as required.
4. If the concern remains after the inspection, connect the scan tool to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the scan tool menu. If the vehicle selection cannot be entered: Check that the program card is correctly installed. Check the connections to the vehicle. Check the ignition switch position. If the scan tool still does not allow the vehicle selection to be entered, refer to the scan tool manual.
5. Perform the DATA LINK DIAGNOSTIC TEST using the scan tool. If the scan tool responds with: CKT 914 and CKT 915 = ALL MODULE NO RESPONSE/NOT EQUIPPED, go to Communication System Diagnostics in «COMMUNICATIONS NETWORK»(/ford/explorer-sport-trac/i-2000-2005/remont/communication-devices/#module-communications-network) in MODULE COMMUNICATIONS NETWORK article. If the powertrain control module (PCM) (12A650) is not listed for a communication concern, turn the function selector switch to off and execute self-test diagnostics for the PCM.
6. If any PCM DTCs are retrieved, and are related to the concern, go to the Powertrain Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. (Scheme 90)
7. If no DTCs related to the concern are retrieved, See «SYMPTOM CHART»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) to continue diagnostics.

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Pinpoint Test E: Insufficient Air Conditioning (A/C) Cooling

Note. Make sure the heater control valve is functioning correctly before proceeding with this test. GO to PINPOINT TEST B: INSUFFICIENT, ERRATIC, OR NO HEAT for information regarding the heater control valve operation.

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Pinpoint Test L: The Console Blower Motor Is Inoperative

Note. When the console blower motor is in the off position, airflow may be present from the console registers. This airflow is generated by the front blower motor forcing air through the flow-through console. The console blower motor operates when the console blower motor switch is in the low or high positions, increasing the amount of airflow from the console registers.

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Heater Core

1. Check the integrity of the heater water hose clamps.

Heater Core - Plugged

1. Check to see that the engine coolant is at the correct level.
2. Start the engine and turn on the heater.
3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: The heater control valve is not working correctly. The heater core may have an air pocket. The heater core may be plugged. The thermostat is not working correctly.

Heater Core - Pressure Test

Note. Use Pressure Tester to carry out the pressure test.

Scheme 159

1. Drain the coolant from the cooling system.
2. Disconnect the heater water hoses from the heater core. For additional information, see «HEATER CORE»(/ford/explorer-sport-trac/i-2000-2005/remont/heater/#heating-ventilation) in HEATING & VENTILATION article.
3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the radiator/heater core pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps.
5. Attach the pump and gauge assembly from the Pressure Tester to the adapter.
6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure into the heater core.
7. Observe the pressure gauge for a minimum of three minutes.
8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and carry out the bench test.

Scheme 160

1. Remove the heater core from the vehicle. For additional information, see «HEATER CORE»(/ford/explorer-sport-trac/i-2000-2005/remont/heater/#heating-ventilation) in HEATING & VENTILATION article.
2. Drain all of the coolant from the heater core.
3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the radiator/heater core pressure tester to the adapter.
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water.
5. If a leak is observed, install a new heater core.

A/C Evaporator/Condenser Core - On-Vehicle Leak Test

1. Discharge and recover the refrigerant. For additional information, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. For additional information, see «EVAPORATOR CORE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) or «CONDENSER CORE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
3. Clean the spring lock couplings. For additional information, see «SPRING LOCK COUPLING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections.
5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before installing a new A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. For additional information, see «EVAPORATOR CORE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) or «CONDENSER CORE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.

A/C Compressor - External Leak Test

1. Install the A/C pressure test adapter on the rear head of the A/C compressor using the existing manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as R-134a A/C Service Center to the corresponding fittings on the A/C pressure test adapter.
3. Attach the center hose of the manifold gauge set to a refrigerant container standing in an upright position.
4. Hand-rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft seal and the compressor center seal.
7. If a shaft seal leak is found, install a new shaft seal. For additional information, see «SHAFT SEAL»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article. If an external leak is found at the center joint of the A/C compressor, install a new A/C compressor.
8. When the leak test is complete, recover the refrigerant from the compressor.

AIR CONDITIONING (A/C) SYSTEM CHECK - RETAIL PROCEDURE

Note. This Retail Procedure is not eligible for claiming on Ford paid repair s (warranty and ESP).

Note. The engine should be run at idle for 10 minutes with the air conditioning on and set to MAX A/C before carrying out this retail procedure.

Note. Read and follow all of the Warnings, Cautions and Notes under CLIMATE CONTROL SYSTEM before continuing.

1. Visual Inspection Open the hood and visually inspect the heating and air conditioning systems for the following: Coolant reservoir for correct coolant level. Heater hoses for deterioration or loose connections. Radiator and condenser for debris or damaged fins restricting airflow, loose mounting or connections. Accessory drive belt(s) and cooling fan(s) for wear or physical damage. Refrigerant lines and connections for physical damage or loose connections. Compressor for physical damage or loose connections. Suction accumulator/drier for physical damage or loose connections. Wiring and connectors for excessive wear, loose or damaged connections, or incorrect routing.
2. A/C Refrigerant Analysis To carry out refrigerant analysis perform the following: Carry out air conditioning refrigerant analysis. For additional information, see «REFRIGERANT IDENTIFICATION TESTING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-identification-testing) . If the refrigerant fails the analysis, discontinue diagnosis and make recommendations for repairs. If the refrigerant passes the analysis, carry out the air conditioning system check.
3. Air Conditioning System Check For A/C system check perform the following: Connect manifold gauge set or charging station with gauges to refrigerant system. With the vehicle in park, parking brake set, thermometer installed in center panel vent, and air conditioning system on and set to MAX A/C, start the engine. Record air refrigerant system pressures while running the engine at 1,500 RPM and allow engine to return to idle. Operate the blower motor in all control positions and check for correct blower speed changes. With the blower motor on HI, operate air discharge mode selector in all positions and check for correct airflow in each position. Operate the temperature blend selector in all positions and check for correct change in discharge temperature. Check the air discharge temperature with the selector in the coolest position and the air conditioning on and set to MAX A/C to determine if the air discharge temperature is acceptable for the current ambient air temperature. Carry out the EATC self-test (if applicable). If the refrigerant system pressures were low, carry out the refrigerant system leak test.
4. Refrigerant System Leak Test For refrigerant system leak test perform the following: Use either an ultraviolet (UV) or an electronic leak detector to check for leaks at all refrigerant lines, connections, and components. After all tests have been completed, report all findings and recommended repairs to your service advisor before carrying out further diagnostic procedures.

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1. Remove the A/C tube lock coupling clip (19E746), if equipped.
2. Fit the special tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring (19E576).
4. Pull the spring lock coupling fittings apart.
5. Remove the O-ring seals with a non-metallic tool.
6. Remove the A/C tube lock coupling spring with a small hooked wire.

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1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
2. Cut an abrasive pad from maroon colored 3M Scotch Brite® with the dimensions corresponding to the coupling size.
3. Assemble the pad to the tool.
4. Coat the abrasive pad with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
5. Roll the pad on the tool and install it in a variable speed drill motor.
6. Polish for one minute at moderate speed (less than 1,500 RPM) or until the surface is clean and free of scratches or foreign material.
7. Clean the fitting with a lint-free cloth.
8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, install a new component.
9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string. Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint-free cloth.

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1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
3. Install the O-ring seals. Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) or equivalent.
4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting.
5. Install the A/C tube lock coupling clip.

Scheme 174

1. Remove the nut from the peanut fitting.
2. Pull the peanut fitting apart.
3. Remove the O-ring seal with a non-metallic tool.

Connect

1. Clean all dirt or foreign material from the fittings.
2. Install the O-ring seal. 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. Assemble the male and female fittings together.

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1. Connect the R-134a Manifold Gauge Set. For additional information, see «MANIFOLD GAUGE SET CONNECTION»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
2. Adjust the climate controls for maximum cooling. Start the engine. Select MAX A/C operation. Set the blower motor speed to maximum.
3. Stabilize the in-vehicle temperature at 21-27°C (70-80°F).
4. Maintain the engine speed at 1,500 RPM.
5. Determine the compressor discharge (high) pressure. Record the ambient temperature. Record the discharge (high) pressure. 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.
6. Determine the compressor suction (low) pressure. Record the ambient temperature. Record the suction (low) pressure. 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. Record the ambient temperature. Record the A/C clutch ON time in seconds. 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. Record the ambient temperature. Record the A/C clutch OFF time in seconds. 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.
9. Determine the total A/C clutch cycle time. Record the ambient temperature. Record the time the A/C clutch is engaged plus the time it is disengaged (time ON plus time OFF). 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. Record the ambient temperature. Record the number of A/C clutch cycles occurring in one minute. 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. Record the ambient temperature. Record the center A/C register discharge temperature. 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.

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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, see «CLUTCH & CLUTCH FIELD COIL»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.

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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.
4. Connect the R-134a Manifold Gauge Set low-pressure hose and the R-134a low side quick disconnect to the low-pressure service gauge port valve.
5. Connect the R-134a Manifold Gauge Set high-pressure hose and the R-134a high side quick disconnect to the high-pressure service gauge port valve.

Scheme 190

Electronic Leak Detection

Scheme 191

1. 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, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) . Repair the system. Test the system for normal operation.

Scheme 192

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.

Scheme 193

Scheme 194

1. Check for leaks using a 120 Watt UV spot lamp. Scan 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.

Scheme 195

Air Conditioning (A/C) System Flushing

1. 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: 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. 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, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
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. 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, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
12. Evacuate, leak test and charge the A/C system. For additional information, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
13. Check the system for normal operation.

Scheme 196

Scheme 197

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, see «REFRIGERANT IDENTIFICATION TESTING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-identification-testing) .
2. 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, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
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.

Scheme 198

Scheme 199

1. Install the new A/C compressor. For additional information, see «AIR CONDITIONING (A/C) COMPRESSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
2. Install the new suction accumulator/drier. For additional information, see «SUCTION ACCUMULATOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
3. Install the new A/C evaporator core orifice. For additional information, see «EVAPORATOR CORE ORIFICE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
4. Orient the filter inlet toward the A/C condenser core.
5. Temporarily install the pancake filter between the A/C condenser core and the condenser to evaporator tube. Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. Make the connections using the A/C Test Fitting Set.
6. Correctly oil match the system. For additional information, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
7. Evacuate and charge the system. For additional information, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
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, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
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, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .

REFRIGERANT OIL ADDING

1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring device. If 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. 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. 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. Add 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: Installation of a new A/C evaporator core orifice. Installation of a new A/C compressor pressure relief valve (19D644). Installation of a new refrigerant line. Repair of an O-ring seal leak. 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.

INSPECTION & ASSEMBLY REQUIREMENTS - FOLLOWING AN A/C COMPRESSOR FAILURE

1. Remove and discard the A/C evaporator core orifice. For additional information, see «EVAPORATOR CORE ORIFICE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
2. Remove the A/C compressor. For additional information, see «AIR CONDITIONING (A/C) COMPRESSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article. Drain the residual refrigerant oil from the A/C compressor and measure the volume for correct system oil matching. For additional information, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
3. Remove the suction accumulator/drier. For additional information, see «SUCTION ACCUMULATOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article. Drain the residual refrigerant oil from the suction accumulator/drier and measure the volume for correct oil system matching. For additional information, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
4. Carry out an A/C system flushing or filtering procedure: If A/C system flushing equipment is available, clean the A/C evaporator core and the A/C condenser core by flushing. For additional information, see «AIR CONDITIONING (A/C) SYSTEM FLUSHING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__air-conditioning-ac-system-flushing) . If A/C system flushing equipment is not available, carry out a system filtering procedure. For additional information, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) after A/C component replacement.
5. Install a new A/C compressor. For additional information, see «AIR CONDITIONING (A/C) COMPRESSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
6. Install the new suction accumulator/drier. For additional information, see «SUCTION ACCUMULATOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
7. Install the new A/C evaporator core orifice. For additional information, see «EVAPORATOR CORE ORIFICE»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
8. Correctly oil match the system. For additional information, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
9. Evacuate and charge the system. For additional information, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .

Scheme 200

Refrigerant Identification Testing

1. 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: If 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. 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. 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. Recover any contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. For additional information, see «CONTAMINATED REFRIGERANT HANDLING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__contaminated-refrigerant-handling) .

CONTAMINATED REFRIGERANT HANDLING

1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. 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. The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be installed. Remove the suction accumulator/drier. For additional information, see «SUCTION ACCUMULATOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
4. Clean the A/C evaporator core and the A/C condenser core by flushing. For additional information, see «AIR CONDITIONING (A/C) SYSTEM FLUSHING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__air-conditioning-ac-system-flushing)
5. Install the new suction accumulator/drier. For additional information, see «SUCTION ACCUMULATOR»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#air-conditioning) in AIR CONDITIONING article.
6. Correctly oil match the system. For additional information, see «REFRIGERANT OIL ADDING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information__refrigerant-oil-adding) .
7. Evacuate and charge the system. For additional information, see «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION & CHARGING»(/ford/explorer-sport-trac/i-2000-2005/remont/manual-hvac-system/#climate-control-system-general-information) .
8. Dispose of contaminated refrigerant according to all federal, state and local regulations.

Scheme 201

Scheme 202

1. Measure the length of the damaged area of the mini-tube vacuum hose.
2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini-tube vacuum hose).
3. Cut off the mini-tube vacuum hose on each side of the damaged area.
4. Dip the mini-tube hose ends in commercially available paint thinner containing methyl ethyl ketone (MEK). This solvent will seal the mini-tube in the vacuum hose.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch repair vacuum hose section.
6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged.
7. Test the system for a vacuum leak in the repair area. Use the Vacuum Tester or equivalent.

See also:
• COMMUNICATIONS NETWORK
• HEATER CORE
• EVAPORATOR CORE
• SYMPTOM CHART
• REFRIGERANT IDENTIFICATION TESTING
• REFRIGERANT OIL ADDING
• AIR CONDITIONING (A/C) SYSTEM FLUSHING
• CONTAMINATED REFRIGERANT HANDLING