HVAC System-General Information: Other Ford Focus I рестайлинг

ADDITION OF AIR CONDITIONING REFRIGERANT OIL (WHEN COMPONENTS ARE REMOVED) CHART

ADDITION OF AIR CONDITIONING REFRIGERANT OIL (WHEN COMPONENTS ARE REMOVED) CHART

Air Distribution And Filtering

A new heating and ventilation system has been developed to ensure the even distribution of air. The air distribution valves are operated by means of a simple rotary switch with five positions (footwell, footwell/demist, footwell/headroom, headroom and demist). For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .

Heating/Ventilation

Coolant flows through the heater core constantly. The heating capacity is controlled by means of a mechanical air temperature valve.

All vehicles have a recirculated air function, with the flap controlled by a servo motor. If the recirculated air function is selected, it remains active even when the ignition is switched on or off. For additional information, refer to HEATING & VENTILATION .

Air Conditioning

The vehicle can be supplied with air conditioning (A/C) system on request. This works according to the evaporator core orifice principle.

The user controls the temperature. Semi- or fully automatic temperature control is not available at the present time. The type of the evaporator core orifice and the installation positions for service connections are the same for all model variants.

The vehicles are fitted with the FS10 swash plate A/C compressor. For additional information, refer to AIR CONDITIONING .

A thermo switch is integrated in the A/C compressor; at a temperature of 115 °C in the A/C compressor outlet (high-pressure side), this switch cuts off the power supply to the A/C compressor clutch.

To install a new evaporator core, the entire air distribution housing must be removed.

Control components

For additional information, refer to CONTROL COMPONENTS .

Air Conditioning (A/C) System Check - Retail Procedure

Note. This Retail Procedure is not eligible for claims on Ford paid repairs (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 (if equipped) or FULL COOL and RECIRC (if equipped) before carrying out this retail procedure.

Note. Read and follow all of the Warnings, Cautions and Notes before continuing.

1. 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 foreign material 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 (if equipped) or receiver/drier (if equipped) for physical damage or loose connections Wiring and connectors for excessive wear, loose or damaged connections, or incorrect routing
2. Carry out air conditioning refrigerant analysis. For additional information, refer to «REFRIGERANT IDENTIFICATION TESTING»(ref-207782-S01378264112005120100000) . 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. Check the air conditioning system. Connect an R-134a manifold gauge set or refrigerant service center with gauges to the 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 (if equipped) or FULL COOL and RECIRC (if equipped), start the engine. Record the air refrigerant system pressures while running the engine at 1,500 rpm and allow the 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 MED HI, operate the 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 (if equipped) or FULL COOL and RECIRC (if equipped) to determine if the air discharge temperature is acceptable for the current ambient air temperature. Carry out the ATC self-test (if applicable). If the refrigerant system pressures were low, carry out the refrigerant system leak test.
4. 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.

Scheme 45

Material

MATERIAL SPECIFICATION

Disconnect

1. Remove the spring lock coupling clip, if equipped.
2. Push the tool into the cage opening to release the female fitting from the spring lock coupling spring and pull the fitting apart. Remove the O-ring seals using a non-metallic tool.
3. Remove the spring lock coupling spring with a small hooked wire.

Scheme 46

Scheme 47

Scheme 48

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. COUPLING SIZE RELATION TO PAD SIZE CHART Coupling Size Pad Size 3/8 inch 25 x 50 mm (1 x 2 inch) 1/2 inch 25 x 50 mm (1 x 2 inch) 5/8 inch 25 x 76 mm (1 x 3 inch) 3/4 inch 25 x 102 mm (1 x 4 inch)
3. Assemble the pad to the tool.
4. Coat the abrasive pad with mineral oil.
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.

Scheme 49

Scheme 50

Scheme 51

1. Install the spring lock coupling spring.
2. Lubricate the inside of the coupling with mineral oil.
3. Install the O-ring seals. Lubricate the O-ring seals with mineral oil.
4. Connect the spring lock coupling fittings with a twisting motion until the spring lock coupling spring snaps over the flared end of the female fitting.
5. Install the spring lock coupling clip.

1. Remove the nut and separate the 2 halves of the peanut fitting.
2. 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.
3. Assemble the male and female fittings together.

Scheme 52

Procedure 1 - Ambient Temperature At Or Below 38 °C (100 °F)

Note. The system performance can be evaluated and diagnosed by analysis of the compressor suction and discharge pressures. The following procedure is used to determine if the system is operating at normal pressures.

Note. The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38 °C (100 °F) or lower, follow procedure 1. If the ambient temperature is over 38°C (100°F), follow procedure 2.

Note. If the A/C compressor cycles at any time during this test, refer to the DIAGNOSTIC TABLE .

Scheme 53

Scheme 54

1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a manifold gauge set or refrigerant service center with high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls. If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, HI Blower. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If equipped with ATC, set temperature to 60 ° F (15 ° C) (lowest possible temp setting) with the dual function disabled (if equipped). Manually set blower on high. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If the vehicle is equipped with auxiliary climate control, set the auxiliary controls to full COOL in the PANEL mode at HI blower speed.
4. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction Pressures chart.
11. Proceed to the diagnostic table.

Procedure 2 - Ambient Temperature Above 38 °C (100 °F)

Note. The system performance can be evaluated and diagnosed by analysis of the compressor suction and discharge pressures. The following procedure is used to determine if the system is operating at normal pressures.

Note. The procedure varies depending on the ambient (shop) temperature. If the ambient temperature is 38 °C (100 °F) or lower, follow procedure 1. If the ambient temperature is over 38°C (100°F), follow procedure 2.

Scheme 55

Scheme 56

1. Drive the vehicle or run the engine until it reaches normal operating temperature.
2. Connect a manifold gauge set or refrigerant service center with high-pressure and low-pressure gauges to the refrigerant system.
3. Set the climate controls. If equipped with manual climate control, set the A/C controls for normal A/C-PANEL mode, full COOL temperature, FRESH air, MED LO blower. If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If equipped with ATC, set temperature to 60°F (15°C) (lowest possible temp setting). Manually set blower to MED LO (3 to 4 bars). If the vehicle has a fresh air/recirc button, set it to FRESH. If the vehicle has an A/C switch or compressor on switch, set it to A/C ON. If the vehicle is equipped with auxiliary climate control, set the auxiliary controls to full COOL in the PANEL mode at MED LO blower speed.
4. Open all vehicle windows and leave the hood open for the test. Open the rear hatch and/or rear doors (if equipped).
5. Confirm the compressor clutch is engaged and the engine cooling fan(s) are operating or engaged. Allow the vehicle to idle until the suction (low-side) and discharge (high-side) pressures are stable or fluctuate in a range that repeats.
6. Record the ambient (shop) temperature.
7. Record the discharge pressure. If the pressure is fluctuating, record the average value.
8. Determine if the discharge pressure falls within the normal operating limits using the Normal Refrigerant Discharge Pressures chart.
9. Record the suction pressure. If the pressure is fluctuating, record the average value.
10. Determine if the suction pressure falls between normal operating limits using the Normal Refrigerant Suction Pressures chart.
11. Proceed to the diagnostic table.

Fluorescent Dye Detection

Note. Ford Motor Company vehicles are produced with R-134a fluorescent dye installed in the refrigerant system from the factory. The location of leaks can be pinpointed by the bright yellow-green glow of the fluorescent dye under a UV lamp. Since more than one leak can exist, make sure to inspect each component, line and fitting in the refrigerant system for a leak.

Scheme 57

Scheme 58

1. Check for leaks using a Rotunda-approved UV lamp. Inspect all components, lines and fittings of the refrigerant system.
2. If a leak is found, recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
3. Repair the refrigerant system leak(s).
4. Evacuate and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
5. After the leak(s) is/are repaired, remove any traces of fluorescent dye with a general purpose oil solvent.
6. Verify the repair by running the vehicle for a short period of time and rechecking the area of the leak with a Rotunda-approved UV lamp.

Fluorescent Dye Injection - Using An A/C Refrigerant Center And Dye Injector

Note. Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.

Note. Before using the R-134a fluorescent dye injector for the first time, refer to the manufacturers instructions on evacuation of any non-condensable gasses from the hoses.

Note. Only connect the R-134a fluorescent dye injector to a manifold and gauge set or R-134a service center when fluorescent dye is to be injected. The R-134a fluorescent dye injector has a one way check valve that will prevent refrigerant system recovery and evacuation.

Note. Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24 °C (75°F) with the engine off.

Scheme 59

Scheme 60

1. Connect an R-134a A/C refrigerant service center or a manifold and gauge set to the refrigerant system service port valves.
2. Verify that the valves on the fluorescent dye injector are closed.
3. Fill the fluorescent dye injector reservoir with 7 ml (0.25 oz) of fluorescent dye.
4. Install the fluorescent dye injector between the low-pressure service gauge port valve and the R-134a refrigerant service center or manifold gauge set.
5. Open all valves and inject the fluorescent dye into the refrigerant system.
6. When fluorescent dye injection is complete, close all valves.
7. Recover the refrigerant from the R-134a fluorescent dye injector.
8. Remove the fluorescent dye injector from the low-pressure service gauge port valve and the R-134a A/C refrigerant service center or manifold gauge set.

Fluorescent Dye Injection - Using A Dye Injector Loop Kit

Note. Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Replacement suction accumulators and receiver/driers are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator or receiver/drier is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage.

Note. Before using the R-134a fluorescent dye injector for the first time, refer to the equipment manufacturers instructions on evacuation of non-condensable gasses from the hoses.

Note. Refrigerant system pressure should be between 413-551 kPa (60-80 psi) at 24 °C.

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Verify that the valves on the deluxe injector loop kit are closed.
2. Fill the deluxe injector loop kit reservoir with 7 ml (0.25 oz) of fluorescent dye.
3. Install the deluxe injector loop kit between the high-pressure and low-pressure service gauge port valves.
4. Start the engine.
5. Open the high-pressure service valve.
6. Open the deluxe injector loop kit valves and inject the fluorescent dye into the refrigerant system.
7. Close the high-pressure service valve to allow the pressure inside the deluxe injector loop kit to equalize with the suction side of the refrigerant system.
8. Close the valves on the deluxe injector loop kit.
9. Disconnect the high-pressure and low-pressure service valves and remove the deluxe injector loop kit from the vehicle.

Scheme 66

MATERIAL SPECIFICATION

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

Note. Only the A/C Flush and Purge Machine kit 219-00023, which includes A/C Flush and Purge Machine 219-00022, A/C Flush and Purge Fitting Kit 219-00024 and A/C Systems Flushing Solvent, is approved for use on Ford vehicles. No other flushing device or solvent is approved for flushing heat exchangers (A/C condenser, A/C evaporator). Use of any other flusher or solvent may cause damage to the A/C system and the flushing unit.

Note. Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers. 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 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 and Purge Machine 219-00022 to

1. 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.
2. 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.

1. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
2. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
3. Connect the A/C flush and purge machine fitting kit and the A/C flush and purge machine to the heat exchanger to be flushed. Do not flush through the evaporator core orifice (if equipped), TXV (if equipped), or hoses with mufflers. Internal plumbing and material make-up of these components make it impossible to correctly remove foreign material or residual flushing solvent.
4. Flush the heat exchanger for a minimum of 15 minutes.
5. 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 regulations.
6. Install a new A/C evaporator core orifice (if equipped) and/or TXV (if equipped) in any vehicle being serviced for an internal A/C compressor or desiccant failure.
7. Install new refrigerant hoses with mufflers if clogged with foreign material.
8. Install a new suction accumulator (if equipped) or receiver/drier (if equipped) in any vehicle being serviced for an internal A/C compressor or desiccant failure.
9. Reconnect the heat exchanger being serviced.
10. If a new A/C compressor is not to be installed, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207782-S12228692662005120100000) .
11. If a new A/C compressor is not to be installed, evacuate, leak test and charge the A/C system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .

Scheme 67

MATERIAL SPECIFICATION

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 meter and manifold gauge set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Prior to recovering, you must verify the purity of the refrigerant. For additional information, refer to «REFRIGERANT IDENTIFICATION TESTING»(ref-207782-S01378264112005120100000) .
2. Connect an R-134a refrigerant service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer.
3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer.
4. Once the refrigerant service center has recovered the refrigerant, switch OFF the power supply.
5. Allow the system to set for about 2 minutes, and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment.
6. If the system does lose vacuum, repeat Steps 3 through 5 until the vacuum level remains stable for 2 minutes.
7. Carry out the required repairs.

Refrigerant System Evacuation Using An R-134a Service Center

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 meter and manifold gauge set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Connect an R-134a service center to the low- and high-pressure service gauge port valves following the operating instructions provided by the equipment manufacturer.
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 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again.

Refrigerant System Evacuation Using An R-134a Manifold Gauge Set

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 meter and manifold gauge set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak in vacuum that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Connect the R-134a manifold gauge set to the low-side and high-side service gauge port valves.
2. Connect the center (yellow) hose from the manifold gauge set to the suction port on the vacuum pump.
3. Open all valves on the R-134a manifold gauge set and both service gauge port valves.
4. Turn on the vacuum pump and 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.
5. Close the high-side and low-side valves on the manifold gauge set (not the service gauge port valves) and turn off the vacuum pump.
6. Observe the low-pressure gauge for 5 minutes to make sure that the system vacuum is held. If vacuum is not held for 5 minutes, leak test the system, repair the leak and evacuate the system again.

Refrigerant System Charging Using An R-134a Service Center

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 meter and manifold gauge set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207782-S12228692662005120100000) .
2. Connect an R-134a A/C service center to the low-side and high-side service gauge port valves following the operating instructions provided by the equipment manufacturer.
3. Set the refrigerant charge amount, and charge the refrigerant system following the instructions provided by the equipment manufacturer.

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 meter and manifold gauge set.

Note. Leaks in refrigerant system service equipment, hoses or gauges can cause a leak that may be misinterpreted as a problem with the vehicle's refrigerant system. It is necessary to leak-test all refrigerant system service equipment, hoses and gauges on a weekly basis to verify that no leaks are present.

1. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207782-S12228692662005120100000) .
2. Assemble the R-134a manifold gauge set, automatic refrigerant charging meter and R-134a supply tank following the automatic refrigerant charging meter operating instructions.
3. Charge the refrigerant system following the automatic refrigerant charging meter operating instructions.
4. If the refrigerant flow stops before the refrigerant charge is complete, start the engine, select A/C operation and allow the refrigerant charge to complete.

Scheme 68

MATERIAL SPECIFICATION

Scheme 69

1. Orient the filter inlet toward the A/C condenser core.
2. Disconnect the condenser outlet fitting and temporarily install the pancake filter between the two halves of the fitting. Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating. Make the connections using the A/C Test Fitting Set.
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207782-S12228692662005120100000) .
4. Evacuate and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
5. 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.
6. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select 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.
7. 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.
8. Stop the engine.
9. Recover the refrigerant. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
10. Remove the fittings, flexible hoses and pancake filter from between the condenser and the condenser to evaporator tube.
11. Discard the pancake filter. It can be used one time only.
12. Reconnect the condenser outlet fitting.
13. Evacuate, charge and leak-test the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .

Scheme 70

MATERIAL SPECIFICATION

Refrigerant Oil Adding

Refer to the chart below for refrigerant oil adding amounts and methods of installation.

REFRIGERANT OIL ADDING AMOUNTS

Oil Injection Using A Dye/Lubricant Injector

Note. If fluorescent leak detection dye is also to be added during A/C charging, the dye may be added to the dye/lubricant injector along with the refrigerant oil.

Scheme 71

Scheme 72

1. Evacuate the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
2. Assemble the dye/lubricant injector using the correct adapters to match the amount of PAG oil to be injected.
3. Verify that all the valves on the dye/lubricant injector are closed.
4. Fill the dye/lubricant injector with the correct amount of clean PAG oil.
5. Install the dye/lubricant injector between the low-side service gauge port valve and the refrigerant service station or manifold gauge set.
6. Open all valves and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .

Scheme 73

Contaminated Refrigerant Handling

Note. A new suction accumulator or receiver/drier must be installed as directed by the air conditioning system flushing procedure.

1. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant only. If this equipment is not available, contact an A/C service facility in your area with the correct equipment to carry out this service.
2. Determine and correct the cause of the customers initial concern.
3. Flush the air conditioning system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM FLUSHING»(ref-207782-S20689103812005120100000) .
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations.

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 service facility in your area with the correct equipment to carry out this service.
2. Determine and correct the cause of the customer's initial concern.
3. The suction accumulator/drier cannot be cleaned. A new suction accumulator/drier must be installed. Remove the suction accumulator/drier.
4. Clean the A/C evaporator core and the A/C condenser core by flushing. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM FLUSHING»(ref-207782-S20689103812005120100000) .
5. Install the new suction accumulator/drier.
6. Correctly oil match the system. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-207782-S12228692662005120100000) .
7. Evacuate and charge the system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-207782-S20604127602005120100000) .
8. Dispose of contaminated refrigerant according to all federal, state and local regulations.

Scheme 74

Scheme 75

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 Pump or equivalent.

Scheme 76

MATERIAL SPECIFICATION

A/C Odor Treatment

Note. There are typically 4 types of objectionable odors found in a vehicle

1. Chemical odors
2. Environmental odors
3. Human and other interior-generated odors
4. Microbiological odors

Before determining that A/C order treatment is required, the source and the circumstances under which the odor occurs must be determined.

Note. Chemical odors are usually constant regardless of the climate control system setting although they may be enhanced by A/C operation. Most chemical odors are caused by fluid leaks or incorrectly cured adhesives. Chemical odors can be eliminated by repairing the leaking component and removing any residue.

Note. Environmental odors usually occur for a short time and diminish after the vehicle passes through the affected area. These odors are typically only detected when the vehicle windows are open, or when the climate control system is operating in a mode that allows for fresh air. Environmental odors cannot be eliminated because they are external in source, but they may be minimized by switching to a climate control setting that uses recirculated air.

Note. Human and other interior-generated odors occur while the source is present and may linger for a short time after. These odors may be more noticeable during A/C operation. Human odors may be eliminated by removing the source and cleaning the affected area.

Note. Microbiological odors, if in the A/C system, usually last for about 30 seconds after the system is turned on. They will be detected while the A/C is turned on and using either outside or recirculated air. Microbiological odors that occur in areas other than the A/C system (e.g., water in doors or wet carpeting) may last indefinitely, and will be more intense when recirculated air is used. Microbiological odors will not be present at temperatures at or below 10°C (50°F).

Microbiological odors can be eliminated by removing the source and treating the affected area. Standing water must be allowed to drain and dry out. A/C systems may be treated by using Motorcraft A/C Cooling Coil Coating (YN-29) as described in the service procedure below.

Microbiological odors result from microbial growth supported by warm temperatures and moisture. Microbiological odors are described as musty/mildew type smells and may occur on/in

1. foam seals.
2. rubber seals.
3. adhesives.
4. standing water.
5. water soaked carpet/trim.