HVAC Control System - General Information: Other Ford Taurus IV рестайлинг

Climate Control System

1. Always wear safety goggles when repairing an air conditioning system.
2. Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°F) under atmospheric pressure and it will freeze skin tissue.
3. Never allow refrigerant R-134a gas to escape in quantity in an occupied space. R-134a is non-toxic, but it will displace the oxygen needed to support life.
4. Do not allow any portion of the charged air conditioning system to become too hot. The pressure in an air conditioning system rises as the temperature rises and temperatures of approximately 85°C (185°F) can be dangerous.
5. Allow the engine to cool sufficiently prior to carrying out maintenance or serious burns and injury can occur.

1. The A/C refrigerant of all vehicles must be identified and analyzed prior to refrigerant charging. Failure to do so can contaminate the shop bulk refrigerant and other vehicles.
2. Do not add R-12 refrigerant to an A/C system that requires the use of R-134a refrigerant. These two types of refrigerant must never be mixed. Doing so can damage the A/C system.
3. Charge the A/C system with the engine running only at the low-pressure side to prevent refrigerant slugging from damaging the A/C compressor.
4. Use only R-134a refrigerant. Due to environmental concerns, when the air conditioning system is drained, the refrigerant must be collected using refrigerant recovery/recycling equipment. Federal law REQUIRES that R-134a be recovered into appropriate recovery equipment and the process be conducted by qualified technicians who have been certified by an approved organization, such as MACS, ASI, etc. Use of a recovery machine dedicated to R-134a is necessary to reduce the possibility of oil and refrigerant incompatibility concerns. Refer to the instructions provided by the equipment manufacturer when removing refrigerant from or charging the air conditioning system.
5. Refrigerant R-134a must not be mixed with air for leak testing or used with air for any other purpose above atmospheric pressure. R-134a is combustible when mixed with high concentrations of air and higher pressures.
6. A number of manufacturers are producing refrigerant products that are described as direct substitutes for Refrigerant R-134a. The use of any unauthorized substitute refrigerant can severely damage the A/C components. If repair is required, use only new or recycled Refrigerant R-134a.

1. Never open or loosen a connection before discharging the system.
2. When loosening a connection, if any residual pressure is evident, allow it to leak out before opening the fitting.
3. Evacuate a system that has been opened to install a new component or one that has discharged through leakage before charging.
4. Seal open fitting with a cap or plug immediately after disconnecting a component from the system.
5. Clean the outside of the fittings thoroughly before disconnecting a component from the system.
6. Do not remove the sealing caps from a new component until ready to install.
7. Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open an oil container until ready to use and install the cap immediately after using. Store the oil in a clean, moisture-free container.
8. Install a new O-ring seal before connecting an open fitting. Coat the fitting and O-ring seal with mineral oil before connecting.
9. When installing a refrigerant line, avoid sharp bends. Position the line away from the exhaust or any sharp edges that can chafe the line.
10. Tighten threaded fittings only to specifications. The steel and aluminum fittings used in the refrigerant system will not tolerate over-tightening.
11. When disconnecting a fitting, use a wrench on both halves of the fitting to prevent twisting of the refrigerant lines or tubes.
12. Do not open a refrigerant system or uncap a new component unless it is as close as possible to room temperature. This will prevent condensation from forming inside a component that is cooler than the surrounding air.

The manual climate control system heats or cools the vehicle depending on the function selector switch (19B888) 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 blower motor switch (18578) varies the blower motor speed.

The electronic automatic temperature control (EATC) system maintains the selected vehicle interior temperature by heating or cooling the air.

1. During A/C operation the system also reduces the relative humidity of the air.
2. The driver may override the automatic mode of operation.

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 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 (CASS)

Liquid refrigerant may accumulate in the A/C compressor under certain conditions. To alleviate damage to the A/C compressor, the 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 the engine cranking. The A/C control relay engages the A/C compressor for approximately 4-15 revolutions of the A/C compressor or a maximum of 2 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 condenser core (19712).

The 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 condenser core and enters the inlet side of the evaporator core orifice (19D990).

The evaporator core orifice is the restriction in the refrigerant system that creates the high-pressure buildup upstream of the condenser core 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 evaporator core (19860), it absorbs heat from the passenger compartment airflow passing over the plate/fin sections of the 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 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 evaporator air discharge temperature sensor (19C734) interrupts compressor operation before the external temperature of the evaporator core gets low enough to cause the condensed water vapor (excess humidity) to turn to ice.

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

The low-side line pressure is monitored by the low charge switch (19E561) which disengages the A/C compressor if the system pressure becomes too low due to a low refrigerant charge.

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

Scheme 261

MAX A/C

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 defrost door and floor console duct door (if equipped) vacuum control motors are 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. 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.

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 defrost door vacuum control motors are 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. 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.

PANEL

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 defrost door vacuum control motors are 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 temperature can be adjusted to heat the air, but the air cannot be cooled below the outside temperature.
4. The A/C compressor will not operate.
5. The blower motor is on.

OFF

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 defrost door vacuum control motors are at no vacuum, and the panel/floor door vacuum control motor is at full vacuum, closing off airflow to the defrost duct, side window demisters, floor duct, instrument panel A/C registers.
3. The A/C compressor will not operate.
4. The blower motor is off.

PANEL/FLOOR

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 defrost door vacuum control motors are at full vacuum and the panel/floor door vacuum control motor is at partial vacuum, directing airflow to the floor duct, the instrument panel A/C registers. A small amount of airflow from the side window demisters will be present.
3. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
4. The blower motor is on.

FLOOR

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 defrost door vacuum control motors are at no vacuum, directing airflow to the floor duct.
3. Blended air temperature is available.
4. The A/C compressor will not operate.
5. The blower motor is on.

FLOOR/DEFROST

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 defrost door vacuum control motors are at no vacuum, directing airflow to the floor duct, the defroster duct and the side window demisters.
3. The temperature can be adjusted to heat or cool the air below the outside temperature.
4. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

DEFROST

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, defrost door vacuum control motors are at no vacuum, directing airflow to the defroster duct and the side window demisters.
3. The temperature can be adjusted to heat or cool the air below the outside temperature.
4. The A/C compressor will operate if the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

AUTO

When AUTO is selected

1. The temperature control setting is manually set to the desired settings.
2. The air inlet door vacuum control motor is automatically controlled by the RCC module, based on the temperature setting.
3. The mode door vacuum control motors are automatically controlled by the RCC module based on the temperature setting.
4. The A/C compressor is automatically controlled by the RCC module based on the temperature setting. The A/C compressor will not operate if the outside temperature is lower than approximately 6°C (43°F).
5. The blower motor is on. The blower motor speed is automatically controlled by the RCC module based on the temperature setting, but can be manually overridden.

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 defrost door vacuum control motors are at no vacuum, and the panel/floor door vacuum control motor is at full vacuum, closing off airflow to the defrost duct, side window demisters, floor duct, instrument panel A/C registers.
3. The A/C compressor will not operate.
4. The blower motor is OFF.

When PANEL is selected

1. The recirc request button is enabled. If the recirc request button is selected (indicator on), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator off), the air inlet door actuator admits only outside air into the passenger compartment.
2. The defrost door vacuum control motors are at full vacuum and the panel/floor door vacuum control motor is at no vacuum, directing airflow to the instrument panel A/C registers.
3. Blended air temperature is available. Only when A/C compressor operation has been selected by pressing the A/C request button (indicator on), can the airflow temperature be cooled below the outside air temperature.
4. The A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

When PANEL/FLOOR is selected

1. The recirc request button is enabled. If the recirc request button is selected (indicator on), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator off), the air inlet door actuator admits only outside air into the passenger compartment.
2. The defrost door vacuum control motors are at full vacuum and the panel/floor door vacuum control motor is at partial vacuum, directing airflow to the instrument panel A/C registers and the floor duct.
3. Blended air temperature is available. Only when A/C compressor operation has been selected by pressing the A/C request button (indicator on), can the airflow temperature be cooled below the outside air temperature.
4. The A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

When FLOOR is selected

1. The recirc request button is enabled. If the recirc request button is selected (indicator on), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator off), the air inlet door actuator admits only outside air into the passenger compartment.
2. The panel/floor door vacuum control motor is at full vacuum and the defrost door vacuum control motors are at no vacuum, directing airflow to the floor duct.
3. Blended air temperature is available. Only when A/C compressor operation has been selected by pressing the A/C request button (indicator on), can the airflow temperature be cooled below the outside air temperature.
4. The A/C request button is enabled. The A/C compressor will operate and the indicator will illuminate if the A/C request button is selected and the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

When FLOOR/DEFROST is selected

1. The recirc request button is enabled. If the recirc request button is selected (indicator on), the air inlet door actuator closes off outside air from entering the passenger compartment. If the recirc request button is not selected (indicator off), the air inlet door actuator admits only outside air into the passenger compartment.
2. The panel/floor door vacuum control motor is at partial vacuum and the defrost door vacuum control motors are at no vacuum, directing airflow to the floor duct, the defroster duct and the side window demisters.
3. The temperature can be adjusted to heat or cool the air below the outside temperature.
4. The A/C request button will always toggle the indicator and will only operate the A/C compressor when the recirc button is in fresh air mode and the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

When DEFROST is selected

1. The recirc request button and indicator is enabled. Regardless of button and indicator status, the air inlet door actuator admits only outside air into the passenger compartment.
2. The panel/floor door, defrost door vacuum control motors are at no vacuum, directing airflow to the defrost duct and the side window demisters.
3. The temperature can be adjusted to heat or cool the air below the outside temperature.
4. The A/C request button will illuminate and is enabled. To reduce fogging, the A/C compressor will operate automatically, regardless of indicator status, if the outside temperature is above approximately 6°C (43°F).
5. The blower motor is on.

Scheme 262

Scheme 263

Refer to AIR CONDITIONING (Taurus) or AIR CONDITIONING (Sable) for schematic and connector information.

A/C Performance Check

1. Place the vehicle in the shade with the hood OPEN and windows DOWN in an enclosed shop area to minimize wind gust and sun load effects. Make sure the right front footwell is free of obstruction.
2. If equipped with manual climate control, with the engine running at idle, select MAX A/C (RECIRC) and set the temperature control to full COOL with the blower speed set to MEDIUM (Position 2).
3. If equipped with EATC, with the engine running at idle, select A/C and RECIRC and set the temperature to the lowest setting (60°F) with the blower manually set to MEDIUM blower speed (4 bars displayed).
4. Measure the ambient temperature and humidity adjacent to the passenger side mirror, at approximately evaporator core height.
5. With all vents opened, place a thermometer in the left center register and allow the temperature to stabilize for 6 to 8 minutes.
6. Record 5 vent temperature readings at the center register within 5 minutes.
7. Calculate the Average Center Vent Temperature. Add the 5 recorded vent temperature readings to obtain the sum. Divide the sum of the vent temperature readings by 5 to obtain the Average Center Vent Temperature.
8. Compare the Average Center Vent Temperature to the A/C performance chart for the ambient conditions at the time of testing. If the Average Center Vent Temperature is less than the temperature in the A/C performance chart, no further diagnosis is required. If the Average Center Vent Temperature is greater than the temperature in the A/C performance chart, refer to the «SYMPTOM CHART»(ref-233738-S14768063022006052600000) .

A/C Performance Chart

A/C PERFORMANCE CHART

Heater Core

1. NOTE: Testing of returned heater cores reveals that a large percentage are good and did not require installation of a new heater core. If a heater core leak is suspected, the heater core must be tested by following the plugged heater core component test before the heater core pressure test. Carry out a system inspection by checking the heater system thoroughly as follows: Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose (18472) could follow the heater core tube to the heater core and appear as a leak in the heater core (18476).
2. 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 inlet and outlet hose to see if they are hot. If the inlet hose is not hot: the thermostat is not working correctly. If the outlet hose is not hot: the heater core may have an air pocket. the heater core may be restricted or plugged.

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 at the beginning of this article 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-233738-S34471901732006052600000) . 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.

Disconnect

1. Remove the nut and separate the 2 halves of the peanut fitting.
2. Remove the O-ring seal with a non-metallic tool.

Scheme 264

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 265

Material

MATERIAL SPECIFICATIONS

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 266

Scheme 267

Scheme 268

Scheme 269

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 DIMENSION Coupling Size Pad Size 3/8 inch 25 x 50 mm (1x2 inch) 1/2 inch 25 x 50 mm (1x2 inch) 5/8 inch 25 x 76 mm (1x3 inch) 3/4 inch 25 x 102 mm (1x4 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 270

Scheme 271

1. Install the spring lock coupling spring.
2. Lubricate the inside of the coupling with PAG oil.
3. Install the O-ring seals.
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.

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 272

Scheme 273

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 15°C (60°F) (lowest possible temp setting) with the dual function disabled (if equipped). Manually set blower on HI. 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»(ref-233738-S42052233962006052600000) .

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 274

Scheme 275

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 15°C (60°F) (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»(ref-233738-S42052233962006052600000) .

MATERIAL SPECIFICATIONS

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 276

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-233738-S22395147452006052600000) .
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-233738-S22395147452006052600000) .
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 manufacturer's 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 277

Scheme 278

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 manufacturer's 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 (75°F).

Scheme 279

Scheme 280

Scheme 281

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.

MATERIAL SPECIFICATIONS

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-233738-S22395147452006052600000) .
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 auto 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-233738-S15942385292006052600000) .
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-233738-S22395147452006052600000) .

MATERIAL SPECIFICATIONS

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-233738-S34471901732006052600000) .
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-233738-S15942385292006052600000) .
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-233738-S15942385292006052600000) .
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.

MATERIAL SPECIFICATIONS

Scheme 282

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 2 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 refrigerant compressor oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-233738-S15942385292006052600000) .
4. Evacuate and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-233738-S22395147452006052600000) .
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-233738-S22395147452006052600000) .
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-233738-S22395147452006052600000) .

MATERIAL SPECIFICATIONS

Refrigerant Oil Adding

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

METHOD OF ADDING

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.

1. Evacuate the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-233738-S22395147452006052600000) .
2. Assemble the dye/lubricant injector using the correct adapters to match the amount of refrigerant compressor 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, new 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-233738-S22395147452006052600000) .

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.
4. Dispose of the contaminated refrigerant in accordance with all federal, state and local regulations.

MATERIAL SPECIFICATIONS

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 (for example, 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 A/C cooling coil coating 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.