HVAC - Climate Control System: Other Ford Transit VII

Air Conditioning

The refrigerant system components include the following

1. A/C compressor and clutch assembly
2. A/C condenser core
3. A/C evaporator core
4. Suction accumulator
5. Connecting refrigerant lines
6. Evaporator core orifice

The refrigerant system incorporates an A/C compressor controlled by the PCM through an A/C clutch relay. An A/C cycling switch is used to cycle the A/C compressor off when the pressure in the low-pressure side of the refrigerant system falls below an acceptable level.

An A/C compressor pressure relief valve is installed in the A/C compressor to protect the refrigerant system against excessively high refrigerant pressures.

A/C Pressure Relief Valve

Note. If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the A/C pressure relief valve is leaking around the threads, install a new A/C pressure relief valve and O-ring. If the new A/C pressure relief valve still vents after it is installed, diagnose the refrigerant system for a restriction.

An A/C pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C compressor and other system components by relieving unusually high system discharge pressure buildups. For specifications regarding operating pressure(s), refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

The A/C pressure relief valve is a separate component and can be installed separately from the A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve.

A/C Condenser Core

The A/C condenser is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat, and condenses gas to liquid refrigerant as it is cooled.

A/C Evaporator Core

Note. The evaporator core is not separately serviceable, it is serviced only with the evaporator core housing assembly.

The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of liquid refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet tube as a vapor. During A/C compressor operation, airflow from the blower motor is cooled and dehumidified as it flows through the evaporator core fins.

Evaporator Core Orifice

The evaporator core orifice is located in the condenser-to-evaporator line and can be removed and installed through an access fitting. The evaporator core orifice provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system, and separates the low-pressure and high-pressure sides of the refrigerant system.

Suction Accumulator

Note. Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than 1 hour. If even a slight amount of position refrigerant pressure is present in the refrigerant system before repairs are carried out, the suction accumulator should not be replaced.

The suction accumulator is used to prevent residual liquid refrigerant from reaching the A/C compressor after leaving the evaporator core. The suction accumulator allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system.

The suction accumulator is located behind the RH front corner of the front bumper cover in front of the RH fender splash shield.

A/C Cycling Switch

The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C compressor clutch when the suction pressure in the low-pressure side of the refrigerant system drops below acceptable levels. The PCM monitors the A/C cycling switch. When the A/C cycling switch contacts are open, the PCM will disengage the A/C compressor clutch.

The A/C cycling switch is located on a Schrader-type valve fitting on the evaporator outlet line. It is not necessary to recover the refrigerant to remove the A/C cycling switch.

A/C Pressure Transducer

The A/C pressure transducer monitors the compressor discharge pressure and communicates with the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage.

The A/C pressure transducer is located on the condenser-to-evaporator line behind the RH corner of the front bumper cover. It is not necessary to recover the refrigerant before removing the A/C pressure transducer.

Service Gauge Port Valves

The high-pressure service gauge port valve is located on a vertical extension off the compressor-to-condenser discharge line behind the RH headlamp.

The low-pressure service gauge port valve is located on the suction accumulator behind the RH corner of the front bumper cover, and can be accessed by detaching the front portion of the RH fender splash shield.

Scheme 31

ITEM DESCRIPTION CHART - VALVES AND VALVE CAPS

The fitting is an integral part of the refrigerant system line or component.

1. Special couplings are required for both the high-side and low-side service gauge ports.
2. A very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively.
3. The service gauge port valve caps each include an O-ring seal which is used as a primary seal in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. The service gauge port valve cap O-ring seals should be checked when checking the refrigerant system for leaks and a new cap should be installed if needed. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed.

Refrigerant System Dye

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 black light. 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 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 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 or hose rupture. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

Air Distribution and Filtering

There are 2 sources of air available to the air distribution system

1. Outside air
2. Recirculated air

Recirculated air can be selected in any mode except DEFROST. Outside air is used when in the DEFROST mode, or at any time RECIRC is not selected. An electric mode door actuator is used to position the air inlet door.

Air distribution within the vehicle is determined by the airflow mode selected. Cable controlled airflow mode control doors are used to direct airflow within the heater core and evaporator core housing.

Air enters the passenger compartment from the following outlets

1. Instrument panel registers
2. Floor duct outlets
3. Windshield defroster
4. Side window demisters
5. Rear footwell duct

Passenger compartment air is exhausted from the vehicle through open windows or body air vents.

Manual Climate Control

The manual climate control system control components are used to select

1. Air inlet source (outside or recirculated)
2. Blower motor speed
3. Discharge air temperature (temperature blend)
4. Discharge air location (defrost, panel, floor)
5. A/C compressor operation
6. Rear window defroster operation

Blower Motor Switch

The blower motor switch controls the blower motor speed and enables the A/C request button. When the blower is set to HI, the blower motor switch provides a direct ground for the blower motor, resulting in HI blower speed. When LO, MED LO or MED HI blower is selected the blower motor switch directs the blower motor ground through the blower motor resistor.

The blower motor switch is mounted to the climate control assembly and can be separately replaced.

A/C Switch

The A/C switch is enabled by the blower motor switch. The A/C switch assembly sends a reference signal to the blower motor switch. When the reference signal is grounded (blower motor switch turned ON) the A/C switch is enabled. The A/C switch is disabled when the blower motor switch is in the OFF position. When A/C is selected (indicator ON), an A/C request signal is sent to the PCM. The A/C indicator can be toggled on and off when in the FLOOR/DEFROST or DEFROST mode, but an A/C request signal will be sent to the PCM regardless of the indicator status.

The A/C switch is mounted to the shifter lever trim bezel at the front of the floor console.

Air Inlet Switch

When RECIRC is requested on the air inlet switch (indicator ON), the air inlet mode door actuator will drive to the recirculated air inlet position. When the RECIRC request is deactivated (indicator OFF), the air inlet mode door actuator will drive to the fresh air inlet position. The RECIRC function is disabled when in the FLOOR/DEFROST or DEFROST mode.

Blower Motor Speed

The blower motor speed switch varies the blower motor ground circuit resistance by adding or bypassing series resistance in the blower motor resistor. Increased resistance will lower the blower motor speed, and lowered resistance will increase blower motor speed. When the blower motor is in the HI (4) position, the blower motor resistor is bypassed.

The blower motor resistor is located on the heater core and evaporator core housing near the blower motor.

Air Inlet Mode Door Position

The air inlet mode door actuator is a reversible electric motor which moves the air inlet door, between the fresh and recirculated air inlets, on command from the air inlet switch assembly. When RECIRC is requested, the air inlet mode door actuator moves to the RECIRC position, allowing only recirculated air inlet. When RECIRC is deselected, the air inlet mode door actuator moves to the FRESH air inlet position, allowing only fresh air inlet.

The air inlet mode door actuator is mounted to the air inlet duct and can be accessed through the glove compartment. The air inlet mode door actuator can be installed separately.

Heating and Ventilation

The heating and ventilation system has the following features

1. Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle
2. Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level
3. Cooling or heating can be adjusted to maintain the desired temperature

The heating and ventilation system includes the following components

1. Blower motor
2. Heater core and evaporator core housing
3. Heater core

Blower Motor

The blower motor draws air from the air inlet and forces it into the heater core and evaporator core housing where it is mixed and distributed. The blower motor receives battery voltage at all times when the ignition is in the RUN position, and is grounded by the blower motor switch.

The blower motor is located on the heater core and evaporator core housing below the glove compartment area.

Heater Core and Evaporator Core Housing

The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by an electric motor actuated temperature blend door. After passing through/around the heater core, the airflow is distributed to the selected outlet by the airflow mode doors. The airflow mode doors are actuated by the airflow mode door/temperature blend door actuating assembly mounted to the heater core and evaporator core housing to the right of the accelerator pedal.

Heater Core

The heater core receives a flow of coolant from the engine cooling system through the heater core inlet. The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. The engine coolant is then returned to the engine cooling system through the heater core outlet.

The heater core is located on the heater core and evaporator core housing.

Material

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 32

ITEM DESCRIPTION CHART - A/C/ COMPRESSOR

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 33

ITEM DESCRIPTION CHART - A/C PRESSURE RELIEF VALVE

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 34

ITEM DESCRIPTION CHART - FRONT SPLASH SHIELD AND RADIATOR SUPPORT

Scheme 35

ITEM DESCRIPTION CHART - COMPRESSOR TO CONDENSER DISCHARGE LINE

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 36

ITEM DESCRIPTION CHART - CONDENSER CORE

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 37

ITEM DESCRIPTION CHART - CONDENSER TO EVAPORATOR LINE

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 38

ITEM DESCRIPTION CHART - EVAPORATOR CORE ORIFICE

Scheme 39

Scheme 40

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
2. Disconnect the evaporator core orifice access fitting. Discard the O-ring seal.
3. Inspect the evaporator core orifice for damage before attempting to remove it from the line.
4. If the evaporator core orifice is intact, engage the Fixed Orifice Remover/Installer. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice.
5. If the evaporator core orifice is broken, screw the end of the Broken Orifice Remover into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice.

Scheme 41

1. Lubricate the evaporator core orifice O-ring seals in clean PAG oil and install the evaporator core orifice using the Fixed Orifice Remover/Installer.
2. Connect the evaporator core orifice access fitting. Install a new O-ring seal.
3. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
4. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 42

ITEM DESCRIPTION CHART - EVAPORATOR OUTLET LINE

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 43

ITEM DESCRIPTION CHART - HEATER AND EVAPORATOR

Scheme 44

ITEM DESCRIPTION CHART - HEATER CORE & EVAPORATOR CORE HOUSING

MATERIAL SPECIFICATIONS - PAG REFRIGERANT COMPRESSOR OIL

Scheme 45

ITEM DESCRIPTION CHART - SUCTION ACCUMULATOR