Ford Falcon. Manual — part 307

412-03-1 Air

Conditioning 412-03-1

SECTION : 412-03 Air Conditioning

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412-03-3

DESCRIPTION AND OPERATION

Air Conditioning Safety Precautions . . . . . . . . . . . . . . . . . . . . . ..412-03-4

Climate Control System . . . . . . . . . . . . . . . . . . . . . . . . . ...412-03-5

A/C Compressor and Clutch Assembly . . . . . . . . . . . . . . . . . . . . 412-03-6

A/C Compressor Pressure Relief Valve . . . . . . . . . . . . . . . . . . . ...412-03-6

A/C Condenser Core . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-6

Refrigerant

Lines

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..412-03-7

A/C Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-7

A/C Orifice Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . ..412-03-8

Refrigerant

Dye

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-8

Suction

Accumulator

. . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-8

A/C Cycling Switch (evaporator thermistor) . . . . . . . . . . . . . . . . . . .412-03-8

A/C Pressure Cut-Off Switch (Pressure Transducer) . . . . . . . . . . . . . . ..412-03-9

Quick Joint Connection . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-9

Air Conditioning Joint Design . . . . . . . . . . . . . . . . . . . . . . . .412-03-10

Charge Port Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-11

Engine Cooling Fans (Condenser Fans) . . . . . . . . . . . . . . . . . . ...412-03-11

DIAGNOSIS AND TESTING

Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-12

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . .412-03-12

A/C Functional Inspection Chart . . . . . . . . . . . . . . . . . . . . . . 412-03-12

A/C Fault Symptom Chart . . . . . . . . . . . . . . . . . . . . . . . . ..412-03-12

Air Conditioning System Performance Test . . . . . . . . . . . . . . . . . ...412-03-18

A/C System Leak Test . . . . . . . . . . . . . . . . . . . . . . . . . ...412-03-22

A/C System Noise Test . . . . . . . . . . . . . . . . . . . . . . . . . ..412-03-23

Module

Configuration

. . . . . . . . . . . . . . . . . . . . . . . . . . .412-03-24

WDS Parameter Identifier (PID) chart . . . . . . . . . . . . . . . . . . . . 412-03-24

WDS Diagnostic Trouble Code (DTC) chart . . . . . . . . . . . . . . . . . ..412-03-25

A/C disable strategy chart . . . . . . . . . . . . . . . . . . . . . . . . ..412-03-27

Connector Circuit Reference . . . . . . . . . . . . . . . . . . . . . . . ..412-03-28

Air Conditioning & HVAC Relay and Fuses . . . . . . . . . . . . . . . . . ...412-03-31

Pinpoint

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-31

GENERAL PROCEDURES

Manifold Gauge Set Connection . . . . . . . . . . . . . . . . . . . . . . ..412-03-39

Electronic Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-40

Fluorescent Dye Leak Detection . . . . . . . . . . . . . . . . . . . . . . ..412-03-40

A/C System Discharging and Recovery . . . . . . . . . . . . . . . . . . . ...412-03-42

A/C System Evacuation and Charging . . . . . . . . . . . . . . . . . . . . 412-03-42

Refrigerant Oil Replacement Quantity . . . . . . . . . . . . . . . . . . . . .412-03-43

Replenishment of Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . .412-03-44

A/C System Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-03-44

412-03-2 Air

Conditioning 412-03-2

(Continued)

REMOVAL AND INSTALLATION

A/C Hose/Tube Pad Fitting . . . . . . . . . . . . . . . . . . . . . . . . ..412-03-45

O-Ring Removal and Lubrication . . . . . . . . . . . . . . . . . . . . . . .412-03-46

Air Conditioning (A/C) Compressor — I6 Engine . . . . . . . . . . . . . . . . .412-03-46

Air Conditioning (A/C) Compressor — V8 Engine . . . . . . . . . . . . . . . ...412-03-47

Compressor Clutch, Compressor Pressure Relief Valve and Compressor Shaft Seal . ...412-03-48

Air Conditioning (A/C) Compressor Bracket . . . . . . . . . . . . . . . . . . 412-03-48

Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-03-49

Orifice Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .412-03-50

Quick Joint Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-52

Suction Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 412-03-54

Pressure Cut-off Switch (Pressure Transducer) . . . . . . . . . . . . . . . . ..412-03-55

Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . ...412-03-56

Condenser Inlet Hose Assembly (Discharge Hose) . . . . . . . . . . . . . . . 412-03-57

Compressor Inlet Hose Assembly (I6 & V8 — Suction Hose) and Accumulator Outlet Tube

Assembly (V8 — Suction Tube) . . . . . . . . . . . . . . . . . . . . . . ...412-03-57

Condenser to Evaporator tube assembly (A/C liquid line) . . . . . . . . . . . . ...412-03-58

Evaporator clamp (E-Clamp) . . . . . . . . . . . . . . . . . . . . . . . ...412-03-59

Air Conditioning Cycling Switch (evaporator thermistor) . . . . . . . . . . . . . .412-03-59

Engine Cooling Fans (Condenser Fans) . . . . . . . . . . . . . . . . . . . .412-03-60

412-03-3 Air

Conditioning 412-03-3

SPECIFICATIONS

General Specifications

Description

Nm

Description

Specification

Suction accumulator & A/C liquid line -

15

evaporator E-clamp bolt

A/C compressor 10S17C

Suction tube (V8) clamp - side rail

6

Displacement

188 cc

screw

Cylinder bore

32.0 mm (1.26 in)

Suction hose/tube clamp - spring tower

35

Cylinder stroke

23.38 mm (0.92 in)

nut

Rotation

Clockwise

A/C condenser core - A/C liquid line &

10

Magnetic clutch

discharge hose bolts

Air gap between pulley

0.35 mm - 0.60 mm

A/C condenser core bracket - radiator

7

and hub

(0.014 in 0.024 in)

bolts

A/C cycling switch (evaporator thermistor)

Discharge hose clamp - radiator

8

support bolt

Manual Climate Control

Discharge hose clamp (V8) - cross

8

Air outlet vent

6.00

°C max

member bolt

temperature cycling

Switching temperatures

differential

will increase as the

O-Ring Specifications

blower fan speed

Description

Part No

reduces.

Refrigerant O-Ring, green/blue

BA19S710B

Automatic Climate Control

evaporator inlet (small)

Air outlet vent

6.00

°C max

Refrigerant O-Ring, green/blue

BA19S710A

temperature cycling

Switching temperatures

evaporator outlet (large)

differential

will increase as

temperature selection

Refrigerant O-Ring, black discharge

V890158S

becomes hotter.

hose/tube (small)

A/C pressure relief valve

Refrigerant O-Ring, black suction

V890157S

hose/tube (large)

Open

3,430 - 4,100kPa (497 -

595psi)

A/C pressure cut-off switch (pressure

transducer)
low pressure cut-out

200kPa

high pressure cut-out

3,170kPa

Lubricants
PAG Compressor Oil

200cc (supplied in comp)

ND-Oil 8 (250 cc can -

AY19L000A)
Refrigerant R-134a

650

± 50g

( YN-19)

Torque Specifications

Description

Nm

A/C compressor bolt (black colour)

23

upper front mount
A/C compressor bolts (gold colour)

23

A/C compressor bracket bolts - I6

48

A/C compressor bracket bolts - V8

28

A/C liquid line - front LH apron body

10

clamp bolt
A/C liquid line - rear LH body saddle

8

clamp nut
A/C liquid line - nut joint

23

A/C compressor - suction & discharge

10

hose bolts
Suction accumulator bracket nuts

8

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412-03-4 Air

Conditioning 412-03-4

DESCRIPTION AND OPERATION

Refrigerant oil will absorb moisture from the

Air Conditioning Safety Precautions

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.

WARNING: To avoid accidental deployment

and possible injury, the air bag system backup

Air conditioning O-rings are made from a

power supply must be depleted before repairing

material compatible with refrigerant and

any climate control components. To deplete the

refrigerant oil. Always use the correct

backup power supply, disconnect the battery

replacement air conditioning O-ring, or A/C

positive cable and wait one minute. Failure to

system leakage may occur.

follow these instructions may result in personal

If an A/C O-ring is not supplied with A/C hose

injury.

assembly, coat the refrigerant O-ring with oil

Use only R-134a refigerant

before assembling.
When installing a refrigerant line, avoid sharp

WARNING: R-134a is classified as a safe

bends. Position the line away from the

refrigerant, but misuse can make it dangerous.

exhaust or any sharp edges that can chafe the

The following precautions must be observed.

line.

Failure to follow these instructions may result in

Tighten threaded fittings only to

personal injury.

specifications. The aluminum fittings used in

Always wear safety goggles when repairing an

the refrigerant system will not tolerate

air conditioning system.

overtightening.

Avoid contact with liquid refrigerant R-134a.

When disconnecting a fitting, use a wrench on

R-134a vaporizes at approximately -25

°C

both halves of the fitting to prevent twisting of

(-13

°F) under atmospheric pressure and it will

the refrigerant lines or tubes.

freeze skin tissue.

Do not open a refrigerant system or uncap a

Never allow refrigerant R-134a gas to escape

new component unless it is as close as

in quantity in an occupied space. R-134a is

possible to room temperature. This will

non-toxic, but it will displace the oxygen

prevent condensation from forming inside a

needed to support life.

component that is cooler than the surrounding

Allow the engine to cool sufficiently prior to

air.

carrying out maintenance or serious burns

and injury can occur.

CAUTION: To avoid contamination of the A/C

system:

CAUTION: To avoid damaging the vehicle or

Keep service tools and the work area clean.

A/C components, the following precautions must

Never open or loosen a connection before

be observed:

discharging the system.

Do not add R-12 refrigerant to an A/C system

When loosening a connection, if any residual

that requires the use of R-134a refrigerant.

pressure is evident, allow it to leak out before

These two types of refrigerant must never be

opening the fitting.

mixed. Doing so can damage the A/C system.

Before charging, evacuate a system that has

A number of manufacturers are producing

been opened to install a new component or a

refrigerant products that are described as

system that has discharged through leakage.

direct substitutes for refrigerant R-134a. The

Seal open fittings with a cap or plug

use of any unauthorized substitute refrigerant

immediately after disconnecting a component

can severely damage the A/C components. If

from the system.

repair is necessary, use only new or recycled

refrigerant R-134a.

Clean the outside of the fittings thoroughly

before disconnecting a component from the

Do not remove the sealing caps from a new

system.

component until ready to install.

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