Ford Falcon. Manual — part 321

412-03-57 Air

Conditioning 412-03-57

REMOVAL AND INSTALLATION (Continued)

NOTE: Refer to Refrigerant Oil Replacement Quantity 8. Disconnect the A/C discharge hose assembly

in this section prior to recharging the A/C system.

from the compressor.

7. Recharge the A/C system. For additional

CAUTION: Plug all ports to prevent

information, refer to A/C system evacuation and

contamination from dirt or moisture.

charging in this section.

NOTE: Do not insert screwdriver between fittings,

as damage can easily occur.

Condenser Inlet Hose Assembly

(Discharge Hose)

Removal and Installation

CAUTION: All refrigerant must be recovered

from A/C system.
1. Recover the refrigerant. For additional

information, refer to A/C Discharging and

Recovery in this section.

2. Remove the bolt from the A/C discharge hose to

A/C condenser core inlet tube fitting and

disconnect the hose asy from the condenser.

9. To install, reverse the removal procedure.

Lubricate the O-ring seals with PAG

Compressor Oil ND-Oil 8.

NOTE: Refer to Refrigerant Oil Replacement Quantity

in this section prior to recharging the A/C system.

10. Recharge the A/C system. For additional

information, refer to A/C system evacuation and

charging in this section.

Compressor Inlet Hose Assembly (I6 &

V8 — Suction Hose) and Accumulator

Outlet Tube Assembly (V8 — Suction

CAUTION: Plug all A/C ports to prevent

Tube)

contamination from dirt or moisture.
NOTE: Do not insert screwdriver between fittings, as

Special Tool(s)

damage can easily occur.

Quick joint clamp removal tool

3. Remove the nut from the A/C discharge hose

mounting bracket to the radiator support panel.

4. Remove the bolt from the A/C discharge hose to

radiator hose guide on the front cross member

(V8 only).

5. Disconnect the suction hose assembly from the

discharge hose assembly double bracket adjacent The BA Falcon 6-cylinder petrol/LPG compressor inlet

to the radiator hose guide on the front cross

hoses (suction hoses) from Feb 2004 have been

member (V8 only).

standardised (BA-19997-D) and this is different to the

early level of BA Falcon petrol/LPG suction hoses

6. Disconnect the A/C discharge hose assembly

(BA-19997-A ans BA-19997-C), both in hose material

from the condenser core.

and routing.

7. Remove the bolt from the A/C discharge hose to

Removal and Installation

compressor fitting.

CAUTION: All refrigerant must be recovered

from the A/C system.
1. Recover the refrigerant. For additional

information, refer to A/C System Discharging and

Recovery in this section.

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412-03-58 Air

Conditioning 412-03-58

REMOVAL AND INSTALLATION (Continued)

2. Disconnect the A/C Suction Hose/Tube assembly 10. Recharge the A/C system. For additional

from the suction accumulator at the quick-connect

information, refer to A/C system evacuation and

joint, using the quick joint clamp removal tool.

charging.

(Refer to section on Quick Joint Clamp

Condenser to Evaporator tube

removal/installation.)

assembly (A/C liquid line)

3. Disconnect the suction hose/tube from the

accumulator (using hands only).

4. Remove the nut from the suction hose bracket to

CAUTION: All refrigerant must be recovered

shock absorber stud. Disconnect the suction hose from the A/C system.

bracket by rotating the bracket on the A/C tube.

CAUTION: Ensure the evaporator tube inlet

CAUTION: Plug all A/C ports to prevent

O-ring (refer to Specifications in this section for

contamination from dirt or moisture.

O-ring details) is present and undamaged prior to

5. Disconnect the suction hose assembly from the

assembly of the A/C liquid line.

discharge hose assembly double bracket adjacent Removal and Installation

to the radiator hose guide on the front cross

1. Recover the refrigerant. For additional

member — (V8).

information, refer to A/C System Discharging and

6. Disconnect the suction tube from the suction hose

Recovery in this section.

at the quick connect joint, using the quick joint

2. Disconnect the A/C liquid line (condenser to

clamp removal tool. (Refer to section on Quick

evaporator line) at the evaporator by removing the

Joint Clamp removal/installation — (V8).)

evaporator E-clamp and bolt. (refer to E-Clamp

7. Remove the screw attaching the suction tube

removal and installation in this section)

bracket to the LH side rail — (V8).

8. Remove the bolt from the A/C suction hose to

CAUTION: Plug all A/C ports to prevent

compressor fitting. Disconnect the suction hose

contamination from dirt and moisture.

assembly from the compressor.

3. Remove the bolt from the liquid line condenser

outlet tube joint and disconnect the liquid line from

CAUTION: Plug all A/C ports to prevent

the condenser.

contamination from dirt or moisture.

NOTE: Do not insert screwdriver between fittings, as

NOTE: Do not insert screwdriver between fittings

damage can easily occur.

as damage can easily occur.

NOTE: If the vehicle is fitted with a turbo intercooler

mounted in front of the A/C condenser, the intercooler

will need to be unbolted and slid sideways and

forward in order to obtain tool access for the A/C

liquid line condenser joint bolt. (refer to Section

303-03)

CAUTION: Plug all A/C ports to prevent

contamination from dirt or moisture.
4. Remove the screw attaching the liquid line

bracket to body adjacent to the charge port, and

remove the saddle clamp and nut adjacent to the

ABS module.

5. To install, reverse the removal procedure.

9. To install, reverse the removal procedure.

1. Lubricate O-ring seals with PAG compressor

Lubricate the O-ring seals with PAG

oil ND-Oil8.

compressor oil ND-Oil8.

NOTE: Refer to Refrigerant Oil Replacement Quantity

in this section prior to recharging the A/C system.

CAUTION: The SFLPG (Single Fuel LPG)

6. Recharge the A/C system. For additional

suction hose is different to the petrol 6-cylinder

information, refer to A/C System Evacuation and

suction hose, and the SFLPG hose is labelled with

Charging.

a green stripe.
NOTE: Refer to Refrigerant Oil Replacement Quantity

in this section prior to recharging the A/C system.

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412-03-59 Air

Conditioning 412-03-59

REMOVAL AND INSTALLATION (Continued)

4. Disconnect evaporator sensor plug from HIM

Evaporator clamp (E-Clamp)

connector.

CAUTION: All refrigerant must be recovered

from the A/C system.

CAUTION: Ensure the evaporator tube

genuine Ford green/blue refrigerant O-rings are

present and undamaged prior to assembly of the

evaporator clamp.
Removal and Installation
1. Recover the refrigerant. For additional

information, refer to A/C System Discharging and

Recovery in this section.

2. Remove the evaporator clamp bolt located

between the accumulator inlet tube and the A/C

liquid line.

5. Disengage Grommet from heater case.

3. Lift and rotate the evaporator clamp to remove it

from both tubes. The swing plate attached to the

liquid line will rotate off the accumulator inlet tube.

4. To install, reverse removal procedure, ensuring

that the swing plate on the liquid line is swung

onto the accumulator inlet tube prior to starting

the evaporator clamp bolt.

NOTE: Full insertion of both tubes onto the

evaporator is critical prior to assembly of the

evaporator clamp.

NOTE: Refer to Refrigerant Oil Replacement Quantity

in this section prior to recharging the A/C system.

5. Recharge the A/C system. For more information,

refer to A/C System Evacuation and Charging in

Item

Description

this section.

1

Grommet

Air Conditioning Cycling Switch

2

Sensor

(evaporator thermistor)

6. Pull out Sensor.

Removal

Installation

1. Set A/C controls to face mode.

1. Ensure sleeve on evaporator sensor is straight

between sections A and B.

2. Remove ICC display screen, Refer to Section

413-08.

3. Remove glovebox from instrument panel. Refer to

Section 501-12.

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412-03-60 Air

Conditioning 412-03-60

REMOVAL AND INSTALLATION (Continued)

2. Insert evaporator sensor into heater case in a

5. Insert evaporator sensor plug into HIM connector.

similar fashion to removal procedure.

6. Refit ICC display screen, Refer to Section 413-08.

3. Using a torch and mirror at ICC opening, look into

7. Refit glovebox to instrument panel. Refer to

heater case and ensure sensor is correctly

section 501-12.

directed through the two holes in airmix divider

panel.

Engine Cooling Fans (Condenser

Fans)

For removal and installation of engine/condenser

cooling fans, refer to section 303-03.

4. Securely clip grommet into heater case and

ensure that sleeve is still straight and in position

as described in 3 above.

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