Ford Falcon. Manual — part 317
412-03-41 Air
Conditioning 412-03-41
GENERAL PROCEDURES (Continued)
Joint Locations
Item
Description
Item
Description
9
Compressor front seal
1
A/C Liquid line to evaporator joint
10
Suction hose - Compressor joint
2
Evaporator to accumulator joint
11
Discharge hose - Compressor joint
3
A/C Liquid line, Orifice tube joint
12
Low pressure service gauge charge port
4
High pressure service gauge charge port
13
Accumulator to suction hose quick -
5
A/C pressure cut-off switch (pressure
connect joint
tranducer)
14
Drain hose for evaporator
6
Compressor pressure relief valve
7
Condenser - A/C liquid line joint
NOTE: V8 has extra quick-connect joint between
suction hose and suction tube at front of LH side-rail.
8
Condenser - Discharge hose joint
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412-03-42 Air
Conditioning 412-03-42
GENERAL PROCEDURES (Continued)
8. Carry out the required repairs, then evacuate and
A/C System Discharging and Recovery
recharge the A/C system. For additional
information, refer to the A/C System Evacuation
Special Tool(s)
and Charging procedure in this section.
R-134a A/C Service Centre
176-00002 or equivalent
A/C System Evacuation and Charging
Special Tool(s)
R-134a Refrigerant Centre
176-00002 or equivalent
R-134a A/C Refrigerant Centre
023-00153 or equivalent
R-134a A/C Refrigerant Centre
023-00153 or equivalent
R-134a Manifold Gauge Set
or equivalent
R-134a Manifold Gauge Set
or equivalent
1. Connect the R-134a A/C Refrigerant Centre to the
low and high pressure service gauge charge
ports.
NOTE: Some R-134a service centres require the
use of an A/C manifold gauge set. For additional
1.2 CFM Vacuum Pump
information, refer to the Manifold Gauge Set
023-R0162 or equivalent
Connection in this section.
2. Empty the Refrigerant Recovery Equipment oil
drain glass container, so that an accurate
measurement can be made of the amount of
refrigerant oil removed from the A/C system in the
Discharging & recovery process.
4.0 CFM Vacuum Pump
3. Recover the refrigerant from the system following
023-R0163 or equivalent
the operating instructions provided by the
equipment manufacturer.
4. Once the service centre has recovered the vehicle
A/C system refrigerant, close the service centre
inlet valve (if so equipped). Then switch off the
power supply.
1. Connect the R-134a A/C Refrigerant Centre to the
5. Allow the vehicle A/C system to remain closed for
low and high pressure service gauge charge
about two minutes. Observe the system vacuum
ports.
level as shown on the gauge. If the vacuum does
NOTE: Ford Motor Company recommends use of
not change, disconnect the recovery station
a charging station to carry out evacuation and
hose(s).
charging of the refrigerant system. If a charging
6. If the system pressure rises, repeat Steps 2
station is not available, system charging may be
through 4 until the vacuum level remains stable
accomplished using a separate vacuum pump,
for two minutes.
charging cylinder, and manifold gauge set. For
7. Record the amount of refrigerant oil collected in
additional information, refer to the Manifold Gauge
the Refrigerant Recovery Equipment oil drain
Set Connection in this section.
glass container, so that this oil can be replaced in
the charging process.
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412-03-43 Air
Conditioning 412-03-43
GENERAL PROCEDURES (Continued)
2. Evacuate the system until the low-pressure gauge
Measure the amount of oil recovered with
reads at least 99.4kPa (29.5 in-Hg) (vacuum) and
refrigerant (refer to Recovery Machine
as close to 101.1kPa (30 in-Hg) as possible.
instructions and A/C system Discharging and
Continue to operate the vacuum pump for a
Recovery).
minimum of 45 minutes.
This amount of oil must be added to the
3. Turn off the evacuation pump. Observe the
system before recharging with refrigerant.
low-pressure gauge for five minutes to make sure 2. Compressor Replacement
that the system vacuum is held. If vacuum is not
Rotate the old A/C compressor shaft six to
held for five minutes, leak test the system, service
eight revolutions while collecting the oil in a
the leaks, and evacuate the system again.
clean measuring device. This amount is all
4. To maintain the original total system oil charge, it
that is required to be in the replacement
is necessary to compensate for the oil lost when
service compressor.
discharging the refrigerant or after replacement of
Drain the oil from the service compressor
a system component. For additional information
(approx. 200ml) and remove a quantity of this
on quantity of oil to be added to the system, refer
new oil, so that the amount of oil left in the
to the Refrigerant Oil Replacement Quantity in
service compressor equals the amount of oil
this section.
collected from the old compressor.
5. Charge the system with the specified weight of
If 140ml was drained from the old compressor
refrigerant as determined by A/C label and charge
than remove 60ml from replacement
with the correct amount of refrigerant oil, using the
compressor. (i.e.140 = 200 - 60).
Replenishment of Refrigerant Oil procedure in this
Pour this revised quantity of new oil back into
section.
the service compressor. Also add an extra
6. When no more refrigerant is being drawn into the
40ml of new oil to the service compressor, to
system, start the engine and select MAX A/C
account for oil that was removed from the A/C
operation. Adjust the blower motor fan speed to
system in replacement of the Accumulator.
maximum and allow the remaining refrigerant to
If the A/C system has been flushed prior to a
be drawn into the system. Continue to add
new compressor installation, follow step 7 for
refrigerant into the system until the specified
refrigerant oil replacement quantity.
weight of R-134a has been added. Close the
charging cylinder valve and allow the system to
3. Accumulator
replacement
pull any remaining refrigerant from the hose.
Drill two ½ inch holes in the accumulator and
When the suction pressure drops to
drain the oil into a calibrated container. Add an
approximately 207kPa (30psi), close the charging
equal amount of oil to the new accumulator plus
hose valve.
20 ml for oil not able to be drained from the
accumulator.
Refrigerant Oil Replacement Quantity
4. Condenser,
Evaporator
replacement
NOTE: During normal A/C operation, oil is circulated
Add 40ml of compressor oil for each component
through the system with the refrigerant, and a small
replaced. As system has been opened the
amount is retained in each component. When
accumulator must be replaced as described in
evacuating or if certain components of the system are
step 3.
removed for replacement, some of the refrigerant oil
5. Orifice Tube replacement
will be lost with the component and with the
Additional oil is required for orifice tube
refrigerant gas. To maintain the original total system
replacement, but as the A/C system has been
oil charge, it is necessary to compensate for the oil
opened to atmosphere, the suction accumulator
lost by adding oil to the system with the new part.
must also be replaced . Add additional oil for
accumulator as detailed in step 3, and also add
NOTE: Service A/C compressors are shipped with
10 ml of oil for orifice tube replacement
compressor oil (200cc).
6. Leak Repair (Hose or tube, O-ring, pressure
1. Refrigerant
recovery
switch, charge port repair / replacement)
Each time a system charge is recovered, an
Additional oil is required unless you can
amount of oil will also be recovered with the
determine no evidence of oil loss (No oil stain
refrigerant.
around joint) As the A/C system has been opened
to atmosphere, the suction accumulator must be
The amount will differ with type of Recovery
replaced . Add additional oil for accumulator as
Machine used and time taken to recover
detailed in step 3, and also add 20 ml for oil loss
refrigerant.
at refrigerant leak.
The oil balance of the system must be
maintained for compressor durability.
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412-03-44 Air
Conditioning 412-03-44
GENERAL PROCEDURES (Continued)
7. System Flushing Effect on Oil Quantity
A/C System Flushing
Flushing the system will remove all the refrigerant
Vehicles that have an inoperative A/C compressor,
oil. If a system is flushed prior to a new
due to internal causes, should have the refrigerant
compressor installation, then the total amount of
system cleaned by flushing. This removes any debris
new oil in the service compressor should be used,
or contaminants that may be present to prevent
to maintain an oil capacity level of 200 ml.
damage to the replacement A/C compressor.
Replenishment of Refrigerant Oil
System flushing should be performed prior to the
installation of the replacement A/C compressor. Flush
NOTE: Refrigerant oil should be added to the A/C
only the A/C evaporator core and A/C condenser
system with the replacement accumulator before it is
core. Note that suction accumulator and A/C
installed. The correct oil quantity depends upon which
evaporator core orifice cannot be flushed.
A/C part has been repaired or replaced. For correct oil
quantities, refer to Refrigerant Oil Replacement
Use Rotunda A/C Refrigerant System Flusher
Quantity in this section.
014-00991 or equivalent.
Alternative 1: Add oil to inlet tube of the accumulator
CAUTION: This system is designed to be
(long tube that attaches to evaporator firewall joint).
used only with the Ford A/C system flushing
Alternative 2: Draw in oil through the low pressure
solvent F4AZ-19579- A. Use of other solvents may
charge port before evacuation, as detailed in steps
result in personal injury and/or damage to the
1-4 below.
vehicle and the flusher.
1. Pour the specified amount of refrigerant oil in to a
measuring cylinder.
CAUTION: Do not let the flushing solvent
F4AZ-19579-A come in contact with your eyes or
2. Connect manifold gauge hoses as shown in
skin. If eye contamination occurs, flush eyes with
illustration.
water for 15 to 20 seconds. Remove contaminated
Manifold gauge (high pressure side).. air
clothing, and wash affected skin with soap and
conditioner high pressure charge port.
water. Seek medical attention.
Manifold gauge (centre).. vacuum port.
1. Before removing any refrigerant system
Measuring cylinder (and oil).. air conditioner
components, recover the system refrigerant
low pressure charge port.
following the A/C System Discharging & Recovery
procedure outlined in this section.
3. When vacuum pump is run, oil is drawn into air
conditioning system from low pressure side.
CAUTION: Follow all refrigerant system
4. Switch off vacuum pump after specified amount of
safety and service precautions as outlined.
oil has been drawn into the system.
2. Disconnect the A/C refrigerant lines from the A/C
evaporator core. This will isolate the A/C
CAUTION: When handling the oil, please
evaporator core orifice and suction
wear gloves.
accumulator/drier from A/C evaporator core.
CAUTION: HFC134a oil is very
3. Disconnect the A/C refrigerant lines from the
hygroscopic (absorbs moisture). Keep the oil
condenser core.
container sealed at all times.
4. Clean all dirt and debris from the fittings on the
A/C evaporator core and/or A/C condenser core
CAUTION: HFC134a oil reacts with some
to be flushed.
plastics. Keep it stored in metal container.
(Plastic bottle should only be used for o-ring
5. Select the proper Flusher machine fittings, clean
lubrication.)
and lubricate connections and securely attach
fittings to the A/C evaporator core and/or A/C
CAUTION: Care should be taken not to
condenser core. O-rings must be used with these
spill the HFC134a oil on paint work, and
fittings to ensure proper leak-free connections.
plastic. If this is accidentally done, wipe
6. Follow instructions given on flushing procedure of
immediately.
the refrigerant system flusher used.
CAUTION: Clearly identify the oils when
transferred to a different container.
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