Ford Falcon. Manual — part 318

412-03-45 Air

Conditioning 412-03-45

REMOVAL AND INSTALLATION

4. If damaged remove the O-ring seal with a

A/C Hose/Tube Pad Fitting

non-metallic tool.

CAUTION: Do not use metal tools to

CAUTION: All refrigerant must be recovered

remove the O-ring seal. They can cause axial

from the A/C system.

scratches across the O-ring seal groove

Removal

resulting in refrigerant leaks.

1. Recover the refrigerant. Refer to A/C Discharging

and Recovery in this section.

2. Remove the bolt from the air conditioning line

(pad) fitting.

CAUTION: Support the female fitting with

a wrench to prevent the tubes from twisting.

Installation
1. Clean all dirt or foreign material from the fittings.
2. If removed, install a new O-ring seal.

CAUTION: Use only new genuine Ford

black refrigerant O-ring seals which are

compatible with refrigerant R-134a and

3. Pull the air conditioning line (pad) fitting apart.

refrigerant oil ND-Oil8. The use of any O-ring

seals other than specified may result in

intermittent leakage during vehicle operation.

Lubricate the O-ring seals with PAG

Refrigerant Compressor Oil ND-Oil 8.

3. Lubricate the inside of the fittings with PAG

Compressor Oil ND-Oil 8.

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412-03-46 Air

Conditioning 412-03-46

REMOVAL AND INSTALLATION (Continued)

4. Assemble the male and female pad fittings

2. Before making any hose and tube connections,

together.

apply a few drops of compressor oil to the seat of

o-ring to avoid refrigerant leakage.

NOTE: When correctly assembled, the male and

female pad fittings should be flush.

Air Conditioning (A/C) Compressor —

I6 Engine

Removal and Installation

CAUTION: To prevent refrigerant system

contamination, if you are installing a new A/C

compressor because the A/C compressor has

failed internally, you must use the following

procedures:

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.

5. Tighten the pad fitting bolt to the specified torque.

NOTE: Installation of a new suction accumulator is

NOTE: Once tightened to the specified torque,

required when repairing the air conditioning system

further tightening of the pad fitting bolt will not

except when there is physical evidence of system

improve the sealing performance.

contamination from a failed A/C compressor damage

6. Charge the system. Refer to Air Conditioning

to the suction accumulator, evidence of the A/C

System Evacuation and Charging in this section.

system being open to the atmosphere/leaking or

evidence of moisture absorption.

O-Ring Removal and Lubrication

NOTE: If an A/C Flusher is available, carry out the air

1. When removing an o-ring from a tube, use a

conditioning (A/C) system flushing procedure in this

wooden or nylon tool to prevent damaging the

section.

tube.

2. Install a new A/C orifice tube assembly. For

NOTE: Always replace the existing o-rings with

additional information, refer to Evaporator Core

new genuine Ford O-rings specified for refrigerant

Orifice Tube Assembly in this section.

HFC-134a, as air conditioning O-rings are made

3. Remove the drive belt. For additional information,

of a material compatible with refrigerant and

refer to Section 303-05.

refrigerant oil.

4. Disconnect the A/C clutch electrical connector.

NOTE: The evaporator tube inlet and outlet

green/blue refrigerant O-rings are different

dimensions to the A/C System black refrigerant

O-rings, and should not be mixed. (Refer to

Specifications in this section for O-ring details.)

The evaporator tube green/blue refrigerant

O-rings are also different dimensions from

previous models.

5. Remove the A/C discharge hose assembly bolt

and the suction hose assembly bolt from the side

of the A/C compressor and disconnect the A/C

hose assemblies.

CAUTION: Plug all A/C ports to prevent

contamination from dirt or moisture.

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412-03-47 Air

Conditioning 412-03-47

REMOVAL AND INSTALLATION (Continued)

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 recoveryin

this section.

NOTE: Installation of a new suction accumulator is

required when repairing the air conditioning system

when there is physical evidence of system

contamination from a failed A/C compressor, damage

to the suction accumulator, evidence of the A/C

system being open to the atmosphere/leaking or

evidence of moisture absorption.

NOTE: If an A/C Flusher is available, carry out the air

6. Remove the compressor mounting bolts and the

conditioning (A/C) system flushing procedure in this

A/C compressor.

section.

2. Install a new A/C orifice tube assembly. For

additional information, refer to Evaporator Core

Orifice Tube Assembly in this section.

3. Remove the drive belt. For additional information,

refer to Section 303-05.

4. Disconnect the A/C clutch electrical connector.

7. To install, reverse the removal procedure.

NOTE: Each new compressor is supplied with

200cc of ND-Oil8 for the A/C system lubrication.

Refer to Refrigerant Oil Replacement Quantity in

this section prior to fitting a new compressor.

For installation, black compressor mounting

bolt is to be fitted to upper front location (both

5. Remove the A/C discharge hose assembly bolt

I6 & V8). Remaining 3 gold compressor

and the suction hose assembly bolt from the side

mounting bolts to be fitted to other 3

of the A/C compressor and disconnect the A/C

locations.

hose assemblies.

Lubricate the new A/C manifold O-ring seals

with PAG Compressor Oil ND-Oil 8.

CAUTION: Plug all A/C ports to prevent

contamination from dirt or moisture.

8. Recharge the A/C system. For additional

information, refer to A/C system evacuation and

charging in this section.

Air Conditioning (A/C) Compressor —

V8 Engine

Removal and Installation

CAUTION: To prevent refrigerant system

contamination, if you are installing a new A/C

compressor because the A/C compressor has

failed internally, you must use the following

procedures:

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412-03-48 Air

Conditioning 412-03-48

REMOVAL AND INSTALLATION (Continued)

6. Remove the bolts and the two lower compressor

2. Disconnect the A/C clutch electrical connector.

mounting spacers and the A/C compressor.

3. Remove the compressor mounting bolts and

7. To install, reverse the removal procedure.

position the A/C compressor aside.

NOTE: Each new compressor is supplied with

1. For V8, remove the two lower compressor

200cc of ND-Oil8 for the A/C system lubrication.

mounting spacers.

Refer to Refrigerant Oil Replacement Quantity in

I6 Compressor

this section prior to fitting a new compressor.

For installation, black compressor mounting

bolt to be fitted to upper front location (both I6

& V8). Remaining 3 gold compressor

mounting bolts to be fitted to other 3

locations. For V8 only, spacers to be fitted

between comp & bracket on two lower comp

mounting bolts.
Lubricate the new A/C O-ring seals with

Compressor Oil ND-Oil 8.

8. Recharge the A/C system. For additional

information, refer to A/C system evacuation and

charging in this section.

Compressor Clutch, Compressor

V8 Compressor

Pressure Relief Valve and Compressor

Shaft Seal

Removal and Installation
The compressor clutch, compressor pressure relief

valve and compressor shaft seal are not serviceable.
If any compressor clutch, pressure relief valve or

compressor leakage faults occur, replace the

complete compressor and clutch assembly.

Air Conditioning (A/C) Compressor

Bracket

Removal and Installation
1. Remove the drive belt. For additional information,

refer to Section 303-05.

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