Ford Falcon. Manual — part 319

412-03-49 Air

Conditioning 412-03-49

REMOVAL AND INSTALLATION (Continued)

4. Remove the bracket mounting bolts, and the A/C

5. Remove HVAC Assembly. Refer to Section

compressor bracket.

412-02.

6. Detach the Foam Insulators from the Heater and

V8 Bracket

Evaporator Tubes.

I6 Bracket

7. Remove One Screw retaining the Heater Core

mounting clamp to the HVAC.

5. To install, reverse the removal procedure.

8. Undo One Screw retaining the A/C evaporator

Evaporator Core

tube retaining plate.

CAUTION: All refrigerant must be recovered

from the A/C system.
NOTE: The evaporator tube inlet & outlet green/blue

refrigerant O-rings are different dimensions to the A/C

System black refrigerant O-rings, and should not be

mixed. The evaporator tube green/blue refrigerant

O-rings are also different to previous models.

Removal
1. Recover the refrigerant. For additional

information, refer to Discharging and Recovery in

this section.

2. Drain the water from the engine cooling system

(refer to 303-03).

3. Disconnect the evaporator clamp, A/C liquid line,

suction accumulator and Heater Hoses, at the

Firewall. (refer to details in this section).

4. Remove the Instrument Panel, refer to Section

501-02.

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412-03-50 Air

Conditioning 412-03-50

REMOVAL AND INSTALLATION (Continued)

9. Remove the one screw retaining the HIM Heat

insulator and the core face is parallel to the HVAC

sink to the HVAC.

opening surface.
NOTE: Refer to Refrigerant Oil Replacement Quantity

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

1. Refit all previously removed Components in

reverse order to removal.

CAUTION: Care must be taken when

installing the Evaporator core as the

Aluminium Fins could become damaged and

effect air flow over the Evaporator Core.

CAUTION: Ensure evaporator seal

adequately seals around core to prevent air by

pass.

CAUTION: Ensure evaporator tube inlet

10. Undo the five screws used to retain the Case

and outlet green/blue refrigerant ‘O’ Rings are

scroll housing to the HVAC.

present prior to assembling the accumulator

and liquid lines.

2. Recharge the A/C System. For additional

information, refer to Discharging and Recovery in

this section.

3. Refill the engine cooling system (refer to section

303-03).

Orifice Tube Assembly

Special Tool(s)

Broken Orifice Extractor

412-035 (T83L-19990-B)

11. Gently remove the Case scroll clear of the

Evaporator Tubes from the HVAC Main Case.

12. Lift the Evaporator Core clear of the HVAC Main

Case.

Fixed Orifice Tube Tool

412-034 (T83L-19990-A)

CAUTION: All refrigerant must be recovered

from the A/C system.

CAUTION: Ensure liquid line O-ring is

present at the nut joint prior to assembly of the

A/C liquid line.
NOTE: A dirty A/C Orifice tube assembly or A/C liquid

Installation

line (condenser to evaporator tube) containing black

refrigerant oil and particles indicates that the A/C

CAUTION: Fit the Evaporator core into the

compressor must be inspected.

HVAC Case opening, ensuring that the lower side

of the core rests correctly on the White foam

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412-03-51 Air

Conditioning 412-03-51

REMOVAL AND INSTALLATION (Continued)

Removal

5. Hold the special tool T-handle stationary and

rotate the special tool body to remove the A/C

1. Recover the refrigerant. For additional information

orifice tube assembly.

refer to A/C system Discharging and Recovery.

NOTE: Adjustment or repair cannot be made to the

A/C orifice tube assembly. If damaged or blocked, a

new A/C orifice tube assembly must be installed.

NOTE: Install a new A/C orifice tube assembly

whenever a new A/C compressor is installed.

NOTE: The red orifice tube can not be interchanged

with different colour orifice tubes from previous

models.

2. 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.

6. If the A/C orifice tube assembly is broken, screw

CAUTION: Plug all A/C ports to prevent

the end of the special tool into the broken A/C

contamination from dirt or moisture.

orifice tube assembly.

3. Undo the nut joint half way along the A/C liquid

7. Hold the special tool T-handle stationary and

line.

rotate the special tool body to remove the broken

4. Engage the special tool onto the A/C orifice tube

A/C orifice tube.

assembly.

Installation
1. Lubricate the O-ring seals on the A/C orifice tube.

Use PAG Compressor ND Oil-8 or equivalent

meeting Ford specification WSH-M1C231-B.

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412-03-52 Air

Conditioning 412-03-52

REMOVAL AND INSTALLATION (Continued)

2. Place the A/C orifice tube into the special tool.

5. Connect the liquid line at the orifice tube and

tighten the nut after ensuring the liquid line O-ring

is present and undamaged.

3. Using the special tool, insert the A/C orifice tube

into the A/C liquid line (condenser to evaporator

line) until seated.

6. Refit the screw attaching the liquid line bracket to

the body adjacent to the charge port.

7. Refit the saddle clamp and nut adjacent to the

ABS module.
NOTE: Refer to Refrigerant oil Replacement

Quantity in this section prior to recharging to A/C

system.

8. Recharge the A/C system. For additional

information, refer to A/C system evacuation and

charging in this section.

Quick Joint Clamp

Special Tool(s)

Quick joint clamp removal tool

4. Remove the special tool.

Removal

CAUTION: All refrigerant must be recovered

from A/C system.

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