Ford Falcon. Manual — part 309
412-03-9 Air
Conditioning 412-03-9
DESCRIPTION AND OPERATION (Continued)
been a 2 minute delay since engagement +
A/C Pressure Cut-Off Switch (Pressure
evaporator thermistor registers less than 10ºC +
Transducer)
there are no engine/transmission cooling
requirements for high speed fan.)
The condenser fan is also engaged automatically
if there are engine/transmission cooling
requirements, even if the A/C switch is off.
In both low and high speeds, both condenser fans
operate together.
Quick Joint Connection
The A/C pressure transducer is used to interrupt A/C
compressor operation in the event of high or low
system discharge pressures.
The A/C pressure cut-off switch is mounted on the
high pressure discharge hose assembly.
CAUTION: It is necessary to discharge the
refrigerant system to remove the A/C pressure
cut-off switch.
Item
Description
If the compressor discharge pressure drops below
1
Male fitting
200kPa, the pressure transducer sends a signal
to the EEC which disengages the A/C
2
O-ring, suction
compression.
3
Female fitting
If the compressor discharge pressure rises to
4
Quick joint clamp
approximately 3,170kPa, the pressure transducer
The quick joint connection is a refrigerant line
sends a signal to the EEC which disengages the
coupling held together with a plastic clamp. The
A/C compressor.
plastic clamp has locking tabs that grip the tube shape
When the pressure drops to approximately
and hold tubes together.
2,570kPa, the pressure transducer signal via the
The o-ring seals are black in colour and made of
EEC allows the A/C compressor to re-engage.
a special material compatible with refrigerant &
The pressure transducer is also used for condenser
refrigerant oil. Use only black refrigerant O-Rings
fan control.
in this location.
When the A/C switch is engaged below a set
A special service tool is required to remove the
vehicle speed, the condenser fan is engaged
quick joint connector. Its insertion is important to
automatically if the compressor discharge
proper removal of the quick joint.
pressure is high.
Male fitting (suction hose) must be fully inserted
When the compressor discharge pressure
into female fitting.
reaches approximately 2,100kPa, the pressure
Lubricate o-rings with refrigerant oil to make
transducer signal via the EEC engages the
smooth insertion.
high-speed fan control.
When the pressure drops to approximately 1800
kPa, the pressure transducer signal via the EEC
engages the low speed fan control. (If there has
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412-03-10 Air
Conditioning 412-03-10
DESCRIPTION AND OPERATION (Continued)
Item
Description
Item
Description
1
Female fitting
1
Clamp interlocking tabs
2
Male fitting
2
Stopper lever
3
O-Ring seals
3
Quick joint clamp removal tool
4
Clamp guide
Quick joint clamp wraps around the tube
connection.
Air Conditioning Joint Design
Interlocking tabs on clamp hold clamp in place.
In the A/C system, there are 3 types of joints:
Quick joint clamp clicks shut.
radial seal pad fitting or nut joint
Compression seal 45
° taper joint
Radial seal quick connect joint
For all radial seal joints, the O-ring is retained in a
recessed groove. The O-ring seals against leakage
using radial compression once the joint is fully
assembled, and further tightening of the fitting bolt or
tube nut will not improve the sealing performance. Full
insertion of the tube joint is critical to prevent O-ring
damage. All retained O-rings are black refrigerant
O-rings made from a special material compatible with
refrigerant and refrigerant oil. All quick-connect joints
use two black retained refrigerant O-rings for sealing.
At the evaporator inlet and outlet tube joints,
green/blue refrigerant O-rings are used in a 45
° taper
If gap exists, clamp cannot be closed.
compression seal. Again, these O-rings are made of a
Clamp can rotate freely on tube joint until A/C
special material compatible with refrigerant and
system is charged with refrigerant.
refrigerant oil, and are different dimensions to the
Alignment of clamp guide to quick joint clamp
black refrigerant O-rings. In addition, the evaporator
removal tool is required for clamp removal.
tube green/blue refrigerant O-rings are different
dimensions from previous models.
Prior to making any hose/tube connections, lubricate
the O-ring with compressor oil to avoid refrigerant
leakage.
Fine fibre and dust can affect seal performance.
When disassembling joints, keep O-rings capped to
prevent O-ring damage, contamination and moisture
ingression.
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412-03-11 Air
Conditioning 412-03-11
DESCRIPTION AND OPERATION (Continued)
The fitting is an integral part of the refrigeration line or
component.
Special couplings are required for both the
high-side and low-side charge ports.
The Schraeder-type valve core can be replaced if
the seal leaks.
Always install the appropriate A/C charging valve
cap on the charge port valves after repairing the
refrigerant system.
The high pressure charge port cap located on the
liquid line charge port is smaller than the low
pressure charge port cap located on the suction
hose/tube.
Engine Cooling Fans (Condenser Fans)
The vehicle is fitted with dual electric cooling fans
mounted in a fan shroud directly behind the radiator
assembly.
These fans are used for both engine cooling and air
conditioning condenser cooling. The fans are
controlled by three relays via the Powertrain Control
Module, and when required, operate at low speed
(1400 rpm) or high speed (2300 rpm) depending on
the engine and A/C cooling demands.
Refer to Wiring section and Engine Cooling section
303-03 for further details.
CAUTION: When the ignition is ON, the fans
may start without warning.
Charge Port Valves
The high-pressure charge port valve is located on the
CAUTION: During service operations ensure
A/C liquid line (condenser to evaporator line).
that the fan is not rotated in a direction opposing
The low-pressure charge port valve is located on the
normal operation (designated by an arrow on the
suction hose or tube assembly.
fan blade), or this may damage the motor. For
more information refer to section 303-03.
Item
Description
1
A/C charging valve cap (low pressure)
2
A/C suction hose/tube
3
Charge port valve
4
O-ring seal
5
A/C liquid line
6
A/C charging valve cap (high pressure)
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412-03-12 Air
Conditioning 412-03-12
DIAGNOSIS AND TESTING
Air Conditioning
Inspection and Verification
In order to correctly diagnose the root cause of the
fault, it is advisable that the technician follow the
following Air Conditioning System Fault Test process.
System fault
System test A
System test B
System test C
System test D
A/C Cooling
A/C System
A/C Fault Symptom
A/C System Performance test or
WDS tester or
fault
Functional
Chart, then
A/C system leak test or
Pinpoint tests
Inspection test,
A/C system noise test, then
then
A/C Functional Inspection Chart
A/C component
Result for Inspection Pass
System Fault for Inspection Fail
A/C system
Good cooling performance from
Refer to A/C Fault Symptom Chart
system
A/C compressor
Engages with A/C on (comp clutch Wiring fault, refer pinpoint test A
centre turns)
ICC fault, refer 413-08.
A/C cooling fault, refer A/C Fault
Symptom Chart.
Compressor drive belt
Does not slip or whip when A/C is
Accessory drive fault, refer 303-05
engaged
A/C discharge hose
Hot to touch with A/C on
A/C cooling fault, conduct A/C
Performance test
A/C suction hose
Cold to touch with A/C on
A/C cooling fault, conduct A/C
Performance test
A/C liquid line - before orifice tube
Hot to touch with A/C on
A/C cooling fault, conduct A/C
Performance test
A/C liquid line - after orifice tube
Cool to touch with A/C on
A/C cooling fault, conduct A/C
Performance test
Condenser fan
Air flow across condenser
A/C cooling fault, conduct A/C
Performance test
Wiring fault, refer pinpoint test F
Suction accumulator
Cold to touch with A/C on
A/C cooling fault, conduct A/C
Performance test
System blower fan speed &
Air flow and cooling as
Blower fault, refer 412-04
temperature selection
selectedOperates at all fan speeds Air distribution fault, refer 412-02
A/C cooling fault, refer A/C Fault
Symptom Chart
A/C Fault Symptom Chart
Symptom
Possible Cause
Possible Root
Confirmation Test
Possible Fix
Area
Cause
No A/C cooling
If Comp clutch
If Comp clutch
engages
…
engages
…
Refrigerant fault
Low A/C system
Conduct A/C
Recharge A/C
charge
Performance test
system to
specification
G73303 en
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