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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