Ford Falcon. Manual - part 320

412-03-53 Air 

Conditioning 412-03-53

REMOVAL AND INSTALLATION (Continued)

1.  Needles will release quick joint clamp locking

3.  Align the plastic quick joint clamp to suit the quick

tabs. A plate will hold quick joint clamp in to the

joint clamp removal tool.

tool. Stopper lever will locate tool to tube joint.

NOTE: Guide on quick joint clamp must fit into

slot on tool.

Item

Description

1

Stopper Lever

Item

Description

2

Needles

1

Quick Joint Clamp

3

Plate

2

Stopper Lever

3

Clamp Removal tool

2.  Recover the refrigerant. For additional

information, refer to A/C System Discharging and

4

Clamp Guide

Recovery in this section.

4.  Push tool onto quick joint clamp using thumbs.

NOTE: Do not bend the needles inside the tool

when inserting.

5.  Push with thumbs.

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412-03-54 Air 

Conditioning 412-03-54

REMOVAL AND INSTALLATION (Continued)

6.  Quick joint clamp will release (spring open).

2.  Wrap quick joint clamp about tube joint.

Remove quick joint clamp removal tool by lifting

 

1.  Squeeze to close quick joint clamp

the stopper lever to remove from A/C tube.

3.  Clamp must click

Item

Description

 

1.  No gap at (X) joint between both halves of

1

Lift Stopper Lever

clamp.

2

Slide off removal tool and clamp

Installation
1.  Fully insert tube joint, such that:
 

1.  No gap exists.

 

2.  Lubricate O-Ring seals with PAG Compressor

oil ND-Oil 8.

Suction Accumulator

Special Tool(s)

Quick joint clamp removal

Item

Description

1

Female fitting

2

Male fitting

3

O-Ring seals

The BA Falcon suction accumulator from December

2003 (BA-19C808-B, post December 2003) has a

different mounting to the earlier version of BA Falcon

accumulator (BA-19C808-A, pre December 2003).

Both the later level accumulator bracket and the

welded body apron brackets have been revised, and

the later level accumulator bracket cannot be fitted to

the earlier level body bracket.

 CAUTION: All suction accumulators contain a

dessicant which is very hygroscopic (absorbs

moisture). It is very important to keep the ports of

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412-03-55 Air 

Conditioning 412-03-55

REMOVAL AND INSTALLATION (Continued)

the new accumulator sealed until immediately

4.  Disconnect the accumulator inlet tube from the

prior to its installation.

A/C evaporator core by removing the E-clamp and

bolt. (Refer to E-Clamp Removal and Installation

in this section)

 CAUTION: All refrigerant must be recovered

from the A/C system.

 CAUTION: Ensure the evaporator outlet

Removal

tube o-ring (Refer to Specifications in this

1.  Recover the refrigerant. For additional

section for O-ring details) is present and

information, refer to A/C system discharging and

undamaged prior to assembly of the A/C

recovery in this section.

suction accumulator.

2.  Disconnect the A/C suction hose assembly from

 CAUTION: Plug all A/C ports to prevent

the suction accumulator at the quick connect joint,

contamination from dirt or moisture.

using the quick joint clamp removal tool. (Refer to

section on quick-connect joint removal/assembly.)

 CAUTION: Plug all A/C ports to prevent

contamination from dirt or moisture.

5.  Remove the suction accumulator.
Installation

 CAUTION: Refer to Refrigerant Oil

Replacement Quantity in this section prior to

3.  Remove the two suction accumulator mounting

fitting a new accumulator.

nuts.

1.  To install, reverse the removal procedure.

Install the new suction accumulator with the

correct amount of PAG Compressor Oil

ND-Oil 8.
Lubricate the O-ring seals with PAG

Compressor Oil ND-Oil 8.

2.  Recharge the A/C system. For additional

information, refer to A/C system evacuation and

charging in this section.

Pressure Cut-off Switch (Pressure

Transducer)

Removal and Installation

 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.

2.  Disconnect the A/C pressure cut-off switch

electrical connector (pressure transducer).

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412-03-56 Air 

Conditioning 412-03-56

REMOVAL AND INSTALLATION (Continued)

3.  Remove the A/C pressure cut-off switch (pressure

sideways & forward (refer to Section 303-03) to

transducer) from the A/C discharge hose

obtain tool access for the A/C liquid

assembly.

line-condenser joint bolt.

4.  To install, reverse the removal procedure.

4.  Remove the mounting bolts from the A/C

Lubricate the O-ring seals with PAG

condenser core brackets.

Compressor Oil ND-Oil 8.

 CAUTION: Prior to removing the

NOTE: Refer to Refrigerant Oil Replacement Quantity

condenser assembly, insert a sheet of

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

cardboard either side of the core to protect the

tubes and fins.

5.  Recharge the A/C system. For additional

information, refer to A/C system evacuation and

NOTE: The condenser assembly can be removed

charging in this section.

from the top of the vehicle, if the engine cooling

fan and shroud has been removed and the

Condenser Assembly

radiator assembly has been loosened and tilted

rearwards. (refer to Section 303-03)

Removal and Installation

NOTE: The condenser assembly can be removed

 CAUTION: All refrigerant must be recovered

from underneath the vehicle, if the air deflector

from the A/C system.

has been removed. (refer to Section 501-02)

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 condenser core leak is suspected,

the A/C condenser core should be leak tested before

it is removed from the vehicle. For additional

information, refer to Electronic Leak Detection and

Fluorescent Dye Leak Detection in this section.

1.  Recover the refrigerant. For additional

information, refer to A/C System Discharging and

5.  Remove the A/C condenser core.

Recovery in this section.

6.  To install, reverse the removal procedure.

2.  Remove radiator grille sight cover to access front

of condenser.

Lubricate the new A/C condenser core with

the correct amount of PAG Compressor Oil

3.  Remove the bolts from the two hose assemblies

ND-Oil 8 or equivalent meeting Ford

attached to the condenser inlet & outlet tube

specification WSH-M1C231-B. For additional

fittings. Disconnect the two hose assemblies.

information, refer to Refrigerant and Oil

 CAUTION: Plug all A/C ports to prevent

Adding in this section.

contamination from dirt or moisture.

Lubricate the O-ring seals with PAG

NOTE: If the vehicle is fitted with a turbo

Compressor Oil ND-Oil 8 or equivalent

intercooler, mounted in front of the condenser, the

meeting Ford specification WSH-M1C231-B.

intercooler will need to be loosened and slid

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