2003 FORD MUSTANG air condition

GENERAL PROCEDURES
Contaminated Refrigerant Handling
1. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant
into your recovery/recycling equipment.
Recover the contaminated refrigerant using suitable recovery- only equipment designed for
capturing and storing contaminated refrigerant.
zThis equipment must only be used to recover contaminated refrigerant to prevent the
spread to other vehicles.
z If this equipment is not available, contact an A/C repair facility in your area with the
correct equipment to carry out this repair.
2. Determine and correct the cause of the customer's initial concern.
3. NOTE: Residual refrigerant oil in the suction accumulator/drier must be drained and measured
for correct oil system matching. For additional information, refer to Refrigerant Oil Adding in this
section.
The suction accumulator/drier cannot be cleaned and a new suction accumulator/drier must be
installed.
Remove the suction accumulator/drier. For additional information, refer to Section 412 - 03 .
4. Clean the A/C evaporator core and the A/C condenser core by flushing. For additional information, refer to Air Conditioning (A/C) System Flushing in this section.
5. Install the new suction accumulator/drier. For additional information, refer to Section 412 - 03 .
6. Correctly oil match the system. For additional information, refer to Refrigerant Oil Adding in this
section.
7. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
8. Dispose of contaminated refrigerant according to all federal, state and local regulations.
SECTION 412-
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DESCRIPTION AND OPERATION
Heating and Defrosting
The heating and defrosting system has the following features:
zControls the temperature and, during A/C operation, reduces the relative humidity of the air
inside the vehicle.
z Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
z Controls the A/C blower motor speed.
z Cooling or heating can be adjusted to maintain the desired temperature.
z System uses a reheat method to provide conditioned air to the passenger compartment.
z The blower motor (19805) draws outside air through the air inlet duct from just below the
windshield during all system operations except for MAX A/C cooling (when recirculated air is
used).
z All airflow from the blower motor passes through the A/C evaporator core (19860).
z The temperature is then regulated by reheating a portion of the air and blending it with the
remaining cool air to the desired temperature.
z The temperature blending is varied by the air temperature control door, which regulates the
amount of air that flows through and around the heater core (18476), where it is then mixed and
distributed.
Heater Core
The heater core (18476) consists of fins and tubes arranged to extract heat from the engine coolant
and transfer it to air passing through the heater core. Blower Motor SECTION 412-
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SPECIFICATIONS
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual General Specifications
Item Specification
Lubricant
PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-
DA (MC YN-12-
C) WSH-
M1C231-
B
Torque Specifications Description Nm lb-
ft lb-
in A/C compressor mounting bolts 25 18 —
A/C manifold retaining bolt 20 15 —
3.8L engine A/C compressor mounting bracket bolts 47 35 —
3.8L engine A/C compressor mounting bracket nut 25 18 —
A/C compressor clutch retaining bolt 13 10 —
Suction accumulator/drier clamp screw 8 — 71
Coolant bottle bolts 10 — 89
Peanut fittings 8 — 71
Radiator bracket bolts 9 — 81
Condenser core bracket bolts 5 — 44
A/C muffler bracket nut 25 18 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Air Conditioning
The A/C refrigerant system is a clutch cycling orifice tube type. The system components are:
zA/C compressor (19703)
z A/C clutch (2884)
z A/C condenser core (19712)
z A/C evaporator core (19860)
z suction accumulator (19C836)
z connecting refrigerant lines
The refrigeration system operation is controlled by the:
zA/C evaporator core orifice (19D990).
z A/C cycling switch (19E561).
z A/C compressor pressure relief valve (19D644).
z Refrigerant containment switch (3.8L) (19D594).
z Dual- function pressure switch (4.6L) (19D594).
The refrigerant system incorporates an A/C compressor controlled by an A/C cycling switch.
The A/C cycling switch senses A/C evaporator core pressure to control A/C compressor operation.
An A/C compressor pressure relief valve is installed in the A/C manifold and tube (19D734) to protect
the refrigerant system against excessively high refrigerant pressures.
An evaporator core orifice is installed in the A/C evaporator core inlet tube to meter the liquid
refrigerant into the A/C evaporator core.
A refrigerant containment switch is installed on 3.8L vehicles to cut- off A/C compressor operation in
the event of abnormally high refrigerant system pressure.
A dual- function pressure switch is used on 4.6L vehicles for cooling fan control, and to cut- off A/C
compressor operation in the event of abnormally high refrigerant system pressure. Refrigeration System Components SECTION 412-
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A/C Evaporator Core
NOTE:
The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
The A/C evaporator core is the plate/fin type with a unique refrigerant flow path.
zA mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C
evaporator core inlet tube and moves out of the A/C evaporator core through the A/C
evaporator core outlet tube.
z This flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator core.
Evaporator Core Orifice
NOTE: The evaporator core orifice is an integral part of the condenser to evaporator line and should
be installed as an assembly with the line.
NOTE: A new evaporator core orifice should be installed whenever a new A/C compressor is installed.
The evaporator core orifice has the following characteristics:
zIt is located in the A/C condenser to evaporator line.
z It has filter screens located on the inlet and outlet ends of the tube body.
z The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the evaporator
core orifice.
z O-ring seals on the evaporator core orifice prevent the high- pressure liquid refrigerant from
bypassing the evaporator core orifice. Klj . 5 ba
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z
Adjustment or repair cannot be made to the evaporator core orifice assembly. A new evaporator
core orifice must be installed as a unit.
Suction Accumulator
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of contamination from a failed A/C compressor or
damage to the suction accumulator.
In addition to the preceding condition, a new suction accumulator should be installed if one of the
following conditions exist:
zThe suction accumulator is perforated.
z The refrigerant system has been opened to the atmosphere for a period of time longer than
required to make a minor repair.
z There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines
or the refrigerant oil is thick and dark. Item Part Number Description
1 19E561 A/C cycling switch
2 — O-
ring seal (part of 19C836) 3 19D701 Low pressure service gauge port valve
4 — Inlet from A/C evaporator core (part of 19C836)
5 — Outlet to A/C compressor (part of 19C836)
6 — Anti-
siphon hole (part of 19C836) 7 — Desiccant bag (part of 19C836)
8 — Oil return orifice filter (part of 19C836)
9 — Vapor return tube (part of 19C836)
10 — Suction accumulator dome (part of 19C836) Klj . 6 ba
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DIAGNOSIS AND TESTING
Air Conditioning
Refer to
Section 412 - 00 .
SECTION 412-
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REMOVAL AND INSTALLATION
Air Conditioning (A/C) Compressor —
3.8L
Removal and Installation CAUTION: If installing a new air conditioning compressor due to an internal failure of the
old unit, you must carry out the following procedures to remove contamination from the air
conditioning system.
zIf A/C flushing equipment is available, carry out the flushing of the air conditioning
system prior to installing a new air conditioning compressor. For additional information,
refer to Section 412 - 00 .
z If A/C flushing equipment is not available, carry out filtering of the air conditioning
system after a new air conditioning compressor has been installed. For additional
information, refer to Section 412 - 00 .
z Install a new evaporator core orifice (19D990), as directed by the A/C flushing or filtering
procedure.
z Install a new suction accumulator (19C836), as directed by the A/C flushing or filtering
procedure.
NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C compressor
or damage to the suction accumulator.
1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Disconnect the battery. For additional information, refer to Section 414 - 01
3. Unlatch the air breather.
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
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