2003 FORD MUSTANG air conditioning

GENERAL PROCEDURES
Air Conditioning (A/C) Clutch Air Gap Adjustment
1. Check the A/C clutch air gap at three equally- spaced places between the A/C clutch hub (2884)
and the A/C clutch pulley (2E884).
2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. For additional information, refer to Section 412 - 03 .
SECTION 412-
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GENERAL PROCEDURES
Electronic Leak Detection
CAUTION: Good ventilation is necessary in the area where electronic A/C leak testing is to
be carried out. If the surrounding air is contaminated with refrigerant gas, the leak detector will
indicate this gas all the time. Odors from other chemicals such as anti- freeze, diesel fuel, disc
brake cleaner, or other cleaning solvents can cause the same problem. A fan, even in a well-
ventilated area, is very helpful in removing small traces of contamination from the air that
might affect the leak detector.
1. NOTE: The system pressure should be between 413- 551 kPa (60-80 psi) at 24°C (75°F) with
the engine off.
Leak test the refrigerant system using the Refrigerant Leak Detector. Follow the instructions
included with the leak detector for handling and operation techniques.
2. If a leak is found, discharge and recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
z Repair the system.
z Test the system for normal operation.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
H10PM Refrigerant Leak
Detector With Battery
216-
00001 or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Flushing
WARNING: Use extreme care and observe all safety and service precautions related to the
use of refrigerants.
WARNING: Due to refrigerant hazards, always wear safety goggles and non- penetrable
gloves when working on or flushing A/C systems.
CAUTION: An A/C refrigerant analyzer must be used before the recovery of any vehicle's
A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the
vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried
out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery
equipment that is designated for recovering contaminated A/C refrigerant. All contaminated
A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the
equipment manufacturer's procedures and instructions.
CAUTION: Suction accumulator/drier, muffler, hoses, thermal expansion valve, and fixed
orifice tube should be removed when flushing the A/C system. Internal plumbing of these
devices makes it impossible to correctly remove any residual- flushing agent. Except for the
hoses, these components are typically discarded after A/C system contamination. Hoses can
normally be reused unless they are clogged with foreign material. The 3.785 liters (1 gallon) of
A/C Systems Flushing Solvent F4AZ-19579- A and FL1-A filter used in A/C Flush and Purge
Machine 219- 00022 are intended for use on one vehicle only. They may be used to flush both
the A/C condenser core and the A/C evaporator core on an individual vehicle, but under no
circumstances should they be used on more than one vehicle.
1. NOTE: Prior to using the A/C Flush and Purge Machine 219- 00022 for the first time, review the
operating instructions.
NOTE: Only the A/C Flush and Purge Machine kit 219- 00023, which includes A/C Flush and
Purge Machine 219- 00022, A/C Flush and Purge Fitting Kit 219- 00024, and the Ford Part
number F4AZ-19579- A A/C Systems Flushing Solvent, is approved for use on Ford vehicles. No
other flushing device or solvent is approved for flushing heat exchangers. Use of any other
flusher or solvent may cause damage to the A/C system and the flushing unit.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
A/C Flush and Purge Machine
219-
00022 (part of 219- 00023)
or equivalent A/C Flush and Purge Fitting Kit
219-
00024 (part of 219- 00023)
or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Air Conditioning (A/C) System Recovery, Evacuation and
Charging
Refrigerant System Recovery
NOTE:
Ford Motor Company recommends use of an A/C service center to carry out recovery,
evacuation, and charging of the refrigerant system. If an A/C service center is not available, refrigerant
system recovery, evacuation, and charging may be accomplished using a separate recovery station,
vacuum pump, charging cylinder, and manifold gauge set.
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For additional information, refer to Refrigerant Identification Testing in this section.
2. NOTE: Some R- 134a service centers require the use of an A/C manifold gauge set. For
additional information, refer to Manifold Gauge Set Connection in this section.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
R-
134a A/C Refrigerant Center
176- 00002 or equivalent R-
134a A/C Refrigerant Center
023- 00153 or equivalent R-
134a Manifold Gauge Set
176- R032A or equivalent 1.2 CFM Vacuum Pump
023-
00162 or equivalent 4.0 CFM Vacuum Pump
023-
00163 or equivalent Klj . 1 ba
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GENERAL PROCEDURES
Refrigerant System Filtering Following Air Conditioning
(A/C) Component Installation
1. Install the new A/C compressor. For additional information, refer to Section 412 - 03 .
2. Install the new suction accumulator/drier. For additional information, refer to Section 412 - 03 .
3. Install the new A/C evaporator core orifice. For additional information, refer to Section 412 - 03 .
4. Orient the filter inlet toward the A/C condenser core.
5. NOTE: The pancake filter is not permanently installed and will be removed at the end of this
procedure.
Temporarily install the pancake filter between the A/C condenser core and the condenser to
evaporator tube. 1. Use flexible refrigerant hose of 17,238 kPa (2,500 psi) burst rating.
2. Make the connections using the A/C Test Fitting Set.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Set, A/C Fittings
412-
DS028 (014- 00333, D93L-
19703- B) or equivalent Klj . 1 ba
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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. Check all refrigerant system hoses, lines and the position of the newly installed filters to be sure they do not interfere with other engine compartment components. If necessary, use tie straps to
make adjustments.
9. Provide adequate airflow to the front of the vehicle (with a fan, if necessary). Select MAX A/C operation and set the blower motor speed to maximum. Start the engine and let it idle briefly.
Make sure the A/C system is operating correctly.
10. Gradually bring the engine up to 1,200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1,000 rpm). Set the engine at 1,200 rpm and run it for one hour with the A/C
system operating.
11. Stop the engine.
12. Recover the refrigerant from the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
13. Remove the fittings, flexible hoses and pancake filter from between the and the condenser to evaporator tube.
14. Discard the pancake filter. It can be used one time only.
15. Reconnect the condenser to evaporator tube to the A/C condenser core.
16. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Klj . 2 ba
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GENERAL PROCEDURES
Inspection and Assembly Requirements —
Following an A/C
Compressor Failure
CAUTION: To prevent refrigerant system contamination and possible failure of the new
A/C compressor, carry out the following procedures.
1. NOTE: A dirty A/C evaporator core orifice or a condenser to evaporator tube containing black
refrigerant oil and particles indicates that the A/C compressor has failed and a new A/C
compressor must be installed.
Remove and discard the A/C evaporator core orifice. For additional information, refer to Section 412 - 03 .
2. Remove the A/C compressor. For additional information, refer to Section 412 - 03 .
z Drain the residual refrigerant oil from the A/C compressor and measure the volume for
correct system oil matching. For additional information, refer to Refrigerant Oil Adding in
this section.
3. NOTE: The suction accumulator/drier and A/C evaporator core orifice cannot be cleaned and a
new A/C evaporator core orifice must be installed.
Remove the suction accumulator/drier. For additional information, refer to Section 412 - 03 .
z Drain the residual refrigerant oil from the suction accumulator/drier and measure the
volume for correct oil system matching. For additional information, refer to Refrigerant Oil Adding in this section.
4. NOTE: System flushing is the preferred method of cleaning. However, if flushing equipment is
not available, carry out system filtering.
Carry out an A/C system flushing or filtering procedure:
zIf A/C system flushing equipment is available, clean the A/C evaporator core and the A/C
condenser core by flushing. For additional information, refer to Flushing in this section.
z If A/C system flushing equipment is not available, carry out a system filtering procedure.
For additional information, refer to Refrigerant Oil Adding After A/C Component
Replacement in this section.
5. Install a new A/C compressor. For additional information, refer to Section 412 - 03 .
6. Install the new suction accumulator/drier. For additional information, refer to Section 412 - 03 .
7. Install the new A/C evaporator core orifice. For additional information, refer to Section 412 - 03 .
8. Correctly oil match the system. For additional information, refer to Refrigerant Oil Adding in this
section.
9. Evacuate and charge the system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section.
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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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22003 Mustang Workshop Manual
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