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GENERAL PROCEDURES
Refrigerant Identification Testing
1. NOTE: An A/C refrigerant analyzer must be used to identify gas samples taken directly from the
refrigeration system or storage containers prior to recovering or charging the refrigerant system.
Follow the instructions included with the Deluxe Refrigerant Diagnostic Tool to obtain the
sample for testing.
2. The diagnostic tool will display one of the following: zIf the purity level of R- 134a or R-12 is 98% or greater by weight, the green "PASS" light
emitting diode (LED) will light. The weight concentrations of R- 134a, R-12, R-22,
hydrocarbons, and air will be displayed on the digital display.
z If refrigerants R-134a or R- 12 do not meet the 98% purity levels, the red "FAIL" LED will
light and a horn will sound alerting the user of potential hazards. The weight
concentrations of R-134a, R- 12, R-22, and hydrocarbons will be displayed on the digital
display.
z If hydrocarbon concentrations are 2% or greater by weight, the red "FAIL" LED will light,
"Hydrocarbon High" will be displayed on the digital display, and a horn will sound alerting
the user of potential hazards. The weight concentrations of R- 134a, R-12, R-22, and
hydrocarbons will also be displayed on the digital display.
3. The percentage of air contained in the sample will be displayed if the R- 134a or R-12 content is
98% or greater. The diagnostic tool eliminates the effect of air when determining the refrigerant
sample content because air is not considered a contaminant, although air can affect A/C system
performance. When the diagnostic tool has determined that a refrigerant source is pure (R- 134a
or R- 12 is 98% or greater by weight) and air concentration levels are 2% or greater by weight,
the diagnostic tool will prompt the user if an air purge is desired.
4. If contaminated refrigerant is detected, repeat the refrigerant identification test to verify that the refrigerant is indeed contaminated.
5. CAUTION: If contaminated refrigerant is detected, DO NOT recover the refrigerant
into R- 134a or R- 12 recovery/recycling equipment.
Recover any contaminated refrigerant using suitable recovery- only equipment designed for
capturing and storing contaminated refrigerant. For additional information, refer to
Contaminated Refrigerant Handling in this section.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Refrigerant Identifier with Air-
Radicator
198-
00003 or equivalent Klj . 1 ba
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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-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Klj . 1 ba
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GENERAL PROCEDURES
Vacuum Hose Repair —
Mini-Tube
1. Measure the length of the damaged area of the mini-tube vacuum hose.
2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer than the damaged area of the mini- tube vacuum hose).
3. Cut off the mini-tube vacuum hose on each side of the damaged area.
4. WARNING: Read the warning information on the product label to prevent possible
personal injury.
Dip the mini- tube hose ends in commercially available paint thinner containing methyl ethyl
ketone (MEK). This solvent will seal the mini- tube in the vacuum hose.
5. Insert the ends of the mini- tube vacuum hose approximately 9 mm (3/8 inch) into the ends of
the standard 1/8 inch repair vacuum hose section.
6. Shake the repair joint after assembly to make sure the solvent is dispersed and the vacuum line is not plugged.
7. Test the system for a vacuum leak in the repair area. zUse the Vacuum Tester or equivalent.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual Special Tool(s)
Vacuum Pump Kit
416-
D002 (D95L-7559- A) or
equivalent Klj . 1 ba
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SPECIFICATIONS
SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Torque Specifications
Description Nm lb-
in Steering column reinforcement 9 80
Instrument panel steering column cover bolts 9 80
Duct RH instrument panel register 9 80 Klj . 1 ba
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DESCRIPTION AND OPERATION
Air Distribution
NOTE:
The air distribution system of this vehicle cannot be equipped with a cabin air filter.
There are two sources of air available to the air distribution system:
zoutside air
z recirculated air
Recirculated air is only used during MAX A/C.
Air distribution within the vehicle is determined by the function selector switch position. Airflow control
doors are used to direct airflow within the air plenum chamber. Vacuum control motors (18A318) are
used to position these airflow control doors. Refer to Section 412 - 00 for a description and operation of
each of the system functions.
The air distribution system is designed to provide airflow from the defrost nozzle when no vacuum is
applied to any of the vacuum control motors. This is done to prevent a situation where defrost cannot
be obtained due to a system vacuum leak.
Air enters the passenger compartment from the:
zinstrument panel A/C register (19893).
z heater outlet floor duct (18C433).
z windshield defroster hose nozzle (18490).
z side window demisters.
Passenger compartment air is exhausted from the vehicle through open windows or body air vents.
Instrument Panel Registers
There are A/C registers on the left and right sides of the instrument panel and in the center instrument
panel finish panel.
The LH and RH A/C registers are only serviceable as assemblies.
The center A/C registers are not serviceable as assemblies. The registers are installed with the
instrument panel center finish panel assembly. Component Locations SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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