2003 FORD MUSTANG air filter

Ford Motor Company has approved a procedure to provide technicians with a non-
CFC method
of flushing contaminated A/C system heat exchangers, A/C evaporator core, and A/C
condenser core. The procedure allows the specific components to be cleaned and flushed while
installed in their normal in- vehicle location. The types of contamination flushed include particle
matter that results from A/C compressor or desiccant failure within the suction accumulator/drier
and gummy residue that can form when refrigerant oil is overheated during A/C compressor
seizure. The flushing process is a two- step procedure that involves the use of an A/C Flush and
Purge Machine 219- 00022 to:
z Circulate the flushing solvent through the heat exchanger in the reverse direction of
normal refrigerant flow (back- flushing). Particulate matter picked up during flushing is
filtered from the returning solvent before the solvent is returned to the reservoir for
continued circulation.
z Remove the flushing solvent from the heat exchanger. In this step of the procedure,
pressurized air 621- 862 kPa (90-125 psi) is used to push and evaporate any remaining
flush solvent from the heat exchanger.
2. Discharge the A/C system. Observe all safety precautions. For additional information, refer to the procedure in this section.
3. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.
4. Connect the A/C Flush and Purge Machine 219- 00022 and A/C Flush and Purge Fitting Kit 219-
00024 to the heat exchanger to be flushed. Do not flush through the A/C evaporator core orifice,
mufflers or hoses. Internal plumbing and material make- up of these components make it
impossible to correctly remove foreign material or residual flushing solvent.
5. Use 3.785 liters (one gallon) of A/C Systems Flushing Solvent part number F4AZ-19579- A to
flush the heat exchanger for a minimum of 15 minutes. The flush solvent may be used for one
or both heat exchangers in the A/C system. However, the flush solvent is intended for one
vehicle only. The filter used on the flushing unit is also intended for use on one vehicle only.
6. Flush the component for a minimum of 15 minutes.
7. Apply 621- 862 kPa (90-125 psi) pressurized air to the component for a minimum of 30 minutes.
The 30- minute purge time is required to force and evaporate all residual solvent from the A/C
system component. Failure to successfully remove all residual solvent within the component
can result in system damage when reconnected and operated. Dispose of the used flush
solvent and filter in accordance with local, state and federal emissions.
8. NOTE: A/C system filtering as described in this section is optional if system flushing is carried
out. However, the filter kit use is recommended after flushing if the A/C system contamination is
extensive.
Install a new A/C evaporator core orifice in any vehicle being serviced for A/C compressor or
desiccant failure.
9. Install new refrigerant hoses if clogged with foreign material.
10. Reconnect the heat exchanger being serviced.
11. Add additional refrigerant oil as required. For additional information, refer to the procedure in this section.
12. Evacuate, leak test and charge the A/C system. For additional information, refer to the procedure in this section.
13. Check the system for normal operation. Klj . 2 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.
SECTION 412-
00: Climate Control System - General Information 2003 Mustang Workshop Manual 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
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DIAGNOSIS AND TESTING
Air Distribution
For additional information, refer to
Section 412 - 00 .
SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Register —
LH
Removal 1. Remove the instrument panel steering column cover bolts.
2. Unsnap and remove the instrument panel steering column cover.
3. Remove the bolts and the steering column reinforcement. 4. Remove the screws. SECTION 412-
01: Air Distribution and Filtering 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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