2003 FORD MUSTANG charging

Connect an R-
134a A/C service center to the low- and high-pressure service gauge port valves.
3. Recover the refrigerant from the system following the operating instructions provided by the equipment manufacturer.
4. Once the service center has recovered the vehicle A/C system refrigerant, close the service center inlet valve (if equipped). Then switch off the power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system vacuum level as shown on the gauge. If the vacuum does not decrease, disconnect the
refrigerant center hose(s).
6. If the system vacuum does decrease, repeat Steps 2 through 5 until the vacuum level remains stable for two minutes.
7. Carry out the required repairs.
Refrigerant System Evacuation
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. Connect an R- 134a service center to the low- and high-pressure service gauge port valves.
2. Evacuate the system until the low- pressure gauge reads at least 99.4 kPa (29.5 in- Hg) of
vacuum and as close to 101.1 kPa (30 in- Hg) as possible. Continue to operate the vacuum
pump for a minimum of 45 minutes.
3. Turn off the vacuum pump. Observe the low- pressure gauge for five minutes to make sure that
the system vacuum is held. If vacuum is not held for five minutes, leak test the system, service
the leak, and evacuate the system again.
Refrigerant System Charging
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. Correctly oil match the system to verify that the correct amount of refrigerant oil is present in the system. For additional information, refer to Refrigerant Oil Adding in this section.
2. Charge the system with the specified amounts of refrigerant oil and refrigerant.
3. When no more refrigerant is being drawn into the system, start the engine and select MAX A/C operation. Adjust the blower motor speed to the maximum and allow the remaining refrigerant to
be drawn into the system. Continue to add refrigerant into the system until the specified weight
of R- 134a has been added. Close the charging cylinder valve and allow the system to pull any
remaining refrigerant from the hose. When the low- pressure drops to approximately 207 kPa
(30 psi), close the charging hose valve. Klj . 2 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-
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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-
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An A/C compressor pressure relief valve is incorporated into the compressor A/C manifold and tube to:
zrelieve unusually high refrigerant system discharge pressure buildups. For specifications
regarding operating pressure(s), refer to Section 412 - 00 .
z prevent damage to the A/C compressor and other system components.
z avoid total refrigerant loss by closing after the excessive pressure has been relieved.
A/C Condenser Core
The A/C condenser core has the following characteristics:
zIt is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator
(8005).
z It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat
and by condensing gas to liquid refrigerant as it is cooled.
Refrigerant Lines
The condenser to evaporator tube (19835) contains the high pressure liquid refrigerant upstream of the
evaporator core orifice.
The A/C manifold and tube (19D734) is attached to the A/C compressor, is sealed with O- ring seals,
and has the following features:
zThe upstream side contains low pressure refrigerant gas.
z The downstream side contains high pressure refrigerant gas and a fitting used to mount a
serviceable high pressure A/C charge port valve.
z The downstream side also contains a fitting used to mount the refrigerant containment switch
(3.8L) or dual- function pressure switch (4.6L). A long- travel Schrader-type valve stem core is
installed in the fitting so that the switch can be removed without discharging the A/C system. Klj . 4 ba
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The suction accumulator (19C836) is mounted to the A/C accumulator bracket (19D606) to the right of
the vehicle centerline. The inlet tube of the suction accumulator attaches directly to the A/C evaporator
core outlet tube and the outlet tube attaches to the A/C manifold and tube.
After entering the inlet of the suction accumulator, the heavier oil-
laden refrigerant contacts an
internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the
canister.
zA small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated
heavier liquid refrigerant and oil mixture to reenter the compressor suction line at a controlled
rate.
z As the heavier mixture passes through the small diameter liquid bleed hole, it has a second
chance to vaporize and recirculate through the A/C compressor without causing compressor
damage due to slugging.
z A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out
refrigerant system contaminant particles.
z A desiccant bag is mounted inside the canister to absorb any moisture which may be in the
refrigerant system.
z A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A
long- travel Schrader- type valve stem core is installed in the fitting so that the A/C cycling switch
can be removed without discharging the A/C system.
A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader- type valve fitting on the top of the suction
accumulator.
zA valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
z This allows the suction pressure inside the suction accumulator to control the operation of the
A/C cycling switch.
z The electrical switch contacts open when the suction pressure drops. The contacts close when
the suction pressure rises. For specifications regarding operating pressure(s), refer to Section 412 - 00 .
z The A/C cycling switch will control the A/C evaporator core pressure at a point where the
plate/fin surface temperature will be maintained slightly above freezing.
z This prevents icing of the A/C evaporator core and blockage of air flow.
z It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Dual- Function Pressure Switch (4.6L)
The dual- function pressure switch is used to interrupt A/C compressor operation in the event of high Klj . 7 ba
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The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular
cage.
zWhen the coupling is connected together, the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
z The garter spring and cage then prevent the flared end of the female fitting from pulling out of
the cage.
z Three O- ring seals are used to seal between the two halves of the A/C condenser core
couplings. All other couplings have two O- ring seals.
z Use only the O- ring seals listed in the Ford Master Parts Catalog for the spring lock coupling.
z A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to
indicate, during vehicle assembly, that the coupling is connected. Once the coupling is
connected, the indicator ring is no longer necessary but will remain captive by the coupling near
the cage opening.
z The indicator ring may also be used during repair operations to indicate connection of the
coupling.
z An A/C tube lock coupling clip (19E746) may be used to secure the coupling but is not required.
Service Gauge Port Valves
The high- pressure service gauge port valve is located on the A/C manifold and tube.
The low pressure service gauge port valve is located on the suction accumulator. 2 — Female fitting (part of 19860)
3 19E746 A/C tube lock coupling clip
4 19E576 A/C tube lock coupling spring
5 — Cage (part of 19D690)
6 — O-
ring seals (part of 19D690) 7 — Male fitting (part of 19835)
Item Part
Number Description
1 19D702 A/C charging valve cap
2 19D701 Low pressure service gauge port valve (part of
19C836)
3 19D701 Schrader-
type valve 4 — O-
ring seal (part of 19D701) 5 19D701 High pressure service gauge port valve (part of Klj . 9 ba
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