2011 FORD KUGA pressure

Perform the leak test, by closing the hand valves
on the gauge set, switching off the service unit
vacuum pump and observing the low pressure
gauge.
10. N O T E : This step is only necessary if the
pressure increase exceeds 20 mbar.
Locate and rectify any leaks in the A/C
refrigerant circuit using a leak tester.
General Equipment: UV Leak Detector
General Equipment: Electronic Leak Detector
General Equipment: Automatic Calibration Halogen Leak Detector
11 . Add refrigerant oil to the air conditioning system.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
Refer to: Refrigerant Oil Adding (412-00 Climate
Control System - General Information, General
Procedures).
12. Fill the air conditioning system with liquid
through the high-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
13. Open the shut-off valve on the high-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
liquid refrigerant (R134a).
14. Fill the air conditioning system with gas through
the low-pressure connection.
Refer to: Specifications (412-00 Climate Control
System - General Information, Specifications).
15. Open the shut-off valve on the low-pressure
side.
1.
2. Switch the service unit to "Fill" mode and fill
the system with the specified quantity of
gaseous refrigerant.
3. Add the remaining amount of refrigerant with the air conditioning switched on. To do so
run the engine at about 1200-1500 rev/min.
Set the air conditioning system to full cooling
power and fresh air mode. Set the blower
motor to the highest setting. Fill with the
remainder of the specified fill capacity.
16. Disconnect the service unit. 17.
Close the shut-off valve.
1.
2. Switch off the service unit.
3. Disconnect the service unit lines from the
filling connections of the air conditioning
system.
4. Screw the protective caps onto the charging connections.
18. Install all components in reverse order.
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412-00- 8
Climate Control System - General Information
412-00- 8
GENERAL PROCEDURES
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Electronic Leak Detection
1.Refer to: Air Conditioning (A/C) System Health
and Safety Precautions (100-00 General
Information, Description and Operation).
2. WARNINGS:
Before starting leak detection, make
sure that the area where it is to be done
is well ventilated. 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 antifreeze, diesel fuel, disc
brake cleaner, or other cleaning
solvents can cause the same problem.
Prevent air movement while performing
leak detection.
The refrigerant identification equipment
must be used before attaching the
manifold gauge set. Otherwise the
manifold gauge set may become
contaminated. Contaminated refrigerant
must be disposed of as special waste.
Follow the manufacturer's instructions
when working with the service unit.
NOTE: At 24°C with the engine switched off,
both manifold gauges should show 4.1 to 5.5
bar.
Attach the manifold gauge set to the service
gauge port valves.
3. For the leak test, close the manual valves on
the gauge set.
4. If little or no pressure is indicated, charge the
system with approx. 300g of refrigerant. Refer
to: Air Conditioning System - Evacuate and
Refill.
5. Use the R-134a Automatic Calibration Halogen
Leak Detector to leak test the refrigerant system.
Follow the instructions included with leak
detector for handling and operation techniques.
6. If any leak is found, extract the refrigerant under
suction. Refer to: Air Conditioning System -
Evacuate and Refill.
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Climate Control System - General Information
412-00- 14
GENERAL PROCEDURES
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412-01-42
Heater Core and Evaporator Core Housing .......................................................................
412-01-45
(34 364 0)
Heater Core — RHD ........................................................................\
...............
412-01-53
Suction Accumulator ........................................................................\
...................................
412-01-56
Suction Accumulator to Air Conditioning (A/C) Compressor Line ......................................
412-01-57
Suction Accumulator to Air Conditioning (A/C) Compressor Line — 2.5L Duratec
(147kW/200PS) - VI5 ........................................................................\
................................
412-01-58
Low-Pressure Cutoff Switch ........................................................................\
.......................
412-01-59
High-Pressure Cutoff Switch ........................................................................\
.......................
412-01-60
Evaporator ........................................................................\
..................................................
412-01-62
Evaporator Outlet Line ........................................................................\
................................
412-01-65
Evaporator Core Orifice ........................................................................\
..............................
412-01-68
Condenser to Evaporator Line........................................................................\
....................
412-01-71
(34 300 0)
Climate Control Assembly — Vehicles With: Manual Temperature Control ....
412-01-72
(34 300 0)
Climate Control Assembly — Vehicles With: Automatic Temperature Control .
412-01-73
(34 485 4)
Footwell Air Discharge Temperature Sensor ..................................................
412-01-74
Center Register Air Discharge Temperature Sensor ..........................................................
412-01-75
In-Vehicle Temperature Sensor ........................................................................\
..................
412-01-76
(34 676 0)
Ambient Air Temperature Sensor ...................................................................
412-01-77
(34 665 0)
Sunload Sensor ........................................................................\
......................
412-01-78
(34 591 0)
Footwell Vent/Duct Blend Door Actuator — RHD ...........................................
412-01-79
(34 606 0)
Air Inlet Blend Door Actuator ........................................................................\
..
412-01-80
(34 608 0)
Driver Side Temperature Blend Door Actuator ...............................................
412-01-81
(34 608 0)
Passenger Side Temperature Blend Door Actuator .......................................
412-01-82
(34 591 0)
Defrost Vent/Register Blend Door Actuator — RHD ......................................
412-01-2
Climate Control
412-01- 2
.
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Climate control
32
1
4
5
6
789
E97591
Description
Item
Condenser
1
Air conditioning compressor
2
High pressure filling connection
3
Refrigerant drier
4Description
Item
Dual pressure switch
5
Low pressure filling connection
6
Low pressure limiting switch
7
Evaporator Core Orifice Tube
8
Evaporator assembly
9
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412-01- 7
Climate Control
412-01- 7
DESCRIPTION AND OPERATION
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Air conditioning system - vehicles with manual temperature control
18
6
7
3
9
2
5
4
E97576
HS-CAN
MS-CAN
Description
Item
Air conditioning compressor
1
Climate control system control assemblyRefer to Component Description: Control
assembly, climate control - vehicles with
manualtemperaturecontrol(page24)
2
Genetic electronic module (GEM).
3Description
Item
Ambient air temperature sensorRefer to Component Description:
Ambienttemperaturesensor(page26)
4
instrument cluster
5
High pressure limiting switch
6
Dual pressure switch
7
G1034947en2008.50 Kuga8/2011
412-01- 17
Climate Control
412-01- 17
DESCRIPTION AND OPERATION
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Description
Item
High pressure limiting switch
6
Dual pressure switch
7Description
Item
Powertrain control module (PCM)
8
Air conditioning clutch relay
9
System Operation
Climate control housing
General overview
13
12
11
8
7
9
6
4
5
2
3
E97261
1
10
G1034947en2008.50 Kuga8/2011
412-01- 19
Climate Control
412-01- 19
DESCRIPTION AND OPERATION
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1
2
3
5
4
67
8
9
10
11
E100819
Description
Item
Condenser
1
Air conditioning compressor
2
Suction accumulator
3
Evaporator assembly
4
Blower motor
5Description
Item
Evaporator Core Orifice Tube
6
Cooling fans.
7
High - pressure (liquid and warm)
8
Low - pressure (liquid and cool)
9
Low pressure (gaseous and cold)
10
High pressure (gaseous and hot)
11
The engine driven refrigerant compressor (2) sucks
in gaseous refrigerant from the suction accumulator
and compresses it. The temperature of the
refrigerant rises to a value between 70 °C and 110
°C. It passes to the condenser (1) under high
pressure.
At this point heat is drawn from the refrigerant by
the air being forced past the cooling fins. Because
of this heat loss, the refrigerant liquefies and leaves
the condenser.
A fixed orifice tube (6), which separates the
refrigerant at high pressure from that at low
pressure, is located between the condenser and
the evaporator (5). This fixed orifice tube slows
down the flow of the refrigerant from the compressor, so that pressure builds up in the
condenser.
After passing through the fixed orifice tube the
liquid refrigerant expands in the circuit to the
evaporator, where it becomes gaseous. This
causes heat to be extracted from the air coming
into the vehicle. The air cools down, and excess
moisture contained in it is condensed and is
drained off. The refrigerant coming from the
evaporator flows into the refrigerant accumulator
and is again sucked in by the refrigerant
compressor.
The system is protected by a high-pressure limiting
switch, in order to prevent damage by excessive
pressure (e.g. because of overfilling with
refrigerant). If the pressure exceeds the maximum
G1034947en2008.50 Kuga8/2011
412-01-
23
Climate Control
412-01- 23
DESCRIPTION AND OPERATION
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permitted, the high-pressure switch turns off the
refrigerant compressor.
The compressor on-off cycle is controlled by the
dual pressure switch depending on the pressure
in the refrigerant accumulator. The dual pressure
switch turns the refrigerant compressor off
permanently if the pressure falls below a permitted
value (e.g. if there is a leak).
Component Description
Air conditioning compressor
E100826
The special feature of a compressor with variable
swash plate is that the stroke of the pistons can
be varied by means of the variable swash plate.
The swash plate is mounted on a slide rail in the
axial direction.
The piston stroke and thus the delivery rate are
determined by means of the variable obliqueness
of the swash plate.
The obliqueness of the swash plate is dependent
upon the chamber pressure and thus on the
pressure conditions at the top and bottom of the
piston. This is supported by springs in front of and
behind the swash plate.
The chamber pressure is determined by the high
and low pressure applied to the control valve and
by a calibrated orifice bore. If the low pressure is
relatively high, the control valve is opened and the
chamber pressure is reduced.
If the low pressure is relatively low, the control
valve is closed and the chamber pressure is
increased. The force due to the chamber pressure
exerted on the piston bottom, is higher than the
sum of the force due to the low pressure on the
piston top and the spring force.
Pollen filter
E97720
The fresh air flowing into the vehicle through the
air inlet housing passes through a pollen filter which
is located on the left-hand side of the climate
control housing (LHD and RHD) and removes
pollen and dust particles measuring 0.003 mm or
more.
Control assembly, climate control -
vehicles with manual temperature control
E97721
In vehicles with manual temperature control, the
heating and air conditioning are operated using
three rotary switches. The air distribution flaps are
actuated via the air distribution flap/temperature
control flap actuating unit, which is connected via
a rod to the control assembly for the climate
control. The temperature control flap is also
actuated via the air distribution flap/temperature
control flap actuating unit, which is connected via
a cable to the control assembly. In addition, the
operating switch for recirculated air mode and the
on/off switch for the air conditioning are located on
the control assembly.
G1034947en2008.50 Kuga8/2011
412-01-24
Climate Control
412-01- 24
DESCRIPTION AND OPERATION
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