frostbite. They must also not be
discharged in an enclosed space, as there
is a risk of suffocation. The refrigerant is
heavier than air, and so must never be
discharged over a pit.
b)
The refrigerant must not be allowed to
come in contact with a naked flame,
otherwise a poisonous gas will be created
- under certain circumstances, this can
form an explosive mixture with air. For
similar reasons, smoking in the presence
of refrigerant is highly dangerous,
particularly if the vapour is inhaled
through a lighted cigarette.
c)
Never discharge the system to the
atmosphere - R134a is not an ozone-
depleting ChloroFluoroCarbon (CFC) as is
R12, but is instead a hydrofluorocarbon,
which causes environmental damage by
contributing to the “greenhouse effect” if
released into the atmosphere.
d)
R134a refrigerant must not be mixed with
R12; the system uses different seals (now
green-coloured, previously black) and has
different fittings requiring different tools,
so that there is no chance of the two
types of refrigerant becoming mixed
accidentally.
e)
If for any reason the system must be
disconnected, entrust this task to your
Ford dealer or a refrigeration engineer.
f)
It is essential that the system be profes-
sionally discharged prior to using any
form of heat - welding, soldering, brazing,
etc - in the vicinity of the system, before
having the vehicle oven-dried at a
temperature exceeding 70ºC after
repainting, and before disconnecting any
part of the system.
14 Air conditioning system
components -
removal and refitting
2
Warning: Refer to the
precautions given in the previous
Section before proceeding.
Note: This Section refers to the components
of the air conditioning system itself - refer to
Sections 11 and 12 for details of components
common to the heating/ventilation system.
Condenser
1 Have the refrigerant discharged at a dealer
service department or an automotive air
conditioning repair facility.
2 Disconnect the battery negative (earth) lead
(see Chapter 5, Section 1).
3 Secure the radiator to the front body panel
using string or wire to prevent it dropping
when the mounting bracket is removed in a
subsequent operation.
4 Apply the handbrake, then raise the front of
the vehicle and securely support it on axle
stands.
5 Undo the six plastic screws, and remove
the cover from under the condenser/radiator
mounting bracket.
6 Using the Ford service tool 34-001,
disconnect the refrigerant lines from the
condenser. Immediately cap the open fittings,
to prevent the entry of dirt and moisture.
7 Undo the two bolts and one nut securing
the dehydrator to the condenser/radiator
mounting bracket, and move the dehydrator
to one side.
8 Undo the two bolts each side securing the
condenser/radiator mounting bracket to the
body side members.
9 Detach the condenser and mounting
bracket from the right-hand then the left-hand
upper radiator mountings, and withdraw the
assembly from under the car.
10 Release the clips and remove the air
deflector from the condenser, then undo the
two nuts and remove the mounting bracket. If
required, unscrew the two mountings.
11 Refitting is the reversal of removal.
12 Have the system evacuated, charged and
leak-tested by the specialist who discharged
it.
Evaporator and blower motor
13 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
14 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1), followed
by the positive lead, then remove the battery
from its location.
15 For improved access, refer to Chapter 4
for details, and remove the air cleaner (where
applicable).
16 Peel back the seal strip from the top edge
of the bulkhead.
17 Cut the ties and detach the hose and
wiring loom from the bulkhead.
18 Undo the three bolts, and detach the air
conditioning pipe gasket retaining plate
complete with gasket, from the bulkhead.
19 Undo the six retaining bolts, and remove
the cover from the air chamber.
20 Release the evaporator housing cover
from its guides and remove it.
21 Undo the retaining bolt, and disconnect
the compressor low-pressure pipe and the
dehydrator liquid pipe from the front of the
expansion valve.
22 Disconnect the blower motor resistor
multi-plug, and disconnect the blower motor
earth lead at the connection on the body.
23 At the vacuum reservoir, disconnect the
multi-plugs for the vacuum motor switch and
de-ice switch, and detach the two vacuum
hoses. Undo the screw and remove the
vacuum reservoir assembly from the
evaporator housing.
24 Disconnect the two condensation hoses
from the front of the evaporator housing.
25 Undo the two bolts and two nuts, and
remove the evaporator housing from the
vehicle.
26 From the side of the evaporator housing,
release the vacuum motor linkage clamp
screw, then undo the two nuts and remove
the vacuum motor. Undo the two screws
securing the de-ice switch, and withdraw the
switch sensor.
27 Disconnect the blower motor resistor
wiring plug, then undo the three screws and
withdraw the evaporator housing cover.
28 Undo the two screws, release all the
retaining clips securing the upper and lower
halves of the evaporator housing, and lift off
the upper half.
29 Undo the two screws, and detach the
expansion valve from the side of the
evaporator. Recover the valve seals.
30 Lift the evaporator out of the lower half of
the housing.
31 To remove the blower motor, undo the
securing bolt from the motor retaining strap,
and lift out the motor.
32 Refitting is a reversal of the removal
procedure, but use new seals where
applicable, and tighten all fastenings to the
specified torque wrench settings (where
given).
33 Have the system evacuated, charged and
leak-tested by the specialist who discharged
it.
Compressor
34 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
35 Disconnect the battery negative (earth)
lead (see Chapter 5, Section 1).
36 Apply the handbrake, then raise the front
of the vehicle and securely support it on axle
stands.
37 Remove the auxiliary drivebelt (see
Chapter 1).
38 Undo the six plastic screws, and remove
the cover from under the condenser/radiator
mounting bracket.
39 Disconnect the compressor clutch wiring
multi-plug, then undo the retaining bolt to
detach the compressor high- and low-
pressure pipes.
40 Undo the four bolts, and remove the
compressor from its mounting bracket. Note:
Keep the compressor level during handling
and storage. If the compressor has seized, or
if you find metal particles in the refrigerant
lines, the system must be flushed out by an air
conditioning technician, and the dehydrator
must be renewed.
41 Refit the compressor in the reverse order
of removal; renew all seals disturbed.
42 Have the system evacuated, charged and
leak-tested by the specialist that discharged
it.
Dehydrator
43 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
44 Disconnect the battery negative (earth)
lead (see Chapter 5, Section 1).
45 Unscrew the pipe to the expansion valve
and the compressor connecting pipe at the
dehydrator.
46 Disconnect the high-pressure switch
3•12 Cooling, heating and air conditioning systems