CLIMATE CONTROL—A/C SERVICE TECH TIPS
Contents
1. procedures should not be performed by do it yourselfers Do not assume that a condition described affects your car or truck Contact a Ford Lincoln or Mercury dealership to determine whether the Bulletin applies to your vehicle PAGE 62. AG Refrigerant Compressor Oil service part number YN 12 C meeting Ford specification WSH M1C231 B No other compressor oil or refrigerant stop leak should be used even if it has an OEM recommendation on the label as use of non approved products may reduce system capability or cause system damage Fluorescent Refrigerant Leak Detection Dye A product used in conjunction with a Rotunda approved ultraviolet black light to detect refrigerant leaks In production fluorescent refrigerant dye is added to the refrigerant system via a dye wafer located within the desiccant bag inside the accumulator or receiver dryer The dye binds to the refrigerant compressor oil and is transported with the compressor oil throughout the refrigerant system The dye contains chemical elements that fluoresce glow when excited with the use of a Rotunda approved ultraviolet black light The presence of the glow may indicate a possible refrigerant leak In addition all service accumulators and receiver dryers are shipped with a fluorescent dye wafer already present within the internal desiccant bag When replacing an accumulator it may take up to 30 minutes of continuous A C operation to liquefy and distribute the dye throughout the refrigerant system It may take many days for the dye to leach out of a very small leak and become visible by black light Fluorescent Refrigerant Dye Overdose A refrigerant system can become overdosed with fluorescent refrig
3. CLIMATE CONTROL A C SERVICE TECH TIPS Article No 02 20 8 FORD 1992 1997 THUNDERBIRD 1992 2003 CROWN VICTORIA ESCORT MUSTANG TAURUS 1995 2000 CONTOUR 2000 2003 FOCUS 2002 2003 THUNDERBIRD 1995 2003 WINDSTAR 1997 2003 E SERIES EXPEDITION EXPLORER F 150 1999 2003 SUPER DUTY F SERIES 2000 2003 EXCURSION EXPLORER SPORT TRAC EXPLORER SPORT 2001 2003 ESCAPE 2000 2003 F 650 F 750 LINCOLN 1992 2002 CONTINENTAL 1992 2003 TOWN CAR 1993 1998 MARK VIII 2000 2003 LS 1998 2003 NAVIGATOR 2002 BLACKWOOD 2003 AVIATOR MERCURY 1992 1997 COUGAR 1992 1999 TRACER 1992 2003 GRAND MARQUIS SABLE 1995 2000 MYSTIQUE 1999 2002 COUGAR 1993 2002 VILLAGER 1997 2003 MOUNTAINEER ISSUE ACTION The following A C tech tips are to assist the Refer to the following A C System Service Tips and technician with the proper procedures for servicing Procedures for service and repair guidelines A C systems Copyright 2002 Ford Motor Company PAGE 1 Article No 02 20 8 Cont d SERVICE INFORMATION The Clean Air Act of 1990 contains requirements that ban the release of refrigerants during the service maintenance and disposal of air conditioning and refrigeration equipment Shops are required by law to use approved recovery or recycling equipment when servicing air conditioning systems Also the technicians must be certified in the proper use of the equipment Some state and local jurisdictions have adopted their own requirements
4. FRIGERANT JOINT O RING PART Control No Problem Found related work NUMBERS See the ACESII User Manual for further e The previously claimed refrigerant O ring details base part numbers 19700 19B596 and 19D690 are not legitimate part numbers or O ring kit part numbers for any model year 1994 or forward vehicle Each refrigerant joint has a specific individual O ring associated with it Please reference the following list for the correct part numbers available from Ford FCSD When entering the O ring part number in the claim enter the entire part number including the prefix and suffix The dealer may exhaust current O ring parts inventory and charge the O rings to 19E889 PAGE 5 Article No 02 20 8 Cont d 7 REFRIGERANT SYSTEM FLUSH GUIDELINES The refrigerant system should only be flushed for two reasons 1 Catastrophic compressor YN 12 C PAG Refrigerant Oil failure or 2 Catastrophic accumulator failure TEN 9579 A ee Solvent involving a ruptured desiccant bag Use Ford 5 lota nemgerani 1W1Z 19E889 EA A C O Ring A C System Flushing Solvent part 1W1Z 19E889 LA AIC O Ring F4AZ 19579 A 1W1Z 19E889 HA AIC O Ring e If the system is flushed due to one of the two WZ 95989A AG O Ring bove noted reasons the accumulator and LAZ ee AOO Bing aoo 1W1Z 19E889 KA AIC O Ring orifice should be replaced and the correct 1W1Z 19E889 AA AIC O Ring amount of PAG refrigerant compressor oil 1W1Z 19E889 BA A C O Ring should be adde
5. Nearly 100 of the dye remains in the system dissolved in the refrigerant compressor oil Adding more dye may lead to dye overdosing SYMPTOM Refrigerant component replacement e g compressor condenser evaporator hose or tube assembly accumulator receiver dryer TXV orifice tube 1 Question If oil in refrigerant were added should dye be added too 2 Response No Component replacement is an oil match operation Not all of the system oil is lost when replacing a component usually 1 2 to 3 oz The original production concentration of dye will absorb this additional oil No additional fluorescent refrigerant dye is necessary d SYMPTOM Flushed the refrigerant system PAGE 4 bag It may take up to 30 minutes of continuous A C operation to liquefy and distribute the dye throughout the refrigerant system No additional dye is necessary Adding more fluorescent refrigerant dye may lead to dye overdosing SYMPTOM Removed or replaced the engine or transmission 1 Question The refrigerant system was opened to allow for the repair Refrigerant was added Should dye also be added 2 Response No When adding R134a refrigerant there is no need to add fluorescent refrigerant dye Nearly 100 of the dye will still be in the system dissolved in the refrigerant compressor oil Adding more fluorescent refrigerant dye may lead to dye overdosing SYMPTOM Added a significant amount of refrig
6. Tuge visual indication of oil at the joint Refrigerant 1W1Z 19E889 BA compressor oil is used on every refrigerant 1W1Z 19E889 CA joint to aid in assembly at the vehicle 1W1Z 19E889 DA assembly plant This assembly refrigerant oil 1F1H 19E889 AA Compressor Manifold or N806959 S or can leach out in normal vehicle operating W704589 8300 conditions and begin to collect dirt and dust incorrectly appearing to be a leaking joint A joint with evidence of oil dust and dirt may be a perfectly leak free joint Until the 6 CLIMATE CONTROL NO PROBLEM FOUND NPF PART NUMBER presence of a refrigerant leak is verified using e The correct causal part number for a Climate a Rotunda approved ultraviolet black light or Control No Problem Found NPF is NPF electronic refrigerant leak detector the joint The labor operation is NPF which cannot should not be disassembled and repaired Do exceed 2 5 hours The Customer Concern not replace O rings on joints as a Codes CCC range from C01 through C20 preventative maintenance measure If dye is and C24 The Condition Code CC is 82 for added to the system with a new accumulator Freight Postage Maintenance When it may take several days for the dye to leach diagnosing a climate control system warranty out of the leak and become visible by black issue this combination of the NPF causal light part NPF labor operation CCC and CC will allow the technician to claim for Climate 5 RE
7. d Do not add dye since it is 1W1Z 19E889 CA A C O Ring contained within the replacement 1W1Z 19E889 DA A C O Ring accumulator Use only a Ford approved PAG refrigerant compressor oil meeting the OTHER APPLICABLE ARTICLES NONE appropriate Ford specification Refer to the WARRANTY STATUS INFORMATION ONLY vehicle s Workshop Manual or Owner s Guide OASIS CODES 208000 208200 208999 290000 to determine the correct product that should be used Most but not all vehicles equipped with R134a refrigerant require the use of Motorcraft PAG Refrigerant Compressor Oil service part number YN 12 C meeting Ford specification WSH M1C231 B No other compressor oil or refrigerant stop leak should be used even if it has an OEM recommendation on the label as use of non approved products may reduce system capability or cause system damage e There is no need to flush a refrigerant system if refrigerant contaminants such as any non R134a refrigerant are detected during a refrigerant identifier test The contaminated refrigerant should be collected and the refrigerant system should be recharged with R134a NOTE The information in Technical Service Bulletins is intended for use by trained professional technicians with the knowledge tools and equipment to do the job properly and safely It informs these technicians of conditions that may occur on some vehicles or provides information that could assist in proper vehicle service The
8. e charge valve or low pressure service valve Neither a short release wisp of R134a refrigerant nor the presence of dye in the valve stem is an indicator that the high pressure charge valve or low pressure service valve failed Since the caps are the final seal if the valve leaks even a very small amount the R134a refrigerant pressure and leak detection dye will build up under the cap and hence the R134a refrigerant release wisp and or presence of leak detection dye when the cap is removed The correct procedure to employ when diagnosing a suspected high pressure charge valve or low pressure service valve is as follows a Blow out the valve with dry shop air to clear any refrigerant and dye b Point an electronic refrigerant leak detector into the valve stem to determine if the leak rate is greater than 0 25 ounces per year only the Rotunda approved electronic leak detector should be used If the leak rate is greater than 0 25 ounces per year replace the valve If the leak rate is less than 0 25 ounces per year the valve is good Cc If a Rotunda approved electronic refrigerant leak detector is not available inspect the valve for the presence of dye using a Rotunda approved ultraviolet black light If no dye is visible using the ultraviolet black light assume that the valve is not faulty ACCUMULATOR amp ORIFICE TUBE REPLACEMENTS o 9 R134a refrigerant systems are much more tolerant to moisture than the previ
9. erant dye More than three applications of fluorescent refrigerant dye in a refrigerant system can negatively impact the lubricity of the PAG refrigerant compressor oil and the durability of the compressor PAGE 3 Article No 02 20 8 Cont d 1 Question Because oil and refrigerant e Since 1995 all North American built Ford Motor were added is there a need to add Company vehicles have been equipped with a fluorescent refrigerant dye There is no need to dye too add additional fluorescent refrigerant dye when 2 diagnosing a possible refrigerant leak The following six leak detection symptoms technical concerns and responses will address the most common scenarios possible when diagnosing refrigerant leaks Response No When a refrigerant system flush is performed the accumulator receiver dryer is replaced due to desiccant contamination The new service accumulator receiver dryer has fluorescent refrigerant dye a SYMPTOM Poor A C performance contained within the internal desiccant 1 Question Does dye need to be added to look for leaks 2 Response No Every Ford refrigerant system built since 1995 is equipped with fluorescent leak detection dye Adding more dye may lead to dye overdosing SYMPTOM Low Charge or no charge 1 Question If R134a refrigerant is added should more dye be added too 2 Response No When adding refrigerant there is no need to add fluorescent refrigerant dye
10. erant oil 1 Question It is necessary to add refrigerant oil because of a fitting separation hose rupture component damage from road debris etc Does dye need to be added 2 Response Yes 1 1 4 ounces of Rotunda approved fluorescent R 134a refrigerant leak detection dye may be added but only if more than 50 of the system s oil capacity had to be replaced and the accumulator receiver dryer was not replaced Article No 02 20 8 Cont d 4 REFRIGERANT JOINT FITTINGS LEAK DIAGNOSTICS e There are two primary leak detection tools Service Part i O Ring j O Ring i ee Number Color Size Refrigerant Joint Type available to assist in the leak diagnosis of refrigerant joints or fittings 1 fluorescent leak 1W1Z 19E889 EA Pressure Relief Valve i PRV detention dye with ihe ae ora 3 19E889 LA y Cycling Switch Rotunda approved ultraviolet black light or 2 1W1Z 19E889 HA l Refrigerant Containment an electronic refrigerant leak detector When or Dual Function Switch diagnosing leaks in refrigerant components 1W1Z 19E889 HA Spring Lock Coupling either leak detection tool is acceptable at SLC or Tube O however diagnosis using the fluorescent dye Mien l a ies i method is preferred and is typically more W1Z 19E889 GA Spring Lock Coupling reliable SLC or Tube O e Under no circumstances should a refrigerant 1WTZ cae me ra ny joint be diagnosed as leaking with only a 1W1Z 19E889 AA ORO Or
11. for credentials so check with your state and local authorities for details The purpose of this article is to review No problem found NPF warranty claim charging process Proper refrigerant charge service valve diagnostics Accumulator and orifice tube replacement guidelines Leak detection dye addition recommendations Refrigerant joint leak detection guidelines Clarify the correct usage of refrigerant joint O ring part numbers Correct procedure for a refrigerant system flush PAGE 2 1 CHARGE amp SERVICE VALVE DIAGNOSTICS e The high pressure charge valve and low pressure service valve are not absolutely perfect seals Both valves may leak a very small amount of R134a refrigerant less than 0 25 ounces per year and still be within acceptable limits e The high pressure charge valves and low pressure service valves should always be sealed with a finger torqued high pressure charge cap or low pressure service cap The cap keeps the valve clean and is the final seal that ensures a leak tight refrigerant system that prevents the potential valve leaks of less than 0 25 ounces per year of R134a refrigerant from reaching the atmosphere e When servicing the refrigerant system and initially untorquing the high pressure charge cap or low pressure service cap a short release wisp of R134a refrigerant may be seen or heard In addition fluorescent leak detection dye may be present within the valve stem of the high pressur
12. ous R12 refrigerant systems The only time that an accumulator or orifice tube should be replaced is if there is a catastrophic failure of the compressor or if a non repairable accumulator failure is leaking refrigerant There is no need to replace the accumulator or orifice tube if replacing a refrigerant system component hose evaporator condenser refrigerant switches O rings charge or service valves or non catastrophic compressor failure Orifice tubes should be checked for Orifice tube presence Correct size Correct orientation Debris on the filter e If more than 75 of the filter screen is clogged with debris the orifice tube can be replaced Tests have shown that A C performance does not degrade until more than 90 of the screen area is totally blocked LEAK DETECTION DYE ADDITION Article No 02 20 8 Cont d Definitions e Polyalkylene Glycol PAG Refrigerant Compressor Oil A product necessary to maintain compressor lubricity within a refrigerant system The PAG refrigerant compressor oil circulates throughout the entire refrigerant system and is transported under pressure by the flowing refrigerant Use only a Ford approved PAG refrigerant compressor oil meeting the appropriate Ford specification Refer to the vehicle s Workshop Manual or Owner s Guide to determine the correct product that should be used Most but not all vehicles equipped with R134a refrigerant require the use of Motorcraft P
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