A/C - Compressor Cuts Out in High Temperatures
TSB 07-26-312/24/07
A/C COMPRESSOR - CUTS OUT HIGH AMBIENT
TEMPERATURES/SEIZED - POOR A/C
PERFORMANCE - BUILT BEFORE 11/1/2007
FORD:
2007-2008 Expedition
LINCOLN:
2007-2008 Navigator
This article supersedes TSB 07-25-1 to update the symptoms, Service Procedure and vehicle built date.
ISSUE
Some 2007-2008 Expedition and Navigator vehicles built before 11/1/2007 may exhibit symptoms of slow to cool, not cool enough or variations in cooling performance. This may be due to lack of desiccant cartridge filtering causing system contamination and/or shifting of the desiccant cartridge in the integrated receiver/drier causing erratic condenser performance.
Additionally, some vehicles may exhibit a loss of A/C compressor operation in ambient temperatures greater than 110 °F (43 °C) when the vehicle is stationary for longer than 15 minutes, with the transmission in gear. Placing the vehicle in Park does not resume A/C operation. This may be due to high A/C head pressures caused by contamination in the system.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Follow standard workshop manual diagnostic procedures for customer complaints of A/C slow to cool, not cool enough. If no issues are identified and on-road evaluations indicate a lack of cooling performance relative to similar vehicles, use the following.
Proceed directly to the Flushing Service Procedure steps, to correct the condition of A/C compressor seized or high A/C head pressures.
NOTE
AFTER PERFORMING THE TSB FOR THE A/C SHUT DOWN, DURING HIGH AMBIENT TEMPS AND EXTENDED IDLE, ADVISE CUSTOMER TO RUN THE A/C IN THE MAX A/C POSITION, REDUCE BLOWER FAN SPEED FROM THE HIGHEST SETTING, TURN OFF THE AUXILIARY A/C AND PUT THE VEHICLE'S TRANSMISSION INTO THE PARK GEAR POSITION TO CONTINUE TO RECEIVE COOL AIR FROM YOUR A/C SYSTEM.
NOTE
CHECK THE AIR DEFLECTORS THAT SURROUND THE CONDENSER FOR BEING OUT OF POSITION OR BEING UNSECURED. THIS MAY ALLOW THE HOT ENGINE COMPARTMENT AIR TO RECIRCULATE AND CAUSE ADDITIONAL LOAD ON THE A/C SYSTEM.
NOTE
WHEN DEBRIS IS PRESENT THROUGHOUT THE ENTIRE SYSTEM, IT IS IMPERATIVE TO COMPLETELY CLEAN THE A/C SYSTEM TO PREVENT REPEAT FAILURES FROM RESIDUAL DEBRIS THAT CONTAMINATES THE SYSTEM AFTER THE INITIAL FAILURE. TO PREVENT REPEAT FAILURES, THE FOLLOWING SERVICE PROCEDURE MUST BE PERFORMED, FOR ALL SYMPTOMS LISTED IN THIS TSB.
A/C SLOW TO COOL/NOT COOL ENOUGH
1. Measure compressor suction and discharge pressures and compare them with the ranges shown in Workshop Manual (WSM), Section 412-00.
2. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures.
3. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and inspect for debris at the bottom of the cartridge below the lip seal before discarding.
4. If there is no debris below the cartridge lip seal and the compressor suction and discharge pressures are within the shop manual ranges, only replace the desiccant cartridge. Install a new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle.
5. If debris is found below the cartridge lip seal or the compressor suction/discharge pressure are not within shop manual ranges, proceed to the Flushing procedure below.
When debris is present throughout the entire system, it is imperative to completely clean the A/C system to prevent repeat failures from residual debris that contaminates the system after the initial failure. To prevent repeat failures, the following service procedure must be performed.
FLUSHING SERVICE PROCEDURE With Rotunda A/C Flush And Purge Machine:
1. Conduct the evacuation of R134a per Workshop Manual (WSM), Section 412-00: Climate Control System - General Procedures.
2. Drain and refill the Rotunda A/C Flush and Purge machine with a new 1 gallon can of A/C Flushing Solvent. Replace the filter (Motorcraft(R) FL-1A) on the machine.
3. Remove the defective compressor from the vehicle per WSM, Section 412-01. Pour 2 fl.oz. of PAG oil into the suction port of the new compressor. Install the new compressor.
4. Remove and replace the A/C discharge and muffler line from the system.
5. Remove the condenser from the vehicle.
6. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard.
7. Install the original plug with 0-rings and snap ring back into the condenser without a cartridge present.
8. With the Rotunda A/C Flush and Purge machine, attach the appropriate adapters, and flush the solvent through the condenser for a minimum of 30 minutes, followed by a minimum of 20 minutes of the purge mode of the machine.
9. Remove the original plug and snap-ring and discard.
10. Install the new Receiver Drier Cartridge, plug with 0-rings, snap-ring and dust cap included in the kit, and install condenser into the vehicle.
NOTE
IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY.
11. Remove and replace the Front Thermal Expansion Valve (TXV). Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place.
12. With the Rotunda A/C Flush and Purge machine, attach the appropriate spring lock connectors and flush solvent through the front evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes.
13. For units with auxiliary A/C, disconnect the rear A/C lines underneath the rear of the vehicle.
14. Remove the rear TXV and discard if equipped.
15. With the Rotunda A/C Flush and Purge machine, attach the correct TXV pass-through adapter to the rear evaporator (FS-00707 part of Rotunda 219-00074 Adaptor Kit). Flush the evaporator for a minimum of 20 minutes followed by a purge of a minimum of 20 minutes.
16. Install a new rear TXV.
17. Using fittings included with the Flushing Adapter kit, and a section of hose with hose clamps, loop the underbody lines together at the rear of the vehicle.
18. With the Rotunda A/C Flush and Purge machine, attach the appropriate fittings to the under body lines in the engine compartment where they connect to the A/C under hood lines. Flush the underbody lines for 5 minutes followed by not less than a 10 minute purge. Remove the loop connection in the rear, and reattach to the rear TXV and rear evaporator.
19. Reconnect all A/C fittings.
20. Ensure the entire A/C system is now fully assembled. Put the system under a vacuum for not less than 1 hour. (Required to ensure that all solvent has been evaporated).
21. Recharge the A/C system with the correct amount of R134a and inject 5 fl.oz. of PAG oil during the charging process into the low-side service port.
^ 22 oz. - Front A/C
.33 oz. - With Auxiliary A/C
22. Leak test and evaluate the system for proper operation. Run system at least 30 minutes.
A/C Flush And Purge - Without Rotunda
Machine:
1. Conduct the evacuation of R134a per the standard procedures in the WSM, Section 412-00: Climate Control System - General Procedures.
2. Remove the defective compressor from the vehicle per WSM Section 412-01. Add the appropriate amount of PAG oil per WSM, Section 412-00. Add refrigerant oil recommendations based on system damage level. Install the new compressor into the vehicle.
3. Remove and replace the discharge line.
4. Remove and replace the front TXV and rear lxv if equipped. Be sure to re-use the insulating foam from the original TXV and apply electrical tape or tie straps to hold it in place.
5. Remove the Receiver Drier Cartridge from the vehicle per the WSM, Section 412-01 and discard.
6. Reinstall the original cartridge's plug with 0-rings and snap ring back into the condenser.
7. Remove the right front headlamp assembly per the WSM, Section 417-01.
8. Disconnect the lower (liquid) line connection to the condenser.
9. Pull the liquid line slightly forward so it will clear the condenser.
10. Attach the A/C Pancake Filter Kit with the 1/2" DSL A/C filter adapter fittings and lines (Rotunda Parts 219-00077 & 023-00185). Ensure that the side of the filter with the label "Inlet from Condenser" is connected to the condenser.
11. Charge the system with the correct amount of R134a.
^ 22 oz. - Front A/C
^ 33 oz. - With Auxiliary A/C
12. Follow WSM, Section 412-00 "Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation". Ensure that the elevated RPM (1200) running of the engine is run for not less than the recommended 1 hour. If equipped with Auxiliary A/C, ensure that the REAR system is on, high blower, coldest temperature.
13. Recover the R134a in the system.
14. Remove the condenser.
15. Remove the original desiccant cartridge plug and 0-rings and discard.
16. Install a new desiccant cartridge, plug w/O-rings, snap ring, and cap.
NOTE
IF THE RECEIVER DRIER CARTRIDGE IS NOT AVAILABLE, REPLACE THE CONDENSER ASSEMBLY.
17. Install the condenser
18. Install the headlamp assembly per WSM, Section 417-01.
19. Charge system with correct amount of R134a and leak test and evaluate the system for proper operation. Run at least 30 minutes. If pulley, clutch and coil are damaged, replace per WSM.
22 oz. - Front A/C
33 oz. - With Auxiliary A/C
NOTE
COMPONENTS OF THE ROTUNDA 1/2" DSL A/C FILTER ADAPTER KIT ARE A SMALL SUBSET OF THE A/C FLUSHING ADAPTER KITS 219-00074 AND 219-00024. PURCHASE OF THE TWO LARGER KITS WILL PROVIDE ADAPTERS FOR THE ENTIRE F/L/M VEHICLE LINES
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT072603 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor
Performed As Actual Time
DEALER CODING
CONDITION
BASIC PART NO. CODE
19C836 42
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