Air Conditioning (A/C) System Flushing
Air Conditioning (A/C) System Flushing
WARNING: Take the following precautions when repairing an air conditioning system containing R-134a:
- Always wear safety goggles.
- Avoid contact with liquid refrigerant R-134a. R-134a vaporizes at approximately -25°C (-13°F) under atmospheric pressure and will freeze skin tissue.
- Never allow refrigerant R-134a gas to escape in quantity in an occupied space. It will displace the oxygen needed to support life.
- Never use a torch in an atmosphere containing R-134a gas. R-134a is non-toxic at all normal conditions, but it decomposes when exposed to high temperatures such as a torch flame. During decomposition it releases irritating and toxic gasses (as described in the MSDS sheet from the manufacturer). Decomposition products are hydrofluoric acid, carbon dioxide and water.
Failure to follow these instructions may result in serious personal injury.
NOTICE: Motorcraft(R) Electric A/C Compressor Oil only must be used as a refrigerant system lubricant for hybrid vehicles. Addition of any oil other than Motorcraft(R) Electric A/C Compressor Oil to the hybrid vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor and contaminate the refrigerant system. Refer to Refrigerant Oil Adding Refrigerant Oil Adding.
NOTICE: An Air Conditioning (A/C) refrigerant analyzer must be used before the recovery of any vehicle's A/C refrigerant. Failure to do so puts the shop's bulk refrigerant at risk of contamination. If the vehicle's A/C refrigerant is contaminated, refer the customer to the service facility that carried out the last A/C service. If the customer wishes to pay the additional cost, use the A/C recovery equipment that is designated for recovering contaminated A/C refrigerant. All contaminated A/C refrigerant must be disposed of as hazardous waste. For all equipment, follow the equipment manufacturer procedures and instructions.
NOTICE: Receiver/drier cartridge, Thermostatic Expansion Valve (TXV), and hoses with mufflers should be removed when flushing the Air Conditioning (A/C) system. Internal plumbing of these devices makes it impossible to correctly remove any residual-flushing agent. These components are typically discarded after A/C system contamination. Hoses without mufflers can normally be reused unless they are clogged with foreign material. The 3.785L (1 gal) of A/C System Flushing Solvent YN-23 and FL1-A filter used in A/C Flush and Purge Machine 219-00022 are intended for use on one vehicle only. They may be used to flush both the A/C condenser core and the A/C evaporator core on an individual vehicle, but under no circumstances should they be used on more than one vehicle.
NOTICE: Only the A/C Flush and Purge Machine 219-00022 and A/C Systems Flushing Solvent, is approved for use on Ford vehicles. No other flushing device or solvent is approved for flushing heat exchangers (Air Conditioning [A/C] condenser, A/C evaporator). Use of any other flusher or solvent may cause damage to the A/C system and the flushing unit.
NOTE: Prior to using the A/C Flush and Purge Machine 219-00022 for the first time, review the operating instructions.
NOTE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers. The procedure allows the specific components to be cleaned and flushed while installed in their normal in-vehicle location. The types of contamination flushed include particle matter that results from A/C compressor or desiccant failure and gummy residue that can form when refrigerant oil is overheated during A/C compressor seizure. The flushing process is a 2-step procedure that involves the use of an A/C Flush and Purge Machine 219-00022 to:
- circulate the flushing solvent through the heat exchanger in the reverse direction of normal refrigerant flow (back-flushing). Particulate matter picked up during flushing is filtered from the returning solvent before the solvent is returned to the reservoir for continued circulation.
- remove the flushing solvent from the heat exchanger. In this step of the procedure, pressurized air 621-862 kPa (90-125 psi) is used to push and evaporate any remaining flush solvent from the heat exchanger.
1. Remove the receiver/drier cartridge. For additional information, refer to Climate Control Service and Repair.
2. NOTE: The condenser core must be flushed with the receiver/drier cartridge removed. Do not install a new receiver/drier cartridge at this time.
With the receiver/drier cartridge removed, reinstall the receiver/drier plug and snap ring into the condenser core.
3. Remove the condenser inlet and outlet fitting nuts and disconnect the fittings.
4. Connect the A/C Flush and Purge Machine to the condenser inlet and outlet fittings using the correct adapters from the A/C Flush Adapter Kit.
5. Flush the condenser core for a minimum of 30 minutes.
6. Turn the A/C Flush and Purge machine to the PURGE mode and run for a minimum of 20 minutes.
7. Disconnect the A/C Flush and Purge machine and adapters from the condenser core.
8. Install new gasket seals and connect the A/C condenser inlet and outlet fittings.
9. Remove the snap ring and receiver/drier plug.
10. NOTE: Do not charge the refrigerant system after the condenser core is installed.
Install a new receiver/drier cartridge. For additional information, refer to Climate Control Service and Repair.
11. Remove the Thermostatic Expansion Valve (TXV). For additional information, refer to Climate Control System - General Information and Diagnostics Service and Repair.
12. Connect the A/C Flush and Purge Machine to the evaporator core fitting using the correct adapter from the A/C Flush and Purge Fitting Kit.
13. Flush the evaporator core for a minimum of 20 minutes.
14. Turn the A/C Flush and Purge Machine to the PURGE mode and run for a minimum of 20 minutes.
15. Disconnect the A/C Flush and Purge Machine and adapter from the evaporator core fitting.
16. Install a new front TXV. For additional information, refer to Climate Control Service and Repair.
17. NOTE: It is necessary to evacuate the refrigerant system for a minimum of one hour to evaporate any traces of flush solvent that may remain in the system.
Evacuate the refrigerant system for one hour. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Air Conditioning (A/C) System Recovery, Evacuation and Charging.
18. NOTICE: Motorcraft(R) Electric A/C Compressor Oil only must be used as a refrigerant system lubricant for hybrid vehicles. Addition of any oil other than Motorcraft(R) Electric A/C Compressor Oil to the hybrid vehicle refrigerant system will damage the electric Air Conditioning (A/C) compressor and contaminate the refrigerant system. Refer to Refrigerant Oil Adding Refrigerant Oil Adding.
If a new A/C compressor is not to be installed, lubricate the refrigerant system with the correct amount of clean PAG oil (non-hybrid vehicles) or electric A/C compressor oil (hybrid vehicles). For additional information, refer to Refrigerant Oil Adding Refrigerant Oil Adding.
19. If a new A/C compressor is not to be installed, evacuate, leak test and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging Air Conditioning (A/C) System Recovery, Evacuation and Charging.