A/C System Flushing
SYSTEM FLUSHING
Use Rotunda A/C Refrigerant System Flusher 014-00991 or equivalent.
WARNING: This equipment is designed to be used only with the Ford A/C system flushing solvent F4AZ-19579-A. Use of other solvents may result in personal injury and/or damage to the vehicle and the flusher.
Vehicles that have an inoperative A/C compressor, due to internal causes, should have the refrigerant system cleaned by flushing or filtering. This removes any debris or contaminants that may be present to prevent damage to the replacement A/C compressor.
System flushing is the preferred method of cleaning. However, if flushing equipment is not available, system filtering may be performed as an alternative.
System flushing should be performed prior to installation of the replacement A/C compressor. Flush only the A/C evaporator core and the A/C condenser core. The suction accumulator/drier, A/C evaporator core orifice, hoses, and mufflers cannot be flushed. Hoses can be reused unless they contain debris.
WARNING: Do not let the flushing solvent F4AZ-19579-A come in contact with your eyes or skin. If eye contamination occurs, flush eyes with water for 15 to 20 seconds. Remove contaminated clothing, and wash affected skin with soap and water. Seek medical attention.
The flushing procedure is a two-step process which involves:
1. Circulating the flushing solvent through the A/C evaporator core and/or the A/C condenser core, filtering particulate material from the returning solvent and returning the filtered solvent into the reservoir for continued circulation.
2. Removing the flushing solvent from the A/C evaporator core and/or the A/C condenser core being cleaned. In this step of the procedure, pressurized air (90-125 psi) is used to push and evaporate any remaining flushing solvent.
The Rotunda A/C Refrigerant System Flusher 014-00991 is a closed loop device which contains the following principle components:
^ An enclosed reservoir for the flushing solvent. The reservoir is equipped with both fill and drain plugs.
^ A pneumatic pump which is used to circulate the flushing solvent.
^ A particulate filter which removes debris from the returning flushing solvent.
^ Flush/purge valves which switch the flushing device from the circulation mode to the purge mode of operation.
^ A reservoir mounted venting device which filters/traps flushing solvent vapors, minimizing the release of any flushing solvent vapors to the atmosphere.
^ Fittings which allow the A/C flusher to be connected to the A/C evaporator core and/or the A/C condenser core.
^ A pressurized air processing system which attaches to a shop air supply, making the air suitable for use in the purging operation.
The air processing system contains the following components:
^ A connection to a pressurized air supply (90-125 psi shop air).
^ A condenser unit which allows moisture to be removed from the pressurized air supply.
^ An orifice to meter air through the condenser
^ A coalescent-type outlet moisture trap.
^ A purge air supply valve capable of being fixed in the full flow mode of operation.
Caution: Follow all refrigerant system safety and service precautions.
1. Before removing any refrigerant system components, recover the system refrigerant.
2. Disconnect the A/C refrigerant lines from the A/C evaporator core and/or the A/C condenser core.
3. Remove the A/C evaporator core orifice and the suction accumulator/drier from the A/C evaporator core.
4. Clean all dirt and debris from the fittings on the A/C evaporator core and/or the the A/C condenser core to be flushed.
5. Select the proper fittings, clean, and lubricate the connections and securely attach the fittings to the A/C evaporator core and/or the A/C condenser core. O-rings must be used with these fittings to ensure proper leak-free connections.
6. All flushing/purging will be performed in the direction opposite the normal flow of refrigerant in an operating A/C system.
a. When flushing the A/C condenser core, connect the flusher outlet hose to the liquid side fitting. This fitting can be identified as being normally connected by a hose to the A/C evaporator core. Connect the return hose to the other fitting.
b. When flushing the A/C evaporator core, connect the flusher outlet hose to the suction fitting. This fitting can be identified as being normally connected by a hose to the A/C compressor. Connect the return hose to the other fitting.
CAUTION: The gallon of solvent and the filter used in this flusher are intended for use on one vehicle only. They may be used to flush both the A/C evaporator core and the A/C condenser core on an individual vehicle, but under no circumstances should they be used on more than one vehicle. Residual contamination may contaminate other vehicles, causing possible damage to A/C system components.
7. Place the flusher on the garage floor and fill the flusher with 3.8 liters (one gallon) of Ford A/C System Flushing Solvent F4AZ-19579-A and a new Motorcraft filter FL-1A.
8. Connect the static ground strap to vehicle engine ground.
9. Verify the purge air supply valve is released from its locked-on position. Place valve No. 1 in PURGE position. Place valve No. 2 in FLUSH position. Attach the shop air supply to the flush quick coupler.
10. SLOWLY turn valve No. 1 to FLUSH position. Observe for flush solvent flow through the outlet hose.
a. If the pump stalls during operation, remove the air supply immediately. Pump stalling may occur as a result of large particulate debris.
b. To dislodge debris which impedes pump operation, connect the air supply to the purge quick coupler and gradually depress the purge air supply valve to force the debris and flush the solvent back into the reservoir.
c. Reconnect the air supply to the flush quick coupler and observe for flow.
d. Let the flusher pump run for a minimum of 15 minutes to flush all debris and dissolve any gummy oil residues which may be present in the component being flushed.
11. After 15 minutes of continuous operation, return valve No. 1 to PURGE position.
12. Disconnect the shop air hose from the flush quick coupler.
13. Attach the shop air hose to the purge quick coupler. Gradually engage the purge air supply valve to full flow for approximately one minute to remove the majority of the flushing agent from the component being flushed.
14. Stop all purge air flow by releasing the purge air supply valve lever.
15. Place valve No. 2 in the PURGE position.
16. Gradually engage the purge air supply valve, and LOCK IN FULL FLOW POSITION.
CAUTION: Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure.
17. Allow the system air purge to continue for a minimum of 30 minutes.
18. Periodically during the 30 minute air purge, observe the outlet moisture trap on the A/C flusher. Drain any water buildup using the petcock-type valve located on the bottom of the moisture trap.
19. After completion of the 30 minute air purge, release the purge air supply valve to stop all air flow.
20. Disconnect the shop air supply from the A/C flusher.
21. Disconnect the A/C flusher hoses from the flushed A/C evaporator core or the A/C condenser core.
22. Disconnect the static ground strap. Move the A/C flusher away from the vehicle.
23. Disconnect the A/C flusher fittings from the A/C evaporator core or the A/C condenser core.
24. Repeat steps 1-23 to flush the remaining A/C evaporator core or the A/C condenser core.
25. Drain the flushing solvent from the A/C flusher reservoir, and replace the particulate filter with a new Motorcraft filter (FL-1A). If the filter is difficult to remove, use Rotunda Oil Filter Wrench D79L-6731-B or equivalent to loosen it.
26. Dispose of the drained flushing solvent and the filter according to federal, state, and local regulations.
CAUTION: Service each replacement A/C component with refrigerant oil while making sure the total amount of oil added to the system equals the oil capacity specification for the vehicle.
27. Install the replacement A/C compressor, the suction accumulator/drier, and the A/C evaporator core orifice.
28. Evacuate and charge the system.
29. Check the operation of the system in all control function selector positions.