Ford Mustang (1999-2004) Service Manual: Air Conditioning (A/C) System Flushing

Special Tool(s)

	A/C Flush and Purge Machine 219-00022 (part of 219-00023) or equivalent
	A/C Flush and Purge Fitting Kit 219-00024 (part of 219-00023) or equivalent

WARNING: Use extreme care and observe all safety and service precautions related to the use of refrigerants.

CAUTION: Suction accumulator/drier, muffler, hoses, thermal expansion valve, and fixed orifice tube should be removed when flushing the A/C system. Internal plumbing of these devices makes it impossible to correctly remove any residual-flushing agent. Except for the hoses, these components are typically discarded after A/C system contamination. Hoses can normally be reused unless they are clogged with foreign material. The 3.785 liters (1 gallon) of A/C Systems Flushing Solvent F4AZ-19579-A 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.

1. NOTE: Prior to using the A/C Flush and Purge Machine 219-00022 for the first time, review the operating instructions.

NOTE: Only the A/C Flush and Purge Machine kit 219-00023, which includes A/C Flush and Purge Machine 219-00022, A/C Flush and Purge Fitting Kit 219-00024, and the Ford Part number F4AZ-19579-A A/C Systems Flushing Solvent, is approved for use on Ford vehicles. No other flushing device or solvent is approved for flushing heat exchangers. Use of any other flusher or solvent may cause damage to the A/C system and the flushing unit.

Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers, A/C evaporator core, and A/C condenser core. 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 within the suction accumulator/drier and gummy residue that can form when refrigerant oil is overheated during A/C compressor seizure. The flushing process is a two-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.

2. Discharge the A/C system. Observe all safety precautions. For additional information, refer to the procedure in this section.

3. Disconnect the refrigerant lines from the heat exchanger(s) to be flushed.

4. Connect the A/C Flush and Purge Machine 219-00022 and A/C Flush and Purge Fitting Kit 219- 00024 to the heat exchanger to be flushed. Do not flush through the A/C evaporator core orifice, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to correctly remove foreign material or residual flushing solvent.

5. Use 3.785 liters (one gallon) of A/C Systems Flushing Solvent part number F4AZ-19579-A to flush the heat exchanger for a minimum of 15 minutes. The flush solvent may be used for one or both heat exchangers in the A/C system. However, the flush solvent is intended for one vehicle only. The filter used on the flushing unit is also intended for use on one vehicle only.

6. Flush the component for a minimum of 15 minutes.

7. Apply 621-862 kPa (90-125 psi) pressurized air to the component for a minimum of 30 minutes.

The 30-minute purge time is required to force and evaporate all residual solvent from the A/C system component. Failure to successfully remove all residual solvent within the component can result in system damage when reconnected and operated. Dispose of the used flush solvent and filter in accordance with local, state and federal emissions.

8. NOTE: A/C system filtering as described in this section is optional if system flushing is carried out. However, the filter kit use is recommended after flushing if the A/C system contamination is extensive.

Install a new A/C evaporator core orifice in any vehicle being serviced for A/C compressor or desiccant failure.

9. Install new refrigerant hoses if clogged with foreign material.

10. Reconnect the heat exchanger being serviced.

11. Add additional refrigerant oil as required. For additional information, refer to the procedure in this section.

12. Evacuate, leak test and charge the A/C system. For additional information, refer to the procedure in this section.

13. Check the system for normal operation.