Air Conditioning (A/C) System Recovery, Evacuation and Charging - 2.5L Duratec - Hybrid (121kW/164PS) (BG)

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Special Tool (s) / General Equipment 

Check 

• For all equipment, follow the manufacturer's instructions.
• Follow and inspect all charging instructions.

1. Start and run the engine at idle until normal operating temperature is reached.
2. Set Heaters front and rear (if equipped) to full hot.
3. Connect the following items:
   1. FOLLOW the recovery process of the refrigerant analyzer and its importance.

   Recovery 

   NOTE: Use an A/C refrigerant analyzer before recovering any of the 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. Dispose of all contaminated A/C refrigerant as hazardous waste in accordance with all federal, state and local regulations. For all equipment, follow the manufacturer's instructions.
4. NOTE: Use only Ford Approved R134a or R1234yf refrigerant management equipment.

   Verify the refrigerant purity prior to recovery.

   • Follow the Refrigerant Identification Testing process. Refer to: Refrigerant Identification Testing .
   • NOTE: For R1234yf the A/C Refrigerant Analyzer is equipped in the A/C machine. For R134a refrigerant the analyzer is a separate tool. For the A/C Refrigerant Analyzer. See A/C System Recovery, Evacuation and Charging Service Tools.

     198-RI2012yfp A/C Refrigerant Analyzer for use with R134a and R1234yf vehicles Refer to: Climate Control Tools and Equipment .

5. NOTE: It is important to make sure that the oil recovery bottle is cleaned and free of any oil from any previous recovery. Cross contamination of oil can damage A/C components.
   • CLEAN and INSPECT the oil recovery bottle. Make sure it is dry and clean.

6. Connect the tool to the low-side and high-side service gauge port valves following the manufacturer's instructions.
   • For the A/C Refrigerant Management Center and A/C Service Unit. See A/C System Recovery, Evacuation and Charging Service Tools. Refer to: Climate Control Tools and Equipment .

7. Connect the following items:
   1. All Warranty claims require paper print outs for the claims to be paid. FOLLOW the step and complete the vehicle Make, Model, Vin number and RO information.
   2. Connect battery charger. Refer to CHARGING SYSTEM - GENERAL INFORMATION .
   3. NOTE: For PHEV only
      NOTE: Never attempt to recover from only the low side service gauge port valve (solenoid valves in the system will not allow for full recovery). Open solenoid valves.

      Connect FDRS scan tool. GO TO SOBDMC module. Actuate the following PIDS: AC_DV_B_CMD#, AC_DV_C_CMD#

8. 1. Pushing the recovery button, warm-up process begins the refrigerant identifier and starts the calibration process. Upon completion of the calibration process purity of the refrigerant within the system is complete.
   2. The machine asks if you wish to take an A/C system pressure snapshot. Selections are (OK) to continue and (ESC) to Exit. Selection here is (ESC).
   3. The machine starts a self-cleaning process for the recovery process. This process will clean the internals of the recovery parts. Total time approximately 4 minutes.
   4. Actual recovery process starts. Total time approximately 10 minutes.
   5. Recovery process finishes. Then clears lines and recovery equipment. Total time approximately 3 minutes.
9. Recover the refrigerant from the system following the manufacturer's instructions. Note the amount of oil removed during the refrigerant recovery (if any). Add that same amount back into the system once repairs are complete. Refer to Refrigerant Oil Adding procedure in GENERAL PROCEDURES . For the PHEV this process takes approximately 3 minutes. Refer to: Refrigerant Oil Adding - 2.5L Duratec - Hybrid (121kW/164PS) (BG) .
10. 1. CHECK recovery oil bottle on machine. This amount to be returned back into refrigerant system along with amount of oil needed for the replacement component. REFER to Refrigerant Specifications for oil amounts. Refer to: SPECIFICATIONS .
    2. RECOVERY complete. CHECK paper and printout results of refrigerant recovered. The printout paper is to be submitted with the warranty claim.
11. Allow the system to set for about 2 minutes and observe the system vacuum reading. If the vacuum is not lost, disconnect the recovery equipment.
12. If the system loses vacuum, repeat Steps 6 through 8 until the vacuum level remains stable for 2 minutes.
13. Carry out the required repairs.

    Evacuation 

14. NOTE: Use an A/C refrigerant analyzer before recovering any of the vehicle's 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. Dispose of all contaminated A/C refrigerant as hazardous waste in accordance with all federal, state and local regulations. For all equipment, follow the manufacturer's instructions.
    NOTE: Use only Ford Approved R134a or R1234yf refrigerant management equipment.
    1. Verify the refrigerant purity prior to recovery. Refer to: Refrigerant Identification Testing .

15. Connect the tool to the low-side and high-side service gauge port valves following the manufacturer's instructions.
    • NOTE: For the A/C Refrigerant Management Center and A/C Service Unit. See A/C System Recovery, Evacuation and Charging Service Tools.

      For Ford Approved R134a or R1234yf refrigerant management equipment. Refer to: Climate Control Tools and Equipment .

16. NOTE: Never attempt to recover from only the low side service gauge port valve (solenoid valves in the system will not allow for full recovery). Open solenoid valves.

    Evacuate the system until the low-pressure gauge reads at least 99.4 kPa (29.5 in-Hg) of vacuum and as close to 101.1 kPa (30 in-Hg) as possible. Continue to operate the vacuum pump for a minimum of 45 minutes. For warranty claims the vacuum time of 45 minutes should be added to the print out.

    Charging 

17. NOTE: Use an A/C refrigerant analyzer before recovering any of the vehicle's 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. Dispose of all contaminated A/C refrigerant as hazardous waste in accordance with all federal, state and local regulations. For all equipment, follow the manufacturer's instructions.
    • 198-RI2012yfp A/C Refrigerant Analyzer for use with R134a and R1234yf vehiclesUse the General Equipment: Refrigerant Identification Equipment

1. Lubricate the refrigerant system with the correct amount of clean POE oil. The A/C oil recovered during evacuation is injected back into system, in addition to the amount of oil recommended by the service information (WSM) for a component replacement. Refer to: Refrigerant Oil Adding - 2.5L Duratec - Hybrid (121kW/164PS) (BG) .
2. Per the low-side and high-side service gauge port valves following the manufacturer's charge instructions.
   1. Choose HP+LP Charge mode.
   2. Choose Refrigerant and the refrigerant amount. This amount is indicated on the underhood sticker or in the service information (WSM). Refer to: SPECIFICATIONS .
   3. The machine asks if the vehicle that is using a POE oil is equipped with a high voltage system. Select (YES) for either a HEV or PHEV.
   4. To prevent any contamination, flush the service hoses. Connect both HP and LP hoses to the storage ports on the machine. OPEN both coupler valves. Press OK to confirm.
   5. The machine flushes the internals and lines (Service Hoses are being flushed Please wait). Process takes 5 minutes.
   6. Machine recovers the refrigerant that it uses to clean the lines. Process takes 5 minutes.
   7. Clears the lines then purges the air/contaminates from the system. Hose Flush complete. PRESS OK to confirm.

3. Connect the tool to the low-side and high-side service gauge port valves following the manufacturer's instructions.
   • For the A/C Refrigerant Management Center and A/C Service Unit. See A/C System Recovery, Evacuation and Charging Service Tools. Refer to: Climate Control Tools and Equipment .

4. 1. Charge step begins with an air purge.
   2. CONNECT both service lines back on the vehicle. OPEN both coupler valves. PRESS OK to confirm.
5. 1. (Charge) Vacuum Leak Test begins. Runs for 5 minutes.
6. 1. Pre-Charge Leak Test Low and High Pressure Side. Machine does a partial charge.
7. 1. Turn HVAC Blower on LOW.
   2. A/C switch OFF.
   3. Air distribution set to floor.
   4. Leak check front evaporator. Recommend also checking the repaired area in conjunction with the evaporator checks.
   5. FOLLOW machine instructions using a J2913 compliant leak detector for the evaporator.
   6. Was the test performed? PRESS OK to confirm.
8. • Was a leak found? OK for Yes. ESC for No.
9. • Is there a rear evaporator? Press OK for Yes. Press ESC for No.
   • If Yes, Leak check rear evaporator.
   • FOLLOW machine instructions using a J2913 compliant leak detector for the rear evaporator.
   • Was the test performed? PRESS OK to confirm.

10. 1. Charge Leak Test Low and High Pressure Side. Machine finishes charge.
11. 1. The machine asks if you wish to take an A/C system pressure snapshot. Selections are (OK) to continue and (ESC) to Exit. Selection here is (ESC).
12. 1. For charge, Disconnect the HP hose.
    2. Leave the LP hose connected.
    3. KOER, A/C system set to Maximum cool. PRESS OK to confirm.
    4. Charge, Hose Equalize pressure.
13. • Charge complete, Charge results. Print for warranty claim. CHECK paper. PRESS OK to print.