Technically Speaking AUTOMOTIVE ELECTRICAL & AIR ...

1 Technically Speaking AUTOMOTIVE ELECTRICAL & AIR conditioning NEWS. FG Falcon A/C system The Auto-Tech Technical Helpline has been receiving a number of enquiries on the FG Falcon A/C system, particularly with regard to the correct refrigerant charge. With the introduction of the FG Falcon range, came significant R-134a Fluorescent Tracer Dye is added at the factory. This has a changes to the HVAC System (Heating Ventilation and Air limited life of approximately 500 hours of A/C operation. conditioning ) over the previous BA to BFII models. Compressor Oil FG models are available with one of three HVAC systems: Compressor oil specification is PAG Compressor Oil ND-Oil 8 . Heater Only Manual HVAC (no A/C) - option on some Utes. A 250 cc can goes by the part number AY19L000A. 120 cc of oil is Single Zone Automatic Climate Control. stored in a new compressor (previous models held 200 cc). Dual Zone Automatic Climate Control (driver and front passenger zones). Replacement Liquid Line A replacement liquid line (condenser to evaporator) has two The TXV extra joints compared to the original factory pipe.

2 This makes replacement easier as the original pipe must be cut to remove it. With these systems came another significant change. Gone is the old Orifice Tube as a means of controlling refrigerant flow. The TXV makes its return in this Cycling Clutch TXV A/C System . Pollen filter & Screen Servicing These vehicles may be fitted with a standard fresh air wire filter Screen or a Pollen filter . The Pollen filter is an optional fit. Factory Log book servicing requires the wire filter Screen to be removed and cleaned every 45,000 k. Pollen filters are generally inspected and replaced annually. This is important to maintain effective A/C performance. Standard Fresh Air Wire filter Screen Each vehicle you service should be checked for fitment of the pollen filter . There is the opportunity to up sell a pollen filter if not already fitted. FG Falcon Interior Command Centre (ICC). To Check Pollen filter 30% Less Refrigerant 1. Open glovebox and unclip limiting stop. Refrigerant capacity as well as charge tolerance is significantly 2.

3 Drop down glove box. reduced from BFII models: 3. Slide filter cover flap to the left. FG BA to BFII 4. Remove filter or screen. 470 30 grams 650 50 grams 16 OCTOBER NOVEMBER 2010. Technically Speaking AUTOMOTIVE ELECTRICAL & AIR conditioning NEWS. Sub-Cooled Condenser The new Condenser is a sub-cooled type and has an integral Receiver with filter Drier. Refrigerant flow is now in two paths. In the main upper section of the core, the majority of refrigerant gas is condensed into a liquid. It then passes into the Receiver. From the bottom of the Receiver, liquid-only then flows out into the lower sub-cooled rows of the Condenser. filter Drier Service Kit The filter can be removed during service via an access cover at the lower edge of the front bumper bar. With the refrigerant evacuated, a screw-in plug at the base of the Receiver can be removed, allowing the filter and Desiccant Sack to be removed. Slide Blower Cover to the left to access filter Ford say the each time the system is opened to the atmosphere, the filter and Desiccant must be replaced.

4 A new plastic screw-in Battery Reconnection Procedure plug comes with the filter Service Kit. If the battery has been disconnected, the Powertrain Control Module (PCM) reverts to the factory assembly Compressor Run-in Strategy. When the Run-in Strategy is in place, the PCM will switch OFF. the Compressor clutch when engine speed exceeds 1,400 RPM. To reset Compressor strategy: 1. Start engine 2. Allow A/C to run at idle for at least 1 minute. 3. Compressor operation returns to normal. The above situation can also occur if the vehicle has had a flat battery A/C System Controlled via CAN. The A/C system is electronically controlled by the HVAC. Remote Transmitters Store A/C Settings Integrated Module (or HIM). This is located behind the dash and Each individual Remote key fob transmitter will retain the same can be accessed from the glovebox side. With FG, the HIM can A/C temperatures that were in use when that particular Remote now be removed without removing the dash. was last used to lock the vehicle.

5 Switching of the Compressor Clutch Relay is controlled by the Powertrain Control Module (PCM). Cooling Fan/s Run With Ignition OFF. The A/C controls are physically situated on the lower part of the The cooling fan/s on FG may run for up to four minutes AFTER Interior Command Centre (ICC). These switches are hard wired to the ignition has been switched OFF. the Face Display Module located at the top of the ICC. This is to minimise coolant loss during high heat soak loads. The switch requests are then sent via the Mid Speed CAN Bus to the Instrument Cluster, then on the High Speed CAN Bus to ENSURE THE BATTERY IS DISCONNECTED PRIOR TO the HVAC Integrated Module (HIM). This is a different CAN Bus UNDERTAKING WORK UNDER THE HOOD DURING THE FIRST configuration to the previous model. FOUR MINUTES AFTER SWITCHING OFF THE IGNITION. Breathing Your Own Air Is Bad! It is important to remind customers not to operate the HVAC. system for extended periods in the Recirculated mode. This will significantly reduce air quality in the vehicle cabin.

6 New A/C System Components Virtually all components have changed on FG, including a new HVAC case and seals, Evaporator, Thermistor and Cabin Temperature Sensor. The new Ambient Temperature Sensor is A/C Request Signal Communication to HVAC Module located in the passenger side external mirror housing. It is not serviced separately from the mirror housing. Regards from the Auto-Tech Team The TXV is located at the end of the evaporator pipes on the For more information contact Repco Auto-Tech on 1300 300. engine side of the firewall. 352 or by Priority Fax on 1300 300 354. OCTOBER NOVEMBER 2010 17.