Section 12-00: Climate Control System—Service
1993 Mustang Workshop Manual
DIAGNOSIS AND TESTING

Evaporator Core and Condenser On-Vehicle Leak Test

Tools Required:

If an evaporator core or condenser is suspected of leaking, the leak must be verified prior to removing the component from the vehicle. This leak test should be performed as outlined below. DO NOT rely solely on the results of an electronic leak detector as chemicals other than R-12 will activate the leak detector.

  1. Discharge the refrigerant from the system with a recovery machine such as the Rotunda A/C Reclaim System (078-00800) or equivalent, following the recommended service procedure.
  1. Disconnect the inlet and outlet connections from the evaporator core or condenser, immediately install protective caps on the disconnected connections to prevent excess moisture from entering the system.
  1. Install the mating adapters from the evaporator core/condenser Leak Test Adapter Kit, Tool D88P-19703-B or equivalent on both fittings of the component being tested.


Evaporator Core Leak Test Adapters and Test Connections




  1. Connect the two outside hoses of a manifold gauge set to the adapter fittings. Be sure the connections are tight.
  1. Connect the center hose of the manifold gauge set to a vacuum pump. Start the vacuum pump and open the valves of the gauge set.
  1. Operate the vacuum pump and watch the low pressure gauge. It should show almost 30 in-Hg within one or two minutes. Then, close the gauge set valves and stop the vacuum pump.
  1. Observe the low pressure gauge for fifteen minutes and watch for a drop in the gauge reading. If the gauge reading drops, the component is leaking and should be replaced. If a slow leak is suspected, leave the component connected to the gauge set overnight. If the gauge reading does NOT drop, the component is not leaking. Look elsewhere for the source of the leak.
  1. Disconnect the vacuum pump, manifold gauge set and the adapters from the component being tested.
  1. Assemble the original component into the system if it was not leaking. Use new green O-rings lubricated with clean refrigerant oil.
  1. If the component was leaking, install a new part and a new suction accumulator. Use new green O-rings lubricated with clean refrigerant oil.
  1. Leak test, evacuate and charge the system following the recommended service procedures.