Refrigerant Recovery

Refrigerant recovery systems and recycling stations are in use in most automotive A/C service facilities. The use of such equipment makes possible the recovery and reuse of R-12 system refrigerant after contaminants and moisture have been removed.

If a refrigerant recovery or recycling station is used, the following general procedures should be observed, in addition to the operating instructions provided by the equipment manufacturer.

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

1. Connect refrigerant recycling station hose(s) to vehicle A/C service ports and recovery station inlet fitting.

   NOTE: Hoses should have shut off devices or check valves within 25.4cm (12 inch) of the hose end to minimize the introduction of non-condensable gases (air) into the recycling station and to minimize the amount of refrigerant released when the hose(s) is disconnected.

2. Turn power to the recycling station on to start recovery process. Allow recycling station to pump refrigerant from the system until the vehicle system pressure goes into a vacuum. On some stations, the pump will be shut off automatically by a low pressure switch in the electrical system. On other units it may be necessary to manually turn off the pump.

3. Once recycling station has evacuated vehicle A/C system, close the station inlet valve (if so equipped). Then, switch off electrical power.

4. Allow vehicle refrigerant system to remain closed for about two minutes. Observe system pressure/vacuum level as shown on the gauge. If pressure does not rise, disconnect recycling station hose(s).

5. If system pressure rises, repeat Steps 2, 3 and 4 until the vacuum level remains stable for two minutes.

6. Perform required service operations, evacuate and recharge the A/C system.

Connecting the Manifold Gauge Set

Tools Required:

• Rotunda Adapter D81L-19703-A

1. Turn both manifold gauge set valves all the way to the right to close the high and low-pressure hoses to the manifold center hose. A Rotunda Adapter D81L-19703-A, Motorcraft Tool YT-354 or 355 or equivalent must be used to connect the manifold gauge set or charging station to the high-pressure service gauge port valve.

2. Remove the caps from the high and low-pressure service gauge port valves.

3. If the manifold gauge set or charging station hoses do not have valve depressing pins in them, install Fitting Adapters T71P-19703-S and R (which have pins) on the low and high-pressure hoses.

4. Connect the high and low-pressure hose adapters to the respective high and low-pressure service gauge port valves. The adapter shown must be used on the high-pressure gauge port valve.

System Discharging

Tools Required:

• Rotunda A/C Refrigerant Reclaim System 078-00800

In order to minimize the discharge of ozone depleting chlorofluorocarbons into the atmosphere, the Ford Motor Company supports the efficient usage, recovery and recycling of the R-12 used in passenger car, compact truck, and light truck air conditioners. Ford Motor Company recommends the use of a U.L.-approved recovery/recycling device such as Rotunda Model 078-00800 or equivalent (which meets SAE Standard J 1991), during any A/C system repair and recharge procedure which requires that the system be discharged.

System Evacuating

1. Connect manifold gauge set as outlined, if not yet connected.

2. Leak test the system as outlined.

3. Remove the refrigerant from the system as outlined.

4. Ensure both manifold gauge valves are turned all the way to the right.

5. Ensure the center hose connection at the manifold gauge is tight (closed).

6. Connect manifold gauge set center hose to a vacuum pump.

7. Open manifold gauge set valves and start the vacuum pump.

8. Evacuate the system with the vacuum pump until low-pressure gauge reads at least 84.2 kPa (25 in.-Hg) (vacuum) and as close to 101.04 kPa (30 in.-Hg) as possible. Continue to operate the vacuum pump for 30 minutes.

9. When evacuation of system is complete, close manifold gauge set valves and turn the vacuum pump off.

10. Observe low-pressure gauge for a minimum of five minutes to ensure system vacuum is held. If vacuum is held, charge the system. If vacuum is not held for five minutes, leak test the system, service the leaks, and evacuate the system again.

System Charging Set-Up

Ford Motor Company recommends using a charging station to perform evacuation and charging of the refrigerant system. Follow the instructions provided with the charging station.

If a charging station is not available, system charging may be accomplished using a separate vacuum pump, charging cylinder and manifold gauge set. The use of small cans of R-12 is NOT recommended.

If the charging cylinder method is used, the center port of the manifold gauge set should have two refrigerant hoses with integral shut-off valves built into the manifold gauge set. If the gauge set is the type that does not have shut-off valves and two hoses at the center port, a tee fitting and two hoses should be installed at the center port. In addition, the hoses attached to the center port should have shut-off valves at the other ends of the two center hoses to prevent air from entering the hoses when not connected to the vacuum pump and charging cylinder.

Charging with a Charging Cylinder:

1. If the vehicle suction (low) side service port is located on the accumulator, connect the gauge set center hose to the liquid port of the charging cylinder. If the suction (low) side service port is NOT on the accumulator (located on the suction hose), connect the center hose to the GAS port of the charging cylinder.

    WARNING: LIQUID CHARGE INTO THE VEHICLE SUCTION ACCUMULATOR ONLY. TO PREVENT COMPRESSOR SLUGGING, DO NOT LIQUID CHARGE INTO A REFRIGERANT HOSE WHILE THE ENGINE IS OPERATING.

2. When evacuating the system with the vacuum pump, the gauge set second center hose should be connected to the charging cylinder and opened to the gauge set so that the hose will evacuated with the system.

3. When evacuation of the system is completed, close the center hose valve to the vacuum pump and turn the pump off.

4. Open the charging cylinder valve and the gauge set low side valve to allow refrigerant to enter the system.

5. When no more refrigerant is being drawn into the system, start the engine and select an A/C function on the control assembly. Then, move the blower function setting to high to allow the remaining refrigerant to be drawn into the system. Continue to add refrigerant into the system until the specified weight of R-12 has been added. Then, close the charging cylinder valve and allow the system to pull any remaining refrigerant from the hose. When the suction pressure drops to approximately 30 psi, close the gauge set center hose valve.

6. Operate the system until the pressures stabilize to verify normal operation and system pressures.

7. In high ambient temperatures, it may be necessary to operate a high volume fan positioned to blow air through the condenser and radiator to aid in cooling the engine and prevent excessive refrigerant system pressures.

8. When charging is complete, close the valves at the ends of the low and high hoses if not equipped with automatic closing valves. Then, disconnect the manifold gauge set hoses from the vehicle and install the protective caps on the service gauge port fittings.