Spring Lock Coupling

Tools Required:

• Spring Lock Coupling Tools T81P-19623-G1, T81P-19623-G2, T83P-19623-C, T85L-19623-A

To Disconnect Coupling

1. Discharge refrigerant from system with a refrigerant recycling machine. Fit Spring Lock Coupling Tools T81P-19623-G1 (3/8-inch), T81P-19623-G2 (1/2-inch), T83P-19623-C (5/8-inch) or T85L-19623-A (3/4-inch) to the coupling.

2. Close tool and push into open side of cage to expand garter spring and release female fitting.

   NOTE: The garter spring may not release if the tool is cocked while pushing it into the cage opening.

3. After garter spring is expanded, pull fitting apart.

4. Remove tool from disconnected coupling.

To Connect Coupling

1. Check to ensure that garter spring is in cage of male fitting. If garter spring is missing, install a new spring by pushing it into cage opening. If garter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring.

2. Clean all dirt or foreign material from both pieces of coupling.

3. Lubricate and install new green O-rings on male fitting.

   Use only the specified green O-rings as they are made of a special material. The use of any O-ring other than the specified green O-ring may allow the connection to leak intermittently during vehicle operation. Refer to service parts list.

4. Lubricate male fitting and O-rings and inside of female fitting with clean refrigerant oil.

5. Install plastic indicator ring into cage opening if indicator ring is to be used.

6. Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting.

   If plastic indicator ring is used, it will snap out of cage opening when coupling is connected to indicate engagement.

7. If indicator ring is not used, ensure coupling engagement by visually checking to verify garter spring is over flared end of female fitting.

Fixed Orifice Tube Replacement Kit Installation

1. Discharge the A/C refrigerant system. Refer to System Discharging.

2. Remove the liquid line from the vehicle.

3. Locate the orifice tube by the three indented notches or a circular depression in the metal portion of the liquid line.

4. Note the angular position of the ends of the liquid line so that it can be reassembled in correct position.

5. Cut a 63.5mm (2 1/2 inch) section from tube at orifice tube location. Do not cut closer than 25.4mm (1 inch) from the start of a bend in tube.

6. Flush the two pieces of liquid line to remove any contaminants.

7. Lubricate fitting O-rings with clean refrigerant oil and assemble orifice tube kit (with orifice tube installed) to liquid line as shown in. Ensure flow direction arrow is pointing toward evaporator end of liquid line, and taper of each compression ring is pointing toward compression nut.

NOTE: The inlet tube will be positioned against the orifice tube tabs when correctly assembled.

8. While holding hex of tube in a vise, tighten each compression nut to 88-94 Nm (65-70 lb-ft) with a crow foot wrench.

9. Assemble liquid line to vehicle using new green O-rings lubricated with clean refrigerant oil. Use only specified green O-rings at spring lock coupling.

10. Leak test, evacuate and charge system following approved procedures.

11. Check system for proper operation.

Suction Accumulator/Drier Replacement Guidelines

Replacement of the suction accumulator/drier is necessary anytime a major component of the refrigerant system is replaced. A major component includes condenser, compressor, evaporator core or a refrigerant hose/line. An orifice tube or O-ring is not considered a major component but the orifice tube should be replaced whenever the compressor is replaced for lack of performance.

In addition to the preceding condition, the accumulator/drier should also be replaced if one of the following conditions exist:

• The accumulator/drier is perforated.
• The refrigerant system has been opened to the atmosphere for a period of time longer than required to make a minor repair.
• There is evidence of moisture in the system such as internal corrosion of metal refrigerant lines or the refrigerant oil is thick and dark.

NOTE: The compressor oil from vehicles equipped with an FX-15 compressor may have a dark color while maintaining a normal oil viscosity. This is normal for this compressor because carbon from the compressor piston rings will discolor the oil.

When replacing the suction accumulator/drier, the procedure given here must be followed to ensure that the total oil charge in the system is correct after the new accumulator/drier is installed.

1. Drain the oil from the removed accumulator/drier into a suitable measuring container. Drill one or two 1/2 inch holes in the bottom of the old accumulator/drier to ensure that all the oil has drained out.

2. Add the same amount of clean new refrigerant oil plus two fluid ounces to the new accumulator/drier. Use only the oil specified for the specific vehicle being serviced (Motorcraft YN-9 or an equivalent oil containing the same additives).

Opposition to Charging From Small Containers

The refrigerant charge level of A/C systems currently being used is critical to optimum performance. Either an under-charge or an over-charge will adversely affect performance. Using small cans to charge these systems is not recommended because the charge level cannot be accurately controlled. A charging cylinder or a charging station is the only recommended method.

Refrigerant System Purging to Remove Moisture Vapor

The triple evacuation procedures should be used when there are definite indications of moisture in the system.

The principle of the three evacuations is simple. Evacuate the system for at least 10 minutes.

The first purge with new, dry Refrigerant-12 mixes with the moisture and removes most of the moisture when the refrigerant is removed.

With the next evacuation, approximately 10 percent of the remaining air and moisture vapors remain.

The second purge with new, dry Refrigerant-12 will mix with this 10 percent, and will be removed when the refrigerant is recycled. The third evacuation will finish the job by drawing out practically all the remaining vapors.

If any water was present in the system at the start of this procedure, most of it will still be there. A short period of vacuum is not long enough to boil and vaporize the water. The Refrigerant-12 purges, in passing over the liquid, will absorb only a relatively small amount of water.

This procedure is effective only when no water is in the system and should not be used if there is any indication of water in the system.