FG Falcon A/C system - Repco Trade Zone

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
changes to the HVAC System (Heating Ventilation and Air
Conditioning) over the previous BA to BFII models.
FG models are available with one of three HVAC systems:
• Heater Only Manual HVAC (no A/C) - option on some Utes.
• Single Zone Automatic Climate Control.
• Dual Zone Automatic Climate Control (driver and front
passenger zones).
The TXV Returns....
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”.
FG Falcon Interior Command Centre (ICC)
30% Less Refrigerant
Refrigerant capacity as well as charge tolerance is significantly
reduced from BFII models:
FG BA to BFII
470 ± 30 grams 650 ± 50 grams
16 OCTOBER NOVEMBER 2010
R-134a Fluorescent Tracer Dye is added at the factory. This has a
limited life of approximately 500 hours of A/C operation.
Compressor Oil
Compressor oil specification is “PAG Compressor Oil ND-Oil 8”.
A 250 cc can goes by the part number AY19L000A. 120 cc of oil is
stored in a new compressor (previous models held 200 cc).
Replacement Liquid Line
A replacement liquid line (condenser to evaporator) has two
extra joints compared to the original factory pipe. This makes
replacement easier as the original pipe must be cut to remove it.
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.
To Check Pollen Filter
1. Open glovebox and unclip limiting stop.
2. Drop down glove box.
3. Slide filter cover flap to the left.
4. Remove filter or screen.

Technically Speaking AUTOMOTIVE ELECTRICAL & AIR CONDITIONING NEWS
Slide Blower Cover to the left to access Filter
Battery Reconnection Procedure
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
Remote Transmitters Store A/C Settings
Each individual Remote key fob transmitter will retain the same
A/C temperatures that were in use when that particular Remote
was last used to lock the vehicle.
Cooling Fan/s Run With Ignition OFF
The cooling fan/s on FG may run for up to four minutes AFTER
the ignition has been switched OFF.
This is to minimise coolant loss during high heat soak loads.
ENSURE THE BATTERY IS DISCONNECTED PRIOR TO
UNDERTAKING WORK UNDER THE HOOD DURING THE FIRST
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.
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
located in the passenger side external mirror housing. It is not
serviced separately from the mirror housing.
The TXV is located at the end of the evaporator pipes on the
engine side of the firewall.
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.
Ford say the each time the system is opened to the atmosphere,
the Filter and Desiccant must be replaced. A new plastic screw-in
plug comes with the Filter Service Kit.
A/C System Controlled via CAN
The A/C system is electronically controlled by the HVAC
Integrated Module (or HIM). This is located behind the dash and
can be accessed from the glovebox side. With FG, the HIM can
now be removed without removing the dash.
Switching of the Compressor Clutch Relay is controlled by the
Powertrain Control Module (PCM).
The A/C controls are physically situated on the lower part of the
Interior Command Centre (ICC). These switches are hard wired to
the Face Display Module located at the top of the ICC.
The switch requests are then sent via the Mid Speed CAN Bus
to the Instrument Cluster, then on the High Speed CAN Bus to
the HVAC Integrated Module (HIM). This is a different CAN Bus
configuration to the previous model.
A/C Request Signal Communication to HVAC Module
Regards from the Auto-Tech Team
For more information contact Repco Auto-Tech on 1300 300
352 or by Priority Fax on 1300 300 354
OCTOBER NOVEMBER 2010 17