Ranger 2WD V6-245 4.0L VIN X SFI (1997)
Condenser HVAC: Testing and Inspection
A/C CONDENSER CORE
If an A/C condenser core leak is suspected, the leak test procedure should be performed before replacing the A/C condenser core. Use of this leak
test procedure will help to prevent unnecessary replacement of non-leaking A/C condenser cores. If a leak is indicated at a refrigerant line
connection to the A/C condenser core, recover the refrigerant from the system and disassemble the fitting. Clean the fitting components and
inspect for damage. Service as necessary.
NOTE: Use the previous procedure to also test the A/C condenser core.
ON-VEHICLE LEAK TEST
Disconnect the lines from the condenser core tubes. DO NOT leak test an A/C condenser core with the lines attached to the A/C condenser core. If
the condenser core tube fittings are the female spring lock design, check the inside of each fitting if possible for scratches and/or corrosion. If
scratches or corrosion are found, the leak test results may not be accurate if a leak is indicated because of possible leaks at the fitting(s).
Connect the appropriate test fittings from Test Adapter Set D93L-19703-B or equivalent to the condenser tube connections. Then. connect the
gauge set RED and BLUE hoses to the test fittings. Connect the YELLOW gauge set hose to a known quality vacuum pump.
Before leak testing the A/C condenser core, attach the high-side and low-side manifold gauge set hoses together and apply vacuum to verify the
manifold gauge set and the hoses do not leak.
NOTE: The automatic cutoff valves on some gauge set hoses do not open when connected to the test fittings. Use hoses without cutoff valves if
available. If hoses with cutoff valves are used, check to be sure the valve opens when attached to the test fittings before installing the fittings and
proceeding with the leak test. The test is not valid if the cutoff valve does not open because only the hose will be tested.
Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low
pressure gauge indicates 30 in-Hg. This evacuation is necessary to remove any refrigerant from oil left in the A/C condenser core. If the
refrigerant is not completely removed from the oil, gassing will occur and degrade the vacuum and appear as a refrigerant leak. After evacuating
for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge. It should remain at the 30 mark.
NOTE: Use only a known quality vacuum pump. Make sure pump is maintained according to manufacturer's directions.
If the low-pressure gauge reading will not drop to 30 in-Hg when the valves are open and the vacuum pump is operating, close the gauge set
valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and
gauge set connections before replacing the A/C condenser core.
If the low pressure gauge reading rises 10 or more inches of vacuum from the 30 inch position in ten minutes, a leak is indicated. If a small leak
is suspected, wait 30 minutes and observe the vacuum gauge. If a small amount of vacuum is lost, operate the vacuum pump with the gauge valves
open for an additional 45 minutes with the system blower motor on low to remove any remaining refrigerant from the oil in the A/C condenser
core. Then, recheck for loss of vacuum. If a very small leak is suspected, allow the system to sit overnight with vacuum applied and check for
vacuum loss. Always remember that a leaking fitting, gauge set or hose connection will appear as a leaking A/C condenser core.
If a vehicle passes the vacuum leak test and is returned within 60 days for loss of cooling due to no refrigerant charge, look elsewhere in the
system for refrigerant leaks such as the compressor shaft seal or refrigerant line connections.
