Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the evaporator core or condenser core. Connect the yellow hose to a known good vacuum
pump.
6. 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 101 kPa
(30 inches-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the evaporator core or condenser core. If the refrigerant is not completely removed
from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 inches-Hg) when the valves on the gauge and manifold set 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 installing a new evaporator core or condenser core.
8. 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 101 kPa (30 inches-Hg) mark.
If the low pressure gauge reading rises 34 kPa or more (10 inches-Hg or more) of vacuum from the 101 kPa (30 inches-Hg) position in 10 minutes, a leak is indicated.
If a very 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 gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the
evaporator core or condenser core. Then recheck for loss of vacuum.
If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss.
9. If the evaporator core or condenser core does leak, as verified by the above procedure, install a new evaporator core or condenser core. Refer to Section 412-03.
A/C Compressor—External Leak Test
1. Install the A/C pressure test adapter on the rear head of the A/C compressor (19703) using the existing manifold retaining bolt.
2. Connect the high and low pressure lines of a manifold gauge set or a refrigerant recovery/recycling station such as the R-134a A/C Refrigerant Center to the corresponding fittings on
the A/C pressure test adapter.
3. Attach the center hose of the R-134a Manifold Gauge Set to a refrigerant container standing in an upright position.
4. Hand-rotate the compressor shaft 10 complete revolutions to distribute the oil inside the A/C compressor.
5. Open the low pressure gauge valve, the high pressure gauge valve and the valve on the refrigerant container to allow the refrigerant vapor to flow into the A/C compressor.
6. Using the Refrigerant Leak Detector, check for leaks at the compressor shaft seal and the compressor center seal.
7. If a shaft seal leak is found, install a new shaft seal. Refer to Section 412-03. If an external leak is found at the center joint of the A/C compressor, install a new A/C compressor.
8. When the leak test is complete, recover the refrigerant from the compressor.
2003 Taurus/Sable Workshop Manual
http://www.fordtechservice.dealerconnection.com/pubs/content/~WS3H/~MUS~LEN/19/
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