854785 Mercury SERVICE MANUAL

Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Note: Recover the refrigerant before any lines are loosened or before any bolts are loosened.
Recover the air conditioner refrigerant from the air conditioner system. Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134A Refrigerant" for the correct procedure. Refer to Dealer Service Tool Catalog, NENG2500, "Air Conditioning Tools" for the correct tools.
Illustration 1 g00722281
The alternator is removed for photographic purposes.
Disconnect the electrical wiring connection (1) .
Illustration 2 g00711005
Remove two bolts (3) and the washers.
Disconnect two tube assemblies (2) . Put tape over the ends of the tube assemblies. Put tape over the holes in the refrigerant compressor. Tape will help to prevent contaminating the refrigerant system.
Illustration 3 g00711064
Remove four bolts (4) and the washers. Remove refrigerant compressor (5) .Installation Procedure
Illustration 4 g00711064
Place refrigerant compressor (5) in position. Install the washers and four bolts (4) .
Illustration 5 g00711093
Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.
Remove the tape from tube assemblies (2) . Replace O-ring seals (6) with new O-ring seals.
Illustration 6 g00711005
Remove the tape from the refrigerant compressor. Connect tube assemblies (2) . Install the washers and bolts (3) . Tighten the bolts to a torque of 10 2 N m (88.5 17.7 lb in).
Illustration 7 g00722281
The alternator is removed for photographic purposes.
Connect the electrical wiring connection (1) .
Personal injury can result from contact with refrigerant.Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.Always use precaution when a fitting is removed. Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated area.Personal injury or death can result from inhaling refrigerant through a lit cigarette.Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or death.Do not smoke when servicing air conditioners or wherever refrigerant gas may be present.Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
Charge the air conditioning system. The correct charge is 1.1 kg (2.4 lb). Refer to Service Manual, SENR5664, "Air Conditioning and Heating Systems with R-134A Refrigerant" for the correct procedure. Refer to Dealer Service Tool Catalog, NENG2500, "Air Conditioning Tools" for the correct tools.
Check the air conditioning system for leaks.Note: Use a 4C-2964 Refrigerant Leak Detector to check the system.End By:
Install the V-belt on the refrigerant compressor. Refer to Disassembly and Assembly, "V-Belts - Remove and Install" in this manual.
Install the hood on the refrigerant compressor. Refer to Disassembly and Assembly, "Hood - Remove and Install" in this manual.