Auto Repairing 2005-2009 Ford Focus A/C – White Flakes Are Blowing From Dash Vents
ISSUE Some vehicles may experience white flakes coming from the A/C vents when the blower motor is engaged. This may be caused by flux utilized in the manufacturing process of the evaporator core. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Hazard and Risk Warnings for White Flakes WARNING MAY CAUSE EYE AND RESPIRATORY TRACT IRRITATION. PROLONGED REPEATED EXPOSURE MAY CAUSE BONE DAMAGE (FLUOROSIS) AND HARM TO THE RESPIRATORY SYSTEM (BASED ON ANIMAL DATA). ^ Avoid inhaling dust. ^ Avoid contact with eyes. ^ Store away from acids. ^ Wash thoroughly after handling. ^ Avoid release to the environment.
NOTE THE USE OF DUST PROOF GOGGLES, CHEMICAL RESISTANT GLOVES (PVC) AND DUST MASK IS RECOMMENDED. Using compressed air (maximum inlet pressure) 100 PSI (689 kPa), clean the A/C ducts through the registers and blow off theevaporator core through the blower motor opening. NOTE THE ENTIRE EVAPORATOR CORE SURFACE MUST BE DRY FOR BEST RESULTS. NOTE WHILE PERFORMING THIS PROCEDURE AND SELECTING DIFFERENT VENT MODES SUCH AS FLOOR / PANEL AND FLOOR / DEFROST, IT MAY BE NECESSARY TO TEMPORARILY START THE ENGINE TO ENABLE MODE DOOR MOVEMENT. Clean A/C Ducts: 1. Remove floor duct trim. 2. Using masking tape, connect one end of the vacuum cleaner hose to the floor duct on driver side. 3. Tape closed all the other floor duct openings. 4. Obtain about two feet (61 cm) of rubber vacuum line large enough to fit the end of a small shop air blowgun. Secure the hose to the end of the blowgun using a worm clamp. 5. Close all instrument panel registers. 6. Set temperature setting to full cold. 7. Place mode in floor / panel.
8. Turn on vacuum cleaner. 9. Working with one register at a time insert the vacuum line down each duct and blow shop air through each duct for 30 seconds. Be sure to close each register before moving on to the next register. 10. Change mode to floor I defrost. 11. Blow down each defroster duct for 30 seconds. 12. Alternate mode door between floor and floor / defrost three (3) times, giving the door time to move between each change. 13. Turn off vacuum cleaner. Clean Evaporator Core: 1. Change mode to full floor. 2. Ensure temperature is full cold. 3. Remove blower motor per Workshop Manual (WSM), Section 412. 4. Turn on vacuum cleaner. 5. Reach into blower opening with vacuum line and proceed to blow shop air for a minimum of 5 minutes, utilizing a very slow sweeping action. 6. Blow the entire core face with an up and down motion, then repeat moving from side to side. NOTE ATTENTION TO THE BLOW-OFF OF THE EVAPORATOR CORE SURFACE WILL DETERMINE EFFECTIVENESS OF REPAIR. 7. Install the blower motor per WSM, Section 412. 8. Open all registers. 9. Operate the A/C system in Max mode with the blower on the lowest setting. Monitor the temperature with a thermometer until the lowest temp is achieved. Switch to vent and monitor the temperature until ambient temperature is reached. 10. Repeat Step 9 three (3) additional times. 11. Switch the blower motor to high speed with the vent mode still selected. white flakes should not come out of the vents. If no white flakes are present continue to Step 12. 12. Disconnect vacuum cleaner and remove tape from floor duct. 13. Reassemble floor duct trim. 14. Blow powder off or vacuum dash board and vehicle interior as required.
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