Removal and Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system.

If A/C flushing equipment is available, carry outflushing of the air conditioning system prior to installing a new air conditioning compressor. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
Install a new evaporator core orifice (19D990) as directed by the A/C flushing or filtering procedure.
Install a new suction accumulator (19C836) as directed by the A/C flushing or filtering procedure.

NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

If flushing of the air conditioning system has not been carried out, recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
Remove the accessory drive belt (8620) from the A/C compressor pulley.
Raise the vehicle.

NOTE: Access the compressor manifold and tube assembly bolt from the RH front fender well, between the frame and body.

Fig 1: Detaching Compressor Manifold And Tube Assembly From A/C Compressor

Courtesy of FORD MOTOR CO.

Loosen the bolt and detach the compressor manifold and tube assembly from the A/C compressor.
Remove the splash shield.
Disconnect and detach the crankshaft position sensor electrical connector and position aside the wiring harness.

Fig 2: Disconnecting And Detaching Crankshaft Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the wiring harness from the bracket.

Fig 3: Detaching Wiring Harness From Bracket
Courtesy of FORD MOTOR CO.
Disconnect the A/C compressor clutch field coil electrical connector.

Fig 4: Disconnecting A/C Compressor Clutch Field Coil Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the A/C compressor mounting bolt.

Fig 5: Removing A/C Compressor Mounting Bolt
Courtesy of FORD MOTOR CO.
Remove the bolts and the A/C compressor.
- Discard the O-ring seals.
  
  Fig 6: Removing Bolts And A/C Compressor
  Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
- If a new A/C compressor is to be installed, the A/C compressor clutch field coil (2987), the A/C compressor pulley (2E884), and the A/C clutch plate (2884) must be transferred from the old unit. For additional information, refer to CLUTCH AND CLUTCH FIELD COIL - COMPRESSOR .
- If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
- Install new O-ring seals lubricated in clean PAG oil.
If filtering of the refrigerant system is not to be carried out, evacuate, leak test, and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .