Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.

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

Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
Remove the upper headliner trim panel.

Fig 1: Removing Upper Headliner Trim Panel
Courtesy of FORD MOTOR CO.
Detach and position the LH D-pillar trim panel aside.

Fig 2: Positioning LH D-Pillar Trim Panel Aside
Courtesy of FORD MOTOR CO.
Detach the upper rear portion of the LH quarter trim panel and position away from the thermostatic expansion valve.
Remove the 4 retainers and the thermostatic expansion valve cover (if equipped).
Remove the insulating tape.
- Retain the tape for reuse.
  
  Fig 3: Removing Insulating Tape
  Courtesy of FORD MOTOR CO.
Remove the temperature sensing bulb clip and detach the temperature sensing bulb from the evaporator outlet line.

Fig 4: Removing Temperature Sensing Bulb Clip
Courtesy of FORD MOTOR CO.
Disconnect the 2 thermostatic expansion valve fittings and remove the thermostatic expansion valve.
- Discard the O-ring seals.
- To install, tighten to 23 Nm (17 lb-ft).
To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
Evacuate, leak test and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .