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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.
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.
  1. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  2. Remove the air cleaner assembly.
  3. Disconnect the pressure cutoff switch electrical connector.
    Fig 1: Disconnecting Pressure Cutoff Switch Electrical Connector
    G01452980Courtesy of FORD MOTOR CO.
  4. Position aside the compressor discharge line isolator.
    1. Remove the screw.
    2. Position aside the isolator.
      Fig 2: Positioning Aside Compressor Discharge Line Isolator
      G01452981Courtesy of FORD MOTOR CO.
    5. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  5. Disconnect the compressor manifold and tube assembly from the suction accumulator.
    • Discard the O-ring seal.
      Fig 3: Disconnecting Compressor Manifold And Tube Assembly From Suction Accumulator
      G01452982Courtesy of FORD MOTOR CO.
    6. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  6. Disconnect the compressor manifold and tube assembly from the condenser.
    • Discard the O-ring seal.
      Fig 4: Disconnecting Compressor Manifold And Tube Assembly From Condenser
      G01452983Courtesy of FORD MOTOR CO.
  7. Remove the compressor manifold and tube assembly.
    1. Loosen the bolt.
    2. Detach and remove the compressor manifold and tube assembly.
      • Discard the O-ring seals.
        Fig 5: Removing Compressor Manifold And Tube Assembly
        G01452984Courtesy of FORD MOTOR CO.
  8. To install, reverse the removal procedure.
    • If a new compressor manifold and tube assembly is to be installed, transfer the pressure cutoff switch to the new compressor manifold and tube assembly.
    • 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.
  9. Evacuate, leak test, and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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