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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. Disconnect the battery ground cable (14301). For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  3. Remove the engine air cleaner (ACL) (9600) and the air cleaner outlet tube (9B659).
  4. Remove the bolt and detach the compressor manifold and tube from the A/C compressor.
    • Discard the O-ring seals.
      Fig 1: Removing Bolt And Detaching Compressor Manifold And Tube From A/C Compressor
      G01452991Courtesy of FORD MOTOR CO.
  5. Disconnect the pressure cutoff switch electrical connector.
    Fig 2: Disconnecting Pressure Cutoff Switch Electrical Connector
    G01452992Courtesy 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 suction accumulator.
    • Discard the O-ring seal.
      Fig 3: Disconnecting Compressor Manifold And Tube Assembly From Suction Accumulator
      G01452993Courtesy of FORD MOTOR CO.
    7. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  7. Disconnect the compressor manifold and tube assembly from the condenser and remove the compressor manifold and tube assembly.
    • Discard the O-ring seal.
      Fig 4: Removing Compressor Manifold And Tube Assembly
      G01452994Courtesy 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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