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Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 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 out flushing 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.
CAUTION: Refrigerant Compressor Oil (Mineral Oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to R-134a refrigerant systems as an AC compressor lubricant. PAG Refrigerant Compressor Oil F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant.
NOTE: If installing a new A/C compressor, the A/C clutch disc and hub (19D786), A/C compressor pulley (19D784) and A/C clutch field coil (19D798) must be inspected and transferred from the old unit to the new unit if suitable for reuse.
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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. 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 .
  3. Remove the accessory drive belt (8620) from the A/C compressor pulley.
    4. NOTE: Access the compressor manifold and tube assembly bolt from the RH front fender well, between the frame and body.
    Fig 1: Assembling From A/C Compressor
    G02766400Courtesy of FORD MOTOR CO.
  4. Loosen the bolt and detach the compressor manifold and tube assembly from the A/C compressor.
  5. Remove the splash shield.
  6. Disconnect and detach the crankshaft position sensor electrical connector and position the wire harness aside.
    Fig 2: Disconnecting And Detach Crankshaft Position Sensor Electrical Connector
    G02766401Courtesy of FORD MOTOR CO.
  7. Detach the wire harness from the bracket.
    Fig 3: Detaching Wire Harness From Bracket
    G02766402Courtesy of FORD MOTOR CO.
  8. Disconnect the A/C compressor clutch field coil electrical connector.
    Fig 4: Disconnecting A/C Compressor Clutch Field Coil Electrical Connector
    G02766403Courtesy of FORD MOTOR CO.
  9. Remove the A/C compressor mounting bolt.
    Fig 5: Removing A/C Compressor Mounting Bolt
    G02766404Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the A/C compressor.
    • Discard the A/C O-ring seals.
    Fig 6: Removing Bolts And A/C Compressor
    G02766405Courtesy of FORD MOTOR CO.
  11. To install, reverse the removal procedure.
    • If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. For additional information, refer to CLUTCH AND CLUTCH FIELD COIL .
    • Install new O-ring seals lubricated in clean mineral oil.
    • 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 .
  12. 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 .
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