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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: 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 A/C 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: 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. Remove the A/C compressor. For additional information, refer to AIR CONDITIONING (A/C) COMPRESSOR - 6.0L DIESEL .
  2. Remove the RH intercooler tube.
    Fig 1: Removing RH Intercooler Tube
    G02766482Courtesy of FORD MOTOR CO.
  3. Disconnect the condenser fittings.
    • Discard the O-ring seals.
    Fig 2: Disconnecting Condenser Fittings
    G02766483Courtesy of FORD MOTOR CO.
  4. Disconnect the compressor manifold and tube suction fitting.
    1. Remove the screw.
    2. Disconnect the fitting.
      • Discard the O-ring seal.
    Fig 3: Disconnecting Fitting
    G02766484Courtesy of FORD MOTOR CO.
  5. Remove the compressor manifold and tube bracket bolt.
    Fig 4: Removing Compressor Manifold And Tube Bracket Bolt
    G02766485Courtesy of FORD MOTOR CO.
  6. Disconnect the pressure cutoff switch electrical connector.
  7. Remove the compressor manifold and tube assembly.
  8. To install, reverse the removal procedure.
    • Install new O-ring seals lubricated in clean mineral oil.
    • Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
  9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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