Removal and Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. 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 contamination from a failed A/C compressor or damage to the suction accumulator.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .
Recover the refrigerant. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .
Vehicles equipped with auxiliary climate control
Disconnect the auxiliary line fitting.
- Discard the O-ring seal.
  
  Fig 1: Removing Auxiliary Line Fitting With Torque Specifications
  Courtesy of FORD MOTOR CO.
All vehicles
Disconnect the compressor manifold and tube fitting at the suction accumulator.
- Discard the O-ring seal.
  
  Fig 2: Disconnecting Compressor Manifold And Tube Fitting At Suction Accumulator With Torque Specifications
  Courtesy of FORD MOTOR CO.
Remove the tube clamp.

Fig 3: Removing Tube Clamp
Courtesy of FORD MOTOR CO.
Remove the pin-type retainers and the sight shield.

Fig 4: Removing Pin-Type Retainers And Sight Shield
Courtesy of FORD MOTOR CO.
Disconnect the condenser inlet fitting.
- Discard the O-ring seal.
  
  Fig 5: Disconnecting Condenser Inlet Fitting With Torque Specifications
  Courtesy of FORD MOTOR CO.
Remove the turbo charge air inlet pipe.
- Loosen the clamp at the turbo.
- Loosen the clamp at the intercooler.
- Remove the air inlet pipe.
  
  Fig 6: Removing Turbo Charge Air Inlet Pipe
  Courtesy of FORD MOTOR CO.
Disconnect the pressure cutoff switch electrical connector.

Fig 7: Disconnecting Pressure Cutoff Switch Electrical Connector
Courtesy of FORD MOTOR CO.

Excursion, 4x2 F-250 and 4x2 F-350 vehicles
Remove the RH fender splash shield. Refer to FRONT END BODY PANELS .
All vehicles
Loosen the bolt and remove the compressor manifold and tube assembly.
- Discard the O-ring seals.
  
  Fig 8: Removing Bolt And Compressor Manifold And Tube Assembly With Torque Specifications
  Courtesy of FORD MOTOR CO.
Remove the pressure cutoff switch.
- Discard the O-ring seal.
  
  Fig 9: Removing Pressure Cutoff Switch With Torque Specifications
  Courtesy of FORD MOTOR CO.
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. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .
Evacuate, leak test and charge the refrigerant system. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .