A/C Compressor - Moaning/Vibration
Article No. 85-24-1AIR CONDITIONING - COMPRESSOR MOAN ON (HR980) VEHICLES BUILT BEFORE JULY 1, 1985 WITH 3.8L ENGINES
FORD 1983-85 THUNDERBIRD, LTD
LINCOLN-MERCURY 1983-85 COUGAR, MARQUIS
If an objectionable moan and vibration noise is transmitted to the passenger compartment during air conditioning compressor operation at engine speeds ranging from 1200 to 1800 RPM, replace the existing A/C compressor mounting braces and brackets with new design mounting braces and brackets. Also, replace the existing power steering pulley with a new power steering pulley. The new power steering pulley reduces the A/C drive ratio which will reduce the compressor pumping capacity.
SERVICE PROCEDURE
TESTING
1. Start the engine and accelerate the engine to speeds between 1200 and 1800 RPM. With the air conditioner operating, verify the moan/vibration noise condition.
2. If the moan/vibration noise occurs, switch the air conditioner to OFF and verify that the noise condition does or does not stop.
A. If the noise does not stop with the A/C OFF, refer to the Noise, Vibration and Harshness (NVH) diagnosis located in Group 18 of the appropriate shop manual.
B. If the noise stops with the A/C OFF,continue to Step 3.
3. Replace the compressor mounting brackets and braces as outlined in the attached service procedures. Also, replace the existing power steering pulley with a new reduced A/C drive ratio power steering pulley.
COMPRESSOR BRACE AND BRACKET REPLACEMENT
Removal
1. Loosen the idler pulley, move the pulley inboard and remove the poly-V belt from the power steering pump pulley.
2. Remove two (2) retaining bolts from the top of the radiator shroud and move the shroud from the radiator support.
Figure 1:
3. Loosen the three (3) A/C compressor adjusting bolts (part numbers N801179-S2 (2) and N802- 917-S2 (2) and rotate the compressor inboard (Figure 1). Remove and discard the compressor drive belt.
4. Reposition the radiator shroud as necessary and, using a power steering pulley removal tool, remove the power steering pulley from the vehicle and discard the pulley.
5. Remove retaining bolt (N801179-S2) and nut (N800359-S2) from rear brace (19D897) and discard the brace only. The rear brace extends from the top of adjusting bracket assembly (19N586) to an intake manifold stud (Figure 1). Loosen bolt (57102-S), located near the alternator, that retains the bottom end of brace (19D894), rotate the brace out of the way and remove and discard brace (19B897).
6. Remove one (1) screw each from the A/C discharge line retaining clip located at the top of the compressor bracket assembly (19D586) and the suction line retaining clip located at the rear of the compressor brace assembly (19D895).
7. Remove the three (3) nuts (N620482-S2) retaining the large compressor bracket assembly (19N586) to the three (3) water pump studs (Figure 1).
Figure 1:
9. Remove three (3) retaining bolts (N801179-S2) from brace assembly (19D895), one (1) from the top left side of the large compressor bracket assembly (19N586) and two (2) retaining the brace assembly to the engine head (Figure 1). Remove and discard the brace assembly (19D895).
NOTE: For LTD/Marquis vehicles with an engine damper shock assembly, remove the retaining nut and disconnect the engine damper shock mounting bracket from the engine damper shock assembly and discard the bracket only.
Figure 2 - A/C COMPRESSOR (HR980) BRACKETRY - 3.8L ENGINE:
Installation
1. Install two (2) new studs (N802378-S2) into the threaded holes in the front of the left cylinder head (Figure 2) replacing bolts (N801179-S2) removed in Step 9. Tighten the studs to the stud's center shoulder.
2. Position new bracket (E5DZ-6F036-A) onto the two
(2) new studs (N802378-S2) (Figure 2).
3. Install new bracket (E5DZ-2882-B) onto the new studs and over bracket (E5DZ-6F036-A) and install two (2) new nuts (N802827-S2) (Figure 2). Do not tighten.
NOTE: For LTD/Marquis vehicles with an engine damper assembly, position the engine damper mounting bracket assembly (E5DZ-6F037-A) to bracket (E5DZ- 6F036-A) and install two (2) retaining bolts (N801179-S100). Do not tighten. Then, connect the outboard end of damper bracket to the engine damper shock assembly (Figure 2). Install and tighten the bracket-to-shock retaining nut.
4. Position the large plate bracket assembly (19N- 586) into place on the three (3) existing water pump mounting studs and install the three (3) retaining nuts (N620482-S2) (Figure 2). Do not tighten.
5. Position bracket (19D625) between front bracket assembly (19N586) and bracket (E5SZ-2882-B). Then, align the pivot bolt holes and install pivot bolt (N802917-S2) through these three (3) brackets only.
6. Position the embossed (raised hole) end of new rear bracket (E5SZ-2882-C) between bracket (E5DZ-6F036-A) and bracket (E5SZ-2882-B) and install the pivot bolt through the rear brace into the threaded hole in the engine head. Do not tighten.
7. Tighten the two (2) nuts retaining the lower rear portion of bracket (E5SZ-2882-A) to the engine head. Torque to 30-45 ft.lbs.
Figure 2 - A/C COMPRESSOR (HR980) BRACKETRY - 3.8L ENGINE:
8. Remove compressor retaining bolt (N606663-S2) from the bottom mounting ear of the compressor and discard, then install retaining bolt (N606564- S43B) (Figure 2). Install the new bolt through new bracket (E5SZ-2882-C), the compressor bottom mounting ear and existing bracket (19D625). Do not tighten.
9. Remove compressor retaining bolt (N606663- S43B) from the top mounting ear of the A/C compressor and discard. Position new upper support (E5SZ-2889-B) into place and install retaining bolt (N606564-S2). Install the new bolt through new upper support (E5SZ-2889-B) the compressor's top mounting ear and bracket (19D625) (Figure 2).
10. Install new bolt (N606066-S2) through the adjusting slot of upper support (E5SZ-2889-B) and into bracket (E5SZ-2882-B) and bracket assembly (19N- 586). Install new nut (N80827-S2) onto the new bolt (N606066-S2) but do not tighten.
Figure 2 - A/C COMPRESSOR (HR980) BRACKETRY - 3.8L ENGINE:
11. Tighten the top and bottom A/C compressor retaining bolts (N606564-S2) to specification.
12. Remove the A/C compressor inboard retaining bolt (N606663-S2) and discard. Install new inboard retaining bolt (N606066-S2) through the A/C compressor inboard mounting ear, bracket (19D625) and through the slot opening in bracket (19N586) (Figure 2). Tighten to 30-45 ft.lbs. Install nut (N802827-S2) but do not tighten.
13. Install new rear brace (E5SZ-2889-C) by connecting the slotted end to the top inboard bolt hole of bracket assembly (19N586). Secure the rear brace and the disconnected end of brace assembly (19D- 894) to the bracket assembly with previously removed retaining bolt (N801179-S2) (Figure 2). Connect the other end (round hole) of rear brace (E5SZ-2889-C) to the engine manifold stud with nut (N800359-S2) and tighten to specification. Also, tighten brace (19D894) retaining bolt (57102- S) to 30-45 ft.lbs.
14. Check for proper bracket and brace alignment. Then tighten all previously hand tighten nuts and bolts not used for compressor adjustment to 30-45 ft.lbs. See Step 16 (following) for compressor adjustment nuts and bolts.
15. Using a power steering pulley installing tool, install a new power steering pump pulley (E5DZ- 3A733-B).
16. Install the compressor drive belt (C9PZ-8620-GY) (Refer to Car Shop Manual, page 27-02-4 for routing), adjusting belt tension to 130 lbs., then tighten the five (5) adjustment fasteners: two (2) nuts (N802827-S2), two (2) bolts (N801179-S2) and one (1) bolt (N802917-S2).
17. Position the radiator shroud to the radiator support and install the two (2) retaining bolts.
18. Install the previously removed poly-V belt and tighten the idler pulley and belt using belt tension gauge T63L-8620-A or equivalent, to specifications.
19. Install one (1) screw each to the A/C suction and A/C discharge line retaining clips.
20. Start the engine and, with the air conditioner operating, accelerate the engine from 1200 to 1800 RPM to assure the noise condition has been corrected.
Parts - Information - Compressor Brackets and Braces
Old parts - remove and discard:
PART NUMBER PART NAME QTY. CLASS
- Belt - Compressor 1 - Drive
19D897 Brace - Rear 1 -
389820-S2 Spacer - (T'Bird/ 1 -
Cougar Only)
390046-S100 Spacer - (LTD/ 1 -
Marquis Only)
N801179-S2 Bolt 1 -
19D895 Brace Ass'y - Rear 1 -
- Bracket - Engine - - Damper
6F036 Shock Mounting 1 -
(LTD/Marquis Only)
N606663-S2 Bolt - Compressor 3 -
Mounting
3D673 Pulley - Power 1 -
Steering Pump
Old parts - remove and reinstall:
PART NUMBER PART NAME QTY. CLASS
- Belt - Power 1 - Steering Pulley (poly-V)
N801179-S2 Bolt *5 -
N800359-S2 Nut 1 -
N620482-S2 Nut 3 -
N802917-S2 Bolt (Pivot) 1 -
* Reinstall two (2) bolts on LTD/Marquis only.
New parts - install:
PART NUMBER PART NAME QTY. CLASS
N802378-S2 Stud (Shoulder) 2 S
E5DZ-6F036-A Bracket 1 C
E5SZ-2882-B Bracket - A/C 1 C
Compressor Mntg.
N802827-S2 Nut 4 S
E5DZ-6F037-A Bracket Assembly 1 C
(Ltd/Marquis only)
N606564-S43B Bolt 2 S
N606066-S2 Bolt 2 S
E5SZ-2882-C Bracket - A/C 1 C
Compressor Rear
E5SZ-2889-B Support (Upper) 1 C
E5SZ-2889-C Brace - A/C 1 C
Compressor Rear
E5DZ-3A733-B Pulley - Power 1 C
Steering Pump
C9PZ-8620-GY Belt - A/C 1 C
Compressor Drive (Warner A/C Clutch)
OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP2882A85
TIME: 1.9 Hrs. DLR. CODING: Basic Part No. 2882 - Code: 56