Compressor HVAC: Service and Repair

CAUTION: When the A/C compressor is inoperative due to internal causes, clean the refrigerant system to remove any debris or contaminants to prevent damage to the replacement A/C compressor.

Replacement of the suction accumulator/drier is necessary when the A/C compressor is replaced. The A/C evaporator core orifice should be replaced whenever the A/C compressor is replaced for lack of performance, or when there is debris in the system.

REMOVAL
1. Recover the A/C refrigerant system following the recommended procedure. Observe all safety precautions.
2. Drain and save the radiator coolant.
3. Disconnect the battery ground cable.
4. Disconnect and remove the constant control relay module.
5. Disconnect and remove the fan and the shroud assembly.
6. Disconnect the upper and the lower radiator hoses.
7. Remove the radiator.
8. Disconnect the A/C compressor clutch wire at the clutch field coil connector on the A/C compressor.
9. Remove the top two A/C compressor mounting bolts.
10. Raise the vehicle on a hoist.
11. From underneath the vehicle, loosen and remove the accessory drive belt.
12. Disconnect the Heated Oxygen Sensor (HO2S) wire connector.
13. Remove the A/C muffler supporting strap bolt from the subframe.
14. Disconnect the A/C manifold and tube from the inlet tube of the A/C condenser core and the outlet tube of the suction accumulator/drier using the spring lock coupling tool or equivalent.

CAUTION: Immediately install protective caps on open lines.

15. Ensure the A/C compressor is properly supported as the bolts are removed. Remove the bottom two A/C compressor mounting bolts.
16. Remove the A/C compressor and the A/C manifold and tube assemblies from the vehicle as a unit. Remove the assembly from the bottom, using care not to scrape it against the the A/C condenser core.
17. Remove the A/C manifold and tube from the A/C compressor.
18. If the old A/C compressor is to be replaced with a new one, remove the A/C clutch and the field coil assembly.

INSTALLATION
1. Service the replacement A/C compressor with the correct amount of clean Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B.
2. Lubricate the new O-ring seals with clean refrigerant oil and position them in the O-ring seal grooves of the A/C manifold and tube. Use only the O-ring seals specified for the type of A/C manifold and tube being used.

NOTE: When replacing an A/C compressor, use the original manifold bolt from the removed A/C compressor to attach A/C manifold and tube to new A/C compressor. Do not use the shipping cap bolts.

3. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSH-M2G350-A2 to the threads of the manifold retaining bolt.
4. Position the A/C manifold and tube with the O-ring seals to the A/C compressor. Install the retaining bolt and tighten to 17-23 Nm (12.5-17.0 ft lb).
4. Install the A/C compressor and the A/C manifold and tube onto the A/C compressor mounting bracket.
6. Using new O-ring seals lubricated with clean Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B, connect the A/C manifold and tube to the inlet tube of the A/C condenser core.
7. Using new O-ring seals lubricated with clean Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B, connect the A/C manifold and tube to the outlet tube of the suction accumulator/drier.
8. Install the muffler support onto the subframe.
9. Connect the HO2S wire connector.
10. Install the accessory drive belt.
11. Lower the vehicle to the floor and perform the following operations from the top.
12. Install the radiator.
13. Connect the radiator hoses and tighten the hose clamps.
14. Install the fan and the shroud assembly.
15. Install and connect the constant control relay module connector.
16. Connect the battery ground cable.

NOTE: On vehicles equipped with Electronic Engine Control (EEC), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

17. Fill the radiator with the reserved coolant.
18. Leak-test, evacuate, and charge the A/C system following the recommended procedures.
19. Check the A/C system for proper operation.