Removal and Installation

WARNING: This page is about a different car, the 2002 Ford Windstar. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

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. 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. 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.

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.

NOTE: The A/C compressor mounting bolts must be removed with the A/C compressor.

If flushing of the refrigerant system has not been performed, recover the refrigerant. Refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .
Remove the generator. Refer to GENERATOR .
Raise the vehicle.
Completely loosen the lower A/C compressor mounting bolts.

Fig 1: Loosening Lower A/C Compressor Mounting Bolts
Courtesy of FORD MOTOR CO.
Loosen the bolt and disconnect the compressor manifold and tube assembly from the A/C compressor.

Fig 2: Disconnecting Compressor Manifold And Tube Assembly From A/C Compressor
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Disconnect the A/C compressor clutch field coil electrical connector.

Fig 3: Disconnecting A/C Compressor Clutch Field Coil Electrical Connector
Courtesy of FORD MOTOR CO.
Completely loosen the A/C compressor mounting bolt.

Fig 4: Loosening A/C Compressor Mounting Bolt
Courtesy of FORD MOTOR CO.
Remove the three bolts from the A/C mounting bracket.

Fig 5: Removing A/C Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the bolts from the generator mounting bracket.

Fig 6: Removing Generator Mounting Bracket Bolts (1 Of 2)
Courtesy of FORD MOTOR CO.
Completely loosen the generator mounting bracket bolt.

Fig 7: Removing Generator Mounting Bracket Bolts (2 Of 2)
Courtesy of FORD MOTOR CO.
Lift the generator mounting bracket until the remaining bolt clears the frame rail and remove the bolt. Remove the generator mounting bracket.

Fig 8: Removing Generator Mounting Bracket
Courtesy of FORD MOTOR CO.
Detach the wiring harness pin-type retainer from the A/C mounting bracket and remove the bracket.

Fig 9: Removing Wiring Harness Pin-Type Retainer From A/C Mounting Bracket
Courtesy of FORD MOTOR CO.

Vehicles with auxiliary climate control
Disconnect the auxiliary refrigerant line from the compressor manifold and tube assembly.
- Discard the O-ring seal.
  
  Fig 10: Disconnecting Auxiliary Refrigerant Line From Compressor Manifold And Tube Assembly
  Courtesy of FORD MOTOR CO.
All vehicles
Disconnect the compressor manifold and tube assembly from the suction accumulator. Position the compressor manifold and tube assembly aside.
- Discard the O-ring seal.
  
  Fig 11: Disconnecting Compressor Manifold And Tube Assembly From Suction Accumulator
  Courtesy of FORD MOTOR CO.
Completely loosen the remaining bolt and remove the A/C compressor and A/C mounting brace.
- Discard the O-ring seals.
  
  Fig 12: Removing A/C Compressor And A/C Mounting Brace
  Courtesy of FORD MOTOR CO.
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. Refer to CLUTCH AND CLUTCH FIELD COIL .
- If filtering of the refrigerant system is not be to performed, lubricate the refrigerant system with the correct amount of clean PAG oil or equivalent. Refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION for refrigerant oil addition.
- Install new O-ring seals lubricated with clean PAG oil or equivalent.
If filtering of the refrigerant system is not to be performed, evacuate, leak test and charge the refrigerant system. Refer to AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING .