Ford Mustang (1999-2004) Service Manual: Air Conditioning (A/C) Compressor - 3.8L

Material

Item Specification
PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN- 12-C) WSH-M1C231- B

Removal and Installation

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 the flushing of the air conditioning system prior to installing a new air conditioning compressor. For additional information, refer to Section.
  • 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. For additional information, refer to Section.
  • 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: 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. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to Section.

2. Disconnect the battery. For additional information, refer to Section.

3. Unlatch the air breather.

Air Conditioning (A/C) Compressor - 3.8L

4. Disconnect the mass airflow (MAF) sensor electrical connector.

Air Conditioning (A/C) Compressor - 3.8L

5. Remove the air cleaner outlet tube (9B659).

1. Loosen the clamp.

2. Disconnect the crankcase ventilation tube (6758).

3. Remove the air cleaner outlet tube assembly.

Air Conditioning (A/C) Compressor - 3.8L

6. Remove the drive belt (8620) from the A/C compressor pulley.

7. Disconnect the electrical compressor clutch connector.

Air Conditioning (A/C) Compressor - 3.8L

8. Remove the bolt and disconnect the A/C manifold and tube (19D734).

  • Discard the O-ring seals.

Air Conditioning (A/C) Compressor - 3.8L

9. Remove the bolts and the A/C compressor.

Air Conditioning (A/C) Compressor - 3.8L

10. To install, reverse the removal procedure.

  • Install new O-ring seals lubricated in clean PAG oil.
  • If filtering of the refrigerant system is not to be performed, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Section.

11. If filtering of the air conditioning system is not to be performed, evacuate, leak test and charge the refrigerant system. For additional information, refer to Section.

    Spring Lock Coupling
      The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female f ...

    Air Conditioning (A/C) Compressor - 4.6L
    Material Item Specification PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN- 12-C) WSH-M1C231- B Removal and Installation CAUTION: If installing ...

    Other materials:

    Output Shaft Speed (OSS) Sensor
    Removal and Installation 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. Disconnect the electrical connector. 3. Remove the output shaft speed (OSS) sensor. 4. To install, reverse the removal procedure. ...

    Switch - Seat Regulator Control
    Removal and Installation 1. Disconnect the battery. For additional information, refer to Section. 2. Remove the screws and position the seat regulator control switch aside. 3. Disconnect the electrical connector and remove the seat regulator control swit ...

    Instrument lighting dimmer
    • Move the control up or down to adjust the intensity of the panel lighting. • Move the control to the full upright position, past detent, to turn on the interior lamps. • Move the control down, past detent, to turn off the interior lights. Note: The pa ...