HVAC System - Air Conditioning: Removal & Installation Ford Econoline E250

Removal and Installation

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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
3. Remove the accessory drive belt (8620) from the A/C compressor pulley.
4. Loosen the bolt and detach the compressor manifold and tube assembly from the A/C compressor.
5. Remove the splash shield.
6. Disconnect and detach the crankshaft position sensor electrical connector and position the wire harness aside.
7. Detach the wire harness from the bracket.
8. Disconnect the A/C compressor clutch field coil electrical connector.
9. Remove the A/C compressor mounting bolt.
10. Remove the bolts and the A/C compressor. Discard the A/C O-ring seals.
11. 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. For additional information, refer to «CLUTCH AND CLUTCH FIELD COIL»(ref-210171-S37375341472005121400000) . Install new O-ring seals lubricated in clean mineral oil. If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
12. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
3. Remove the accessory drive belt (8620) from the A/C compressor pulley.
4. Remove the bolt.
5. Remove the A/C compressor mounting bolts.
6. Disconnect the field coil electrical connector.
7. Loosen the bolt and detach the compressor manifold and tube. Discard the O-ring seals.
8. Remove the A/C compressor.
9. 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. For additional information, refer to «CLUTCH AND CLUTCH FIELD COIL»(ref-210171-S37375341472005121400000) . Install new O-ring seals lubricated in clean mineral oil. If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
10. If filtering of the refrigerant system is not to be carried out, evacuate, leak test, and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 4.6L, 5.4L, AND 6.8L»(ref-210171-S01129306672005121400000) or «AIR CONDITIONING (A/C) COMPRESSOR - 6.0L DIESEL»(ref-210171-S17166653642005121400000) .
2. Remove the A/C clutch disc and hub retaining nut. Using the special tool, hold the A/C clutch disc and hub. Remove the nut.
3. Remove the A/C clutch disc and hub.
4. Remove the A/C clutch disc and hub spacer.
5. Remove the A/C clutch pulley snap ring.
6. Using the special tool, remove the A/C clutch pulley.
7. Note the location of the A/C clutch field coil connector.
8. Remove the A/C clutch field coil snap ring.
9. Remove the A/C clutch field coil.

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1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C compressor, A/C clutch field coil and the A/C clutch pulley mounting surfaces.
3. Align and install the A/C clutch field coil onto the A/C compressor.
4. Install the A/C clutch field coil snap ring.
5. Install the A/C clutch pulley. Install the special tool. Install the pulley.
6. Install the A/C clutch pulley snap ring with the bevel side up.
7. Install one nominal thickness A/C clutch disc and hub spacer onto the A/C compressor shaft.
8. Install the A/C clutch disc and hub.
9. Install the clutch disc and hub retaining nut. Using the special tool, hold the A/C clutch disc and hub. Tighten the nut.
10. Measure and adjust (if necessary) the A/C clutch air gap by removing or adding A/C clutch disc and hub spacers.
11. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 4.6L, 5.4L, AND 6.8L»(ref-210171-S01129306672005121400000) or «AIR CONDITIONING (A/C) COMPRESSOR - 6.0L DIESEL»(ref-210171-S17166653642005121400000) .

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.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
4. Remove the battery.
5. Remove the battery tray. Remove the bolts. Remove the battery tray.
6. Remove the bolt and clamp and the oil filler tube.
7. Disconnect the condenser fittings. Disconnect the condenser outlet fitting. Disconnect the condenser inlet fitting. Discard the O-ring seals.
8. Remove junction box bracket bolts.
9. Remove the junction box bracket bolt and position the junction box aside.
10. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
11. Loosen the CAC tube clamps.
12. Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.
13. Remove the conduit and position the wiring aside. Disconnect the locking tab. Remove the bolts. Disconnect the push pin and remove the wiring harness.
14. Remove the bolts for the CAC tube and oil fill tube.
15. Disconnect the oil fill tube at the valve cover.
16. Remove the retaining nuts, CAC tube, oil fill tube and bracket.
17. Remove the bolt and position the MAP sensor aside.
18. Disconnect the condenser fittings. Discard the O-ring seals.
19. Remove the washer reservoir filler tube. Remove the screws. Remove the washer reservoir filler tube.
20. Disconnect the evaporator outlet fitting. Discard the O-ring seal.
21. Disconnect the high-pressure cutoff switch electrical connector.
22. Disconnect the compressor manifold and tube suction fitting. Remove the screw. Disconnect the fitting. Discard the O-ring seal.
23. Disconnect the suction accumulator fitting. Discard the O-ring seals.
24. Disconnect the evaporator inlet fitting. Remove the screw. Disconnect the evaporator inlet fitting. Discard the O-ring seal
25. Remove the screws and the evaporator housing support bracket.
26. Remove the evaporator core cover. Remove the five screws. Remove the four screws. Remove the evaporator core cover.
27. Remove the evaporator core.
28. To install, reverse the removal procedure. Install new O-rings lubricated in clean mineral oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
29. Evacuate, leak-test and charge the refrigerant system. For additional information refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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MATERIAL

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1. Disconnect the fitting. Remove the screw. Disconnect the fitting. For a fixed orifice tube, carry out Steps 2 and 3. For a broken orifice tube, carry out Steps 4 and 5.
2. Engage the Fixed Orifice Tool to the A/C evaporator core orifice (19D990).
3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice.
4. To remove a broken A/C evaporator core orifice, screw the end of the Broken Orifice Extractor into the broken A/C evaporator core orifice.
5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice.

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1. Lubricate and install the O-ring seals on the A/C evaporator core orifice in clean PAG oil.
2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool.
3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated.
4. Remove the Fixed Orifice Tube Tool.
5. Install the condenser to evaporator tube. For additional information, refer to «CONDENSER TO EVAPORATOR LINE»(ref-210171-S16041004202005121400000) .

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.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the battery.
4. Remove the battery tray. Remove the bolts. Remove the battery tray.
5. Position the washer reservoir filler tube aside. Remove the screws. Position the filler tube aside.
6. Disconnect the evaporator outlet fitting. Discard the O-ring seal.
7. Disconnect the compressor manifold and tube suction fitting. Remove the screw. Disconnect the fitting. Discard the O-ring seal.
8. Remove the screw.
9. Disconnect the spring lock coupling. Discard the O-ring seals.
10. Disconnect the A/C cycling switch electrical connector.
11. Remove the suction accumulator. Remove the bolts. Remove the suction accumulator.
12. 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
13. Evacuate, leak test and charge the refrigerant system. For additional information refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Remove the windshield washer reservoir filler neck bolts.
3. Detach and position the junction box aside.
4. Disconnect the compressor manifold and tube suction fitting. Remove the screw. Disconnect the fitting. Discard the O-ring seal.
5. Disconnect the evaporator outlet fitting. Discard the O-ring seal.
6. Detach the wire harness. Disconnect the cycling switch electrical connector. Remove the nut and stud and detach the wire harness.
7. Remove the bolts and the suction accumulator.
8. 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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. If an A/C condenser core leak is suspected, the A/C condenser core must be leak-tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Remove the engine air cleaner and outlet tubes. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
3. Remove the air deflector. Remove the five retaining pins. Remove the air deflector.
4. Disconnect the condenser core refrigerant lines. Disconnect the compressor discharge line. Disconnect the condenser to evaporator tube (19835).
5. Remove the bolts and the two upper radiator mounting brackets.
6. Move the radiator back to gain access.
7. Remove the two A/C condenser mounting brackets (19702). Remove the bolts. Remove the condenser mounting brackets.
8. Remove the A/C condenser core.
9. Remove the two seals. Remove the eight retaining pins. Remove the two seals.
10. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean PAG oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Disconnect the condenser fittings. Discard the O-ring seals.
3. Remove the cooling module. For additional information, refer to «ENGINE COOLING»(ref-210139) .
4. Remove the condenser bracket nuts and the condenser.
5. 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
6. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
3. Loosen the bolt and detach the compressor manifold and tube assembly from the A/C compressor. Discard the O-ring seals.
4. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
5. Disconnect the pressure cutoff switch electrical connector.
6. Disconnect the compressor manifold and tube assembly from the suction accumulator. Discard the O-ring seal.
7. Disconnect the compressor manifold and tube assembly from the condenser and remove the compressor manifold and tube assembly. Discard the O-ring seal.
8. 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
9. Evacuate, leak test, and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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.

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1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 6.0L DIESEL»(ref-210171-S17166653642005121400000) .
2. Remove the RH intercooler tube.
3. Disconnect the condenser fittings. Discard the O-ring seals.
4. Disconnect the compressor manifold and tube suction fitting. Remove the screw. Disconnect the fitting. Discard the O-ring seal.
5. Remove the compressor manifold and tube bracket bolt.
6. Disconnect the pressure cutoff switch electrical connector.
7. Remove the compressor manifold and tube assembly.
8. 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .

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.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
2. Disconnect the condenser fitting. Discard the O-ring seal.
3. Remove the engine air cleaner (9600) and the air cleaner outlet tube (9B659). For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-210150) .
4. Disconnect the condenser core refrigerant lines. Disconnect the compressor discharge line. Disconnect the condenser to evaporator tube (19835). Discard the O-ring seals.
5. Remove the four clamps. Remove the screw. Remove the clamp.
6. Disconnect the underbody tube spring lock coupling. Discard the O-ring seals.
7. Disconnect the A/C evaporator core (19860) fitting. Remove the screw. Disconnect the A/C evaporator core fitting. Discard the O-ring seal.
8. Remove the condenser-to-evaporator tubes.
9. 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .
10. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-210167) .