Air Conditioning System: Removal & Installation Ford Expedition II

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 receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Remove the cooling fan and shroud. For additional information, refer to «COOLING FAN»(ref-209901-S31801808922005121200000) .
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-209921) .
3. Remove the drive belt from the A/C compressor pulley.
4. Loosen the bolt and detach the compressor manifold and tube assembly. Discard the O-ring seals.
5. Disconnect the field coil electrical connector.
6. Raise the vehicle. For additional information, refer to «JACKING & LIFTING»(ref-209881) .
7. Disconnect the crankshaft position sensor electrical connector and detach the wiring harness.
8. Remove the bolts and the stud.
9. Remove the A/C compressor.
10. Lower the vehicle and remove the A/C compressor.
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-209925-S03769675882005121200000) . Install new O-ring seals lubricated in clean PAG 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-209921) .
12. If filtering of the refrigerant system is not to be carried out, evacuate, charge and leak test the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .

Note. Installation of a new receiver/drier 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 receiver/drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
2. Disconnect the negative battery cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-209935) .
3. Disconnect the powertrain control module (PCM) electrical connectors.
4. Remove the bolts and the PCM.
5. Remove the bolts and the PCM bracket.
6. Disconnect the electrical connector.
7. Disconnect the evaporator line fittings. Discard the O-ring seals.
8. Remove the nut and position the wiring harness aside.
9. Remove the bolt and the thermostatic expansion valve. Discard the O-ring seals.
10. To install, reverse the removal procedure.
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .

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1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(ref-209925-S39765002992005121200000) .
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. Do not use air tools. Damage to the A/C clutch pulley may result. 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 to the A/C compressor.
4. Install the A/C clutch field coil snap-ring.
5. Install the A/C clutch pulley.
6. Install the A/C clutch pulley snap-ring with the bevel side up.
7. Install one nominal thickness A/C clutch plate 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. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
11. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(ref-209925-S39765002992005121200000) .

Note. If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.

Note. Installation of a new receiver drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver drier.

Note. A new evaporator core seal is supplied as a kit with the evaporator core service part. Failure to install this seal, or failure to install it correctly, will result in air bypassing the evaporator core and loss of cooling efficiency.

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1. Remove the plenum chamber. For additional information, refer to «PLENUM CHAMBER»(ref-209922-S07456269772005121200000) .
2. Remove the dash panel seal.
3. Detach the wire harness from the evaporator core cover.
4. Disconnect the air inlet vacuum control motor vacuum connector.
5. Remove the screws and detach the blower resistor or blower motor speed control and wire harness from the plenum chamber.
6. Remove the four bottom evaporator core cover screws.
7. Remove the screws and position the heater core cover aside.
8. Remove the five upper evaporator core cover screws.
9. Remove the remaining upper evaporator core cover screws and the evaporator core cover.
10. Remove the evaporator core.
11. To install, reverse the removal procedure.

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
2. Remove the upper radiator sight shield.
3. Remove the nuts and disconnect the condenser line fittings. Discard the O-ring seals.
4. Remove the bolts and the RH and LH radiator brackets.
5. Remove the bolt and the RH and LH condenser core brackets.
6. Remove the condenser core.
7. If a new condenser core is to be installed, transfer the air deflectors from the old unit to the new unit.
8. 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-209921) .
9. Evacuate, charge, and leak test the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
2. Disconnect the pressure cutoff switch electrical connector.
3. Remove the nut and disconnect the A/C fitting. Discard the O-ring seal.
4. Remove the nut and disconnect the auxiliary A/C line fitting. Discard the O-ring seal.
5. Remove the nut and disconnect the A/C fitting. Discard the O-ring seal.
6. Loosen the bolt and remove the compressor manifold and tube assembly. Discard the O-ring seals.
7. 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-209921) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
2. Remove the nut and disconnect the A/C fitting. Discard the O-ring seal.
3. Remove the nut and disconnect the A/C fitting. Discard the O-ring seal.
4. Remove the nut and position the wiring harness aside.
5. Remove the bolt.
6. Loosen the bolts and remove the thermostatic expansion valve manifold and tube assembly. Discard the O-ring seals.
7. 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-209921) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .

Note. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the receiver/drier.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .
2. Disconnect the A/C fitting. Discard the O-ring seal.
3. Disconnect the A/C fitting. Discard the O-ring seal.
4. Remove the nuts and disconnect the A/C fittings. Discard the O-ring seal.
5. Remove the nut, detach the bracket and remove the receiver/drier.
6. 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-209921) .
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-209921) .