Ford repair professionals: How to remove Compressor on 2005 Ford Explorer

Removal & Installation

WARNING

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.

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.

Install a new evaporator core orifice as directed by the A/C flushing or filtering procedure.

Install a new suction accumulator 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.

WARNING

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.

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.

Install a new evaporator core orifice as directed by the A/C flushing or filtering procedure.

Install a new suction accumulator as directed by the A/C flushing or filtering procedure.

NOTE

4.0L (VIN E) SOHC Engine

If flushing of the air conditioning system has not been carried out, recover the refrigerant. Refer to the procedure in this section.

Remove the air cleaner outlet tube.

Remove the drive belt from the A/C compressor pulley.

Remove the bolts and position aside the power steering reservoir.

Fig. Power steering reservoir bolts (arrows)

Remove the bolts and remove the power steering bracket.

Fig. Power steering bracket bolts (arrows)

Disconnect the electrical connector from the A/C compressor.

Remove the bolt and detach the manifold and tube from the A/C compressor.
1. Discard the O-ring seals.
  
  Fig. Remove bolt to detach manifold and tube from A/C compressor

Remove the retaining pins and position aside the inner fender well splash shield.

Fig. Inner fender well splash shield retaining pins (arrows)

Remove the lower A/C compressor bolt and stud.
1. Remove the bolt.
2. Remove the nut and detach the bracket from the stud.
3. Remove the stud.
  
  Fig. Remove the nut and detach the bracket from the stud

Remove the two A/C compressor nuts and studs, and remove the A/C compressor.

Fig. A/C compressor nuts and studs

To install

Installation is the reverse of removal.
1. Install new O-ring seals lubricated in clean PAG oil.
2. If filtering of the air conditioning system is not to be carried out, correctly oil match the system with clean PAG oil.

If filtering of the refrigerant system is not to be carried out, evacuate, leak-test, and charge the refrigerant system. Refer to the procedure in this section.

Observe the following tightening torques:

A/C compressor bolt and stud 18 ft. lbs (25 Nm)

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 A/C system prior to installing a new A/C compressor.

If A/C flushing equipment is not available, carry out filtering of the A/C system after a new A/C compressor has been installed.

Install a new evaporator core orifice, as directed by the -Flushing- procedure.

Install a new suction accumulator, as directed by the -Flushing- procedure.

NOTE

If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil 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 A/C system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

With the vehicle in NEUTRAL, position it on a hoist.

If flushing of the A/C system has not been carried out, recover the refrigerant.

Remove the drive belt from the A/C compressor pulley.

Disconnect the clutch field coil electrical connector.

Remove the upper A/C compressor nut.

Remove the upper A/C compressor stud.

Remove the compressor manifold bolt.

Disconnect the manifold. Discard the O-ring seals.

Remove the 2 lower A/C compressor nuts.

Remove the bracket.

Remove the 2 lower A/C compressor studs.

Remove the A/C compressor.

To install

Install the A/C compressor.

Install the 2 lower A/C compressor studs and tighten to 18 ft. lbs. (25 Nm).

Install the bracket.

Install the 2 lower A/C compressor nuts and tighten to 18 ft. lbs. (25 Nm).

Position the manifold, with new O-rings seals, and tighten the compressor manifold bolt to 15 ft. lbs. (20 Nm).

Install the upper A/C compressor stud and tighten to 10 ft. lbs. (13 Nm).

Install the upper A/C compressor nut and tighten to 18 ft. lbs. (25 Nm).

Connect the clutch field coil electrical connector.

Install the drive belt to the pulley.

Perform the following, as applicable:
1. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. Total compressor oil capacity is:
  
  Without auxiliary A/C system: 9 oz. (266 ml)
  
  With auxiliary A/C system: 13 oz. (384 ml)
2. Install new O-ring seals, lubricated in clean mineral oil.
3. If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.
4. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system:
  
  Without auxiliary A/C system: 32 oz. (0.91 kg)
  
  With auxiliary A/C system: 56 oz. (1.59 kg)

4.0L Ohv Engine (VIN X)

If flushing of the air conditioning system has not been carried out, recover the refrigerant.

Remove the drive belt from the air conditioning compressor pulley.

Disconnect the field coil and pressure cutoff switch electrical connectors.

Fig. Field coil and pressure cutoff switch electrical connectors

Remove the bolt and detach the manifold and tube from the A/C compressor.
1. Discard the O-ring seals.
  
  Fig. Remove bolt to detach manifold and tube from A/C compressor

Remove the bolts and remove the A/C compressor.

Fig. Remove bolts to remove A/C compressor

To install

Installation is the reverse of removal.

Install new O-ring seals lubricated in clean PAG oil.

If filtering of the air conditioning system is not to be carried out, correctly oil match the system with clean PAG oil.

If filtering of the refrigerant system is not to be carried out, evacuate, leak-test, and charge the refrigerant system.

Observe the following tightening torques:

Manifold and tube bolt 13-17 ft lbs (17-23 Nm)

A/C compressor bolts 17-20 ft. lbs (22-28 Nm)

4.6L (VIN H) DOHC Engine

NOTE

New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected.

Position the vehicle on a hoist with the gear selector in NEUTRAL.

If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information. Refer to the procedure in this section.

Remove the drive belt from the A/C compressor pulley.

Remove the lower fan shroud to access the A/C compressor. Remove the nuts.

Fig. Remove nuts (arrows) and lower fan shroud to access A/C compressor

Remove parts 1-9 in the order indicated in the following illustration.
NOTE
If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.

(1) Compressor manifold bolt

(2) Cooler bolt (2 req'd)

(3) Compressor nut (2 req'd)

(4) Compressor stud (2 req'd)

(5) Compressor bolt

(6) Field coil electrical connector

(7) A/C compressor

(8) O-ring

(9) O-ring

Fig. A/C compressor-4.6L DOHC engine

Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage.
1. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat.
2. 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.
3. Inspect for roughness in the A/C compressor pulley bearing.

To install:

installation is the reverse of removal.

If filtering of the air conditioning system is not to be performed, lubricate the refrigerant system with the correct amount of clean PAG oil.

If filtering of the air conditioning system is not to be performed, evacuate, leak test and charge the refrigerant system. Refer to the procedure in this section.

The following tightening torques refer to the illustration:

(1) Compressor manifold bolt, 15 ft. lbs (20 Nm)

(3) Compressor nut (2 req'd), 18 ft. lbs. (25 Nm)

(4) Compressor stud (2 req'd) 10 ft. lbs. (13 Nm)

(5) Compressor bolt 18 ft. lbs. (25 Nm)

NOTE

New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected.

Position the vehicle on a hoist with the gear selector in NEUTRAL.

If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information. Refer to the procedure in this section.

Remove the drive belt from the A/C compressor pulley.

Remove the lower fan shroud to access the A/C compressor. Remove the nuts.

Fig. Remove nuts (arrows) and lower fan shroud to access A/C compressor

Remove parts 1-9 in the order indicated in the following illustration.
NOTE
If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.

(1) Compressor manifold bolt

(2) Cooler bolt (2 req'd)

(3) Compressor nut (2 req'd)

(4) Compressor stud (2 req'd)

(5) Compressor bolt

(6) Field coil electrical connector

(7) A/C compressor

(8) O-ring

(9) O-ring

Fig. A/C compressor-4.6L DOHC engine

Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage.
1. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat.
2. 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.
3. Inspect for roughness in the A/C compressor pulley bearing.

To install:

Installation is the reverse of the removal procedure.

If filtering of the air conditioning system is not to be performed, lubricate the refrigerant system with the correct amount of clean PAG oil.

If filtering of the air conditioning system is not to be performed, evacuate, leak test and charge the refrigerant system. Refer to the procedure in this section.

The following tightening specifications refer to the illustration:

(1) Compressor manifold bolt: 15 ft. lbs (20 Nm)

(3) Compressor nuts (2 req'd): 18 ft. lbs. (25 Nm)

(4) Compressor studs (2 req'd): 10 ft. lbs. (13 Nm)

(5) Compressor bolt: 18 ft. lbs. (25 Nm)

4.6L (VIN W) SOHC Engine

NOTE

New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected.

Position the vehicle on a hoist with the gear selector in NEUTRAL.

If flushing of the air conditioning system has not been performed, recover the refrigerant. Refer to the procedure in this section.

Remove the drive belt from the A/C compressor pulley.

Remove parts 1-11 in the order indicated in the following illustration.

(1) Clutch field coil electrical connector

(2) A/C compressor nut

(3) A/C compressor stud

(4) Compressor manifold bolt

(5) Manifold

(6) O-rings (2 req'd)

(7) A/C compressor nut

(8) Bracket

(9) A/C compressor stud

(10) A/C compressor stud

(11) A/C compressor

Fig. A/C compressor-4.6L SOHC engine

To install:

The following tightening torques refer to the illustration:

(2) A/C compressor nut, 18 ft. lbs. (25 Nm)

(3) A/C compressor stud, 10 ft. lbs. (13 Nm)

(4) Compressor manifold bolt, 15 (20 Nm)

(7) A/C compressor nut (2 req'd), 18 ft. lbs. (25 Nm)

(9) A/C compressor stud, 10 ft. lbs. (13 Nm)

(10) A/C compressor stud, 18 ft. lbs. (25 Nm)

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 A/C system prior to installing a new A/C compressor.

If A/C flushing equipment is not available, carry out filtering of the A/C system after a new A/C compressor has been installed.

Install a new evaporator core orifice, as directed by the -Flushing- procedure.

Install a new suction accumulator, as directed by the -Flushing- procedure.

NOTE

With the vehicle in NEUTRAL, position it on a hoist.

If flushing of the A/C system has not been carried out, recover the refrigerant.

Remove the drive belt from the A/C compressor pulley.

Disconnect the clutch field coil electrical connector.

Remove the compressor manifold bolt.

Disconnect the manifold. Discard the O-ring seals.

Remove the 2 lower A/C compressor nuts.

Remove the 2 lower A/C compressor studs.

Remove the upper A/C compressor nut and stud.

Position the RH wheelhouse panel-to-frame insert forward.

Remove the A/C compressor.

To install

Install the A/C compressor.

Reposition the RH wheelhouse panel.

Install the upper A/C compressor stud and nut and tighten to 18 ft. lbs. (25 Nm).

Install the 2 lower A/C compressor studs and tighten to 10 ft. lbs. (13 Nm).

Install the 2 lower A/C compressor nuts and tighten to 18 ft. lbs. (25 Nm).

Position the manifold, with new O-rings seals, and tighten the compressor manifold bolt to 15 ft. lbs. (20 Nm).

Connect the clutch field coil electrical connector.

Install the drive belt to the pulley.

Perform the following, as applicable:
1. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. Total compressor oil capacity is:
  
  Without auxiliary A/C system: 9 oz. (266 ml)
  
  With auxiliary A/C system: 13 oz. (384 ml)
2. Install new O-ring seals, lubricated in clean mineral oil.
3. If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.
4. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system:
  
  Without auxiliary A/C system: 32 oz. (0.91 kg)
  
  With auxiliary A/C system: 56 oz. (1.59 kg)

5.0L Engine

If flushing of the air conditioning system has not been carried out, recover the refrigerant. Refer to the procedure in this section.

Remove the air cleaner outlet pipe.

Remove the drive belt from the A/C compressor pulley.

Remove the bolts and position aside the power steering reservoir.

Fig. Power steering reservoir bolts (arrows)

Disconnect the field coil electrical connector.

Remove the bolt and detach the compressor manifold and tube assembly from the A/C compressor.
1. Discard the O-ring seals.
  
  Fig. Remove the bolt and detach the compressor manifold and tube assembly from the A/C compressor

Partially raise the vehicle.

Remove the retaining pins and position the inner fender well access panel out of the way.

Fig. Inner fender well splash shield retaining pins (arrows)

Remove the lower A/C compressor bolt and stud.
1. Remove the bolt.
2. Remove the nut and detach the bracket from the stud.
3. Remove the stud.
  
  Fig. Lower A/C compressor bolt and stud

Lower the vehicle.

Remove the upper A/C compressor bolt and stud.
1. Remove the bolt.
2. Remove the nut and detach the bracket from the stud.
3. Remove the stud.
  
  Fig. A/C compressor bolt (1), nut (2) and stud (3)

Remove the A/C Compressor.

To install

Installation is the reverse of removal.
1. Install new O-ring seals lubricated in clean PAG oil.
2. If filtering of the air conditioning system is not to be carried out, correctly oil match the system with clean PAG oil.

If filtering of the refrigerant system is not to be carried out, evacuate, leak-test and charge the refrigerant system. Refer to the procedure in this section.