FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Air Conditioning (A/C) Pressure Relief Valve —
4.6L
Removal and Installation
NOTE: Installation of a new suction accumulator 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 suction accumulator.
1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Raise the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the A/C compressor pressure relief valve (19D644). zDiscard the O- ring seal.
4. To install, reverse the removal procedure. zInstall a new O- ring seal lubricated in clean PAG oil.
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Condenser Core
Removal and Installation
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 Section 412 - 00 .
NOTE: Installation of a new suction accumulator 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 suction accumulator.
All vehicles
1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Remove the pin- type retainers and remove the upper radiator sight shield.
3. Remove the air cleaner and air cleaner outlet tube. For additional information, refer to Section 303 - 12 .
4.6L (2V), 4.6L (4V) vehicles 4. Remove the bolts and position the coolant bottle aside.
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

4.6L (4V) vehicles
5. Remove the bolts and position the coolant bottle aside.
3.8L vehicles 6. Remove the bolts.
7. Remove the bracket and the coolant bottle. Klj . 2 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

All vehicles
8. Remove the nuts and disconnect the lines. zDiscard the O- ring seals.
Vehicles with 4WABS 9. Remove the hydraulic control unit upper bracket bolts.
10. Raise the vehicle.
11. Remove the hydraulic control unit lower bracket bolt and position the hydraulic control unit aside.
12. Lower the vehicle.
All vehicles 13. Remove the bolts and the radiator brackets. Klj . 3 ba
52003 Mustang Workshop Manual
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14. Position the radiator rearward.
15. Remove the pin-
type retainers.
16. Position the wiring harness rearward. 17. Remove the condenser bolts. Klj . 4 ba
52003 Mustang Workshop Manual
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18. Remove the condenser core.
19. To install, reverse the removal procedure.
zInstall new O- ring seals lubricated in clean PAG oil.
z Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Section 412 - 00 .
20. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 5 ba
52003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Compressor Manifold and Tube Assembly —
3.8L
Removal and Installation
NOTE: Installation of a new suction accumulator 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 suction accumulator.
1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Unlatch the air breather.
3. Disconnect the mass air flow (MAF) sensor electrical connector.
4. Remove the air cleaner outlet tube. 1. Loosen the clamp.
2. Disconnect the crankcase ventilation tube.
3. Remove the air cleaner outlet tube.
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Material
Item Specification
PAG Refrigerant Compressor
Oil (R-
134a Systems)
F7AZ- 19589- DA (Motorcraft YN-
12- C) WSH-
M1C231-
B Klj . 1 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

5. Disconnect the refrigerant containment switch (RCS) electrical connector.
6. Remove the RCS.
7. Remove the nut and disconnect A/C fitting.
zDiscard the O- ring seal.
8. Disconnect the spring lock coupling. zDiscard the O- ring seals. Klj . 2 ba
42003 Mustang Workshop Manual
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9. Remove the bolt.
10. Remove the manifold and tube assembly. zDiscard the O- ring seals.
11. To install, reverse the removal procedure. zInstall new O- ring seals lubricated in clean PAG oil.
z Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Section 412 - 00 .
12. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 3 ba
42003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...