AC system FORD MUSTANG 2003 Workshop Manual

REMOVAL AND INSTALLATION
Evaporator Core
Removal and Installation
NOTE:
The evaporator core is not separately serviceable, it is serviced only with the evaporator core
housing assembly.
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.
NOTE: If an evaporator core leak is suspected, the evaporator core must be leak tested before it is
removed from the vehicle. For additional information, refer to Section 412 - 00 .
1. Remove the evaporator core housing. For additional information, refer to Section 412 - 02 .
2. Transfer the components from the old evaporator core housing to the new evaporator core housing.
3. Install the evaporator core housing. For additional information, refer to Section 412 - 02 .
SECTION 412-
03: Air Conditioning 2003 Mustang Workshop Manual Klj . 1 ba
12003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Suction Accumulator
Removal and Installation
1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Disconnect the A/C cycling switch electrical connector.
3. Remove the cycling switch.
4. Disconnect the suction line spring lock coupling. zDiscard the O- ring seals.
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
32003 Mustang Workshop Manual
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z
Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional
information, refer to Section 412 - 00 .
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 3 ba
32003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

REMOVAL AND INSTALLATION
Air Conditioning (A/C) Pressure Relief Valve —
3.8L
Removal and Installation 1. Recover the refrigerant. For additional information, refer to Section 412 - 00 .
2. Unlatch the 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
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

5. Remove the A/C compressor pressure relief valve.
zDiscard the O- ring seal.
6. To install, reverse the removal procedure. zInstall a new O- ring seal lubricated in clean PAG oil.
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Section 412 - 00 . Klj . 2 ba
22003 Mustang Workshop Manual
18. 11. 2011file:///C:/Ford/2000 - 2004/tsocache/SHEF_5108/S3B~us~en~ ...

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~ ...

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~ ...

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
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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~ ...

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~ ...