Compressor HVAC: Service and Repair

An Aerostar equipped with either a 3.OL or 4.OL engine will have an FS-10 compressor and clutch assembly. Refer to Compressor and Compressor Clutch for detailed coverage of the FS-10. The illustrations that follow show the drive belt arrangement for each of the engines involved.

Removal

1. Remove battery ground cable.

2. Remove accessory drive belt.

3. Remove refrigeration line retaining bolt from A/C manifold and tube. Plug tube ports in the A/C compressor and A/C manifold and tube immediately to prevent moisture and dirt from entering the refrigerant system, and also to prevent the refrigerant oil from draining from the A/C compressor.

4. Disconnect compressor electrical connector.

5. Remove the four compressor retaining bolts from engine block.

6. Remove A/C compressor.

Installation

1. Prior to installing a replacement A/C compressor, drain the refrigerant oil from the removed compressor into a calibrated container. Rotate the shaft several revolutions to completely drain the A/C compressor.

2. Add the exact amount of clean specified refrigerant oil into the replacement A/C compressor, which is equal to the amount of refrigerant oil drained from the removed compressor. Plug compressor tube ports and install A/C compressor immediately.

3. Position the A/C compressor into position for installation.

4. Install four retaining bolts to engine block.

5. Connect compressor electrical connection.

6. Unplug compressor A/C manifold and tube and refrigerant tubes. Position A/C manifold and tube onto A/C compressor. Install and tighten retaining bolt.

7. Install accessory drive belt.

8. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy.

Connect the battery ground cable.