Ford Mustang (1999-2004) Service Manual: Installation

1. CAUTION: To prevent refrigerant system contamination, do not allow dirt or other foreign materials to enter the A/C compressor.

Clean the A/C compressor nose area.

2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with PAG oil or equivalent.

Air Conditioning (A/C) Compressor Shaft Seal

3. Position the shaft seal and the special tool over the A/C compressor shaft.

Air Conditioning (A/C) Compressor Shaft Seal

4. Using the special tool, push the shaft seal onto the A/C compressor shaft until seated.

Air Conditioning (A/C) Compressor Shaft Seal

5. Install the shaft seal snap ring.

Air Conditioning (A/C) Compressor Shaft Seal

6. Carry out the A/C compressor external leak test. For additional information, refer to Component Tests in Section.

7. Install the shaft seal felt.

Air Conditioning (A/C) Compressor Shaft Seal

8. Install the A/C clutch hub spacer.

Air Conditioning (A/C) Compressor Shaft Seal

9. Install the A/C disc and hub assembly.

Air Conditioning (A/C) Compressor Shaft Seal

10. Using the special tool, install the A/C disc and hub assembly retaining bolt.

Air Conditioning (A/C) Compressor Shaft Seal

11. Measure and adjust the clutch air gap by removing or adding spacers as needed.

Air Conditioning (A/C) Compressor Shaft Seal

12. Install the A/C compressor. For additional information, refer to Air Conditioning (A/C) Compressor-3.8L or Air Conditioning (A/C) Compressor-4.6L in this section.

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.

1. Remove the evaporator core housing. For additional information, refer to Section.

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.

    Removal
    1. Remove the A/C compressor (19703). For additional information, refer to Air Conditioning (A/C) Compressor-3.8L or Air Conditioning (A/C) Compressor-4.6L in this section. 2. Remove the bolt. 1. ...

    Suction Accumulator
    Material Item Specification PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN- 12-C) WSH-M1C231- B Removal and Installation 1. Recover the refriger ...

    Other materials:

    Cylinder Head
    Special Tool(s) Compressor, Valve Spring 303-163 (T81P-6513-A) Material Item Specification SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent WSS-M2C153- H Disassembly and Assembly CAUTION: If the com ...

    Fuel Charging And Controls
    The fuel injection supply manifold (9F792): delivers fuel to the fuel injector. receives fuel from the fuel supply line. The throttle body (9E926): controls air supply to the upper intake manifold (9424) by positioning the throttle plate. connects the ...

    Roller Followers
    Special Tool(s) Compressor, Valve Spring 303-452 (T93P-6565-AR) Removal and Installation 1. Remove the LH and RH valve cover. For additional information, refer to Valve Cover LH and Valve Cover RH in this section. 2. Position the piston of t ...