How to replace Ac Compressor on Ford Fusion, Lincoln MKZ & Mercury Milan?

The procedure is similar for both Ford, Lincoln and Mercury car models:---

The details to replace Ac compressor is as follows:----

Removal & Installation

2.3L ENGINE

3.0L & 3.5L ENGINES:---

2.3L Engine

Specific to:

Ford Fusion 2008-2009

Mercury Milan 2008-2009

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 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 Thermostatic eXpansion Valve (TXV), as directed by the A/C flushing or filtering procedure.

Install a new receiver/drier desiccant bag as directed by the A/C flushing or filtering procedure.

NOTE

The O-ring seals used on this vehicle are not interchangeable with all similarly sized O-ring seals used on other Ford products. Use only the O-ring seals specified for this vehicle in the Ford master parts catalog.

NOTE

Installation of a new receiver/drier desiccant bag 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 receiver/drier desiccant bag.

1. If flushing of the A/C system has not been carried out, recover the refrigerant.
2. Raise and safely support the vehicle.
3. Remove the lower engine splash shield.
4. Remove the drive belt from the A/C compressor pulley.
5. Disconnect the field coil electrical connector.
6. Remove the A/C compressor manifold bolt. Discard the gasket seals.
7. Remove the 3 secondary air injection pump bolts and position the pump aside (if equipped).
8. Remove the 3 A/C compressor bolts.
9. Remove the A/C compressor.

To install:

1. To install, reverse the removal procedure, noting the following tightening specifications:
   1. A/C compressor bolts: 18 ft. lbs. (25 Nm)
   2. Secondary air injection pump bolts: 22 ft. lbs. (30 Nm)
   3. A/C compressor manifold bolt: 11 ft. lbs. (15 Nm)
      
      NOTE

      If a new A/C compressor is to be installed, the clutch assembly may need to be transferred from the old unit to the new unit.
2. 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.
3. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system.

3.0L & 3.5L Engines

Specific to:

Ford Fusion 2008-2009

Lincoln MKZ 2008-2009

Mercury Milan 2008-2009

WARNING

If installing a new air conditioning (A/C) compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the A/C system. Failure to remove contamination from the A/C system, if present, will result in poor A/C performance and/or damage to the new A/C compressor and other components.

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 thermostatic expansion valve (TXV), as directed by the A/C flushing or filtering procedure.

Install a new receiver/drier cartridge as directed by the A/C flushing or filtering procedure.

NOTE

A new A/C compressor may come equipped with an A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil already installed. If these components are not pre-installed, it will be necessary to transfer these parts from the old A/C compressor to the new compressor prior to installation of the A/C compressor if suitable for reuse.

NOTE

Installation of a new receiver/drier cartridge 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 receiver/drier cartridge. Damage to the receiver/drier cartridge includes physical damage or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the receiver/drier cartridge does not need to be replaced.

1. If flushing of the A/C system has not been carried out, recover the refrigerant.
2. Raise and safely support the vehicle.
3. Remove the lower engine splash shield (if equipped).
4. Remove the drive belt from the A/C compressor pulley.
5. Remove the A/C compressor manifold bolt. Discard the gasket seals.
6. Disconnect the field coil electrical connector.
7. On 3.0L engines, remove the 3 A/C compressor bolts.
8. On 3.5L engines, perform the following:
   1. Remove the 2 A/C compressor bolts.
   2. Remove the A/C compressor stud.
   3. Remove the A/C compressor nut.
   4. Remove the A/C compressor stud.
      
      
      

      

      Fig. View of the A/C compressor stud (1) and nut (2)-3.5L engine
9. Remove the A/C compressor.
   
   
   

   

   Fig. Exploded view of the A/C compressor-3.0L engine shown, 3.5L engine similar

To install:

1. Installation is the reverse of the removal procedure, noting the following tightening specifications:
   1. A/C compressor nut (3.5L engine): 18 ft. lbs. (25 Nm)
   2. A/C compressor stud (3.5L engine): 80 inch lbs. (9 Nm)
   3. A/C compressor bolts (3.0L & 3.5L engines): 18 ft. lbs. (25 Nm)
   4. A/C compressor manifold bolt: 11 ft. lbs. (15 Nm)
2. If a new A/C compressor is to be installed, the clutch assembly may need to be transferred from the old unit to the new unit.
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.

 

These details will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html