This procedure covers the removal and replacement of the AC condenser on a 2011-2014 Ford F-150 with the 3.5L EcoBoost engine, including refrigerant recovery, radiator support removal, and system recharge.

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC O-ring kit × 1 — Use OEM AC line O-ring assortment
• PAG 46 refrigerant oil × 1 — Use Motorcraft PAG 46
• R-134a refrigerant × 1 — As needed per system capacity
• Condenser mounting insulators (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
3. Allow engine to cool completely if recently operated
4. Verify refrigerant type using identifier tool (should be R-134a)
5. Record refrigerant amount during recovery for proper recharge
6. Take photos of AC line routing and connections for reference during reassembly

Procedure

1. 1

   Recover refrigerant from AC system
   Connect AC recovery machine to service ports. Follow machine instructions to completely recover all refrigerant from the system. Record the amount recovered for recharge reference. Verify system is fully evacuated before proceeding.
   ⚠️Use only certified refrigerant recovery equipment. Never vent refrigerant to atmosphere.
2. 2

   Remove front grille assembly
   Remove the two upper grille retaining screws. Remove push pins securing the grille to radiator support. Disconnect any electrical connectors for grille lighting if equipped. Carefully pull grille forward and remove from vehicle.
3. 3

   Remove active grille shutter (if equipped)
   If vehicle is equipped with active grille shutters, disconnect electrical connector. Remove mounting bolts and carefully remove shutter assembly. Set aside for reinstallation.
4. 4

   Disconnect AC refrigerant lines from condenser
   Using appropriate spring lock coupling tools, disconnect the AC liquid line and suction line from the condenser. Cap all open refrigerant line connections immediately to prevent moisture and debris entry. Note the positions and orientations of lines for reinstallation.
   ⚠Some residual refrigerant or oil may be released when disconnecting lines. Wear safety glasses and gloves.
5. 5

   Remove hood latch and support components
   Disconnect hood latch cable from latch mechanism. Remove bolts securing hood latch to radiator support. Remove any additional brackets or wiring harnesses attached to the upper radiator support that will interfere with support removal.
6. 6

   Remove upper radiator support
   Remove bolts securing the upper radiator support to the frame rails on both sides. There are typically 4-6 bolts total. Carefully lift the upper support assembly upward and away from vehicle. This will expose the condenser mounting points.
   ⚠Upper support is bulky and may have sharp edges. Use care when removing to avoid injury or damage to radiator and other components.
7. 7

   Remove condenser mounting hardware
   Remove the condenser mounting bolts securing condenser to lower radiator support. Depending on production date, bolts may require 12 Nm or 15 Nm torque specification. Note which specification applies to your vehicle by checking bolt size and location.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
8. 8

   Remove AC condenser
   Carefully tilt the top of condenser toward the engine and lift upward to clear lower mounting tabs. Maneuver condenser out from between radiator and front of vehicle. Inspect mounting insulators and replace if damaged or deteriorated.
   ⚠Work slowly to avoid damaging radiator fins or transmission cooler lines. Condenser may still contain residual oil.
9. 9

   Prepare new condenser for installation
   Remove shipping caps from new condenser. Check if condenser is pre-charged with PAG oil (consult manufacturer documentation). If pre-charged, subtract that amount from total system oil capacity. If not pre-charged, add the appropriate amount of PAG 46 oil to condenser. Install new O-rings on all condenser port connections, lightly lubricating with refrigerant oil.
   ℹ️Total system PAG oil capacity for 3.5L EcoBoost is typically 7-8 oz. Verify exact specification and account for oil in new condenser and recovered from old condenser.
10. 10

    Install new condenser
    Carefully position new condenser into location between radiator and vehicle frame. Align lower mounting tabs with radiator support. Tilt condenser upright and ensure proper seating. Install condenser mounting bolts and torque according to specification for your vehicle variant.
    Torque spec

    Condenser Mounting Bolts12 Nm (9 lb-ft)
11. 11

    Reconnect AC refrigerant lines
    Install new O-rings on all AC line connections, lubricating lightly with PAG oil. Connect liquid line and suction line to condenser ports, ensuring proper alignment. Torque AC line fittings to appropriate specification (20 Nm with PAG oil added to O-rings, or 22 Nm standard).
    ℹ️Ensure spring lock couplings are fully engaged and properly seated before tightening.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
12. 12

    Reinstall upper radiator support
    Position upper radiator support back onto vehicle, aligning mounting holes with frame rails. Install and tighten all support mounting bolts. Reinstall hood latch assembly and reconnect cable. Verify latch operates correctly before proceeding.
13. 13

    Reinstall grille components
    If equipped, reinstall active grille shutter assembly and reconnect electrical connector. Position front grille and secure with push pins and retaining screws. Reconnect any grille lighting electrical connectors. Verify grille is properly seated and aligned.
14. 14

    Evacuate and recharge AC system
    Connect AC evacuation equipment to service ports. Evacuate system to proper vacuum (minimum 29 inches Hg) for at least 30 minutes. Monitor for vacuum decay to verify no leaks. Recharge system with appropriate amount of R-134a refrigerant as recorded during recovery (typically 1.75-2.0 lbs for this system). Add UV dye if desired for future leak detection.
    ⚠If vacuum does not hold, there is a leak. Do not charge system until leak is identified and repaired.

Reassembly

1. Reconnect negative battery cable
2. Verify all electrical connectors are properly reconnected
3. Verify hood latch operates correctly and hood closes properly
4. Check all refrigerant line connections for proper routing and clearance

Verification

• Start engine and turn AC to maximum cold with blower on high
• Allow system to run for 5-10 minutes and verify cold air output from vents
• Check compressor clutch engages and disengages properly
• Inspect all AC line connections for signs of refrigerant leaks (oil residue or frost)
• Verify system pressures are within specification using manifold gauges (typically 25-45 psi low side, 200-300 psi high side at idle with 80-90°F ambient)
• Use electronic leak detector or UV light to verify no leaks at condenser connections
• Check cooling fan operation cycles properly when AC is engaged
• Verify active grille shutters operate correctly if equipped

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