This procedure covers the removal and replacement of the AC hose assembly on a 2011-2014 Ford F-150 3.5L EcoBoost, including refrigerant recovery, hose replacement, and system recharge.

Warnings

Tools required

Parts

• AC hose assembly × 1 — Use OEM specification or exact match replacement
• AC O-ring kit × 1 — Use OEM specification
• PAG oil (compatible with R-134a) × 1 — Use OEM specification
• R-134a refrigerant × 1 — Approximately 1.75 lbs total system capacity

Preparation

1. Park vehicle on level surface and apply parking brake
2. Allow engine to cool completely if recently operated
3. Verify you have the correct replacement hose assembly for your specific AC line routing
4. Connect AC recovery machine and verify proper operation
5. Document the amount of refrigerant recovered for recharge reference
6. Photograph hose routing and connection points before disassembly

Procedure

1. 1

   Recover refrigerant from AC system
   Connect the AC recovery machine to the low and high-side service ports. Follow machine instructions to fully recover all refrigerant from the system. Record the amount recovered. Allow system to equalize for 5 minutes, then verify zero pressure on gauge before proceeding.
   ⚠️Ensure recovery machine is EPA-certified and properly maintained. Never vent refrigerant to atmosphere.
2. 2

   Access AC hose assembly
   For EcoBoost models, the AC hoses run along the passenger side of the engine bay. Remove the engine cover by pulling upward on the front clips and lifting off. If replacing the suction or discharge hose near the compressor, you may need to remove the air intake tube for better access. Mark or photograph the hose routing before removal.
3. 3

   Disconnect AC line fittings at firewall
   Locate the AC line connections at the firewall (passenger side). Using a flare nut wrench to prevent rounding, carefully loosen the fittings. If replacing hoses that connect at the firewall, disconnect both the liquid and suction lines. Support the lines as you remove fittings to prevent bending or stress on connections.
   ⚠Slowly crack fittings first to verify system is fully depressurized before complete removal.
4. 4

   Disconnect fittings at compressor or condenser
   Depending on which hose assembly is being replaced, disconnect the fittings at either the compressor (lower passenger side of engine) or condenser (front of radiator). Use flare nut wrenches to avoid damaging the fittings. Cap all open ports immediately with plugs or tape to prevent contamination and moisture entry.
   ⚠Cap all open AC system ports within 15 minutes to prevent moisture contamination which can damage the system.
5. 5

   Remove mounting brackets and hose assembly
   Remove any mounting bolts or clips securing the hose assembly to the chassis or engine. The hose may be secured with rubber-isolated mounting brackets. Carefully route the old hose assembly out, noting how it passes through the engine bay and any points where it may be clipped or supported.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Inspect old hose and system ports
   Examine the old hose assembly for signs of damage, abrasion, or oil residue that might indicate the failure point. Inspect all connection ports on the compressor, condenser, and firewall fittings for damage, debris, or old O-ring material. Remove any old O-ring remnants using a pick tool, being careful not to scratch sealing surfaces.
7. 7

   Prepare new hose assembly
   Remove protective caps from new hose assembly only when ready to install. Inspect new O-rings included with the hose or from your O-ring kit. Lightly coat new O-rings with fresh PAG oil (compatible with R-134a refrigerant). Install new O-rings in the proper grooves on the hose fittings. Add approximately 1-2 oz of PAG oil into the open hose ends to replace oil lost with the old hose.
   ℹ️Use only refrigerant-compatible PAG oil. Do not use petroleum-based lubricants which will damage the AC system.
8. 8

   Route and position new hose assembly
   Carefully route the new hose assembly through the engine bay following the exact path of the original. Ensure the hose does not contact any sharp edges, hot exhaust components, or moving parts. Position mounting brackets loosely in place but do not fully tighten yet to allow for alignment adjustment.
9. 9

   Connect and torque AC line fittings
   Hand-thread all AC line fittings first to ensure proper engagement and prevent cross-threading. Once hand-tight, use a flare nut wrench and torque wrench to tighten all AC line fittings to specification. Torque the firewall connections, compressor connections, and condenser connections as applicable to your specific hose assembly being replaced.
   ⚠Do not over-torque AC fittings as this can damage O-rings and cause leaks. Use a torque wrench for all AC connections.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Secure mounting brackets
    With all line fittings torqued, verify the hose routing is correct and has adequate clearance. Tighten all mounting bracket bolts to specification. Ensure hoses have no kinks, sharp bends, or tension that could cause premature failure.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Vacuum and leak test system
    Connect vacuum pump to AC system service ports. Evacuate the system to at least 500 microns and hold vacuum for 30 minutes minimum. System should hold vacuum with less than 500 micron rise, indicating no leaks. If vacuum does not hold, locate and repair leak before proceeding to recharge.
    ⚠Proper evacuation is critical to remove all moisture from the system. Moisture can freeze at the expansion valve and damage components.
12. 12

    Recharge AC system
    Using a refrigerant scale and charging machine, add the documented amount of R-134a refrigerant that was recovered (typically 1.75 lbs total system capacity for F-150 EcoBoost). Add refrigerant to both low and high side as needed. Follow charging machine instructions for proper procedure. If adding UV dye for future leak detection, add at this time per dye manufacturer instructions.
13. 13

    Test system operation
    Start engine and turn AC to maximum cold with blower on high. Allow system to run for 10 minutes. Monitor high and low-side pressures to verify proper operation (typical: 25-45 PSI low side, 200-250 PSI high side at 80°F ambient). Check all new connections with leak detector or soap solution. Verify cold air output at vents (typically 40-50°F colder than ambient).
    ℹ️AC pressures vary with ambient temperature. Consult pressure charts for your specific conditions.

Reassembly

1. Reinstall air intake tube if removed, ensuring all clamps are secure
2. Reinstall engine cover by aligning rear tabs first, then pressing down on front clips until seated
3. Verify no tools or materials were left in engine bay
4. Clean any spilled PAG oil or refrigerant residue from engine bay surfaces

Verification

• Start vehicle and run AC system on maximum cold for 15 minutes
• Verify center dash vents blow cold air (40-50°F below ambient temperature)
• Check for any unusual noises from compressor or hissing sounds indicating leaks
• Inspect all new AC line connections for signs of oil residue which would indicate a leak
• Verify AC system maintains proper cooling during a test drive with varying engine loads
• Re-check all connection points with leak detector after system has cycled several times
• Monitor system pressures are within normal range for ambient temperature

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