This procedure covers the removal and replacement of the AC compressor on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• AC Compressor assembly × 1 — Use OEM specification or quality aftermarket
• AC compressor O-ring kit × 1 — Use OEM specification
• PAG 46 compressor oil × 1 — Motorcraft YN-12-C or equivalent
• Serpentine belt × 1 — Replace if worn or contaminated with oil
• R-134a refrigerant × 1 — Approximately 1.75 lbs total system capacity

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for at least 2 hours
3. Disconnect negative battery cable and isolate from terminal
4. Using certified AC recovery equipment, fully recover refrigerant from the system and record amount recovered
5. Raise front of vehicle and support securely on jack stands
6. Remove engine splash shield and lower air deflectors for access
7. Document or photograph serpentine belt routing before removal

Procedure

1. 1

   Remove serpentine belt
   Using serpentine belt tool, rotate tensioner clockwise to release tension. Remove belt from all pulleys including AC compressor pulley. Inspect belt for oil contamination or damage and replace if necessary.
2. 2

   Disconnect compressor electrical connector
   Locate the AC compressor clutch electrical connector on the front of the compressor. Press the release tab and disconnect the connector. Remove the connector bolt if equipped and set aside.
   Torque spec

   Clutch Connector Bolt8 Nm (6 lb-ft)
3. 3

   Disconnect AC discharge line
   Using appropriate crowfoot wrench, loosen and remove the discharge line (high pressure side) fitting from the top rear of the compressor. Immediately cap both the line and compressor port to prevent moisture and contamination entry. Remove and discard the O-ring from the line.
   ⚠Even after recovery, residual refrigerant or pressure may remain. Work slowly and wear safety glasses.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
4. 4

   Disconnect AC suction line
   Remove the suction line (low pressure side) fitting from the compressor, typically located on the lower portion. Use crowfoot wrench to avoid rounding the fitting. Immediately cap both openings. Remove and discard the O-ring.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
5. 5

   Remove compressor mounting bolts
   Locate the three compressor mounting bolts securing the compressor to the engine bracket. The 3.5L EcoBoost has bolts accessible from the front and side. Remove all mounting bolts and support the compressor weight as the final bolt is removed.
6. 6

   Remove AC compressor
   Carefully maneuver the compressor out of the engine bay, working it past the frame rail and other components. The compressor may need to be tilted and rotated to clear obstructions. Lower it through the bottom of the vehicle if necessary.
7. 7

   Drain and measure compressor oil
   Drain oil from the old compressor into a clean graduated container by rotating it and draining from both ports. Measure and record the amount of oil recovered. This determines how much oil to add to the new compressor. Inspect oil for metal particles or contamination.
   ⚠If metal particles are present in the oil, the AC system may be contaminated and require full system flush before installing new compressor.
8. 8

   Prepare new compressor
   Remove shipping caps from new compressor. Drain pre-filled oil and measure. Add correct amount of fresh PAG 46 oil to match what was removed from old compressor (typically 4-6 oz total). Rotate compressor pulley 10-15 times to distribute oil internally.
9. 9

   Install new compressor
   Maneuver new compressor into position in the engine bay, reversing removal path. Align compressor with mounting bracket and start all three mounting bolts by hand before tightening any. Ensure compressor is properly seated on bracket.
10. 10

    Torque compressor mounting bolts
    Using torque wrench, tighten all three compressor mounting bolts in a star pattern to ensure even seating. Torque to specification.
11. 11

    Install new O-rings and connect AC lines
    Install new O-rings onto both AC line fittings, coating them lightly with fresh PAG oil. Remove caps from compressor ports. Connect suction line first, then discharge line. Hand-tighten fittings, then use crowfoot wrench and torque wrench to torque to specification. Do not overtighten as this can damage O-rings.
    Torque spec

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

    Reconnect electrical connector
    Reconnect the AC compressor clutch electrical connector, ensuring it clicks into place. Install connector bolt if equipped and torque to specification.
    Torque spec

    Clutch Connector Bolt8 Nm (6 lb-ft)
13. 13

    Install serpentine belt
    Route new or existing serpentine belt around all pulleys according to routing diagram. Use belt tool to rotate tensioner and slip belt onto final pulley. Release tensioner slowly and verify belt is properly seated in all pulley grooves.
14. 14

    Evacuate and recharge AC system
    Reconnect battery. Using AC vacuum pump, evacuate the system to at least 29 inches Hg vacuum for minimum 45 minutes to remove all moisture. System should hold vacuum for 30 minutes without loss. Recharge system with R-134a refrigerant to specification (approximately 1.75 lbs total). Add UV dye if desired for future leak detection.
    ℹ️AC system must be evacuated to remove all moisture introduced during compressor replacement. Moisture will damage new compressor and reduce system performance.

Reassembly

1. Reinstall engine splash shield and lower air deflectors
2. Lower vehicle from jack stands
3. Verify all tools and materials are removed from engine bay
4. Double-check all electrical connections and line fittings for security

Verification

• Start engine and set AC to maximum cold and high fan speed
• Verify AC compressor clutch engages and disengages properly with AC switch
• Check for abnormal noises from compressor during operation
• Monitor AC manifold gauges: low side should be 25-45 psi, high side 200-250 psi at idle (ambient temp dependent)
• Verify cold air output from vents reaches appropriate temperature (typically 38-42°F at vent)
• Inspect all AC line connections for signs of refrigerant leaks using leak detector or soap solution
• Allow system to run for 10-15 minutes and recheck pressures and outlet temperature
• Verify no oil leaks from compressor or line fittings after test run

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