This procedure covers the removal and replacement of the AC compressor on a 2021-2024 Ford F-150 with the 3.5L V6 EcoBoost engine, including refrigerant recovery, component removal, and system recharge.

Warnings

Tools required

Parts

• AC Compressor assembly × 1 — Use OEM specification
• AC line O-ring kit × 1 — Motorcraft YF-3563 or equivalent
• Serpentine belt × 1 — Replace if worn or contaminated with oil
• PAG oil (appropriate viscosity for compressor) × 1 — Motorcraft PAG oil - verify spec for refrigerant type

Fluids

• R-134a or R-1234yf refrigerant (verify system label)

Preparation

1. Verify refrigerant type using the underhood label or refrigerant identifier tool
2. Park vehicle on level surface and engage parking brake
3. Allow engine to cool completely if recently operated
4. Disconnect negative battery terminal and wait 2 minutes
5. Record the total refrigerant charge amount from the underhood AC specification label
6. Place drain pan under compressor area to catch any residual oil

Procedure

1. 1

   Recover refrigerant from AC system
   Connect the AC recovery machine to the service ports (low side on suction line, high side on discharge line). Follow recovery machine instructions to completely evacuate all refrigerant from the system. Record the amount of oil recovered with the refrigerant for reference during refill. Verify system pressure reaches 0 psig and holds for at least 5 minutes.
   ⚠️Ensure recovery machine is rated for the refrigerant type in this vehicle. Cross-contamination of refrigerant types can damage equipment and the AC system.
2. 2

   Remove serpentine belt
   Locate the serpentine belt tensioner on the passenger side of the engine. Using a 3/8" ratchet or belt removal tool, rotate the tensioner clockwise to release tension. Slide the belt off the compressor pulley first, then remove from remaining pulleys. Inspect belt for oil contamination or damage; replace if necessary.
   ⚠Take a photo of the belt routing before removal or refer to the underhood belt routing diagram. Incorrect belt routing can cause engine damage.
3. 3

   Disconnect compressor electrical connector
   Locate the clutch electrical connector on the front of the compressor. Press the release tab and pull the connector straight off the compressor clutch. If equipped, remove the connector retaining bolt first.
   Torque spec

   Clutch Connector Bolt8 Nm (6 lb-ft)
4. 4

   Disconnect AC line fittings
   Using the appropriate AC line disconnect tool, separate the suction line (larger diameter) and discharge line (smaller diameter) from the compressor. Cap all open fittings immediately using clean plugs to prevent moisture and debris entry. Discard the old O-rings from the fittings.
   ⚠A small amount of refrigerant and oil may escape even after recovery. Wear safety glasses and have a clean rag ready.
5. 5

   Remove compressor mounting bolts
   Support the compressor weight with one hand. Remove the compressor mounting bolts (typically 3-4 bolts securing the compressor to the mounting bracket on the engine block). The compressor is located low on the passenger side of the engine. Once all bolts are removed, carefully maneuver the compressor out from below, tilting as needed to clear surrounding components.
6. 6

   Drain and measure oil from old compressor
   Drain the old compressor completely into a clean, graduated container by rotating it and pouring oil out through one of the ports. Measure the amount of oil removed. This helps determine how much fresh PAG oil to add to the new compressor. Typical amount is 4-6 ounces.
   ℹ️Do not reuse old compressor oil. Always use fresh PAG oil matched to the refrigerant type and compressor specification.
7. 7

   Prepare new compressor
   Remove shipping plugs from the new compressor ports. Drain any shipping oil from the new compressor. Add the correct amount of fresh PAG oil: if the old compressor contained 4-6 oz, add the same amount to the new unit. If oil measurement was unclear, add 5 oz. Slowly rotate the compressor clutch hub by hand 10 revolutions to distribute oil internally.
   ⚠Verify PAG oil viscosity matches system requirements. R-1234yf systems typically use PAG-46, while R-134a may use PAG-46 or ND-8. Check compressor label or service information.
8. 8

   Install new compressor
   Position the new compressor into the mounting bracket, aligning the bolt holes. Thread in all mounting bolts by hand first to ensure proper alignment. Tighten bolts in a cross pattern to the specified torque.
9. 9

   Install new O-rings and connect AC lines
   Install new O-rings onto both the suction and discharge line fittings. Lightly coat the O-rings with clean PAG oil (not compressor oil or other lubricants). Connect the lines to the compressor, ensuring they seat fully with an audible click. Tighten the line fittings to specification.
   ⚠Do not over-tighten AC line fittings. Excessive torque can damage the O-ring seal and cause leaks.
   Torque spec

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

    Reconnect electrical connector
    Push the clutch electrical connector onto the compressor until it clicks into place. If equipped with a retaining bolt, install and torque to specification.
    Torque spec

    Clutch Connector Bolt8 Nm (6 lb-ft)
11. 11

    Reinstall serpentine belt
    Route the serpentine belt according to the belt routing diagram, leaving the tensioner pulley for last. Rotate the tensioner clockwise and slip the belt onto the tensioner pulley. Release the tensioner slowly and verify the belt is properly seated in all pulley grooves.
12. 12

    Reconnect battery and perform vacuum test
    Reconnect the negative battery terminal. Connect the vacuum pump to the AC service ports and evacuate the system to at least 29 inches of mercury (Hg) vacuum. Hold vacuum for a minimum of 30 minutes. System should not lose more than 1 inch Hg; if it does, locate and repair the leak before proceeding.
    ⚠Proper vacuum is critical to remove all moisture from the system. Moisture will react with refrigerant to form acids that damage internal components.
13. 13

    Recharge AC system
    With the system still under vacuum, connect the refrigerant supply to the low-side service port. Charge the system with the exact amount of refrigerant specified on the underhood label (typically 1.75-2.2 lbs for this engine). Use an electronic scale for accuracy. Charge liquid refrigerant into the high side with engine off, then start engine and complete charging with vapor into the low side with AC running on maximum cooling.
    ⚠Overcharging the AC system can cause compressor damage and poor cooling performance. Never exceed the specified refrigerant capacity.

Reassembly

1. Verify all AC line fittings are tight and properly torqued
2. Ensure serpentine belt is properly seated on all pulleys and has correct tension
3. Confirm electrical connector is fully seated and secured
4. Double-check that no tools or parts were left in the engine compartment

Verification

• Start the engine and turn AC to maximum cold with blower on high
• Verify compressor clutch engages within 30 seconds (listen for click and observe clutch spinning)
• Check center vent temperature after 5 minutes; should be 40-50°F cooler than ambient
• Inspect all AC line connections for signs of oil or refrigerant leaks using a leak detector
• Verify low-side pressure is approximately 25-45 psi and high-side is 150-250 psi at idle (varies with ambient temperature)
• Listen for unusual noises from the compressor indicating bearing or internal damage
• Check engine compartment for proper belt operation with no squealing or slipping

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