A/c-Heater System - Manual Ford Bronco II I

DESCRIPTION

Integral A/C-Heater system uses outside air at all times except during "MAX A/C" operation. Evaporator-blower assembly is mounted on engine side of dash. Heater core with plenum chamber is mounted on passenger side of dash. Refrigerant system is a cycling clutch orifice tube type, using a 6-cylinder axial swash plate compressor. Three control cables are used to control system air flow, temperature regulation and outside or recirculation air source.

TEMPERATURE LEVER OPERATION

Temperature lever operates a blend air door by cable to direct air around and/or through heater core to control discharge air temperature. All air passes through evaporator core.

MODE CONTROL LEVER OPERATION

Mode control lever operates a control cable connected to a cam on top side of evaporator assembly. The cam operates floor-defrost door and panel-defrost door, depending upon position of mode control lever.

AIR DOOR LEVER OPERATION

Air door lever is connected by cable to outside/recirculated air door. In "MAX A/C" position, door allows only recirculated air to be cooled.

A/C PUSH BUTTON SWITCH OPERATION

The A/C push button switch is for on-off operation of air conditioning compressor clutch circuit.

BLOWER SWITCH OPERATION

Operates blower at one of 4 speeds selected when mode lever is not in "OFF" position. Switch also has an "OFF" position.

A/C-Heater Control Panel. Scheme 1

Scheme 2

1. Check operation by moving mode control lever to "PANEL" and then back past "DEFROST" position. When released, lever should bounce back slightly.
2. Drop glove box by squeezing sides together to disengage tabs and let box hang free. Working through opening, remove cable housing from metal attaching clip on top of plenum by depressing clip tab and pulling cable up. (Scheme 2) Cable should remain attached to door cams and and/or crank arms.
3. Set temperature control lever to "COOL" position. With cable end attached to temperature door cam, push gently on cable housing (Blue) to seat blend air door (push until resistance is felt). Reinstall cable to clip by pushing cable jacket into clip from top until it snaps in.
4. Set mode control lever in "DEFROST" position and hold. With cable end attached to mode cam, pull on cable housing until cam travel stops. Reinstall cable to clip.
5. Set air door lever to "MAX A/C" position and hold. Set air door crank arm (White) in down position. With cable end attached to door crank, reinstall cable to clip. Reinstall glove box. With blower on "HIGH," check operation. (Scheme 2): Temperature Control Cable Connection

TROUBLE SHOOTING & DIAGNOSIS

See the MANUAL A/C DIAGNOSIS article in this section.

ACCUMULATOR

1. Disconnect battery ground. Discharge A/C refrigerant system using approved refrigerant recovery/recycling equipment. Disconnect electrical connector from pressure sensing switch. Unscrew pressure switch from accumulator. Disconnect suction hose from accumulator and cap hose.
2. Loosen fitting connecting accumulator to evaporator core. Remove lower forward screw holding flanges of case and bracket together. Remove screw holding evaporator core inlet tube to accumulator bracket.
3. Disconnect accumulator from evaporator core. Removebracket from accumulator. To install, reverse removal procedure, using new "O" ring lubricated with clean refrigerant oil. Leak test, evacuate and recharge system.

BLOWER MOTOR & FAN

1. Disconnect battery ground. In engine compartment, disconnect wiring harness connector from blower motor by pressing down on tab while pulling connector off at motor. Remove emission control "shoe box" (forward of blower motor) attaching bolts (if equipped).
2. Disconnect blower motor cooling tube from blower motor. (Scheme 5) Remove 3 blower motor mounting plate attaching screws. Remove blower motor and wheel from evaporator assembly. Remove attaching spring clamp and blower wheel.
3. To install, push wheel on blower motor shaft until itbottoms on blower motor hub. Install a new spring clamp. To complete installation, use a new blower mounting seal on blower housing. Reverse removal procedure.

CLUTCH CYCLING PRESSURE SWITCH

Disconnect wire connector from pressure switch. Unscrew pressure switch from accumulator. To install, use a new "O" ring lubricated with clean refrigerant oil. Screw pressure switch on accumulator and tighten. Connect wire connector to switch and check operation.

Note. When tightening switch, tighten switches with plastic base finger tight only, and switches with metal base to 5-10 ft. lbs. (7-13 N.m).

Scheme 3

Scheme 4

1. Discharge A/C refrigerant system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant line and compressor discharge line at condenser. Both lines are connected with spring-locked couplings.
2. Attach special tool (T81P-19623-G) to release spring. (Scheme 3) Close tool around coupling and push into cage toward condenser. Pull hose away from condenser and unclamp tool from disconnected coupling.
3. Drain cooling system. Disconnect upper radiator hose from radiator. From under vehicle, remove 2 nuts attaching 2 condenser lower mounting brackets to the front of radiator support.
4. Remove radiator upper retaining brackets. Tilt top of radiator rearward. Remove 2 screws or bolts attaching 2 condenser upper mounting brackets to the rear side of radiator support. Lift condenser from vehicle.
5. To install, reverse removal procedure, using new "O" rings lubricated with clean refrigerant oil. Leak test, evacuate and recharge system. (Scheme 3): Spring Lock Coupling and Tool
6. Working from top of control panel, release flag of temperature control cable (Blue) and air door cable flag (White). Rotate control panel 90° down.
7. Disconnect temperature control cable wire from temperature control lever and air door cable from air door control lever. To install, reverse removal procedure. Check A/C system for proper operation. (Scheme 4): Heater Control Panel Removal. Release control cable snap-in flags with needle-nose pliers.

Scheme 5

1. Disconnect battery ground. Discharge A/C refrigerant system using approved refrigerant recovery/recycling equipment. Drain coolant from radiator. Disconnect blower motor connector, motor resistance wires and wires connected to pressure switch. (Scheme 5)
2. Disconnect refrigerant line from evaporator and suction line from accumulator and cap lines. Disconnect heater hoses from heater core and plug openings.
3. Remove emission control "shoe box" attaching bolts from fender (if equipped). Remove bolt (upper outboard location) and 4 nuts from engine compartment side of evaporator assembly.
4. Remove evaporator case assembly from vehicle. To install, reverse removal procedure using new "O" rings lubricated with clean refrigerant oil. Leak test, evacuate and recharge system. (Scheme 5): Exploded View of Evaporator Assembly

EVAPORATOR CORE

1. Disconnect battery ground. Discharge refrigerant system using approved refrigerant recovery/recycling equipment. Disconnect electrical connector from pressure switch on side of accumulator. Remove pressure switch from accumulator. Disconnect suction hose from accumulator and refrigerant hose from evaporator and cap openings.
2. Remove 9 screws holding evaporator case service cover to evaporator case assembly. Remove mounting nut from bottom of service cover mounting stud of evaporator case.
3. From passenger compartment, remove nut from stud located near heater core cover attaching evaporator case assembly. From engine compartment, remove service cover from evaporator case.
4. Remove evaporator core and accumulator from vehicle. Toinstall, reverse removal procedure, using new "O" rings lubricated with clean refrigerant oil. Leak test, evacuate and recharge system. NOTE: When tightening pressure switch, tighten switch with plastic base finger tight only, and switch with metal base to 5-10 bs. (7-13 N.m).

Scheme 6

1. Discharge A/C refrigerant system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant line from evaporator core. Lubricate refrigerant and orifice tube "O" rings by pouring small amount of refrigerant oil into liquid line. Engage removal tool (Motorcraft YT-1008 or equivalent) with 2 tangs on fixed orifice tube. (Scheme 6) NOTE: Do not twist or rotate orifice tube in liquid line or breakage may occur. (Scheme 6): Fixed Orifice Tube Removal
2. Hold T-handle of tool and run nut down against refrigerant line until orifice tube is pulled from refrigerant line. If orifice tube breaks in refrigerant line, it must be removed with extractor tool (Motorcraft YT-1009 or equivalent).
3. To remove broken orifice tube, insert screw end of extractor tool into refrigerant line and threaded end of tool into brass tube in center of broken orifice tube. Run tool nut down against refrigerant line, removing orifice tube.
4. To install orifice tube, use "O" rings lubricated withrefrigerant oil. Place fixed orifice tube in removal tool. Insert fixed orifice tube into evaporator core tube until orifice is seated at stop. Remove tool and reconnect lines. Leak test, evacuate and recharge A/C system.

HEATER CORE

Note. These procedures are for vehicles with air conditioning systems only. For replacement on vehicles equipped with heater systems only, see appropriate article in HEATER SYSTEMS section.

1. Drain coolant from radiator. Disconnect heater hoses from heater core tubes. Cap hoses. In passenger compartment, remove 5 screws attaching heater core access cover to plenum assembly.
2. Pull heater core rearward and down, removing it fromplenum assembly. To install, reverse procedure.

1983-85 Bronco II & Ranger A/C-Heater Wiring Diagram. Scheme 7

1986-87 Bronco II & Ranger A/C-Heater Wiring Diagram. Scheme 8

1988 Bronco II & Ranger A/C-Heater Wiring Diagram. Scheme 9