Heater System Ford Econoline E150

BRONCO, "F" SERIES & "E" SERIES

The standard and hi-output heaters are blend-air design heating systems. The major difference between the 2 systems is the heater core size and heater case. The hi-output heater has a larger heater core and a modified heater case to accept the larger heater core than the standard heater.

The heater system consists of 3 major components: the heater case assembly, plenum and defroster nozzle. The heater is located in engine compartment and contains the blower motor and wheel, heater core, temperature blend door and blower resistor.

The plenum is located in the passenger compartment and contains the heater defroster door. The defroster nozzle is a 3-outlet nozzle and connects to the defroster outlet of the plenum.

BRONCO II & RANGER

The heater-ventilation system is a blend-air design and consists of the following major components: heater blower assembly, plenum, air distribution ducts, registers, control assembly, control cables and defroster nozzle. The heater blower assembly is located in engine compartment and contains the blower motor, wheel, and blower resistor.

The plenum is located in the passenger compartment and contains the heater-defroster door, temperature blend door, vent-heater door, air shut-off door and heater core. The defroster nozzle is a 3-outlet nozzle and connects to defroster outlet and plenum.

The ventilation system is operated by ram air from the forward motion of the vehicle. Air enters through the cowl top grille and is forced through cowl ducts to the vent assemblies located in each side cowl. Sliding vent knob rearward opens vent. Airflow can be regulated by positioning knob as desired between open and closed positions.

The ventilation system receives outside air from the cowl top grille for system operation. Outside air enters blower from cowl air intake. Air is forced through and/or around heater core on plenum. Air is then directed either to the floor, defroster nozzle, to both the floor and defroster nozzle, to instrument panel registers, or to registers and floor, depending on the function control lever setting.

The system is controlled by cables connected between the control panel assembly, through cams to the air door in plenum. The function lever operates heater-defroster door and vent-heater door located in plenum by means of a cable and cam. The temperature control lever operates temperature blend door in plenum.

Temperature Lever

When temperature lever is in "COOL" position, blend-air door directs outside air to by-pass heater core. When in "WARM" position, air is directed through heater core. Positioning of lever in intermediate positions results in a blending of cool and warm air to desired temperature.

Mode Selector Lever (Bronco, "F" Series & "E" Series)

When in "OFF" position, blower motor circuit is open, heater-defrost door is closed, and there is no air flow in the system. When in "HEAT" position, heater-defrost door moves to discharge air from plenum chamber to floor area. A small amount of air is directed to defroster outlets. In "DEFROST" position, heater-defrost door directs air to defroster nozzles.

Air flow may be modulated between heat and defrost outlets by moving mode control lever. Heating can be obtained from auxiliary heater by moving mode selector to any heating position, moving auxiliary mode lever to any position and turning auxiliary blower switch to any blower speed.

Mode Selector Lever (Bronco II & Ranger)

The mode selector lever moves horizontally to provide the following function settings: "OFF", "PANEL", "PNL/FLR", "FLOOR", "FLOOR/DEFROST" and "DEFROST". This function lever determines where the airflow is to be directed. The fan switch provides 4 speed and an off position.

In "PNL/FLR" position, airflow is divided between the floor outlets and panel registers. This position is designed to be used only when the temperature control lever is set at full "WARM" or full "COOL" positions only.

Blower Switch

Blower switch has 4-positions on all other models. Bronco II and Ranger models have 5-positions.

Auxiliary Blower Switch ("E" Series)

Auxiliary blower switch is a 4-position switch. Auxiliary blower operates independently of main system.

CONTROL CABLES ADJUSTMENT

Note. Check condition of cables before making adjustments.

MODE, OUTSIDE AIR & TEMPERATURE CONTROL CABLES (BRONCO II & RANGER)

1. Disengage glove box by squeezing sides together to disengage tabs and let box hang free. Working through glove box opening, remove cable housing from metal clip on top of plenum by depressing clip tab and pulling cable up.
2. Cable core wire end loop should remain attached to control cam on plenum. To adjust temperature control cable, move control lever to "COOL" position and hold.
3. Push cable housing (Blue) to seat blend door (push until you feel resistance). Install cable housing to clip by pushing it from top until it snaps into place.
4. To adjust mode control cable, move control lever to "DEFROST" position and hold. Pull on cam jacket until cam travel stops. Reinstall cable housing to clip by pushing it from top until it snaps into place.
5. To adjust outside air cable, move outside air control lever to "OFF" position and hold. Set door arm (White) in down position (door closed to shut off air flow).
6. With cable end attached to door arm, reinstall cable to clip. Turn blower switch to "HI" position and check for proper operation. Install glove box.

TEMPERATURE CONTROL CABLE (BRONCO & "F" SERIES)

1. Disengage glove box door by squeezing sides together. Remove pin retaining check strap from opposite side. Allow door to hang free.
2. Through glove box opening, remove cable jacket from metal attaching clip on top of plenum, by depressing clip tab and pulling cable rearward. Cable end should remain attached to door cam or crank arm.
3. Set temperature control lever to "COOL" position and hold firmly. Gently push on cable jacket to seat blend door (push until resistance is felt). Install cable into clip by pushing cable jacket from top until it snaps into place. Check for proper system operation.

TEMPERATURE CONTROL CABLE ("E" SERIES)

Note. The temperature control cable does not normally require adjustment. Check for proper cable operation.

1. Set temperature selector lever in "COOL" position. Remove cable from retaining clip, located on top of heater case. Do not disconnect cable from Yellow crank.
2. Rotate Yellow crank counterclockwise until temperature blend door seats. Ensure temperature selector is in "COOL" position. Install cable housing into retaining clip by pushing it in from top until it snaps into place. Set blower switch on "HIGH". Move temperature lever through its range to verify cable adjustment.

ALL MODELS

1. On "E" Series, place temperature selector lever in "WARM" position. On all other models, place temperature selector lever in mid-range position.
2. On "E" Series, place function selector lever in "FLOOR" position. On all other models, place function control lever in "PANEL" position. Connect voltmeter probes into connector at rear of blower motor.
3. With engine running, measure voltage drop across motor. Voltage reading for each blower switch position should be as specified. See BLOWER MOTOR TEST SPECIFICATIONS table.

BRONCO, BRONCO II, RANGER & "F" SERIES

1. Disconnect blower motor electrical connector. Connect an ammeter between left (positive) terminal on motor and corresponding terminal of wire harness connector. Connect a jumper wire between right (ground) terminal on blower motor and corresponding terminal of wire harness connector.
2. Place temperature control lever in mid-range position. Place function control lever in "PANEL" position. With engine running, record current draw for each blower speed. Current draw (amperage) should be as specified for each blower speed. See BLOWER MOTOR TEST SPECIFICATIONS table.

"E" SERIES

1. Separate blower motor ground (Black) wire at blower motor resistor. Connect positive ammeter lead to female spade connector and negative ammeter lead to resistor terminal.
2. Place temperature selector lever in mid-range position and function selector lever in the "HEAT" position. Turn ignition on. Blower current draw (amperage) should be as specified. See BLOWER MOTOR TEST SPECIFICATIONS table.

BLOWER MOTOR TEST SPECIFICATIONS

Scheme 1

1. Disconnect battery ground cable. Pull center finish panel from instrument panel. Remove 4 screws attaching control panel assembly to instrument panel. (Scheme 1)
2. Pull control panel assembly far enough from opening and disengage electrical connector for blower switch and illumination light. Disconnect vacuum harness connector from function selector valve on control panel.
3. Disconnect vacuum harness from plenum assembly connector. Carefully release temperature control snap-in flag from underside of control panel assembly.
4. Rotate control assembly 90 degrees and disconnect temperature control cable from lever. Remove control panel assembly from instrument panel. To install, reverse removal procedure.

Scheme 2

1. Disconnect battery ground cable. Remove ashtray, ashtray retainer and illumination bulb. Gently pull out finish panel away from instrument panel. On 4WD vehicles, disconnect wire from rear of 4WD transfer switch before removing finish panel from instrument panel. (Scheme 2)
2. Remove 4 screws attaching control panel assembly to instrument cluster. Pull control panel assembly through instrument panel assembly. Remove electrical connections from blower switch and illumination light.
3. Remove vacuum hose harness connector from vacuum switch on control panel. Release temperature and function cable snap-in flags from White control bracket.
4. Remove temperature control cable (Black cable with Blue snap-in flag) from control panel by rotating cable until "T" pin releases cable. Pull enough cable through instrument panel until function cable (White cable with Black snap-in flag) can be held vertical to control panel.
5. Remove control cable from function lever. Remove control panel assembly from instrument panel. To install, reverse removal procedure.

REMOVAL & INSTALLATION ("E" SERIES)

1. Remove trim applique. Remove 4 screws retaining control panel assembly to mounting bracket. Pull control panel assembly from opening. Disconnect electrical connectors, vacuum hoses and illumination bulb.
2. Remove push-on vacuum hoses retaining clips from vacuum selector and remove harness. Remove temperature control cable from control assembly.
3. Using Control Cable Remover (T83P-18532-AH) or needle-nose pliers, compress retaining ears of bullet-type cable retainer. Remove cable "S" bend from bottom side of lever by rotating cable 90 degrees to lever. To install, reverse removal procedure.

1. Remove first bench seat. Remove auxiliary heater cover attaching screws and remove cover. Drain cooling system. Disconnect heater hoses and plug openings. From under vehicle, disconnect auxiliary blower motor wires at connectors and disengage wiring harness from retaining strap.
2. Remove case assembly retaining screws and lift case assembly. Disengage wiring harness grommet from floor seal and remove case from vehicle. To install, reverse removal procedure.

REMOVAL & INSTALLATION (BRONCO & "F" SERIES)

1. Loosen all instrument panel retaining screws. Move panel to rear to gain access to plenum assembly. Remove glove box. Remove floor air distribution duct from plenum.
2. Remove plenum 2 nuts and one screw retaining left end of plenum to firewall. Disconnect temperature cable and vacuum connections from control panel assembly.
3. Disconnect source vacuum block secured to right side of heater core cover. Pull heater case forward to disengage 3 heater case studs from firewall.
4. On some vehicles, removal of instrument panel lower right hand attaching screw and braces to lower center area of instrument panel may be necessary. Lower plenum assembly. To install, reverse removal procedure.

REMOVAL & INSTALLATION (BRONCO II & RANGER)

1. Disconnect battery ground cable. Remove heater hoses from core tubes and plug hoses. Remove heater blower assembly. Remove 2 nuts from plenum studs at firewall in engine compartment.
2. In passenger compartment, remove instrument cluster finish panel. Remove instrument cluster, steering column upper and lower shrouds. Disconnect wiring from steering column switches.
3. Remove retaining screws to dash panel, glove box and braces. Remove parking brake and hood release cables from bottom of instrument panel. From behind instrument panel, disconnect electrical connectors, vacuum lines and heater control cables. Remove instrument panel.
4. Pull plenum rearward from firewall and remove plenum assembly. To install, reverse removal procedure.

1. Remove instrument panel. Disconnect vacuum hoses from panel/defrost vacuum motor and floor/defrost vacuum motor.
2. Remove retainers attaching center register duct and heater air outlet air duct to plenum. Separate plenum from heater housing, center register duct, and heater air outlet dust.
3. Remove plenum. Remove vacuum motors from plenum. To install, reverse removal procedure.

1. Disconnect battery ground cable. On California models, remove emission module forward of blower motor.
2. Disconnect wire harness connector from blower motor. Remove 4 screws attaching blower motor and wheel from heater case. Remove blower motor and wheel from heater case.
3. Remove blower wheel hub clamp spring and tab lock washer from motor shaft. Pull blower wheel from motor shaft. To install, reverse removal procedure.

1. Disconnect battery ground cable. Remove air cleaner. Disconnect wire harness connector from blower motor. Disconnect blower motor cooling tube at blower motor.
2. Remove 3 screws attaching blower motor and wheel to heater blower assembly. Hold cooling tube aside. Pull blower motor and wheel from heater blower assembly and remove from vehicle. Remove blower wheel hub clamp from motor shaft. Pull blower wheel from motor shaft. To install, reverse removal procedure.

1. Disconnect blower motor lead wire at wiring harness. Remove ground wire mounting screw from firewall.
2. Remove 4 screws from blower motor mounting plate. Carefully remove blower motor assembly. To install, reverse removal procedure.

1. Allow engine to cool. Place thick cloth over radiator cap. Turn cap slowly to its first stop to release system pressure. When pressure has been released, tighten radiator cap.
2. Disconnect heater hoses from heater core tubes, and plug hoses. For easier access, remove glove compartment. From inside passenger compartment, remove 7 screws which attach heater core access cover to plenum.
3. Disconnect vacuum source. Leave vacuum harness attached to cover. Remove cover. Remove heater core from plenum. To install, reverse removal procedure.

1. Drain coolant from radiator. Disconnect heater hoses from heater core and plug openings. In passenger compartment, remove 4 screws from heater core access cover on plenum assembly.
2. Remove access cover. Pull heater core rearward and down, removing from plenum. To install, reverse removal procedure.

1. Remove heater hoses from heater core in engine compartment. Plug hoses. Remove 2 screws retaining sound deadening panel to underside of instrument panel. Remove sound deadening panel.
2. Remove 4 screws from heater core cover. Remove heater core cover. Remove screw and retaining bracket at bottom of heater core. Remove heater core and seal from case. To install, reverse removal procedure.

1. Remove first bench seat (if equipped). Remove auxiliary heater cover attaching screws and remove cover assembly. Remove strap retaining heater core in auxiliary heater case.
2. Drain coolant from radiator. Disconnect heater hoses from auxiliary heater core. Plug openings. Disengage wire assembly from auxiliary heater core seal. Slide heater core and seal assembly out of case. To install, reverse removal procedure.

Bronco & "F" Series Heater Wiring Diagram. Scheme 3

Bronco II & Ranger Heater Wiring Diagram. Scheme 4

"E" Series Heater Wiring Diagram. Scheme 5