HVAC - Climate Control System Ford Econoline E250

SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

Air Conditioning

The A/C refrigerant system is a clutch cycling orifice tube type. The system components are the

1. A/C compressor.
2. A/C compressor clutch.
3. condenser core.
4. evaporator core.
5. suction accumulator.
6. connecting refrigerant lines.

The refrigeration system operation is controlled by the

1. evaporator core orifice.
2. A/C cycling switch.
3. A/C pressure relief valve.
4. high pressure cutoff switch.

The refrigerant system incorporates an A/C compressor controlled by an A/C cycling switch and high-pressure cutoff switch (refrigerant containment switch). The A/C cycling switch senses low-side refrigerant pressure to control A/C compressor operation and prevent evaporator core freeze-up. The high-pressure cutoff switch senses high-side refrigerant pressure to interrupt A/C compressor operation in the event of excessively high refrigerant pressure.

An A/C pressure relief valve is installed in the A/C compressor to protect the refrigerant system against excessively high refrigerant pressures.

An evaporator core orifice is installed in the evaporator core inlet tube to meter the liquid refrigerant into the evaporator core.

A/C Compressor and Clutch Assembly

Note. Internal FS18 A/C compressor components are not serviced separately. The A/C compressor is serviced only as an assembly. The clutch disc and hub, A/C compressor pulley and bearing and clutch field coil are serviceable.

Note. Installation of a new suction accumulator is not required when repairing the A/C system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

The FS18 A/C compressor

1. uses a non-serviceable shaft seal.
2. has a pressure relief valve installed in the rear of the compressor to protect the refrigerant system against excessively high refrigerant pressures.
3. uses PAG oil or equivalent. This oil contains special additives required for the A/C compressor. PAG oil may have some slightly dark-colored streaks while maintaining normal oil viscosity. This is normal for this A/C compressor because of break-in wear that can discolor the oil.

Use standard oil matching procedures when installing new compressors.

Scheme 126

The magnetic A/C clutch has the following characteristics

1. The A/C clutch drives the compressor shaft.
2. When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch plate and hub assembly is drawn toward the A/C clutch pulley.
3. The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate.
4. When B+ is removed from the A/C clutch field coil, springs in the clutch plate and hub assembly move the clutch plate away from the A/C clutch pulley.

A/C Pressure Relief Valve

Note. If the A/C compressor is operating within limits and the A/C pressure relief valve is venting, or if the A/C pressure relief valve is leaking around the threads, replace the A/C pressure relief valve and O-ring. If the A/C pressure relief valve still vents after it is replaced, diagnose the refrigerant system for a restriction.

An A/C pressure relief valve is incorporated in the A/C compressor to prevent damage to the A/C compressor and other system components by relieving unusually high system discharge pressure buildups. For specifications regarding operating pressure(s), refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

The A/C pressure relief valve is a separate component and can be replaced separately from the A/C compressor. It is necessary to recover the refrigerant before removing the A/C pressure relief valve.

Condenser Core

The condenser core has the following characteristics

1. it is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator.
2. it cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled.

Evaporator Core

The evaporator core is the plate/fin type and has the following characteristics

1. a mixture of liquid refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and is routed so it flows through the partitioned plate/fin sections.
2. refrigerant then moves out of the evaporator core through the evaporator core outlet tube as a vapor.
3. during A/C operation, air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins.

Evaporator Core Orifice

Note. A new evaporator core orifice should be installed whenever a new A/C compressor is installed.

The evaporator core orifice has the following characteristics

1. it is located in the evaporator core inlet tube.
2. it has filter screens located on the inlet and outlet ends of the tube body.
3. the inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice.
4. O-ring seals on the evaporator core orifice prevent the high-pressure liquid refrigerant from bypassing the evaporator core orifice.
5. adjustment or service cannot be made to the evaporator core orifice assembly, a new evaporator core orifice assembly must be installed as a unit.

Suction Accumulator

Note. Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced.

The suction accumulator is mounted to the RH inner fender to the right of the battery.

After entering the suction accumulator inlet, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister.

1. A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate.
2. As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging.
3. A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles.
4. A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system.
5. A fitting located on the top of the suction accumulator is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling switch can be removed without recovering the refrigerant.

A/C Cycling Switch

The A/C cycling switch is mounted on a Schrader-type valve fitting on the top of the suction accumulator.

1. A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem, allowing the suction pressure inside the suction accumulator to control the operation of the A/C cycling switch.
2. The electrical switch contacts open when the suction pressure drops. The contacts close when the suction pressure rises. For specifications regarding operating pressure(s), refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
3. When the A/C cycling switch contacts close, the A/C compressor clutch field coil is energized.
4. When the A/C cycling switch contacts open, the A/C compressor clutch field coil is de-energized and A/C compressor operation stops.
5. The A/C cycling switch will control the evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing.
6. This prevents icing of the evaporator core and blockage of airflow.
7. It is not necessary to recover the refrigerant to remove the A/C cycling switch.

High-Pressure Cutoff Switch

The high-pressure cutoff switch is installed on the compressor-to-condenser discharge line to interrupt A/C compressor operation in the event of high system discharge pressures.

1. The high-pressure cutoff switch is mounted on a Schrader-type valve fitting on the A/C compressor discharge line.
2. A valve depressor, located inside the threaded end of the high-pressure cutoff switch, presses on the Schrader valve stem.
3. This allows the high-pressure cutoff switch to monitor the compressor discharge pressure.
4. When the A/C compressor discharge pressure rises, the switch contacts open, disengaging the A/C compressor. When the pressure drops, the contacts close to allow operation of the A/C compressor. Refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
5. It is not necessary to recover the refrigerant to remove the high-pressure cutoff switch.

Service Gauge Port Valves

The high-pressure service gauge port valve is located on the compressor-to-condenser discharge line.

The low-pressure service gauge port valve is located on the suction accumulator.

Scheme 127

The fitting is an integral part of the refrigeration line or component.

1. Special couplings are required for both the high-side and low-side service gauge ports.
2. A very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively.
3. The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed.

Refrigerant System Dye

Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda-approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. New suction accumulators are shipped with a fluorescent dye "wafer" included in the desiccant bag which will dissolve after approximately 30 minutes of continued A/C operation. It is not necessary to add dye after flushing or filtering the refrigerant system because a new suction accumulator is installed as part of the flushing or filtering procedure. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture or other damage. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

Air Distribution and Filtering

Note. The air distribution system of this vehicle cannot be equipped with a cabin air filter.

There are 2 sources of air available to the air distribution system

1. Outside air
2. Recirculated air

Recirculated air is only used during MAX A/C (if equipped) and OFF modes.

Air distribution within the vehicle is determined by the function selector switch position. Airflow mode doors are used to direct airflow within the plenum chamber. Vacuum control motors are used to position these airflow mode doors.

The air distribution system is designed to provide airflow from the defrost nozzle when no vacuum is applied to any of the vacuum control motors. This is done to prevent a situation where defrost cannot be obtained due to a system vacuum leak.

Air enters the passenger compartment from the

1. instrument panel registers.
2. floor duct.
3. windshield defroster nozzle.
4. side window demisters.

Passenger compartment air is exhausted from the vehicle through open windows or cab air vents.

Control Components

The manual climate control system heats or cools (if equipped with A/C) the vehicle interior depending on the function selector position and the temperature selected. Function selector position determines heating or cooling (if equipped with A/C) and air distribution. The temperature blend control setting determines air temperature.

The manual climate control components are used to

1. select air inlet source (outside or recirculated).
2. select blower motor speed.
3. select discharge air temperature (temperature blend).
4. select discharge air location (DEFROST, PANEL, FLOOR).
5. select A/C compressor clutch operation (if equipped with A/C).

Climate Control Assembly

The climate control assembly has 3 system controls

1. The function selector switch combines a vacuum selector valve with 2 electrical switches to supply battery positive voltage to the A/C clutch circuit (if equipped with A/C) and the blower motor control circuit.
2. The temperature selection is accomplished with a potentiometer connected to the electric temperature blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (blue) to WARM (red) causes a corresponding movement on the temperature blend door and determines the temperature that the system will maintain.
3. The blower motor switch controls blower motor speed by adding or bypassing resistors in the blower motor resistor.

Blower Motor Resistor

The blower motor resistor has the following features

1. The assembly is located on the passenger side of the vehicle on the evaporator housing.
2. Three resistance elements are mounted on the resistor board to provide 4 blower motor speeds.
3. Depending on the blower switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed.
4. An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds except HI.
5. The thermal limiter cannot be reset and is not serviceable.

Vacuum Control Motors

The 3 vacuum control motors

1. are actuated by vacuum from the function selector switch.
2. position the airflow mode doors to direct system airflow to the vehicle's interior as determined by the function selector switch setting.

Temperature Blend Door Actuator

The temperature blend door actuator

1. is located on the RH side of the heater core housing.
2. moves the temperature blend door on command from the temperature control switch.

Heating and Ventilation

The heating and defrosting system has the following features

1. Controls the temperature and, during A/C operation (if equipped), reduces the relative humidity of the air inside the vehicle.
2. Delivers heated or cooled air (if equipped with A/C) to maintain the vehicle interior temperature and comfort level.
3. Controls the blower motor speed.
4. Cooling or heating can be adjusted to maintain the desired temperature.
5. System uses a reheat method (if equipped with A/C) to provide conditioned air to the passenger compartment.
6. The blower motor draws outside air through the air inlet duct from just below the windshield during all system operations except for OFF and MAX A/C, if equipped (when recirculated air is used).
7. All airflow from the blower motor passes through the A/C evaporator core, if equipped.
8. The temperature is then regulated by reheating a portion of the air and blending it with the remaining cool air to the desired temperature.
9. The temperature blending is varied by the air temperature blend door, which regulates the amount of air that flows through or around the heater core, where it is then mixed and distributed.

Heater Core

The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core.

Blower Motor

The blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. The blower motor has 4 speeds and is controlled by the blower motor switch and resistor.

Air Conditioning (A/C) Compressor

MATERIAL SPECIFICATIONS

Scheme 128

Removal and Installation

Note. If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, carry out the following procedures to remove contamination from the A/C system. Failure to remove contamination from the A/C system, if present, will result in poor A/C performance and/or damage to the new A/C compressor and other components. If A/C flushing equipment is available, carry out flushing of the A/C system prior to installing a new A/C compressor. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS . If A/C flushing equipment is not available, carry out filtering of the refrigerant system after a new A/C compressor has been installed. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS . Install a new evaporator core orifice. For additional information, refer to EVAPORATOR CORE ORIFICE . Install a new suction accumulator. For additional information, refer to SUCTION ACCUMULATOR .

Note. Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced.

Note. A new A/C compressor may come equipped with an A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil already installed. If these components are not pre-installed, it will be necessary to transfer these parts from the old A/C compressor to the new compressor prior to installations of the A/C compressor if suitable for reuse.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) .
2. If flushing of the refrigerant system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
3. Remove the lower engine splash shield (if equipped).
4. Remove the drive belt from the A/C compressor pulley.
5. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
6. Disconnect the clutch field coil electrical connector and position the wire harness aside.
7. Completely loosen the 3 A/C compressor bolts and position the A/C compressor to allow access to the fitting nuts. To install, tighten to 25 Nm (18 lb-ft).
8. Remove the 2 A/C compressor fitting nuts and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (133 lb-in).
9. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. If a new A/C compressor is to be installed, the clutch assembly may need to be transferred from the old unit to the new unit. For additional information, refer to «CLUTCH AND CLUTCH FIELD COIL»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system__clutch-and-clutch-field-coil) . If not filtering the A/C system, add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
10. If not filtering the A/C system, evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

Scheme 129

Scheme 130

1. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Remove the battery.
3. Disconnect the A/C cycling switch electrical connector.
4. Remove the A/C cycling switch.
5. To install, reverse the removal procedure. Install a new O-ring seal.

All vehicles

Scheme 131

Scheme 132

Scheme 133

Scheme 134

1. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Remove the battery.
3. Remove the battery tray. Remove the bolts. Remove the battery tray. To install, tighten to 28 Nm (21 lb-ft). Vehicles equipped with A/C
4. Position the suction accumulator aside. Remove the 3 screws. Position the suction accumulator aside. All vehicles
5. Remove the blower motor. Disconnect the blower motor electrical connector. Remove the vent tube. Remove 4 screws. Remove the retaining clip. Remove the blower motor.
6. Remove the blower motor wheel. Remove the retaining clip. Remove the blower motor wheel.
7. To install, reverse the removal procedure.

Scheme 135

Scheme 136

1. Disconnect the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
2. Remove the battery.
3. Remove the battery tray. Remove the battery tray bolts. Remove the battery tray. To install, tighten to 28 Nm (21 lb-ft).
4. Disconnect the blower motor resistor electrical connector.
5. Remove the blower motor resistor. Remove the 2 blower motor resistor screws. Remove the blower motor resistor.
6. To install, reverse the removal procedure.

Scheme 137

1. Remove the climate control assembly. For additional information, refer to «CLIMATE CONTROL ASSEMBLY»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
2. Remove the blower motor switch knob.
3. Remove the blower motor switch. Remove the screw. Remove the blower motor switch.
4. To install, reverse the removal procedure.

Scheme 138

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/econoline-e250/2012-2013/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Remove the 3 climate control assembly screws.
3. Remove the climate control assembly.
4. To install, reverse the removal procedure.

Clutch and Clutch Field Coil

SPECIAL TOOLS CHART Holding Tool, Compressor Clutch 412-134 Installer, A/C Compressor Coil 412-065 (T89P-19623-EH) Installer, A/C Compressor Field Coil 412-078 (T91L-19623-CH) Remover, A/C Compressor Field Coil 412-067 (T89P-19623-FH) Remover, Compressor Pulley 412-001 (T71P-19703-B)

Scheme 139

Scheme 140

Scheme 141

Scheme 142

1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system__air-conditioning-ac-compressor) .
2. Remove the A/C clutch disc and hub bolt. Using the Compressor Clutch Holding Tool, hold the A/C clutch disc and hub. Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub.
4. Remove the A/C clutch disc and hub spacer(s).
5. Remove the A/C compressor pulley snap ring.
6. Remove the A/C compressor pulley. Install the Compressor Pulley Remover. Remove the A/C compressor pulley.
7. Remove the A/C clutch field coil. Install the A/C Compressor Field Coil Remover. Install the Compressor Pulley Remover. Remove the A/C clutch field coil.

Installation

Note. A new A/C compressor may come equipped with a clutch and pulley. If not, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.

Scheme 143

Scheme 144

1. Visually inspect the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil for damage. Inspect for physical damage, including cracked or melted components or discoloration due to excessive heat. Inspect for excessive wear, including grooving in the A/C clutch disc and hub or A/C compressor pulley that is more than fingernail depth. Inspect for roughness in the A/C compressor pulley bearing.
2. Clean the A/C clutch field coil and pulley mounting surfaces.
3. Install the A/C clutch field coil. Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector correctly positioned. Place the A/C Compressor Field Coil Remover on the A/C clutch field coil. Place the A/C Compressor Coil Installer on the A/C Compressor Field Coil Installer. Use the Compressor Pulley Remover to install the A/C clutch field coil.
4. Install the A/C compressor pulley.
5. Install the A/C compressor pulley snap ring.
6. Install the A/C clutch disc and hub spacer(s) and the A/C clutch disc and hub.
7. Install the A/C clutch disc and hub bolt. Hold the A/C clutch disc and hub with the Compressor Clutch Holding Tool. Tighten to 13 Nm (115 lb-in).
8. Measure and adjust the clutch air gap by adding or removing A/C clutch disc and hub spacers.
9. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system__air-conditioning-ac-compressor) .

Compressor to Condenser Discharge Line

MATERIAL SPECIFICATIONS

Scheme 145

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
3. Remove the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/econoline-e250/2012-2013/remont/wheel-tire-system/#wheels-tires) .
4. Remove the A/C compressor discharge fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
5. Disconnect the high-pressure cutoff switch electrical connector.
6. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
7. Remove the compressor-to-condenser discharge line.
8. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
9. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

MATERIAL SPECIFICATIONS

Scheme 146

Note. If an A/C condenser core leak is suspected, the A/C condenser core must be leak-tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
2. Remove the engine Air Cleaner (ACL) and outlet tubes. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/econoline-e250/2012-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) .
3. Remove the upper radiator air deflector.
4. Remove the condenser fitting nuts and disconnect the condenser fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (133 lb-in).
5. Remove the 4 radiator bracket bolts and the 2 radiator brackets. To install, tighten to 20 Nm (177 lb-in).
6. Remove the 2 condenser bracket bolts and the 2 condenser brackets. To install, tighten to 12 Nm (106 lb-in).
7. Position the radiator rearward to provide clearance for condenser removal.
8. Remove the condenser core.
9. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

Condenser to Evaporator Line

MATERIAL SPECIFICATIONS

Scheme 147

Scheme 148

Note. The condenser-to-evaporator line for vehicles equipped with auxiliary climate control is supplied as an assembly with the auxiliary suction line.

Vehicles with auxiliary climate control

Scheme 149

1. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) . All vehicles
2. Remove the engine Air Cleaner (ACL) and the ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/econoline-e250/2012-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) .
3. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
4. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
5. Remove the evaporator inlet fitting bracket screw. To install, tighten to 2 Nm (18 lb-in).
6. Disconnect the evaporator inlet fitting. Discard the O-ring seal. To install, tighten to 18 Nm (159 lb-in). Vehicles with auxiliary A/C
7. Remove the 2 condenser-to-evaporator line bracket screws. To install, tighten to 3 Nm (27 lb-in).
8. Remove the condenser-to-evaporator line bracket nut.
9. Disconnect the auxiliary evaporator inlet line fitting. Discard the O-ring seals.
10. Disconnect the auxiliary evaporator outlet line fitting. Discard the O-ring seals.
11. Remove the suction accumulator outlet line bracket screw. To install, tighten to 2 Nm (18 lb-in).
12. Remove the compressor suction line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
13. Remove the 2 washer reservoir filler tube bolts and position the filler tube aside. To install, tighten to 9 Nm (80 lb-in).
14. Remove the oil filler tube bolt. To install, tighten to 9 Nm (80 lb-in).
15. Detach the wire harness pin-type retainer and disconnect the vacuum supply line connector.
16. Remove the cowl ground strap bolt. To install, tighten to 8 Nm (71 lb-in).
17. Remove the 3 wire harness screws and position the wire harness aside.
18. Disconnect the suction accumulator outlet fitting. Discard the O-ring seals.
19. Release the brake booster vacuum hose clamp and disconnect the vacuum hose. All vehicles
20. Remove the condenser-to-evaporator line.
21. To install, reverse the removal procedure. Install new gasket seals and new O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
22. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

MATERIAL SPECIFICATIONS

Note. If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

All vehicles

Scheme 150

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
2. Remove the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/econoline-e250/2012-2013/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system) .
3. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
4. Remove the battery tray. Remove the bolts. Remove the battery tray. To install, tighten to 28 Nm (21 lb-ft).
5. Remove the bolt and clamp and the oil filler tube. To install, tighten to 9 Nm (80 lb-in).
6. Remove the 2 A/C condenser fitting nuts and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (133 lb-in).
7. Remove the washer reservoir filler tube. Remove the 2 washer reservoir filler tube bolts. Remove the washer reservoir filler tube. To install, tighten to 9 Nm (80 lb-in).
8. Disconnect the evaporator outlet fitting. Discard the O-ring seal. To install, tighten to 40 Nm (30 lb-ft).
9. Disconnect the high-pressure cutoff switch electrical connector.
10. Disconnect the compressor suction line fitting. Remove the suction accumulator outlet line bracket screw. Remove the compressor suction line fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten the fitting to 15 Nm (133 lb-in). To install, tighten the screw to 2 Nm (18 lb-in). Vehicles with auxiliary A/C
11. Disconnect the suction accumulator fitting. Discard the O-ring seals. All vehicles
12. Disconnect the evaporator inlet fitting. Remove the evaporator inlet fitting bracket screw. Disconnect the evaporator inlet fitting. Discard the O-ring seal. To install, tighten the fitting to 18 Nm (159 lb-in). To install, tighten the screw to 2 Nm (18 lb-in).
13. Remove the screws and the evaporator core housing support bracket.
14. Remove the evaporator core cover. Remove the 5 screws. Remove the 4 screws. Remove the evaporator core cover.
15. Remove the evaporator core.
16. To install, reverse the removal procedure. Install new gasket seals and new O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
17. Evacuate, leak test and charge the refrigerant system. For additional information refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

Scheme 159

Scheme 160

Scheme 161

Scheme 162

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

Scheme 169

1. Remove the heater core housing. For additional information, refer to «HEATER CORE HOUSING»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
2. Remove the evaporator core. For additional information, refer to «EVAPORATOR CORE»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
3. Detach the wire harness. Remove the nut and stud. Disconnect the electrical connector and position the wire harness aside.
4. Remove the 2 suction accumulator bolts and the suction accumulator. To install, tighten to 12 Nm (106 lb-in).
5. Remove the washer reservoir. Remove the nut. Remove the bolt. Remove the washer reservoir. Disconnect the washer pump hose and electrical connector.
6. Disconnect the blower motor electrical connector.
7. Disconnect the blower motor resistor electrical connector.
8. Disconnect the vacuum connector and detach the wire harness pin-type retainer.
9. Remove the screws and position the wire harness aside.
10. Position the auxiliary A/C lines aside (if equipped). Remove the auxiliary A/C line bracket bolt. Position the auxiliary A/C lines aside.
11. Working inside the vehicle, disconnect the vacuum harness connector and detach the 2 wire harness retainers from the evaporator core housing studs.
12. Remove the 3 evaporator core housing nuts.
13. Position the evaporator core housing forward and remove the 2 fresh air inlet duct screws.
14. Remove the fresh air inlet duct. Remove the screw. Remove the fresh air inlet duct. Detach the vacuum line retainer.
15. Deflect the LH battery tray bracket to provide clearance for evaporator core housing removal.
16. Remove the evaporator core housing.
17. To install, reverse the removal procedure.

SPECIAL TOOLS CHART Remover, Damaged Evaporator Core Orifice 412-035 (T83L-19990-B) Remover/Installer, Evaporator Core Orifice 412-034 (T83L-19990-A)

Scheme 170

Scheme 171

MATERIAL SPECIFICATIONS

Scheme 172

Scheme 173

Scheme 174

1. Disconnect the evaporator inlet fitting. Discard the O-ring seal.
2. Inspect the evaporator core orifice for damage before attempting to remove it from the evaporator core inlet line.
3. If the evaporator core orifice is intact, engage the Evaporator Core Orifice Remover/Installer. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice.
4. If the evaporator core orifice is broken, screw the end of the Damaged Evaporator Core Orifice Remover into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice.

Scheme 175

1. Lubricate the evaporator core orifice O-rings with clean PAG oil and install the evaporator core orifice using the Evaporator Core Orifice Remover/Installer.
2. Connect the evaporator inlet fitting. Install a new O-ring seal. Tighten to 18 Nm (159 lb-in).

Scheme 176

1. Remove the climate control assembly. For additional information, refer to «CLIMATE CONTROL ASSEMBLY»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
2. Remove the function selector switch knob.
3. Remove the function selector switch. Remove the screw. Remove the function selector switch.
4. To install, reverse the removal procedure.

Scheme 177

Note. If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .

Scheme 178

1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/econoline-e250/2012-2013/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the heater hoses at the heater core.
3. Remove the glove compartment. Remove the 4 glove compartment screws. Remove the glove compartment.
4. Remove the 8 heater core cover screws and the heater core cover.
5. Remove the heater core.
6. To install, reverse the removal procedure. Clean and lubricate the coolant hoses with distilled water only, if needed.
7. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/econoline-e250/2012-2013/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 179

1. Remove the heater core. For additional information, refer to «HEATER CORE»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
2. Remove the 3 heater core housing nuts and the heater core housing. Disconnect the temperature blend door actuator electrical connector.
3. To install, reverse the removal procedure.

Scheme 180

Scheme 181

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/econoline-e250/2012-2013/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Disconnect the plenum chamber vacuum harness connector.
3. Disconnect the vacuum hose.
4. Remove the 2 plenum chamber screws.
5. Remove the plenum chamber.
6. To install, reverse the removal procedure.

Scheme 182

Driver or passenger side register

1. Using a suitable tool, carefully pry around the outer perimeter of the register to release the register retaining tabs and remove the register.
2. To install, reverse the removal procedure. Center register
3. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/econoline-e250/2012-2013/remont/gauges-instrument-panels/#instrument-panel-and-console) .
4. Detach the center register retaining tabs and remove the center register(s) from the instrument cluster finish panel.

MATERIAL SPECIFICATIONS

Scheme 183

Note. Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present in the system before repairs are carried out, the suction accumulator should not be replaced.

Note. Care should be taken to minimize exposure of the suction accumulator desiccant to the atmosphere. Do not remove the shipping caps from the new suction accumulator until immediately before the line fittings are to be attached.

All vehicles

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
2. Remove the battery. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/econoline-e250/2012-2013/remont/charging-system/#battery-battery-mounting-battery-cables) .
3. Remove the battery tray. Remove the battery tray bolts. Remove the battery tray. To install, tighten to 28 Nm (21 lb-ft).
4. Remove the 2 washer reservoir filler tube bolts and position the washer reservoir filler tube aside.
5. Disconnect the evaporator outlet fitting. Discard the O-ring seal. To install, tighten to 40 Nm (30 lb-ft).
6. Remove the suction accumulator outlet line bracket screw. To install, tighten to 2 Nm (18 lb-in). Vehicles without auxiliary A/C
7. Remove the suction accumulator outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in). Vehicles with auxiliary A/C
8. Disconnect the suction accumulator outlet spring lock coupling. Discard the O-ring seals. All vehicles
9. Disconnect the A/C cycling switch electrical connector.
10. Remove the 2 suction accumulator bolts. To install, tighten to 12 Nm (106 lb-in).
11. Remove the suction accumulator.
12. To install, reverse the removal procedure. Install a new gasket seal and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding Procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
13. Evacuate, leak test and charge the refrigerant system. For additional information refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

Suction Accumulator to Compressor Line

MATERIAL SPECIFICATIONS

Scheme 184

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/econoline-e250/2012-2013/remont/hoistjack/#jacking-lifting) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
3. Remove the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/econoline-e250/2012-2013/remont/wheel-tire-system/#wheels-tires) .
4. Remove the A/C compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
5. Remove the suction accumulator outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
6. Remove the suction accumulator-to-compressor line.
7. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics) .

Scheme 185

1. Remove the temperature blend door actuator. Disconnect the temperature blend door actuator electrical connector. Remove the 4 screws. Remove the temperature blend door actuator.
2. To install, reverse the removal procedure.

Scheme 186

1. Remove the climate control assembly. For additional information, refer to «CLIMATE CONTROL ASSEMBLY»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
2. Remove the temperature control switch knob.
3. Remove the temperature control switch. Remove the screw. Remove the temperature control switch.
4. To install, reverse the removal procedure.

Scheme 187

Scheme 188

1. Remove the glove compartment. Remove the 4 glove compartment screws. Remove the glove compartment.
2. Disconnect the air inlet door vacuum control motor vacuum connector.
3. Remove the 2 air inlet door vacuum control motor screws.
4. Remove the air inlet door vacuum control motor.
5. To install, reverse the removal procedure.

Scheme 189

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/econoline-e250/2012-2013/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Disconnect the floor/defrost door vacuum control motor vacuum connectors.
3. Remove the 2 floor/defrost door vacuum control motor screws.
4. Remove the floor/defrost door vacuum control motor.
5. To install, reverse the removal procedure.

Scheme 190

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/econoline-e250/2012-2013/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Disconnect the panel door vacuum control motor vacuum connector.
3. Remove the 2 panel door vacuum control motor screws.
4. Remove the panel door vacuum control motor.
5. To install, reverse the removal procedure.

Scheme 191

Scheme 192

1. Remove the evaporator core housing. For additional information, refer to «EVAPORATOR CORE HOUSING»(/ford/econoline-e250/2012-2013/remont/automatic-hvac-system/#hvac-climate-control-system) .
2. Remove the vacuum reservoir tank. Remove the screw. Drill out the heat stake. Remove the vacuum reservoir tank.
3. Disconnect the vacuum harness.
4. To install, reverse the removal procedure.

See also:
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• JACKING & LIFTING
• BATTERY, MOUNTING AND CABLES
• INSTRUMENT PANEL AND CONSOLE
• WHEELS AND TIRES
• INTAKE AIR DISTRIBUTION & FILTERING
• ENGINE COOLING
• EVAPORATOR CORE ORIFICE
• CLUTCH AND CLUTCH FIELD COIL
• AIR CONDITIONING (A/C) COMPRESSOR