HVAC Control System: Removal & Installation Ford Excursion I

Removal

Note. Lay out the new lines in vehicle position to assist in the installation.

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

1. Drain the cooling system. For additional information, refer to ENGINE COOLING .
2. Raise and support the vehicle.
3. Remove the front and rear RH wheels.
4. Remove the four screws, three bolts, and three pin-type retainers for the fender splash shield.
5. Remove the vacuum reservoir retaining nuts.
6. Detach the ABS wiring harness and remove the fender splash shield.
7. At the rear of the vehicle, disconnect the auxiliary heater inlet line.
8. Remove the five line bracket retaining nuts.
9. Remove the five line brackets by inserting a screwdriver in the stud hole and twisting.
10. Disconnect the auxiliary heater inlet line quick coupling. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
11. Remove and discard the auxiliary heater inlet line.

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

1. Install the rear auxiliary heater inlet line and connect it to the auxiliary heater inlet hose. Lubricate the coolant hoses with MERPOL® meeting Ford specification ESE-M99B144-B or plain water only, if needed.
2. Snap the rear auxiliary heater inlet line into the line brackets.
3. Install the front auxiliary heater inlet line through the fender well and connect it to the engine compartment heater inlet line. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
4. Snap the front auxiliary heater inlet line into the brackets.
5. Install the brackets over the studs and loosely install the nuts.
6. Connect the two auxiliary heater inlet lines.
7. Tighten the five bracket nuts.
8. Reattach the ABS wiring harness and position the fender splash shield in the wheel well.
9. Install the vacuum reservoir retaining nuts.
10. Install the fender splash shield four screws, three bolts, and three pin-type retainers.
11. Install both RH wheels.
12. Lower the vehicle.
13. Fill the cooling system. For additional information, refer to ENGINE COOLING .

Note. Lay out the new lines in vehicle position to assist in the installation.

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

1. Drain the cooling system. For additional information, refer to ENGINE COOLING .
2. Raise and support the vehicle.
3. Remove the front and rear RH wheels.
4. Remove the four screws, three bolts, and three pin-type retainers for the fender splash shield.
5. Remove the vacuum reservoir retaining nuts.
6. Detach the ABS wiring harness and remove the fender splash shield.
7. At the rear of the vehicle, disconnect the auxiliary heater outlet line.
8. Remove the five line bracket retaining nuts.
9. Remove the five line brackets by inserting a screwdriver in the stud hole and twisting.
10. Disconnect the auxiliary heater outlet line quick coupling. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
11. Remove and discard the auxiliary heater outlet line.

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

1. Install the rear auxiliary heater outlet line and connect it to the auxiliary heater outlet hose. Lubricate the coolant hoses with MERPOL®: meeting Ford specification ESE-M99B144-B or plain water only, if needed.
2. Snap the rear auxiliary heater outlet line into the line brackets.
3. Install the front auxiliary heater outlet line through the fender well and connect it to the engine compartment heater outlet line. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
4. Snap the front auxiliary heater outlet line into the brackets.
5. Install the brackets over the studs and loosely install the nuts.
6. Connect the two auxiliary heater outlet lines.
7. Tighten the five bracket nuts.
8. Reattach the ABS wiring harness and position the fender splash shield in the wheel well.
9. Install the vacuum reservoir retaining nuts.
10. Install the fender splash shield fasteners, four screws, three bolts, and three pin-type retainers.
11. Install both RH wheels.
12. Lower the vehicle.
13. Fill the cooling system. For additional information, refer to ENGINE COOLING .

Note. Lay out the new lines in vehicle position to assist in the installation.

Scheme 138

Scheme 139

Scheme 140

1. Discharge and recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
2. Remove the right-hand fender splash shield.
3. Remove the rear right-hand wheel.
4. At the rear of the vehicle, disconnect the evaporator inlet line spring lock coupling. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
5. Remove the five line bracket retaining nuts.
6. Remove the five line brackets by inserting a screwdriver in the stud hole and twisting.
7. Disconnect the auxiliary evaporator inlet line fitting. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
8. Remove and discard the auxiliary evaporator inlet line.

Scheme 141

Scheme 142

1. Install the rear auxiliary evaporator inlet line and connect it to the auxiliary evaporator inlet line. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
2. Snap the rear auxiliary evaporator inlet line into the line brackets.
3. Install the front auxiliary evaporator inlet line through the wheel well and connect the evaporator inlet line. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
4. Snap the rear auxiliary evaporator inlet line into the brackets.
5. Install the brackets over the studs and loosely install the nuts.
6. Connect the two auxiliary evaporator inlet lines.
7. Tighten the five bracket nuts. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan.
8. Install the right-hand rear wheel.
9. Install the right-hand fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-204458) .
10. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .

Scheme 143

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
2. Remove the access panel from the RH rear quarter trim panel.
3. Remove the jack.
4. Remove the A/C lines from the A/C evaporator expansion valve (19849). Disconnect the A/C lines from the A/C evaporator expansion valve. Disconnect the A/C evaporator expansion valve from the A/C evaporator core (19860).
5. To install, reverse the removal procedure. NOTE: Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
6. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .

Scheme 144

Scheme 145

Scheme 146

1. Remove the air conditioning and heater assembly (18D283). For additional information, refer to «AIR CONDITIONING AND HEATER ASSEMBLY»(ref-207881-S33162964762005120100000) .
2. Remove the blend door actuator and the mode door actuator. NOTE: The temperature blend door actuator (19E616) is shown; the mode door actuator is similar.
3. Remove the A/C evaporator core (19860).
4. Disassemble the case.
5. Remove the temperature blend door.
6. To install, reverse the removal procedure. NOTE: Make sure to correctly assemble and seal the air conditioning and heater assembly to allow efficient operation of the auxiliary climate control system.

Note. Lay out the new lines in vehicle position to assist in the installation.

Scheme 147

Scheme 148

Scheme 149

Scheme 150

1. Discharge and recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
2. Remove the right-hand fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-204458) .
3. Remove the rear right-hand wheel.
4. At the rear of the vehicle, disconnect the evaporator outlet line spring lock coupling. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
5. Remove the five line bracket retaining nuts.
6. Remove the five line brackets by inserting a screwdriver in the stud hole and twisting. CAUTION: Pull the bracket off the stud before attempting to pry it off the lines to prevent component damage.
7. Disconnect the auxiliary evaporator outlet line fitting. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .
8. Remove and discard the auxiliary evaporator outlet line.

Scheme 151

Scheme 152

Scheme 153

Scheme 154

Scheme 155

1. Install the rear auxiliary evaporator outlet line and connect the spring lock coupling to the auxiliary evaporator outlet line. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) . NOTE: Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
2. Snap the rear auxiliary evaporator outlet line into the line brackets.
3. Install the front auxiliary evaporator outlet line through the wheel well and connect the evaporator outlet line. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) . NOTE: Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
4. Snap the front auxiliary evaporator outlet line into the brackets.
5. Install the brackets over the studs and loosely install the nuts.
6. Connect the two auxiliary evaporator outlet lines. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting. NOTE: Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
7. Tighten the five bracket nuts. CAUTION: Overtightening of the nut will cause the stud to break away from the floor pan.
8. Install the right-hand rear wheel.
9. Install the right-hand fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-204458) .
10. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION»(ref-194768) .

Removal and Installation

Note. The blend door actuator is shown; the mode door actuator is similar.

Scheme 156

1. Remove the third row seat.
2. Position the RH rear quarter trim panel aside.
3. Remove the blend door actuator. Disconnect the connector. Remove the screws. Remove the blend door actuator.
4. To install, reverse the removal procedure.

Scheme 157

Scheme 158

Scheme 159

Scheme 160

1. Remove the third row seat.
2. Position the RH quarter trim panel aside.
3. Remove the fasteners and remove the lower air duct.
4. Remove the mode door actuator. Disconnect the connector. Remove the screws. Remove the mode door actuator.
5. Remove the heater core cover. Remove the 8 screws. Remove the heater core cover.
6. Gently disengage the upper pivot and remove the mode door.

Installation

Note. Make sure to correctly assemble and seal the air conditioning and heater assembly to allow efficient operation of the auxiliary climate control system.

Scheme 161

1. Align the upper pivot and install the mode door. NOTE: The mode door lower pivot is beveled to ease installation.
2. Install the heater core cover and 8 screws.
3. Install the mode door actuator.
4. Install the lower air duct and fasteners.
5. Install the RH quarter trim panel.
6. Install the third row seat.

Scheme 162

1. Remove the RH rear quarter trim panel access panel.
2. Remove the heater blower motor resistor (18591). Disconnect the electrical connector. Remove the screws and remove the blower motor resistor.
3. To install, reverse the removal procedure.