HVAC Control System Ford Explorer Sport Trac II

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Air Conditioning

The A/C system is a clutch cycling orifice tube type. The system components include the following

1. A/C compressor
2. A/C condenser core
3. A/C evaporator core
4. Suction accumulator
5. Connecting refrigerant lines

The A/C system operation is controlled by the following

1. Evaporator core orifice tube
2. A/C cycling switch
3. A/C compressor pressure relief valve
4. A/C pressure transducer

The A/C system incorporates an A/C compressor controlled by the PCM through an A/C clutch relay.

The A/C cycling switch senses evaporator core pressure to control A/C compressor operation.

An evaporator core orifice tube is installed in the condenser-to-evaporator line to meter the liquid refrigerant into the evaporator core.

The A/C compressor clutch will only be engaged by the PCM if all of the following conditions are met

1. The climate control assembly or HVAC module is set to a mode which provides an A/C request to the PCM.
2. The A/C cycling switch is reading an acceptable evaporator core pressure.
3. The A/C pressure transducer is reading an acceptable pressure in the high side of the refrigerant system.
4. The A/C compressor relay is switched to the closed position by the PCM.
5. The engine coolant temperature is not excessively high.
6. The PCM has not detected a wide open throttle (WOT) condition.

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

A/C Compressor and Clutch Assembly

Note. Internal FS18/FS20 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.

The FS18/FS20 A/C compressor has the following characteristics

1. A non-serviceable shaft seal
2. A pressure relief valve is installed in the rear of the compressor to protect the refrigerant system against excessively high refrigerant pressures
3. The A/C compressor uses PAG oil or equivalent. This oil contains special additives required for the A/C compressor
4. The A/C compressor 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
5. Use standard oil matching procedures when installing new compressors

Scheme 170

When battery voltage is applied to the A/C clutch field coil, the clutch disc and hub assembly is drawn toward the A/C compressor pulley. The magnetic force locks the clutch disc and hub assembly and the A/C compressor pulley together as one unit, causing the compressor shaft to rotate. When battery voltage is removed from the A/C clutch field coil, an annular ring in the clutch disc and hub assembly moves the clutch disc away from the A/C compressor 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 compressor pressure relief valve is installed in the compressor to relieve unusually high refrigerant system discharge pressure buildups. The compressor pressure relief valve will avoid total refrigerant loss by closing after the excessive pressure has been relieved.

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 is an aluminum fin and tube design heat exchanger, located in front of the vehicle radiator. 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

Note. If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.

The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet tube. 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 is located in the condenser-to-evaporator line, and can be removed through an access fitting. The evaporator core orifice provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of the refrigerant system.

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 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the suction accumulator should not be replaced.

The suction accumulator is located at the RH rear of the engine compartment. The suction accumulator is used to prevent residual liquid refrigerant from reaching the A/C compressor after leaving the evaporator core. The suction accumulator allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system.

A/C Cycling Switch

The A/C cycling switch is used to prevent icing of the evaporator core by cycling OFF the A/C compressor clutch when the suction pressure in the low-pressure side of the refrigerant system drops below acceptable levels. When the A/C cycling switch circuit is open, the PCM will disengage the A/C compressor clutch.

The A/C cycling switch is installed on a Schrader-type valve core fitting on the suction accumulator. It is not necessary to recover the refrigerant before removing the A/C cycling switch.

A/C Pressure Transducer

The A/C pressure transducer is used by the PCM to monitor the discharge pressure in the high-pressure side of the refrigerant system. When the A/C pressure transducer is reading a discharge pressure above acceptable levels, the PCM will disengage the A/C compressor clutch.

The A/C pressure transducer is installed on a Schrader-type valve core fitting on the compressor-to-condenser discharge line. It is not necessary to recover the refrigerant before removing the A/C pressure transducer.

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 171

The fitting is an integral part of the A/C 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. Replacement 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.

Air Distribution

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 used in OFF and is available in all modes except DEFROST and FLOOR/DEFROST.

Air distribution on vehicles equipped with dual-zone electronic automatic temperature control (EATC) is determined by the HVAC module in the AUTOMATIC mode but can be overridden by the driver if desired.

There are 4 independently actuated airflow mode doors used to direct airflow within the heater core and evaporator core housing and the plenum chamber. Vacuum control motors are used to position these airflow mode doors.

Vehicles with dual-zone EATC use a partitioned heater core and evaporator core housing assembly with 2 separate temperature blend doors. This allows individual temperature settings to be selected for the RH and LH air outlets. The airflow mode doors are not partitioned. Therefore, the airflow mode for the RH and LH outlets will remain similar in all modes, regardless of the temperature settings.

The air distribution system is designed to provide airflow from the defroster duct 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 A/C registers.
2. floor ducts.
3. windshield defroster duct.
4. side window demisters.
5. center flow-through console.

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

Manual Climate Control

The manual climate control components are used to select

1. air inlet source (outside or recirculated).
2. blower motor speed.
3. discharge air temperature (temperature blend).
4. discharge air location (defrost, panel, floor).
5. A/C compressor operation.

Control System Inputs

The climate control assembly has 3 system control inputs.

Climate Control Assembly

The climate control assembly integrates the temperature control switch, A/C request button and rear defog switch into a single unit.

The temperature control switch setting determines air temperature. Temperature selection is accomplished with a potentiometer (temperature control switch) connected to the temperature blend door actuator. Movement of the temperature control switch from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door and determines the air discharge temperature that the air distribution system will maintain. The temperature control switch is an integral part of the manual climate control assembly and a new one cannot be separately installed.

The A/C request switch determines A/C compressor operation, except when the function selector switch is in the OFF, MAX, DEFROST or FLOOR/DEFROST positions. The A/C request switch is an integral part of the manual climate control assembly and a new one cannot be separately installed.

The rear defog button signals activation of the heated backlight and heated mirrors. The rear defog button is an integral part of the manual climate control assembly and a new one cannot be separately installed.

Function Selector Switch

The function selector switch combines a vacuum selector valve that determines air distribution and an electrical switch to supply battery voltage to the A/C compressor circuit and the blower motor circuit. When the function selector switch is in the MAX A/C, DEFROST or FLOOR/DEFROST positions, the A/C compressor will be operational regardless of the A/C request switch status.

Blower Motor Switch

The blower motor switch controls blower motor speed by adding or bypassing resistors in the blower motor switch resistor in all function selector switch positions except OFF.

Control System Outputs

The climate control system has 5 system outputs.

Blower Motor Resistor

The blower motor resistor has 3 resistor elements mounted on the resistor board to provide 4 blower motor speeds. Depending on the blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed. The blower motor resistor has an overheating device (thermal limiter) that opens the resistor coil when the temperature reaches approximately 184°C (363°F), interrupting the blower motor operation in all speeds except HIGH. The thermal limiter cannot be reset and is not serviceable.

Temperature Blend Door Actuator

The temperature blend door actuator moves the temperature blend door on command from the temperature control switch using a reversible electric motor. The temperature blend door actuator contains an internal controller that will recognize the temperature control switch signal and drive the temperature blend door to the desired position.

The temperature blend door actuator is located on the LH side of the heater core and evaporator core housing.

Vacuum Control Motors

The 4 vacuum control motors move the airflow mode doors to direct system airflow to the vehicle interior as determined by the function selector switch. Vacuum control motors are used to control the

1. air inlet door.
2. defrost mode door.
3. panel mode door.
4. floor mode door.

Heater Control Valve Vacuum Switch

The heater control valve vacuum switch applies vacuum to the heater control valve when the temperature blend door is in the full COOL position. The temperature blend door actuates the heater control valve vacuum switch with an arm attached to the RH side of the temperature blend door pivot shaft.

The heater control valve vacuum switch is mounted on the RH side of the heater core and evaporator core housing just below the defrost door vacuum control motor.

Dual-Zone Electronic Automatic Temperature Control (EATC)

The HVAC module analyzes input from the following major sources

1. Temperature, airflow direction and blower selection (made by the vehicle occupants)
2. In-vehicle temperature
3. Ambient temperature
4. Sunload
5. Vehicle speed
6. Engine coolant temperature

Using these inputs, the HVAC module determines the correct conditions for the following outputs

1. A/C compressor operation
2. Blower speed
3. LH side temperature blend door position
4. RH side temperature blend door position
5. Air inlet mode door position
6. Defrost mode door position
7. Panel mode door position
8. Floor mode door position

The dual-zone EATC system has 5 control system inputs.

HVAC Module

Note. If installing a new HVAC module, the new module must be configured for the vehicle. Refer to MODULE CONFIGURATION article.

The HVAC module has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and DTCs. The HVAC module utilizes an on-board diagnostic (OBD) feature to supply the technician with DTCs. These DTCs help direct the technician to the inoperative component.

Steering Wheel Audio/Climate Control Switch

The steering wheel audio/climate control switch is located on the right side of the steering wheel. The steering wheel audio/climate control switch allows the driver to adjust the passenger compartment temperature setting and manually override the blower motor speed setting.

Ambient Temperature Sensor

The ambient temperature sensor signal is received by the HVAC module and indicates the outside air temperature. The ambient temperature sensor is located in front of the radiator on the LH side of the radiator support.

The ambient temperature sensor signal is not the sole factor considered by the HVAC module for the outside air temperature display. Therefore, the ambient temperature PID monitored with a scan tool may not exactly match the HVAC module display. For information regarding the HVAC module outside air temperature display, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

In-Vehicle Temperature Sensor

The in-vehicle temperature sensor contains a thermistor which measures the in-vehicle air temperature and sends that reading to the HVAC module. A hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. The automatic temperature control sensor hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor. The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor.

Solar Radiation Sensor (Sunload Sensor)

The solar radiation sensor supplies information to the HVAC module indicating LH side and RH side sunload.

The dual-zone EATC system has 4 control system outputs.

Automatic Temperature Control (ATC) Solenoid and Manifold

The automatic temperature control (ATC) solenoid and manifold uses 5 internal solenoid-type valves to distribute vacuum to the vacuum control motors and heater control valve based on the HVAC module settings. Manifold vacuum is always available at the ATC solenoid and manifold from the vacuum reservoir when the engine is running. The 4 vacuum control motors and the heater control valve vacuum lines are each connected to a separate internal solenoid. The HVAC module will apply voltage to the desired solenoids to open the solenoid to the manifold vacuum supply and complete the vacuum circuit to the desired component.

Blower Motor Speed Control

The blower speed control converts low power signals from the HVAC module to a high current, variable ground feed for the blower motor. A delay function is used to provide a gradual increase or decrease in blower motor speed under all conditions.

Temperature Blend Door Actuators

The dual-zone EATC system uses 2 temperature blend door actuators to control 2 separate temperature blend doors. The temperature blend doors independently vary the LH side and RH side temperature settings, as desired. The temperature blend door actuators each contain a reversible electric motor and a potentiometer. The HVAC module applies a 5-volt signal to one end of the potentiometer and ground to the other. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft. The voltage available at the wiper indicates the position of the temperature blend door. The actuator wiper voltage is sent to the HVAC module which drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected HVAC module wiper voltage value.

The 4 vacuum control motors move the airflow mode doors to direct system airflow to the vehicle interior as determined by the function selector switch. Vacuum control motors are used to control the

1. air inlet door.
2. defrost mode door.
3. panel mode door.
4. floor mode door.

Heating and Ventilation

The heating and ventilation system has the following features

1. Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle.
2. Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level.
3. Cooling or heating can be adjusted to maintain the desired temperature.
4. On vehicles with dual-zone electronic automatic temperature control (EATC), the temperature can be adjusted individually by the driver and passenger.

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 heater core and evaporator core housing and the plenum chamber where it is mixed and distributed.

Heater Control Valve

The heater control valve is actuated by the heater control valve vacuum switch (manual climate control) or the heater control valve vacuum control circuit (EATC). When the heater control valve is closed (full vacuum), coolant flow through the heater core is shut OFF and A/C cooling efficiency is increased.

Heater Core and Evaporator Core Housing

The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). Vehicles equipped with dual-zone EATC use a partitioned heater core and evaporator core housing with 2 electric actuator-positioned temperature blend doors. This allows for separate temperatures to be selected for the driver and passenger sides of the passenger compartment. Manual systems use a single electric actuator-positioned temperature blend door to direct airflow through or around the heater core.

Air Conditioning (A/C) Compressor - 4.0L SOHC

Material

Scheme 172

REMOVAL AND INSTALLATION

Note. If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

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.

1. If flushing of the A/C system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Remove the drive belt from the A/C compressor pulley.
3. Remove the 2 A/C compressor fitting nuts. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
4. Disconnect the field coil electrical connector and detach the harness from the A/C compressor stud.
5. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. To install, tighten to 7 Nm (62 lb-in).
6. Remove the 2 A/C compressor nuts. To install, tighten to 25 Nm (18 lb-ft).
7. Remove the 2 A/C compressor studs. To install, tighten to 4 Nm (35 lb-in).
8. Remove the A/C compressor bolt. To install, tighten to 25 Nm (18 lb-ft).
9. Remove the A/C compressor.
10. To install, reverse the removal procedure. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. For additional information, refer to «Clutch and Clutch Field Coil»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system__clutch-and-clutch-field-coil) . Install new O-ring seals and gasket seals. If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
11. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Air Conditioning (A/C) Compressor - 4.6L

Material

Scheme 173

Note. If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. If flushing of the A/C system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Remove the drive belt from the A/C compressor pulley.
4. Remove the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/explorer-sport-trac/ii-2006-2010/remont/wheel-tire-system/#tires-and-wheels) article.
5. Remove the front portion of the RH fender splash shield.
6. Remove the 2 A/C compressor fitting nuts and disconnect the compressor suction fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
7. Disconnect the field coil electrical connector and detach the wire harness from the A/C compressor stud.
8. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. To install, tighten to 9 Nm (80 lb-in).
9. Remove the A/C compressor bolt. To install, tighten to 25 Nm (18 lb-ft).
10. Remove the lower rear A/C compressor nut. To install, tighten to 25 Nm (18 lb-ft).
11. Remove the lower rear A/C compressor stud. To install, tighten to 14 Nm (10 lb-ft).
12. Remove the upper A/C compressor nut. To install, tighten to 25 Nm (18 lb-ft).
13. Remove the upper A/C compressor stud. To install, tighten to 14 Nm (10 lb-ft).
14. Disconnect the A/C compressor discharge fitting and remove the A/C compressor. Discard the O-ring seal and gasket seal.
15. To install, reverse the removal procedure. If a new A/C compressor is to be installed, the clutch assembly must be transferred from the old unit to the new unit. For additional information, refer to «Clutch and Clutch Field Coil»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system__clutch-and-clutch-field-coil) . Install new O-ring seals and gasket seals. If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
16. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Air Conditioning (A/C) Pressure Relief Valve

Material

Scheme 174

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer top «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Remove the A/C compressor pressure relief valve and O-ring seal. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
5. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Scheme 175

1. Remove the heater core and evaporator core housing. For additional information, refer to «AUXILIARY CLIMATE CONTROL»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#auxiliary-hvac) article.
2. Remove the air inlet duct. Remove the support bracket screw. Disconnect the air inlet door vacuum control motor vacuum connector. Remove the 3 air inlet duct screws. Remove the air inlet duct.
3. To install, reverse the removal procedure.

Scheme 176

Mountaineer

1. Remove the radiator grille. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(/ford/explorer-sport-trac/ii-2006-2010/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) article.
2. Remove the pin-type retainers and position the air deflector forward.
3. Remove the 2 air deflector pin-type retainers and detach the air deflector from the 2 locator pins on the radiator support.
4. Detach the ambient air temperature sensor electrical connector.
5. Remove the ambient air temperature sensor.
6. To install, reverse the removal procedure.

Scheme 177

1. Remove the vacuum reservoir screw.
2. Position the vacuum reservoir aside.
3. Disconnect the blower motor electrical connector.
4. Remove the 3 blower motor screws.
5. Remove the blower motor.
6. Remove the blower motor wheel from the blower motor. Remove the push clip. Remove the blower motor wheel.
7. To install, reverse the removal procedure.

Scheme 178

1. Remove the two 4X4 control module screws.
2. Disconnect the blower motor resistor electrical connector.
3. Remove the 2 blower motor resistor screws.
4. Remove the blower motor resistor.
5. To install, reverse the removal procedure.

Scheme 179

1. Remove the blower motor speed control screw.
2. Remove the blower motor speed control.
3. Disconnect the blower motor speed control electrical connector.
4. To install, reverse the removal procedure.

Scheme 180

1. Remove the center instrument panel finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Remove the 4 climate control assembly screws.
3. Remove the climate control assembly.
4. Remove the 3 climate control knobs.
5. Depress the tabs and remove the blower motor switch.
6. Depress the tabs and remove the function selector switch.
7. To install, reverse the removal procedure.

Clutch and Clutch Field Coil

Special Tools Illustration Tool Name Tool Number Holding Fixture, Compressor Clutch Disc and Hub 412-134 Remover, Compressor Pulley 412-001 (T71P-19703-B) Coil Replacer (FS18 only) 412-065 (T89P-19623-EH) Field Coil Replacer (FS18 only) 412-078 (T91L-19623-CH) Field Coil Remover (FS18 only) 412-067 (T89P-19623-FH)

Scheme 181

Scheme 182

REMOVAL

All vehicles

1. Remove the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor - 4.0L SOHC»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system__air-conditioning-ac-compressor-40l) or «Air Conditioning (A/C) Compressor - 4.6L»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system__air-conditioning-ac-compressor-46l) .
2. Remove the A/C clutch disc and hub bolt. Hold the A/C clutch disc and hub with the special tool. Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub.
4. Remove the A/C compressor pulley snap ring.
5. Remove the A/C compressor pulley. Install the special tool. Remove the A/C compressor pulley.
6. Remove the A/C clutch field coil. Install the special tool. Install the special tool. Remove the A/C clutch field coil.
7. Remove the A/C clutch field coil snap ring.
8. Remove the A/C clutch field coil electrical connector screw.
9. Remove the A/C clutch field coil.

INSTALLATION

Note. If installing a new A/C compressor, 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.

All vehicles

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 special tool on the A/C clutch field coil. Place the special tool 412-065 on the special tool 412-078. Use the special tool to install the A/C clutch field coil.
4. Install the A/C clutch field coil.
5. Install the A/C clutch field coil electrical connector screw.
6. Install the A/C clutch field coil snap ring.
7. Install the A/C clutch pulley.
8. Install the A/C clutch pulley snap ring with the bevel side out.
9. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
10. Install the A/C clutch disc and hub assembly.
11. Install the A/C clutch disc and hub bolt. Hold the A/C clutch disc and hub with the special tool. Install the A/C clutch disc and hub bolt. Tighten to 14 Nm (10 lb-ft).
12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
13. Install the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor - 4.0L SOHC»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system__air-conditioning-ac-compressor-40l) or «Air Conditioning (A/C) Compressor - 4.6L»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system__air-conditioning-ac-compressor-46l) .

Compressor to Condenser Discharge Line - 4.0L SOHC

Material

Scheme 183

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. To install, tighten to 7 Nm (62 lb-in).
3. Remove the compressor discharge fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Disconnect the A/C pressure transducer electrical connector.
5. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
6. Remove the compressor-to-condenser discharge line.
7. To install, reverse the removal procedure. Install a new gasket seal and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Compressor to Condenser Discharge Line - 4.6L

Material

Scheme 184

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Remove the air cleaner (ACL) and ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
4. Remove the compressor-to-condenser discharge line bracket nut and detach the bracket. To install, tighten to 9 Nm (80 lb-in).
5. Remove the compressor outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
6. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. To install, tighten to 7 Nm (62 lb-in).
7. Disconnect the A/C pressure transducer electrical connector.
8. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
9. Detach the 2 compressor-to-condenser discharge line clips at the cooling module.
10. Remove the compressor-to-condenser discharge line.
11. To install, reverse the removal procedure. Install a new gasket seal and O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
12. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Material

Scheme 185

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Remove the air cleaner (ACL). For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
3. Remove the 2 coolant expansion tank bolts and position the coolant expansion tank aside. To install, tighten to 7 Nm (62 lb-in).
4. Disconnect the A/C pressure transducer electrical connector.
5. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
6. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
7. Detach the 2 compressor-to-condenser discharge line clips.
8. Remove the 2 cooling module bolts and position the cooling module rearward. To install, tighten to 12 Nm (9 lb-ft).
9. Remove the upper radiator air deflector.
10. Remove the 2 condenser core bolts. To install, tighten to 12 Nm (9 lb-ft).
11. Remove the condenser core.
12. Remove the 2 condenser air deflectors.
13. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
14. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Condenser to Evaporator Line

Material

Scheme 186

All vehicles

1. Remove the air cleaner (ACL) and ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#intake-air-distribution-system-and-filtering-system) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Remove the PCM and PCM bracket. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#electronic-engine-controls) article.
4. Disconnect the RH wheel speed sensor electrical connector and detach the wire harness from the condenser-to-evaporator line bracket.
5. Remove the suction accumulator-to-compressor line bracket nut. To install, tighten to 7 Nm (62 lb-in).
6. Disconnect the evaporator core orifice access fitting. Discard the O-ring seal.
7. Remove the condenser-to-evaporator line bracket nut. To install, tighten to 7 Nm (62 lb-in).
8. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
9. Disconnect the auxiliary evaporator inlet line fitting (if equipped). Discard the O-ring seals.
10. Remove the front portion of the condenser-to-evaporator line.
11. Remove the A/C line bracket nut at the dash panel and detach the bracket. To install, tighten to 6 Nm (53 lb-in).
12. Disconnect the evaporator inlet fitting. Discard the O-ring seals.
13. Remove the rear portion of the condenser-to-evaporator line.
14. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
15. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Material

Scheme 187

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 article.

1. Remove the heater core. For additional information, refer to «Heater Core»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) .
2. Remove the 5 outer evaporator core cover screws.
3. Remove the 6 inner evaporator core cover screws.
4. Separate the evaporator core cover from the heater core and evaporator core housing. Discard the rope seal.
5. Remove the evaporator core.
6. To install, reverse the removal procedure. Apply a bead of RTV sealant around the entire evaporator core housing groove joint in place of the rope seal. Tighten the evaporator core cover screws in a diagonal pattern to distribute the RTV sealant evenly.

Special Tools Illustration Tool Name Tool Number Remover, Broken Orifice 412-035 (T83L-19990-B) Remover/Installer, Fixed Orifice 412-034 (T38L-19990-A)

Material

Scheme 188

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Disconnect the evaporator core orifice access fitting. Discard the O-ring seal.
3. Inspect the evaporator core orifice for damage before attempting to remove it from the line.
4. If the evaporator core orifice is intact, engage the special tool. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice.
5. If the evaporator core orifice is broken, screw the end of the special tool into the broken orifice. Hold the T-handle stationary while rotating the tool body to remove the evaporator core orifice.

1. Lubricate the evaporator core orifice O-rings with clean PAG oil and install the evaporator core orifice using the special tool.
2. Install a new O-ring seal and connect the evaporator core orifice access fitting. To install, tighten to 18 Nm (13 lb-ft).
3. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
4. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Scheme 189

Vehicles with 4.0L and oil cooler, without auxiliary climate control

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Disconnect the 2 inlet and outlet heater hose clamps.
4. Disconnect the heater control valve vacuum hose.
5. Remove the heater control valve bolt.
6. Remove the heater control valve.
7. To install, reverse the removal procedure.
8. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.

Scheme 190

Note. If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle.

1. Remove the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) .
2. Remove the 2 LH floor duct screws.
3. Remove the LH floor duct.
4. Remove the 2 RH floor duct screws.
5. Remove the RH floor duct.
6. Remove the 3 housing brace screws.
7. Remove the housing brace.
8. Remove the 3 heater tube cover screws.
9. Remove the heater tube cover.
10. Remove the heater tube seal.
11. Remove the 4 heater core cover screws.
12. Remove the heater core cover.
13. Remove the heater core.
14. To install, reverse the removal procedure.

Material

Scheme 191

Note. If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.

Note. Lubricate the coolant hoses with plain water only if needed.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
3. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
4. Detach the wiring harness bracket and position the harness aside.
5. Remove the heater tube bracket nut.
6. Remove the dash panel A/C line bracket nut. To install, tighten to 11 Nm (8 lb-ft).
7. Disconnect the 2 heater hose clamps at the heater core.
8. Disconnect the evaporator inlet fitting. Discard the O-ring seals.
9. Disconnect the evaporator outlet fitting. Discard the O-ring seals.
10. Disconnect the 2 vacuum connectors.
11. Detach the grommet and push the vacuum lines into the passenger compartment.
12. Remove the 4 heater core and evaporator core housing nuts. To install, tighten to 9 Nm (80 lb-in).
13. Disconnect the ground terminal bolt.
14. Remove the heater core and evaporator core housing.
15. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
16. Fill and the engine cooling system. For additional information, refer to «ENGINE COOLING»(/ford/explorer-sport-trac/ii-2006-2010/remont/cooling-system-mechanical/#engine-cooling-system) article.
17. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Scheme 192

Note. If installing a new HVAC module, the new module must be configured for the vehicle. For additional information, refer to MODULE CONFIGURATION article.

1. Remove the center instrument panel finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Remove the 4 HVAC module screws.
3. Remove the HVAC module.
4. To install, reverse the removal procedure.

Scheme 193

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Remove the in-vehicle temperature sensor.
3. To install, reverse the removal procedure.

Scheme 194

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Remove the audio unit. For additional information, refer to «INFORMATION AND ENTERTAINMENT SYSTEMS»(/ford/explorer-sport-trac/ii-2006-2010/remont/entertainment-systems/#information-system-and-entertainment-systems) article.
3. Remove the 3 plenum chamber screws.
4. Remove the instrument panel upper finish panel.
5. Remove the 3 defroster duct screws.
6. Remove the defroster duct.
7. Remove the plenum chamber.
8. To install, reverse the removal procedure.

Material

Scheme 195

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 1 hour. If even a slight amount of positive refrigerant pressure is present in the refrigerant system before repairs are carried out, the suction accumulator should not be replaced.

All vehicles

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Remove the PCM. For additional information, refer to «ELECTRONIC ENGINE CONTROLS»(/ford/explorer-sport-trac/ii-2006-2010/remont/removal-installation/#electronic-engine-controls) article.
3. Disconnect the A/C cycling switch electrical connector.
4. Remove the suction accumulator bolt. To install, tighten to 11 Nm (8 lb-ft).
5. Remove the PCM bracket bolt.
6. Remove the PCM bracket nut and the PCM bracket.
7. Remove the suction accumulator stud. To install, tighten to 11 Nm (8 lb-ft).
8. Remove the suction accumulator-to-compressor line bracket nut at the condenser-to-evaporator line bracket.
9. Remove the suction accumulator bracket bolt and suction accumulator.
10. Remove the 2 suction accumulator fitting nuts and disconnect the fittings. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).
11. Remove the suction accumulator.
12. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
13. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Suction Accumulator to Compressor Line - 4.0L SOHC

Material

Scheme 196

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/explorer-sport-trac/ii-2006-2010/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
3. Remove the compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
4. Release the brake booster vacuum hose clamp and disconnect the hose.
5. Remove the suction accumulator-to-compressor line bracket bolt at the dash panel. To install, tighten to 11 Nm (8 lb-ft).
6. Remove the suction accumulator outlet fitting nut. To install, tighten to 8 Nm (71 lb-in).
7. Disconnect the auxiliary evaporator outlet line fitting (if equipped). Discard the O-ring seals.
8. Remove the suction accumulator-to-compressor line. Discard the O-ring seal.
9. To install, reverse the removal procedure. Install new O-ring seals and a new gasket seal. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Suction Accumulator to Compressor Line - 4.6L

Material

Scheme 197

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
2. Remove the suction accumulator outlet fitting nut. To install, tighten to 8 Nm (71 lb-in).
3. Disconnect the auxiliary evaporator outlet line fitting. Discard the O-ring seals.
4. Remove the suction accumulator-to-compressor line bracket nut. To install, tighten to 7 Nm (62 lb-in).
5. Remove the suction accumulator-to-compressor line middle fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 Nm (71 lb-in).
6. Remove the rear suction accumulator-to-compressor line. Discard the O-ring seal.
7. Remove the compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the front suction accumulator-to-compressor line.
9. To install, reverse the removal procedure. Install new O-ring seals and a new gasket seal. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Suction Accumulator To Evaporator Line

Material

Scheme 198

All vehicles

1. Remove the suction accumulator. For additional information, refer to «Suction Accumulator»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-control-system) .
2. Remove the A/C line bracket nut at the dash panel and remove the A/C line bracket. To install, tighten to 6 Nm (53 lb-in).
3. Remove the ground strap bolt at the dash panel.
4. Disconnect the evaporator outlet fitting. Discard the O-ring seals.
5. Disconnect he evaporative emissions return line fitting at the intake manifold.
6. Remove the fuel line bracket bolt at the rear of the RH valve cover.
7. Remove the wire harness bolt at the rear of the RH cylinder head.
8. Remove the suction accumulator-to-evaporator line.
9. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/explorer-sport-trac/ii-2006-2010/remont/manual-hvac-system/#hvac-system-general-information-and-diagnostics) article.

Scheme 199

1. Remove the LH floor console finish panel.
2. Position the in-vehicle temperature sensor aspirator hose away from the LH temperature blend door actuator.
3. Remove the 3 LH temperature blend door actuator screws.
4. Disconnect the LH temperature blend door actuator electrical connector.
5. Remove the LH temperature blend door actuator.
6. To install, reverse the removal procedure.

Scheme 200

1. Remove the RH floor console finish panel.
2. Lower the glove compartment.
3. Disconnect the RH temperature blend door actuator electrical connector.
4. Remove the 3 RH temperature blend door actuator screws.
5. Remove the RH temperature blend door actuator.
6. To install, reverse the removal procedure.

Scheme 201

1. Lower the glove compartment.
2. Remove the screws and the heater core and evaporator core housing support brace.
3. Disconnect the air inlet door vacuum control motor vacuum connector.
4. Remove the 2 air inlet door vacuum control motor screws.
5. Rotate the air inlet door vacuum control motor until it clears the retaining arm and remove the vacuum control motor.
6. To install, reverse the removal procedure.

Scheme 202

1. Remove the audio control module (ACM). For additional information, refer to «INFORMATION AND ENTERTAINMENT SYSTEMS»(/ford/explorer-sport-trac/ii-2006-2010/remont/entertainment-systems/#information-system-and-entertainment-systems) article.
2. Remove the lower steering column cover. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
3. Remove the 3 center panel duct screws and position the center panel duct aside.
4. Remove the 2 plenum chamber screws.
5. Disconnect the defrost door vacuum control motor vacuum connector.
6. Remove the 2 defrost door vacuum control motor screws.
7. Rotate the defrost door vacuum control motor until it clears the retaining arm and remove the defrost door vacuum control motor.
8. To install, reverse the removal procedure.

Scheme 203

1. Remove the center instrument panel finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/explorer-sport-trac/ii-2006-2010/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Remove the shield screw.
3. Remove the shield.
4. Lower the glove compartment.
5. Disconnect the floor door vacuum control motor vacuum connector.
6. Detach the instrument panel harness pin-type retainer and position the harness aside.
7. Remove the 2 floor door vacuum control motor screws.
8. Remove the RH floor console finish panel.
9. Partially actuate and rotate the floor door vacuum control motor until it clears the retaining arm and remove the vacuum control motor.
10. To install, reverse the removal procedure.

Scheme 204

1. Remove the audio control module (ACM). For additional information, refer to «INFORMATION AND ENTERTAINMENT SYSTEMS»(/ford/explorer-sport-trac/ii-2006-2010/remont/entertainment-systems/#information-system-and-entertainment-systems) article.
2. Lower the glove compartment.
3. Remove the 3 center panel duct screws and position the center panel duct aside.
4. Remove the 2 plenum chamber screws.
5. Disconnect the panel door vacuum control motor vacuum connector.
6. Remove the 2 panel door vacuum control motor screws.
7. Rotate the panel door vacuum control motor until it clears the retaining arm and remove the panel door vacuum control motor.
8. To install, reverse the removal procedure.

Scheme 205

1. Remove the vacuum reservoir screw.
2. Remove the vacuum reservoir.
3. Disconnect the vacuum connector.
4. To install, reverse the removal procedure.

See also:
• MODULE CONFIGURATION
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• JACKING AND LIFTING
• WHEELS AND TIRES
• AUXILIARY CLIMATE CONTROL
• EXTERIOR TRIM AND ORNAMENTATION
• INSTRUMENT PANEL AND CONSOLE
• INTAKE AIR DISTRIBUTION AND FILTERING
• ELECTRONIC ENGINE CONTROLS
• ENGINE COOLING
• INFORMATION AND ENTERTAINMENT SYSTEMS
• Clutch and Clutch Field Coil
• Air Conditioning (A/C) Compressor - 4.0L SOHC
• Air Conditioning (A/C) Compressor - 4.6L
• Heater Core