HVAC Control System: Removal & Installation Ford Freestyle I

Removal and Installation

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-255244) .
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-255298-S12995940182007053000000) .
3. Remove the 3 A/C compressor pulley shield bolts and the A/C compressor pulley shield (if equipped).
4. Remove the drive belt. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255267-S36767818752007053000000) .
5. Remove the cooling fan assembly. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255255-S20118471902007053000000) .
6. Remove the lower radiator splash shield.
7. Remove the lower compressor nut. To install, tighten to 25 N.m (18 lb-ft).
8. Completely loosen the lower compressor stud. To install, tighten to 9 N.m (80 lb-in).
9. Completely loosen the lower compressor bolt. To install, tighten to 25 N.m (18 lb-ft).
10. Disconnect the A/C pressure transducer electrical connector.
11. Disconnect the field coil electrical connector.
12. Loosen the compressor manifold bolt and position the compressor manifold aside. Discard the O-ring seals. To install, tighten to 21 N.m (15 lb-ft).
13. Remove the upper compressor nut. To install, tighten to 25 N.m (18 lb-ft).
14. Completely loosen the upper compressor stud. To install, tighten to 9 N.m (80 lb-in).
15. Completely loosen the upper compressor bolt. To install, tighten to 25 N.m (18 lb-ft).
16. Remove the 2 compressor studs and the 2 compressor bolts.
17. Remove the A/C compressor.
18. 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»(ref-255259-S08420860612007053000000) . Install new O-ring seals. If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-255298-S05928827502007053000000) .
19. If filtering of the refrigerant system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .

Scheme 1

Note. The A/C evaporator discharge air temperature sensor can be accessed from below the LH side of the instrument panel to the right of the accelerator pedal.

1. Disconnect the A/C evaporator discharge air temperature sensor electrical connector.
2. Remove the A/C evaporator discharge air temperature sensor.
3. To install, reverse the removal procedure.

Scheme 2

1. Remove the heater core and evaporator core housing. For additional information, refer to «HEATER CORE AND EVAPORATOR CORE HOUSING»(ref-255259-S11453879942007053000000) .
2. Disconnect the air inlet door mode door actuator electrical connector and detach the wire harness from the air inlet duct.
3. Remove the 2 front air inlet duct screws.
4. Remove the remaining 5 air inlet duct screws.
5. Remove the air inlet duct.
6. To install, reverse the removal procedure.

Scheme 3

1. Remove the lower radiator splash shield.
2. Disconnect the ambient air temperature sensor electrical connector.
3. Remove the ambient air temperature sensor nut.
4. Remove the ambient air temperature sensor.
5. To install, reverse the removal procedure.

Scheme 4

1. Remove the air cleaner and air cleaner outlet tube. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255254-S23832507712007053000000) and «REMOVAL AND INSTALLATION»(ref-255254-S34187134992007053000000) .
2. Using suitable tools, clamp off the heater hoses at the auxiliary coolant flow pump.
3. Release the 2 hose clamps and disconnect the hoses from the auxiliary coolant flow pump.
4. Remove the LH auxiliary coolant flow pump bolt. To install, tighten to 7 N.m (62 lb-in).
5. Completely loosen the RH auxiliary coolant flow pump bolt. To install, tighten to 7 N.m (62 lb-in).
6. Disconnect the auxiliary coolant flow pump electrical connector.
7. Remove the auxiliary coolant flow pump.
8. To install, reverse the removal procedure. Clean and lubricate the coolant hoses with plain water only, if needed.
9. Fill the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-255255-S00333417942007053000000) .

Scheme 5

1. Remove the RH cowl side trim panel.
2. Remove the RH lower instrument panel insulator.
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 clip.
7. Remove the blower motor wheel.
8. To install, reverse the removal procedure.

Scheme 6

1. Remove the RH lower instrument panel insulator.
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 7

1. Remove the RH lower instrument panel insulator.
2. Disconnect the blower motor speed control electrical connector.
3. Remove the 2 blower motor speed control screws.
4. Remove the blower motor speed control.
5. To install, reverse the removal procedure.

Scheme 8

1. Remove the instrument panel center finish panel. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255306-S15965870882007053000000) and «REMOVAL AND INSTALLATION»(ref-255306-S11949223412007053000000) .
2. Remove the 4 climate control assembly screws.
3. Remove the climate control assembly.
4. To install, reverse the removal procedure.

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

1. Recover the refrigerant. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-255298-S12995940182007053000000) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-255244) .
3. Detach the 2 coolant reservoir hose retainers from the cooling fan shroud.
4. Disconnect the A/C pressure transducer electrical connector.
5. Loosen the bolt and detach the compressor manifold. Discard the O-ring seals. To install, tighten to 21 N.m (15 lb-ft).
6. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. Discard the O-ring seals. To install, tighten to 8 N.m (71 lb-in).
7. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
8. Remove the compressor manifold and tube assembly.
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 «REFRIGERANT OIL ADDING»(ref-255298-S05928827502007053000000) .
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .

Scheme 9

MATERIAL

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

1. Recover the refrigerant. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-255298-S12995940182007053000000) .
2. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-255244) .
3. Remove the radiator grille. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255290-S39122392182007053000000) and «REMOVAL AND INSTALLATION»(ref-255290-S35093747792007053000000) .
4. Remove the bolt and position the horn assembly aside.
5. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
6. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
7. Remove the 4 radiator air deflector pin-type retainers.
8. Remove the 2 radiator air deflector stud retainers.
9. Remove the 2 condenser mounting studs. To install, tighten to 6 N.m (53 lb-in).
10. Remove the condenser core.
11. 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 «REFRIGERANT OIL ADDING»(ref-255298-S05928827502007053000000) .
12. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .

Note. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. Installation of a new receiver/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the receiver/drier.

1. Remove the air inlet duct. For additional information, refer to «AIR INLET DUCT»(ref-255259-S12414159872007053000000) .
2. Remove the heater core. For additional information, refer to «HEATER CORE»(ref-255259-S35338596142007053000000) .
3. Remove the 8 upper evaporator core cover screws.
4. Disconnect the blower motor speed control (if equipped) or blower motor resistor (if equipped) electrical connector and detach the wire harness from the evaporator core cover.
5. Remove the 2 floor duct screws and the floor duct.
6. Remove the 13 lower evaporator core cover screws.
7. Remove the evaporator core cover.
8. Remove the evaporator core.
9. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-255298-S05928827502007053000000) .

Scheme 10

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 HEATER CORE .

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL»(ref-255306-S03581719392007062000000) .
2. Remove the dash panel seal from the heater core tubes.
3. Remove the 2 heater core tube bracket screws and the heater core tube bracket.
4. Disconnect the evaporator discharge air temperature sensor electrical connector.
5. Disconnect the LH temperature blend door actuator electrical connector.
6. Remove the 3 LH temperature blend door actuator screws.
7. Remove the LH temperature blend door actuator.
8. Remove the 3 heater core cover screws.
9. Remove the heater core cover.
10. Remove the heater core.
11. To install, reverse the removal procedure.

Scheme 11

MATERIAL

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL»(ref-255306-S03581719392007062000000) .
2. Position the instrument panel with the passenger side supported.
3. Disconnect the in-vehicle temperature sensor aspirator hose (if equipped).
4. Detach the wire harness from the air inlet duct.
5. Detach the wire harness from the blower motor housing.
6. Detach the wire harness from the heater core and evaporator core housing.
7. Remove the 2 floor duct screws.
8. Remove the floor duct.
9. Remove the 6 heater core and evaporator core housing bolts. To install, tighten to 9 N.m (80 lb-in).
10. Remove the heater core and evaporator core housing.
11. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «REFRIGERANT OIL ADDING»(ref-255298-S05928827502007053000000) .

Scheme 16

Scheme 17

1. Remove the instrument cluster finish panel. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255306-S25004715062007053000000) .
2. Remove the 3 lower steering column cover screws.
3. Remove the lower steering column cover.
4. Remove the 3 lower steering column shroud screws.
5. Remove the lower steering column shroud.
6. Disconnect the in-vehicle temperature sensor electrical connector.
7. Remove the in-vehicle temperature sensor.
8. To install, reverse the removal procedure.

Scheme 18

Note. The defrost/panel/floor mode door actuator can be accessed from below the LH side of the instrument panel.

Scheme 19

1. Remove the steering column cover.
2. Remove the 3 screws and the lower steering column shroud.
3. Remove the speed control deactivator switch. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255307-S02812413952007053000000) .
4. Detach the wire harness pin-type retainer.
5. Remove the 3 defrost/panel/floor mode door actuator screws.
6. Disconnect the defrost/panel/floor mode door actuator electrical connector.
7. Remove the defrost/panel/floor mode door actuator.
8. To install, reverse the removal procedure.

Scheme 20

1. Lower the glove compartment.
2. Disconnect the air inlet mode door actuator electrical connector.
3. Remove the air inlet mode door actuator.
4. To install, reverse the removal procedure.

Scheme 21

MATERIAL

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

1. Recover the refrigerant. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-255298-S12995940182007053000000) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-255244) .
3. Remove the 2 receiver/drier bracket bolts. To install, tighten to 9 N.m (80 lb-in).
4. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
5. Remove the receiver/drier outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
6. Remove the receiver/drier.
7. 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 «REFRIGERANT OIL ADDING»(ref-255298-S05928827502007053000000) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .

Scheme 22

1. Remove the instrument cluster finish panel. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255306-S25004715062007053000000) .
2. Remove the instrument panel trim panel.
3. Disconnect the passenger airbag deactivation (PAD) indicator electrical connector.
4. Disconnect the clock electrical connector (if equipped).
5. Release the 4 clips and remove the passenger side register.
6. To install, reverse the removal procedure.

Scheme 23

1. Remove the instrument cluster finish panel. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255306-S25004715062007053000000) .
2. Remove the instrument panel trim panel.
3. Disconnect the passenger airbag deactivation (PAD) indicator electrical connector.
4. Disconnect the clock electrical connector (if equipped).
5. Release the 4 clips and remove the RH center register.
6. Release the 4 clips and remove the LH center register.
7. To install, reverse the removal procedure.

Scheme 24

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-255306) .
2. Release the 4 clips and remove the driver side register.
3. To install, reverse the removal procedure.

Scheme 25

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

Scheme 26

Note. The LH temperature blend door actuator can be accessed from below the LH side of the instrument panel.

1. Remove the 3 LH temperature blend door actuator screws.
2. Disconnect the LH temperature blend door actuator.
3. Remove the LH temperature blend door actuator.
4. To install, reverse the removal procedure.

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

1. Recover the refrigerant. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-255298-S12995940182007053000000) .
2. Remove the 4 roll restrictor cross beam bolts. To install, tighten to 55 Nm (41 lb-ft).
3. Remove the roll restrictor bracket bolt. To install, tighten to 48 N.m (35 lb-ft).
4. Remove the thermostatic expansion valve (TXV) manifold bolt. Discard the O-ring seals. To install, tighten to 8 N.m (71 lb-in).
5. Remove the 2 TXV bolts. To install, tighten to 8 N.m (71 lb-in).
6. Remove the TXV. Discard the O-ring seals.
7. 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 «REFRIGERANT OIL ADDING»(ref-255298-S34874625932007053000000) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .

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

1. Recover the refrigerant. For additional information, refer to «REFRIGERANT SYSTEM RECOVERY»(ref-255298-S12995940182007053000000) .
2. Remove the 4 roll restrictor cross beam bolts. To install, tighten to 55 N.m (41 lb-ft).
3. Remove the roll restrictor bracket bolt and the roll restrictor cross beam. To install, tighten to 48 N.m (35 lb-ft).
4. Remove the cowl grille. For additional information, refer to «REMOVAL AND INSTALLATION»(ref-255297-S21419825242007053000000) .
5. Disconnect the 2 outer powertrain control module (PCM) electrical connectors.
6. Detach the wire harness bracket from the dash panel.
7. Disconnect the 2 vapor management valve (VMV) fittings.
8. Disconnect the VMV electrical connector.
9. Remove the VMV.
10. Remove the 2 coolant reservoir bolts. To install, tighten to 9 N.m (80 lb-in).
11. Disconnect the coolant sensor electrical connector.
12. Disconnect the washer pump electrical connector.
13. Disconnect the washer fluid sensor electrical connector.
14. Remove the ground strap bolt.
15. Remove the ground harness bolt.
16. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
17. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting (if equipped). Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
18. Remove the thermostatic expansion valve (TXV) manifold bolt and disconnect the manifold. Discard the O-ring seals. To install, tighten to 8 N.m (71 lb-in).
19. Unclip the high-pressure charge port from the washer bottle clip.
20. Unclip the coolant hose from the high-pressure charge port clip.
21. Remove the TXV manifold and tube bracket bolt. To install, tighten to 8 N.m (71 lb-in).
22. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
23. Remove the 2 receiver/drier bracket bolts. To install, tighten to 9 N.m (80 lb-in).
24. Remove the receiver/drier outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 8 N.m (71 lb-in).
25. Remove the TXV manifold and tube assembly.
26. 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 «REFRIGERANT OIL ADDING»(ref-255298-S34874625932007053000000) .
27. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «AIR CONDITIONING (A/C) SYSTEM RECOVERY, EVACUATION AND CHARGING»(ref-255298-S14835036442007053000000) .