HVAC Control System Ford Taurus X I

Material

Material

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

TORQUE SPECIFICATIONS TABLE

Air Conditioning

The A/C system components include the following

1. A/C compressor
2. A/C clutch assembly
3. A/C condenser/transmission oil combo cooler
4. A/C evaporator core
5. Receiver/drier
6. Connecting refrigerant lines
7. Thermostatic expansion valve (TXV)

The refrigerant system incorporates an A/C compressor controlled by the PCM through an A/C clutch relay. The HVAC module sends an A/C request signal to the instrument cluster module (ICM) which relays the request to the PCM. An evaporator discharge air temperature sensor is used to disengage the A/C compressor clutch when the evaporator core temperature falls below 5.5°C (42°F).

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

1. The HVAC module is set to a mode which provides an A/C request to the PCM via the ICM.
2. The evaporator discharge air temperature sensor is reading a temperature above 5.5°C (42°F).
3. The A/C pressure transducer is not reading a pressure above 2,841 kPa (412 psi) 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 pressure relief valve is installed in the bottom rear of the A/C compressor to protect the refrigerant system against excessively high refrigerant pressures.

Refrigerant flow into the evaporator core is metered by a TXV.

A/C Compressor and Clutch Assembly

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

The A/C compressor has the following characteristics

1. A non-serviceable shaft seal.
2. A pressure relief valve is installed in the bottom rear of the A/C compressor to protect the refrigerant system against excessively high refrigerant pressures. The A/C pressure relief valve is a separate component and can be removed and installed separately from the A/C compressor.
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 the oil matching procedure specified for this vehicle when installing a new A/C compressor.

When battery voltage is applied to the A/C compressor clutch field coil, the clutch disc and hub assembly is drawn toward the A/C clutch pulley. The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. When battery voltage is removed from the A/C compressor clutch field coil, springs in the clutch plate and hub assembly move the clutch plate away from the A/C clutch pulley.

A/C Pressure Relief Valve

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

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

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.

A/C Condenser/Transmission Oil Combo Cooler

The A/C condenser/transmission oil combo cooler 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.

The top portion of the A/C condenser/transmission oil combo cooler is partitioned from the refrigerant system and is used for transmission oil cooling.

Evaporator Core

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.

Thermostatic Expansion Valve (TXV)

The TXV is located between the evaporator core and the TXV manifold and tube assembly at the rear of the engine compartment. The TXV 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. Refrigerant entering and exiting the evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures.

Receiver Drier

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

The receiver/drier is mounted to the right of the radiator support. It stores high-pressure liquid after it leaves the condenser core. A desiccant bag mounted inside the receiver/drier removes any retained moisture from the refrigerant.

Evaporator Discharge Air Temperature Sensor

The evaporator discharge air temperature sensor contains a thermistor. The resistance of this thermistor varies by a specific amount based on the evaporator discharge air temperature. The HVAC module measures a voltage ratio between the reference voltage it supplies to the sensor and the sensor return voltage to determine this resistance and the associated discharge air temperature.

The evaporator discharge air temperature sensor maintains evaporator core temperature and prevents icing of the evaporator core. It does this by signaling the HVAC module to switch off the A/C request signal to the instrument cluster when the evaporator discharge air temperature sensor reading falls below acceptable levels. The A/C request will be switched back on when the evaporator temperature rises above acceptable levels.

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

A/C Pressure Transducer

The A/C pressure transducer monitors the compressor discharge pressure and communicates with the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage.

The A/C pressure transducer is located on the compressor-to-condenser discharge line near the condenser inlet fitting. 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 receiver/drier outlet line.

The low-pressure service gauge port valve is located on the evaporator outlet line.

Scheme 149

The fitting is an integral part of the refrigerant 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 black light. 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 receiver/driers 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 receiver/drier 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 or hose rupture. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

Air Distribution and Filtering

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

1. Outside air
2. Recirculated air

Recirculated air is always used when the HVAC module is set to the MAX A/C mode on vehicles equipped with electronic manual temperature control (EMTC). Vehicles equipped with dual-zone electronic automatic temperature control (EATC) use recirculated air only when the RECIRC function is selected in any mode other than DEFROST, or when required by the HVAC module in the AUTOMATIC mode.

Air distribution within the vehicle is determined by the function selector position (EMTC), or the dual-zone EATC system in the AUTOMATIC mode. The air distribution mode on vehicles equipped with dual-zone EATC can be overridden by the driver if desired. Airflow mode control doors are used to direct airflow within the heater core and evaporator core housing. Electric mode door actuators are used to position these airflow mode doors.

Vehicles equipped with dual-zone EATC use 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 for separate RH and LH airflow positions. Therefore, the airflow mode will always remain similar for the RH and LH sides of the vehicle regardless of the temperatures selected.

Air enters the passenger compartment from the

1. instrument panel registers.
2. floor duct.
3. windshield defroster.
4. side window demisters.
5. rear footwell duct (if equipped).

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

Electronic Manual Temperature Control (EMTC)

The electronic manual temperature control (EMTC) 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 EMTC system has 2 system control inputs.

HVAC Module

The HVAC module integrates the temperature control, airflow mode selection, A/C request button, recirculated air request button and rear defog switch into a single unit.

The temperature control switch setting determines air temperature. Movement of the temperature display 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 HVAC module and cannot be separately replaced.

The A/C request button determines A/C compressor operation, except when the function selected is in the OFF, MAX or DEFROST mode. The A/C request button is an integral part of the HVAC module and cannot be separately replaced.

The recirculated air request button can select recirculated air in any mode except DEFROST, and fresh air in any mode except MAX A/C or OFF.

The rear defog button signals activation of the heated backlight. The rear defog button is an integral part of the HVAC module and cannot be installed separately.

The HVAC module is not equipped with self-test capabilities.

Blower Motor Switch

The blower motor switch is mounted in the climate control module and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all modes except OFF.

Control System Outputs

The EMTC system has 4 system outputs.

Blower Motor Speed

The blower motor speed switch varies the blower motor ground circuit resistance by adding or bypassing series resistance in the blower motor resistor. Increased resistance will lower the blower motor speed, and lowered resistance will increase blower motor speed. When the blower motor is in the HI (4) position, the blower motor resistor is bypassed.

The blower motor resistor is located on the heater core and evaporator core housing behind the glove compartment.

Temperature Blend Door Position

The temperature blend door actuator moves the temperature blend door on command from the HVAC module.

The temperature blend door actuator contains a reversible electric motor and a potentiometer. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a contact wiper, which is driven along the variable resistor by the actuator shaft. The signal returned to the HVAC module from the contact wiper indicates the position of the temperature blend door. The HVAC module drives the actuator motor in whichever direction is necessary to make the actuator contact wiper voltage agree with the expected HVAC module value. The expected value is set by the vehicle occupants using the temperature selector knob.

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

Airflow Mode Door Position

The airflow mode door actuator uses a cam and lever assembly to position the airflow mode doors on command from the HVAC module. The mode door actuator contains a reversible electric motor and potentiometer. The potentiometer allows the HVAC module to monitor the position of the airflow mode doors. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a contact wiper, which is driven along the variable resistor by the actuator shaft. The signal returned to the HVAC module from the contact wiper indicates the position of the airflow mode doors. The expected value is set by the vehicle occupants using the mode selector buttons.

The airflow (defrost/panel/floor) mode door actuator is located on the heater core and evaporator core housing to the right of the steering column.

Air Inlet Mode Door Position

The air inlet mode door actuator moves the air inlet door between the fresh and RECIRC positions on command from the HVAC module. The air inlet mode door actuator is driven to, and will automatically stop at, the full RECIRC or full fresh air inlet position and does not require a potentiometer circuit to monitor its position. The airflow mode door does not stop at any point between the RECIRC or fresh air inlet position.

The air inlet mode door actuator is located on the air inlet duct behind the glove compartment.

Dual-Zone Electronic Automatic Temperature Control (EATC)

The HVAC module analyzes input from the following major sources

1. Temperature, airflow direction, blower, A/C and RECIRC selection (made by the vehicle occupants)
2. In-vehicle temperature sensor
3. Ambient temperature sensor
4. Solar radiation sensor
5. Vehicle speed
6. Engine coolant temperature

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

1. A/C compressor operation
2. Blower speed
3. RH and LH temperature blend door positions
4. Defrost/panel/floor airflow mode door position
5. Air inlet door position

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

The HVAC module provides an interface for the vehicle occupants to control the climate control system, or automatically controls the climate control system in the AUTO mode. The HVAC module displays set temperature, airflow direction, blower speed and DTCs. An on-board diagnostic (OBD) feature is incorporated to supply the technician with DTCs. These DTCs help direct the technician to the inoperative component.

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. An aspirator hose is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor. The aspirator hose uses airflow through the heater core and evaporator core housing to create a Venturi-type suction to draw in vehicle air through the in-vehicle temperature sensor (across the thermistor).

Sunload Sensor (Solar Radiation Sensor)

The solar radiation sensor supplies information to the HVAC module indicating sunload. The sunload sensor is located on the center of the instrument panel at the base of the windshield.

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 below the hood latch.

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 outside air temperature display, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

The EATC system has 4 control system outputs. When operating in AUTO mode, the control system outputs will be automatically adjusted by the HVAC module.

Note. Each of the 4 control system outputs may be overridden by the passenger if desired.

The blower motor speed control controls the blower motor speed by converting 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.

The blower motor speed control is located on the heater core and evaporator core housing near the blower motor.

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 potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a contact wiper, which is driven along the variable resistor by the actuator shaft. The signal returned to the HVAC module from the contact wiper indicates the position of the temperature blend door. The HVAC module drives the actuator motor in whichever direction is necessary to make the actuator contact wiper voltage agree with the expected HVAC module contact wiper voltage value, as determined by the control algorithm.

The LH temperature blend door actuator is located on the heater core and evaporator core housing near the accelerator pedal. The LH temperature blend door actuator is located on the heater core and evaporator core housing to the left of the glove compartment.

The airflow mode door actuator uses a cam and lever assembly to position the airflow mode doors on command from the HVAC module. The mode door actuator contains a reversible electric motor and potentiometer. The potentiometer allows the HVAC module to monitor the position of the airflow mode doors. The potentiometer circuit consists of a 5-volt reference signal connected to one end of a variable resistor, and a signal ground connected to the other. A signal return circuit is connected to a contact wiper, which is driven along the variable resistor by the actuator shaft. The signal returned to the HVAC module from the contact wiper indicates the position of the airflow mode doors. The HVAC module drives the actuator motor in whichever direction is necessary to make the actuator contact wiper voltage agree with the expected contact wiper voltage value, as determined by the control algorithm.

The airflow (defrost/panel/floor) mode door actuator is located on the heater core and evaporator core housing to the right of the steering column.

The air inlet mode door actuator moves the air inlet door between the fresh and RECIRC positions on command from the HVAC module. The air inlet mode door actuator is driven to, and will automatically stop at, the full RECIRC or full fresh air inlet position and does not require a potentiometer circuit to monitor its position. The airflow mode door does not stop at any point between the RECIRC or fresh air inlet position.

The air inlet mode door actuator is located on the air inlet duct behind the glove compartment.

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. Uses a reheat method to provide conditioned air to the passenger compartment.
5. All airflow from the blower motor passes through the A/C evaporator core.
6. Temperature blending is controlled by the temperature blend door(s), which regulate(s) the amount of air that flows through and around the heater core, where it is then mixed and distributed.

Heater Core

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

Blower Motor

The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing where it is mixed and distributed.

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 Electronic Automatic Temperature Control (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

Material

Scheme 150

REMOVAL AND INSTALLATION

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

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
3. Release the tensioner and remove the drive belt from the A/C compressor pulley.
4. Remove the 3 compressor splash shield pin-type retainers and the splash shield.
5. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
6. Disconnect the A/C clutch field coil electrical connector.
7. Remove the A/C compressor nut. To install, tighten to 25 Nm (18 lb-ft).
8. Completely loosen the A/C compressor mounting stud. To install, tighten to 9 Nm (80 lb-in).
9. Remove the 2 A/C compressor bolts. To install, tighten to 25 Nm (18 lb-ft).
10. Remove the A/C compressor.
11. 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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system__clutch-and-clutch-field-coil) . Install new gasket seals and 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 «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
12. 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 «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Air Conditioning (A/C) Pressure Relief Valve

Material

Scheme 151

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Scheme 152

1. Remove the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system) .
2. Remove the 5 air inlet duct screws.
3. Remove the air inlet duct.
4. To install, reverse the removal procedure.

Scheme 153

1. Detach the RH scuff plate trim panel from the RH cowl side trim panel.
2. Remove the RH cowl side trim panel.
3. Remove the 2 RH lower instrument panel insulator pin-type retainers and the RH lower instrument panel insulator.
4. Disconnect the blower motor electrical connector.
5. Release the 2 blower motor vent tube clips and detach the blower motor vent tube from the heater core and evaporator core housing.
6. Rotate the blower motor counterclockwise to disengage it from the housing and remove the blower motor.
7. To install, reverse the removal procedure.

1. For additional information, refer to «Blower Motor Speed Control»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system__blower-motor-speed-control) .

Blower Motor Speed Control

Note. Blower motor speed control shown, blower motor resistor similar.

Scheme 154

1. Detach the RH scuff plate trim panel from the RH cowl side trim panel.
2. Remove the RH cowl side trim panel.
3. Remove the 2 RH lower instrument panel insulator pin-type retainers and the RH lower instrument panel insulator.
4. Disconnect the blower motor speed control electrical connector.
5. Remove the 2 blower motor speed control screws.
6. Remove the blower motor speed control.
7. To install, reverse the removal procedure.

Clutch and Clutch Field Coil

Special Tools Illustration Tool Name Tool Number Holding Tool, Compressor Clutch 412-134 Remover, Compressor Pulley 412-001 (T71P-19703-B)

Scheme 155

REMOVAL

1. Remove the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system__air-conditioning-ac-compressor) .
2. Remove the A/C clutch disc and hub bolt. Using the Compressor Clutch Holding Tool, hold the A/C clutch disc and hub. Remove the A/C clutch disc and hub bolt.
3. Remove the A/C clutch disc and hub.
4. Remove the A/C clutch disc and hub spacer(s).
5. Remove the A/C compressor pulley snap ring.
6. Remove the A/C compressor pulley. Install the Compressor Pulley Remover. Using the Compressor Pulley Remover, remove the A/C compressor pulley.
7. Remove the A/C clutch field coil snap ring.
8. Remove the A/C clutch field coil electrical connector bracket screw.
9. Remove the A/C clutch field coil.

INSTALLATION

Note. 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 new A/C compressor pulley must be installed together. Otherwise, each component may be installed individually where needed.

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.
4. Install the A/C clutch field coil snap ring with the bevel side up.
5. Install the A/C clutch field coil electrical connector bracket screw.
6. Install the A/C compressor pulley.
7. Install the A/C compressor pulley snap ring with the bevel side out.
8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
9. Install the A/C clutch disc and hub.
10. Using the Compressor Clutch Holding Tool, install the A/C compressor clutch disc and hub bolt. Hold the A/C clutch disc and hub with the Compressor Clutch Holding Tool. Tighten to 14 Nm (124 lb-in).
11. Measure and adjust the clutch air gap. Measure the clutch air gap at 3 equally spaced locations around the A/C compressor pulley and calculate the average. Adjust the clutch air gap by removing or adding A/C clutch disc and hub spacers.
12. Install the A/C compressor. For additional information, refer to «Air Conditioning (A/C) Compressor»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system__air-conditioning-ac-compressor) .

Compressor to Condenser Discharge Line

Material

Scheme 156

1. Recover the refrigerant.
2. Remove the A/C compressor discharge fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
3. Disconnect the A/C pressure transducer electrical connector.
4. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
5. Remove the compressor-to-condenser discharge line.
6. To install, reverse the removal procedure. Install new gasket seals 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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Condenser Core

Material

Scheme 157

1. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
3. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
4. Remove the front bumper cover. For additional information, refer to «BUMPERS»(/ford/taurus-x/i-2007-2009/remont/exterior-body-panels/#bumper-system) article.
5. Releaser the upper radiator hose clamp at the radiator and disconnect the hose.
6. Remove the engine cooling fan. For additional information, refer to «ENGINE COOLING»(/ford/taurus-x/i-2007-2009/remont/cooling-system-mechanical/#engine-cooling-system) article.
7. Detach the 2 clips on each radiator bracket from the radiator support and position the radiator rearward.
8. Remove the 2 radiator brackets.
9. Remove the 2 condenser fitting nuts and disconnect the fittings. Discard the O-ring seals and gasket seals. To install, tighten to 15 Nm (11 lb-ft).
10. Release the 2 transmission cooler line clamps and disconnect the lines from the condenser core.
11. Remove the 2 A/C condenser bolts. To install, tighten to 6 Nm (53 lb-in).
12. Lift upward and detach the condenser core from the radiator.
13. Remove the condenser core.
14. To install, reverse the removal procedure. Install new gasket seals 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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
16. Fill the transmission fluid level. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50»(/ford/taurus-x/i-2007-2009/remont/automatic-trans/#automatic-transmission-6f50) article.

Note. The evaporator core is available only as part of the evaporator core housing assembly.

1. Remove the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system) .
2. Transfer the components from the old housing to the new housing as needed.
3. Install the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system) .

Scheme 158

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

1. Remove the heater core and evaporator core housing. For additional information, refer to «Heater Core And Evaporator Core Housing»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system) .
2. Remove the dash panel seal.
3. Remove the 3 heater core tube support bracket screws and heater core tube support bracket.
4. Remove the 10 plenum chamber screws and separate the heater core and evaporator housing.
5. Remove the heater core.
6. To install, reverse the removal procedure.

Material

Scheme 159

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

1. Remove the instrument panel assembly. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/taurus-x/i-2007-2009/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Position the instrument panel with the passenger side supported as shown.
3. Remove the 2 floor duct screws and remove the floor duct.
4. Detach the in-vehicle temperature sensor aspirator from the heater core and evaporator core housing.
5. Remove the 6 heater core and evaporator core housing bolts. To install, tighten to 9 Nm (80 lb-in).
6. Disconnect the 3 electrical connectors and detach the wire harness pin-type retainer.
7. Detach the 3 wire harness pin-type retainers and disconnect the electrical connector.
8. Disconnect the 3 electrical connectors, detach the wire harness pin-type retainer and detach the instrument panel wire harness from the heater core and evaporator core housing.
9. Remove the heater core and evaporator core housing.
10. To install, reverse the removal procedure.

Scheme 160

1. Remove the instrument panel center finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/taurus-x/i-2007-2009/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 161

Scheme 162

Taurus/Sable

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/taurus-x/i-2007-2009/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
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 163

1. Detach the damper and lower the glove compartment.
2. Disconnect the air inlet mode door actuator electrical connector.
3. Remove the 2 air inlet mode door actuator screws.
4. Remove the air inlet mode door actuator.
5. To install, reverse the removal procedure.

Scheme 164

1. Remove the instrument cluster. For additional information, refer to «INSTRUMENT CLUSTER (IC), MESSAGE CENTER, AND WARNING CHIMES»(/ford/taurus-x/i-2007-2009/remont/gauges-instrument-panels/#information-center) article.
2. Remove the 3 lower steering column cover screws and the cover.
3. Remove the 3 lower steering column shroud screws and the lower steering column shroud.
4. Remove the speed control deactivator switch. For additional information, refer to «SPEED CONTROL»(/ford/taurus-x/i-2007-2009/remont/cruise-control-systems/#cruise-control-system) article.
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.

1. Remove the heater core. For additional information, refer to «Heater Core»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system) .
2. Transfer the defrost/panel/floor door mode door actuator and temperature blend door actuator(s) from the old plenum chamber to the new plenum chamber.
3. Install the heater core. For additional information, refer to «Heater Core»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system) .

Material

Scheme 165

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

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
2. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
3. Detach the receiver/drier outlet line clip.
4. Remove the receiver/drier outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (11 lb-ft).
5. Remove the 2 receiver/drier bolts.
6. Remove the receiver/drier.
7. To install, reverse the removal procedure. Install new gasket seals 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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Scheme 166

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/taurus-x/i-2007-2009/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
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 167

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/taurus-x/i-2007-2009/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
2. Release the 4 clips and remove the driver side register.
3. To install, reverse the removal procedure.

Scheme 168

1. Remove the instrument cluster finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/ford/taurus-x/i-2007-2009/remont/gauges-instrument-panels/#instrument-panel-and-console) article.
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 169

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

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

Temperature Blend Door Actuator - RH

Note. Taurus X shown, Taurus or Sable similar.

Scheme 170

1. Detach the damper and lower the glove compartment.
2. Working through the glove compartment opening, detach and disconnect the temperature blend door actuator jumper harness electrical connector.
3. Detach the in-vehicle temperature sensor aspirator hose pin-type retainer from the instrument panel support.
4. Detach the instrument panel wire harness pin-type retainer from the heater core and evaporator core housing support.
5. Remove the 2 RH temperature blend door actuator screws.
6. Reposition the RH temperature blend door actuator to allow access to the electrical connector and disconnect the RH temperature blend door actuator electrical connector.
7. Remove the RH temperature blend door actuator.
8. To install, reverse the removal procedure.

Thermostatic Expansion Valve

Material

Scheme 171

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
2. Remove the 4 cross vehicle beam nuts and remove the beam. To install, tighten to 30 Nm (22 lb-ft).
3. Remove the Thermostatic Expansion Valve (TXV) fitting bolt. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).
4. Remove the 2 TXV bolts. To install, tighten to 8 Nm (71 lb-in).
5. Remove the TXV. Discard the O-ring seals.
6. 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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

Thermostatic Expansion Valve Manifold and Tube Assembly

Material

Scheme 172

Vehicles with auxiliary climate control

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the evaporative emissions (EVAP) canister purge valve. For additional information, refer to «EVAPORATIVE EMISSIONS»(/ford/taurus-x/i-2007-2009/remont/auxiliary-emission-control-systems/#evaporative-emissions-system) article.
3. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.
4. Remove the 4 cross vehicle beam nuts and remove the beam. To install, tighten to 30 Nm (22 lb-ft).
5. Remove the evaporator outlet line 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 evaporator inlet line fitting bracket bolt.
7. Remove the evaporator inlet line 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 thermostatic expansion valve (TXV) manifold and tube bracket bolt. To install, tighten to 9 Nm (80 lb-in).
9. Disconnect the evaporative emission (EVAP) canister purge valve lower fitting.
10. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 15 Nm (11 lb-ft).
11. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting (if equipped). Discard the O-ring seal. To install, tighten to 15 Nm (11 lb-ft).
12. Remove the TXV fitting bolt and disconnect the fitting. Discard the O-ring seals. To install, tighten to 8 Nm (71 lb-in).
13. Remove the TXV manifold and tube assembly.
14. To install, reverse the removal procedure. Install new gasket seals 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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-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/taurus-x/i-2007-2009/remont/manual-hvac-system/#hvac-control-system-general-information-and-diagnostics) article.

See also:
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• JACKING AND LIFTING
• ENGINE COOLING
• BUMPERS
• AUTOMATIC TRANSAXLE/TRANSMISSION - 6F50
• INSTRUMENT PANEL AND CONSOLE
• INSTRUMENT CLUSTER (IC), MESSAGE CENTER, AND WARNING CHIMES
• SPEED CONTROL
• EVAPORATIVE EMISSIONS
• Clutch and Clutch Field Coil
• Heater Core And Evaporator Core Housing
• Blower Motor Speed Control
• Air Conditioning (A/C) Compressor