HVAC System - Automatic: Removal & Installation Ford Taurus IV

REMOVAL & INSTALLATION

Note. For removal and installation procedures not covered here, see MANUAL A/C-HEATER SYSTEMS - SABLE & TAURUS article.

Remove grille. Detach ambient air temperature sensor and bracket from grille opening reinforcement. Disconnect wiring from sensor and bracket. To install, reverse removal procedure.

Detach lower, right side instrument panel insulator from instrument panel reinforcement. From under instrument panel, disconnect blower motor speed controller connector. Disconnect vacuum harness connector from bracket. Remove 2 screws retaining blower motor speed controller to A/C-heater housing. Remove blower motor speed controller. Transfer mounting brackets to new assembly, if replacing unit. To install, reverse removal procedure. (Scheme 18)

Scheme 18

1. Remove heater/evaporator housing. See «HEATER/EVAPORATOR CORE HOUSING»(ref-62841-S39133169062001022600000). Remove heater-to-dash panel seal, A/C tubes-to-dash panel seal and evaporator drain tube seal. Remove Remote Climate Control (RCC) module. See «REMOTE CLIMATE CONTROL (RCC) MODULE»(ref-62841-S38272525332001011900000). Remove 2 screws and shield below blend door actuator. Remove blend door actuator motor.
2. Remove damper door assist spring from housing. (Scheme 19) Depress tab and remove A/C evaporator case damper door lever. Rotate primary A/C temperature control door lever downward. Remove metal link from pin.
3. Remove heater core cover. Rotate temperature blend door. Remove heater core cover and seal. Rotate temperature blend door and remove heater core. Remove blower motor speed controller and blower motor as an assembly. Remove support bracket. Remove recirculation air duct. Remove vacuum control motor cover. Label vacuum control motor vacuum hoses (for installation reference), remove screw, lift and rotate to remove vacuum control motor. Remove vacuum and wiring harness. To install, reverse removal procedure.

Scheme 19

1. Remove instrument panel. See «INSTRUMENT PANEL»(ref-62841-S20198016902001022600000). Remove heater/evaporator core housing. See «HEATER/EVAPORATOR CORE HOUSING»(ref-62841-S39133169062001022600000).
2. Remove Remote Climate Control (RCC) module. See «REMOTE CLIMATE CONTROL (RCC) MODULE»(ref-62841-S38272525332001011900000). Remove 4 screws retaining A/C electronic blend door actuator from heater/evaporator housing. Remove actuator. Remove metal cover, disengage spring from heater core cover and remove spring from lever.
3. Depress locking ramp and remove lever from secondary air temperature control door end. (Scheme 19) Rotate temperature control door shaft down, switch metal link and remove from pin.
4. Remove 3 heater core cover screws and heater core cover. Remove cover seal. Remove heater core and heater core seal from heater/evaporator case by pushing on heater core tubes. To install, reverse removal procedure.

Removal

1. Disconnect negative battery cable. Drain coolant from radiator. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove right side cowl vent screen. Remove water shield. Disconnect vacuum supply hose. Disconnect heater hoses from heater core. Plug heater core tubes or drain coolant by blowing coolant from heater core using low pressure compressed air.
2. Disconnect refrigerant lines from evaporator core. Plug refrigerant lines and evaporator core tubes. Remove 2 bolts from firewall side. Remove instrument panel. See «INSTRUMENT PANEL»(ref-62841-S20198016902001022600000) .
3. Remove heater outlet floor duct. Remove 3 nuts securing heater/evaporator case to firewall. Remove 2 screws securing support brackets to cowl top panel. Remove nut retaining heater/evaporator housing to PCM mounting bracket. Carefully pull heater/evaporator case away from firewall. Remove heater/evaporator case.

Installation

To install, reverse removal procedure. Evacuate, charge, and leak test A/C system. Refill cooling system.

Remove Integrated Control Panel (ICP). See INTEGRATED CONTROL PANEL . Press retaining tabs inward, remove in-car temperature sensor. To install, reverse removal procedure.

1. Position front wheels in straight-ahead position. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove push-pins and right side instrument panel lower insulator from panel reinforcement.
2. If equipped with floor shift console, remove console finish panel. On all models, remove 2 screws retaining cover below steering column. Remove cover by holding steel backing plate and unsnapping it from instrument panel. Remove instrument panel brace from below steering column. Remove diagnostic link connector screws and remove instrument panel brace.
3. Remove main wiring harness connectors and vacuum hose harness from heater/evaporator housing and blower motor. Gently insert Radio Removers (T87P-19051-A) into integrated control panel face plate and push in about 1.5" (38 mm) to release spring clips. Apply light spreading force on radio remover and pull integrated control panel out of instrument panel. Detach wiring and vacuum connectors from rear of control panel.
4. Remove center finish panel from integrated control panel opening. Ensure steering column is properly locked, then remove steering column.
5. Remove instrument cluster finish panel screws. Carefully disengage finish panel end clips by pulling cluster finish panel straight out. Remove 4 instrument cluster retaining screws, disconnect 3 electrical connectors and remove instrument cluster.
6. Unsnap and remove upper finish panel from instrument panel. If equipped with Autolamp system, disconnect electrical connector from light sensor amplifier. Remove both end panels from instrument panel. Remove left and right side front scuff plates and pull door weatherstrip away from instrument panel. Remove 3 retaining screws retaining instrument panel to upper cowl top panel. Remove 2 screws from ends of instrument panel.
7. Pull left end of instrument panel away from bulkhead enough to unplug any remaining harness connectors. Remove parking brake cable and switch connector. Using an assistant, remove instrument panel. To install instrument panel, reverse removal procedure.

Disconnect negative battery cable. Install Radio Removers (T87P-19061-A) into integrated control panel face plate. Apply a slight spreading force on removers. Gently pull Integrated Control Panel (ICP) from instrument panel. Disconnect electrical connectors. Disconnect in-car temperature sensor hose and elbow. To install, reverse removal procedure.

Remove integrated control panel. See INTEGRATED CONTROL PANEL. Open glove box. Press sides of glove box inward and lower glove box to floor. Remove 2 screws securing RCC module to evaporator housing. Disconnect harness connector and remove RCC module. To install, reverse removal procedure. (Scheme 20)

Scheme 20

Lift instrument panel upper finish panel. Disconnect sunload sensor. Pull sensor from studs of instrument panel upper finish panel. To install, reverse removal procedure.