HVAC System: Removal & Installation Ford Taurus IV facelift

Removal and Installation

Note. Installation of a new suction accumulator 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 suction accumulator.

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1. If flushing of the air conditioning system has not been performed, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
2. Remove the RH and LH cooling fans. For additional information, refer to «ENGINE COOLING»(ref-212100) .
3. Loosen the tensioner and remove the drive belt from the A/C compressor pulley.
4. Disconnect the compressor manifold and tube assembly. Discard the O-ring seals.
5. Disconnect the compressor field coil electrical connector.
6. Remove the four A/C compressor mounting bolts.
7. Remove the A/C compressor.
8. 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-212122-S31711236242005122300000) . Install new O-ring seals lubricated in clean mineral oil. If not filtering the refrigerant system, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
9. If not filtering the refrigerant system, evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .

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Note. Installation of a new suction accumulator 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 suction accumulator.

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1. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
2. If flushing of the air conditioning system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
3. Remove the accessory drive belt (8620) from the A/C compressor pulley.
4. Remove the RH radiator cooling fan. For additional information, refer to «ENGINE COOLING»(ref-212100) .
5. Remove the lower radiator air deflector.
6. Remove the bolt and detach the compressor manifold and tube assembly. Discard the O-ring seals.
7. Disconnect the field coil electrical connector.
8. Remove the two lower A/C compressor bolts.
9. Disconnect the compressor manifold and tube fitting at the suction accumulator. Discard the O-ring seals.
10. Remove the three bolts and the bracket.
11. Remove the two upper A/C compressor bolts and the A/C compressor.
12. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil. If installing a new A/C compressor, the A/C compressor clutch field coil, the A/C compressor pulley and bearing, and the A/C clutch plate must be transferred from the old unit. For additional information, refer to «CLUTCH AND CLUTCH FIELD COIL»(ref-212122-S31711236242005122300000) . If not filtering the refrigerant system, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
13. If not filtering the refrigerant system, evacuate, charge and leak test the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .

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1. Remove the A/C compressor (19703). For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (2V)»(ref-212122-S25587492902005122300000) or «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (4V)»(ref-212122-S06810974062005122300000) .
2. Remove the A/C clutch hub retaining bolt. Hold the A/C clutch hub with the special tool. Remove the bolt.
3. Remove the A/C clutch disc and hub and the spacer (19D648). Thread an 8 x 1.25 mm bolt into the A/C clutch disc and hub to force it from the compressor shaft. Lift the A/C clutch disc and hub and the spacer from the compressor shaft.
4. Remove the pulley snap ring.
5. Remove the A/C compressor pulley. Install the special tool. Remove the compressor pulley.
6. Remove the A/C compressor clutch field coil. Install the special tool on the nose opening of the A/C compressor. Install the special tool. Remove the A/C compressor clutch field coil.

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1. Clean the A/C compressor clutch field coil and pulley bearing mounting surfaces.
2. Install the A/C compressor clutch field coil. Place the A/C compressor clutch field coil on the A/C compressor with the A/C compressor clutch field coil electrical connector correctly positioned. Place the special tool on the A/C compressor clutch field coil. Place the special tool on the special tool. Use the special tool to install the A/C compressor clutch field coil until bottomed completely against the A/C compressor.
3. Install the A/C clutch pulley.
4. Install the pulley snap ring with the bevel side out.
5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.
6. Install the A/C clutch.
7. Install the A/C clutch hub retaining bolt. Hold the A/C clutch hub with the special tool. Tighten the bolt.
8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
9. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (2V)»(ref-212122-S25587492902005122300000) or «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (4V)»(ref-212122-S06810974062005122300000) .

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Removal

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1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (2V)»(ref-212122-S25587492902005122300000) or «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (4V)»(ref-212122-S06810974062005122300000) .
2. Remove the clutch disc and hub bolt. Hold the A/C clutch disc and hub with the special tool. Remove the bolt.
3. Remove the A/C clutch disc and hub. Thread an 8 x 1.25 mm (0.04 in) bolt into the A/C clutch disc and hub to force it from the A/C compressor shaft (if needed). Lift the A/C clutch disc and hub and the A/C clutch disc and hub spacer(s) from the A/C compressor shaft.
4. Remove the shaft seal felt from the nose of the A/C compressor with the special tool.
5. Clean the compressor nose area.
6. Insert the tip of the special tool into one of the snap ring eyes.
7. Rotate the special tool to position the tool tip and the snap ring eye closest to the A/C compressor shaft.
8. Pull the special tool up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring.
9. Engage the special tool into the inside diameter of the shaft seal.
10. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal.
11. Pull the seal from the A/C compressor.

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1. Clean the A/C compressor nose area.
2. Place the shaft seal on the special tool. Lubricate the shaft seal and the special tool with mineral oil.
3. Position the shaft seal and the special tool over the A/C compressor shaft.
4. Push the shaft seal onto the A/C compressor shaft with the special tool until seated.
5. Install the shaft seal snap ring.
6. Carry out the A/C Compressor - External Leak Test. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
7. Install the shaft seal felt.
8. Install the A/C clutch disc and hub spacer(s) and the A/C clutch disc and hub.
9. Install the A/C clutch disc and hub bolt. Hold the A/C clutch disc and hub with the special tool. Install the bolt.
10. Measure and adjust the clutch air gap by adding or removing spacers as needed.

Note. The evaporator core is serviced as a core and housing assembly. The evaporator core, internal doors, seals and door linkage are included with the housing. Transfer the blower motor and wheel assembly, heater core and cover, dash panel seals and vacuum actuators to the new housing.

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

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1. Remove the heater core and evaporator core housing (19B555). For additional information, refer to «HEATING & VENTILATION»(ref-212120) .
2. Remove the heater-to-dash panel seal (18529), the air conditioner tubes-to-dash panel seal (19B588), and the air conditioner evaporator drain tube seal (19B739).
3. Remove the remote climate control (RCC) module (18C612). Disconnect the electrical connector. Remove the two nuts. Disconnect the vacuum harness. Remove the two screws. Remove the RCC module.
4. Remove the screws and the shield.
5. Remove the temperature blend door actuator (19E616). Disconnect the electrical connector. Remove the screws. Remove the temperature blend door actuator.
6. Remove the A/C evaporator case damper door assist spring.
7. Remove the A/C evaporator case damper door lever. While depressing the tab, disconnect the A/C evaporator case damper door lever. Rotate and remove the A/C evaporator case damper door lever.
8. Remove the metal link.
9. Detach the vacuum harness from the mounting bracket.
10. Remove the heater core cover (18B300). Remove the screws. Rotate the temperature blend door. Remove the heater core cover and seal.
11. Remove the heater core (18476). Rotate the temperature blend door. Remove the heater core.
12. Remove the screws and the blower motor (19805). Remove the screws and the blower motor resistor (19A706).
13. Disconnect the vacuum hose. Remove the screws. Remove the blower motor (19805) and the blower motor speed control (19E624) as an assembly.
14. Remove the in-vehicle temperature sensor hose (19D888).
15. Remove the bracket.
16. Remove the air inlet duct. Disconnect the vacuum hose. Remove the three screws. Remove the air inlet duct.
17. Remove the screws and the shield.
18. Label and disconnect the two vacuum hoses. Remove the screw. Lift, rotate, and remove the vacuum control motor (18A318).
19. Note the vacuum harness and wiring harness routing. Remove the vacuum harness and wiring harness.

Installation

ALL VEHICLES

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1. Install the vacuum and wiring harness as noted during removal.
2. Install the vacuum control motor and the screw. Connect the vacuum hoses.
3. Install the shield and screws.
4. Install the air inlet duct. Position the air inlet duct. Install the three screws. Connect the vacuum hose.
5. Install the bracket.
6. Install the in-vehicle temperature sensor hose (19D888).
7. Install the blower motor and blower motor speed control as an assembly. Install the screws. Connect the vacuum hose.
8. Install the blower motor and the screws. Install the blower motor resistor and the screws.
9. Install the heater core. Rotate the temperature blend door. Install the heater core.
10. Install the heater core cover. Rotate the temperature blend door. Install the heater core cover. Install the screws.
11. Attach the vacuum harness to the mounting bracket.
12. Install the metal link.
13. Install the A/C evaporator case damper door lever. Install the A/C evaporator case damper door lever. Align and insert the A/C evaporator case damper door lever.
14. Install the A/C evaporator case damper door assist spring.
15. Install the temperature blend door actuator (19E616). Install the temperature blend door actuator. Install the screws. Connect the temperature blend door actuator electrical connector.
16. Install the shield and two screws.
17. Install the RCC module. Install the RCC module. Install the two screws. Connect the vacuum harness. Install the two nuts. Connect the RCC module electrical connector.
18. Install the heater-to-dash panel seal (18529), the air conditioner tubes-to-dash panel seal (19B588), and the air conditioner evaporator drain tube seal (19B739).
19. Install the heater core and evaporator core housing (19B555). For additional information, refer to «HEATING & VENTILATION»(ref-212120) .

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1. Remove the condenser to evaporator line (19835). For additional information, refer to «CONDENSER TO EVAPORATOR LINE»(ref-212122-S18337460522005122300000) .
2. Pull back the protective cover.
3. Index-mark and disconnect the two halves of the condenser to evaporator line. Discard the O-ring seal.
4. Inspect the evaporator core orifice (19D990) for damage.
5. Engage the special tool with the evaporator core orifice.
6. Holding the special tool T-handle stationary, rotate the special tool body to remove the evaporator core orifice.
7. Screw the end of the special tool into the broken evaporator core orifice.
8. Holding the special tool T-handle stationary, rotate the special tool body to remove the broken evaporator core orifice.

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1. Install new O-ring seals on the evaporator core orifice. Lubricate the new O-ring seals with mineral oil or equivalent.
2. Position the evaporator core orifice in the special tool.
3. Using the special tool, install the evaporator core orifice.
4. Install a new O-ring seal lubricated in clean mineral oil, align the index marks and connect the two halves of the condenser to evaporator line.
5. Position the protective cover over the evaporator core orifice connection.
6. Install the condenser to evaporator line. For additional information, refer to «CONDENSER TO EVAPORATOR LINE»(ref-212122-S18337460522005122300000) .

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Note. Installation of a new suction accumulator 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 suction accumulator.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
2. Remove the two bolts and remove the roll restrictor.
3. Remove the bolts and position aside the roll restrictor bracket.
4. Position the degas bottle aside. Disconnect the hose. Remove the bolt and nut. Position the degas bottle aside.
5. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-212100) .
6. Remove the two LH roll restrictor crossmember bolts.
7. Remove the RH roll restrictor crossmember bolt.
8. Remove the four bolts and position the RH roll restrictor bracket aside.
9. Detach the wire harness. Remove the nut. Detach the wire harness.
10. Remove the nut.
11. Remove the stud.
12. Disconnect the spring lock coupling at the evaporator outlet. Discard the O-ring seals.
13. Disconnect the vacuum lines.
14. Disconnect the suction accumulator spring lock coupling. Discard the O-ring seals.
15. Disconnect the A/C low charge protection switch electrical connector.
16. Remove the screw.
17. Remove the suction accumulator (19C836).
18. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
19. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .

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Note. Installation of a new suction accumulator 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 suction accumulator.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
2. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
3. Remove the two bolts.
4. Remove the four pin-type retainers and the grille.
5. Remove the two pin-type retainers.
6. Remove the lower radiator air deflector. Remove the five screws. Remove the air deflector, if equipped. Remove the seven screws and the lower radiator air deflector.
7. Remove and discard the plastic wire tie.
8. Disconnect the condenser core refrigerant lines. Discard the O-ring seals.
9. Remove the pin-type retainers and the LH and RH side air deflectors.
10. Remove the bolts.
11. Remove the bolt.
12. Carefully lower and remove the condenser core.
13. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
14. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .

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Note. Installation of a new suction accumulator 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 suction accumulator.

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1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
2. Position the vehicle on a hoist with the gear selector in NEUTRAL. For additional information, refer to «JACKING & HOISTING»(ref-163061-S26137620762004061700000) .
3. Remove the lower radiator air deflector. Remove the five screws. Remove the air deflector, if equipped. Remove the seven screws and the lower radiator air deflector.
4. Disconnect the compressor manifold and tube assembly fitting at the condenser. Discard the O-ring seal.
5. Lower the vehicle.
6. Remove the engine oil indicator and position the ignition coil aside. Remove the engine oil indicator. Remove the bolts. Position the ignition coil aside.
7. Disconnect the compressor manifold and tube assembly spring lock coupling at the suction accumulator. Discard the O-ring seals.
8. Remove the compressor manifold and tube assembly. Disconnect the pressure cutoff switch. Remove the bolt. Remove the compressor manifold and tube assembly. Discard the O-ring seals.
9. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .

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Note. Installation of a new suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

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1. Remove the A/C compressor (19703). For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L (4V)»(ref-212122-S06810974062005122300000) .
2. Disconnect the electrical connectors and detach the wire harness.
3. Remove the dual function pressure switch.
4. Disconnect the compressor manifold and tube assembly fitting at the condenser. Discard the O-ring seals.
5. Remove the compressor manifold and tube assembly.
6. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil.

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Note. Installation of a new suction accumulator 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 suction accumulator.

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1. Remove the suction accumulator (19C836). For additional information, refer to «SUCTION ACCUMULATOR»(ref-212122-S21830220622005122300000) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
3. Disconnect the compressor manifold and tube fitting at the suction accumulator. Discard the O-ring seals.
4. Clamp off and disconnect the coolant hoses at the degas bottle.
5. Remove the bolts.
6. Remove the lower radiator air deflector. Remove the five screws. Remove the air deflector, if equipped. Remove the seven screws and the lower radiator air deflector.
7. Disconnect the condenser to evaporator line at the condenser. Discard the O-ring seal.
8. Remove the bolt and the fuel line bracket.
9. Remove the bolt and the fuel line bracket.
10. Disconnect the fuel line.
11. Remove the suction accumulator line nut.
12. Remove the suction accumulator bracket screw.
13. Disconnect the condenser to evaporator line spring lock coupling at the evaporator core inlet. Discard the O-ring seals.
14. Remove the condenser to evaporator line.
15. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil.
16. To install, reverse the removal procedure. Install new O-ring seals lubricated in clean mineral oil. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .
17. Evacuate, leak test and charge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-212118) .