HVAC - Climate Control System: Removal & Installation Ford Transit VII

Removal and Installation

Note. If installing a new Air Conditioning (A/C) compressor due to an internal failure of the old unit, the following procedures must be carried out to remove contamination from the A/C system. Failure to remove contamination from the A/C system, if present, will result in poor A/C system performance and/or damage to the new A/C compressor and other components. If A/C flushing equipment is available, carry out the A/C system flushing procedure prior to installing a new A/C compressor. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS . If A/C flushing equipment is not available, carry out the refrigerant system filtering procedure following A/C compressor installation. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS . Install a new evaporator core orifice, as directed by the A/C flushing or filtering procedure. Install a new suction accumulator as directed by the A/C flushing or filtering procedure.

Note. Installation of a new suction accumulator is not required when repairing the A/C system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator. Damage to the suction accumulator includes leaks in the suction accumulator, physical damage to the suction accumulator shell or desiccant, or moisture contamination. Moisture contamination results only from a complete loss of refrigerant, and equalization of the refrigerant system pressure with atmospheric pressure for a period longer than one hour. If even a slight amount of positive refrigerant pressure is present, and physical evidence of contamination from an A/C compressor failure is not present in the system before repairs are carried out, a new suction accumulator should not be installed.

Scheme 1

Scheme 2

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Remove the lower radiator air deflector.
4. Remove the 2 drive belt shield bolts and the shield.
5. Release the drive belt tensioner and remove the drive belt from the A/C compressor pulley.
6. Remove the compressor-to-condenser discharge line bracket nut from the lower rear A/C compressor stud-bolt.
7. Remove the power steering line bracket nut at the transmission. To install, tighten to 9 Nm (80 lb-in).
8. Remove the A/C compressor suction and discharge fitting nuts and disconnect the fittings. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
9. Disconnect the clutch field coil electrical connector.
10. Remove the 2 A/C compressor bolts and the A/C compressor stud-bolt. To install, tighten to 25 Nm (18 lb-ft).
11. Remove the A/C compressor.
12. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
13. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Remove the A/C pressure relief valve. To install, tighten to 10 Nm (89 lb-in).
4. To install, reverse the removal procedure. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
5. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

Scheme 3

ITEM DESCRIPTION CHART - AIR INLET DUCT

Scheme 4

1. Remove the heater core and evaporator core housing. For additional information, refer to «HEATER CORE AND EVAPORATOR CORE HOUSING»(ref-356792-S19309043542010022700000) .
2. Remove the floor duct screw and the floor duct.
3. Remove the 2 air inlet duct screws.
4. Remove the 4 air inlet duct clips.
5. Detach and remove the air inlet duct.
6. To install, reverse the removal procedure.

Scheme 5

ITEM DESCRIPTION CHART - BLOWER MOTOR

1. Remove the RH lower instrument panel insulator.
2. Remove the floor duct screw and the floor duct.
3. Disconnect the blower motor electrical connector.
4. Remove the 3 blower motor screws.
5. Remove the blower motor.
6. To install, reverse the removal procedure.

Scheme 6

ITEM DESCRIPTION CHART - BLOWER MOTOR RESISTOR

Scheme 7

1. Lower the glove compartment.
2. Disconnect the blower motor resistor electrical connector.
3. Remove the blower motor resistor. Disconnect the blower motor resistor electrical connector. Remove the blower motor resistor screw. Detach and remove the blower motor resistor.
4. To install, reverse the removal procedure.

Scheme 8

ITEM DESCRIPTION CHART - BLOWER MOTOR SWITCH

1. Remove the floor console. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-356767) .
2. Remove the blower motor switch knob.
3. Remove the blower motor switch screw.
4. Rotate the blower motor switch to disengage it from the climate control assembly and remove the blower motor switch.
5. To install, reverse the removal procedure.

Scheme 9

ITEM DESCRIPTION CHART - CLIMATE CONTROL ASSEMBLY

1. Remove the floor console. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-356767) .
2. Remove the 4 climate control assembly screws.
3. Remove the climate control assembly.
4. To install, reverse the removal procedure.

Installation

Note. The A/C clutch components should be reused unless obvious signs of damage are found.

Scheme 10

Scheme 11

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 4 A/C clutch field coil screws.
5. Install the A/C compressor pulley. Install the A/C compressor on a suitable press. Position the A/C compressor pulley on the A/C compressor. Install the A/C Clutch Installer on the A/C compressor pulley. Using the press, install the A/C compressor pulley.
6. Install the A/C compressor pulley snap ring with the bevel side out.
7. Install one medium thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
8. Install the A/C clutch disc and hub.
9. Install the A/C compressor clutch disc and hub bolt. Hold the A/C clutch disc and hub with a suitable spanner-type wrench. Tighten the bolt to 20 Nm (177 lb-in).
10. Measure and adjust the clutch air gap by removing, replacing or adding A/C clutch disc and hub spacers.
11. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR»(ref-356792-S40562785132010022700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Remove the high-pressure service gauge port valve extension bracket nut.
4. Remove the 4 lower radiator air deflector pin-type retainers and the lower radiator air deflector.
5. Remove the 3 RH lower splash shield screws, the RH lower splash shield pin-type retainer and the RH lower splash shield.
6. Remove the 2 LH lower splash shield screws, the LH lower splash shield pin-type retainer and the LH lower splash shield.
7. Remove the condenser-to-evaporator line bracket nut at the lower radiator support. Discard the O-ring seal and gasket seal. To install, tighten to 11 Nm (97 lb-in).
8. Position a suitable jackstand below the lower radiator support to support the cooling module.
9. Remove the 4 lower radiator support bolts and the lower radiator support. To install, tighten to 25 Nm (18 lb-ft).
10. Remove the compressor-to-condenser discharge line bracket nut. Discard the O-ring seal and gasket seal.
11. Remove the A/C compressor suction fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 15 Nm (133 lb-in).
12. 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 (133 lb-in).
13. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 9 Nm (80 lb-in).
14. Remove the compressor-to-condenser discharge line.
15. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
16. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Remove the 4 lower radiator air deflector pin-type retainers and the lower radiator air deflector.
4. Remove the 3 RH lower splash shield screws, the RH lower splash shield pin-type retainer and the RH lower splash shield.
5. Remove the 2 LH lower splash shield screws, the LH lower splash shield pin-type retainer and the LH lower splash shield.
6. Remove the condenser-to-evaporator line bracket nut at the lower radiator support. To install, tighten to 11 Nm (97 lb-in).
7. Position a suitable jackstand below the lower radiator support to support the cooling module.
8. Remove the 4 lower radiator support bolts and the lower radiator support. To install, tighten to 25 Nm (18 lb-ft).
9. Remove the condenser outlet and inlet fitting nuts and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 9 Nm (80 lb-in).
10. Detach the transmission cooler from the condenser core (if equipped).
11. Using a suitable rubber mallet, gently tap the condenser core toward the RH side of the vehicle, while holding the condenser bracket in-place, to detach the condenser core from the bracket.
12. Remove the condenser core.
13. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
14. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Remove the RH inner fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-356793) .
4. Disconnect the A/C pressure transducer electrical connector.
5. Remove the condenser-to-evaporator line bracket nut at the lower radiator support. To install, tighten to 11 Nm (97 lb-in).
6. Remove the condenser outlet fitting nut and disconnect the fitting. Discard the O-ring seal and gasket seal. To install, tighten to 9 Nm (80 lb-in).
7. Detach the condenser-to-evaporator line from the 2 line brackets at the RH front wheel well.
8. Disconnect the evaporator inlet fitting. Discard the O-ring seals.
9. Remove the condenser-to-evaporator line.
10. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Disconnect the evaporator outlet fitting. Discard the O-ring seals.
4. Disconnect the A/C cycling switch electrical connector.
5. Remove the RH fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-356793) .
6. Disconnect the suction accumulator inlet fitting. Discard the O-ring seals.
7. Detach the evaporator outlet line from the 2 line routing clips.
8. Remove the evaporator outlet line.
9. To install, reverse the removal procedure. Install new gasket seals and O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

Scheme 12

ITEM DESCRIPTION CHART - FUNCTION SELECTOR SWITCH

Note. The function selector switch is supplied as an assembly with the function selector cable assembly.

1. Remove the floor console. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-356767) .
2. Remove the function selector switch knob.
3. Remove the function selector switch screw.
4. Rotate the function selector switch to disengage it from the climate control assembly and remove the function selector switch and cable assembly.
5. To install, reverse the removal procedure.

Scheme 13

ITEM DESCRIPTION CHART - LH/RH FLOOR DUCT

Scheme 14

ITEM DESCRIPTION CHART - HEATER CORE COVER

Scheme 15

ITEM DESCRIPTION CHART - HEATER CORE

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

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-356777) .
3. Remove the floor console. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-356767) .
4. Remove the RH lower instrument panel insulator.
5. Remove the screw and the floor duct.
6. Release the 2 heater hose clamps and disconnect the heater hoses from the heater core.
7. Remove the 6 in-vehicle crossbeam bracket bolts and remove the brackets (RH shown in illustration). To install, tighten to 25 Nm (18 lb-ft).
8. Remove the LH floor duct clip between the heater core and evaporator core housing and the dash panel.
9. Remove the LH floor duct. Remove the LH floor duct clip Remove the LH floor duct screw. Remove the LH floor duct.
10. Remove the RH floor duct. Remove the RH floor duct clip. Remove the RH floor duct screw. Remove the RH floor duct.
11. Remove the heater core cover. Remove the 2 heater core cover screws. Remove the 2 heater core cover clips. Release the heater core cover tab and remove the heater core cover and heater core as an assembly.
12. Remove the heater core tube bracket screw.
13. Remove the heater core.
14. To install, reverse the removal procedure.
15. Fill the engine coolant level. For additional information, refer to «ENGINE COOLING»(ref-356777) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
4. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-356767) .
5. Remove the evaporator drain tube.
6. Release the 2 heater hose clamps and disconnect the 2 heater hoses from the heater core.
7. Remove the 2 Evaporative Emission (EVAP) canister purge valve heat shield pin-type retainers and position the shield aside.
8. Disconnect the evaporator outlet fitting. Discard the O-ring seals.
9. Disconnect the evaporator inlet fitting. Discard the O-ring seals.
10. Remove the 2 exterior heater core and evaporator core housing nuts. To install, tighten to 7 Nm (62 lb-in).
11. Remove the 2 interior heater core and evaporator core housing nuts. To install, tighten to 7 Nm (62 lb-in).
12. Remove the heater core and evaporator core housing.
13. To install, reverse the removal procedure. Install new O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
14. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-356777) .
15. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .

Scheme 22

ITEM DESCRIPTION CHART - AIR INLET MODE DOOR ACTUATOR

1. Remove the blower motor resistor. For additional information, refer to «BLOWER MOTOR RESISTOR»(ref-356792-S21499738812010022700000) .
2. Remove the 3 air inlet mode door actuator screws.
3. Disconnect the air inlet mode door actuator electrical connector.
4. Remove the air inlet mode door actuator.
5. To install, reverse the removal procedure.

Scheme 23

ITEM DESCRIPTION CHART - CENTER REGISTER

Scheme 24

ITEM DESCRIPTION CHART - LH REGISTER

Scheme 25

ITEM DESCRIPTION CHART - RH REGISTER

Center register

1. Remove the upper center instrument panel finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(ref-356767) . LH register
2. Remove the LH instrument panel end panel. RH register
3. Lower the glove compartment.
4. Remove the RH instrument panel end panel. All registers
5. Release the 3 register retaining tabs and push the register out of the register opening.
6. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-356737) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
3. Remove the RH fender splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-356793) .
4. Remove the suction accumulator outlet fitting nut and disconnect the fitting. Discard the O-ring seal. To install, tighten to 9 Nm (80 lb-in).
5. Remove the suction accumulator bracket nut. To install, tighten to 11 Nm (97 lb-in).
6. Remove the 2 suction accumulator bolts. To install, tighten to 7 Nm (62 lb-in).
7. Disconnect the suction accumulator outlet fitting. Discard the O-ring seals.
8. Remove the suction accumulator.
9. To install, reverse the removal procedure. Install new O-ring seals. Add the correct amount of clean PAG oil to the refrigerant system. For additional information, refer to the Refrigerant Oil Adding procedure in «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-356746) .