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HVAC System: Removal & Installation Ford Windstar I

Heater 27 illustrations ~1694 words

REMOVAL & INSTALLATION

WARNINGVehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering column, instrument panel or related components, see service PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT SYSTEMS article.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.
  1. Disconnect battery ground cable.
  2. Remove ashtray and cup holder assembly, by depressing service lever and pulling assembly outward. (Scheme 10)
  3. Remove two trim panel retaining screws over ashtray cup holder assembly cavity.
  4. Remove trim panel by grasping outer edges and pulling carefully outward until retaining clips release panel. (Scheme 11)
  5. Disconnect electrical connectors from finish panel components.
  6. Remove four control assembly retaining screws.
  7. Disconnect electrical connectors and vacuum connector from control assembly.
  8. Remove control assembly. (Scheme 12)
  9. To install, reverse removal procedure.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12
  1. Remove control assembly. See «CONTROL ASSEMBLY»(ref-138026-S36715671972002031800000) .
  2. Remove bulb socket and holder by rotating until it unlocks, and lift out.
  3. To install, reverse removal procedure.
  1. Grasp knob firmly and pull off.
  2. To install, push knob on.
  1. Remove control assembly from instrument panel. See «CONTROL ASSEMBLY»(ref-138026-S36715671972002031800000).
  2. Remove switch knob.
  3. Disconnect electrical connector from heater blower motor switch. (Scheme 13)
  4. Remove retaining screw.
  5. Rotate heater blower motor switch counterclockwise, lift and remove.
  6. To install, reverse removal procedure.

Scheme 13

Scheme 13
Scheme 13
  1. Remove control assembly from instrument panel. See «CONTROL ASSEMBLY»(ref-138026-S36715671972002031800000).
  2. Pull knob off temperature control potentiometer shaft. (Scheme 14)
  3. Remove retaining screw.
  4. Rotate temperature control potentiometer counterclockwise.
  5. Lift and remove temperature control potentiometer.
  6. To install, reverse removal procedure.

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15: Removal & Installation
Scheme 15: Removal & Installation
  1. Remove control assembly. See «CONTROL ASSEMBLY»(ref-138026-S36715671972002031800000).
  2. Grasp function selector switch knob firmly and pull off. (Scheme 15)
  3. Remove retaining screw.
  4. Rotate function control switch clockwise.
  5. Lift and remove mode selector switch.
  6. To install, reverse removal procedure.

Note. The passenger side instrument panel register is removed by pulling outward until it unclips and is installed by carefully pushing inward until the retaining clips are fully seated.

  1. Remove ashtray and cup holder by depressing service lever. (Scheme 16)
  2. Remove trim panel screws over ashtray and cup holder cavity.
  3. Remove trim panel by grasping the edges and pulling outward until retaining clips release.
  4. Remove headlamp switch knob.
  5. Remove headlamp switch knob bezel by pulling outward until retaining clips release.
  6. Remove two screws retaining upper steering column trim panel and remove panel. (Scheme 17)
  7. Remove two screws retaining register trim panel over instrument panel. (Scheme 18)
  8. Carefully pull register panel outward until retaining clips release. (Scheme 19)
  9. To install, reverse removal procedure.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19
  1. Disconnect battery ground cable.
  2. Remove cowl top vent panel. (Scheme 20) Remove wiper arms. See appropriate WIPER/WASHER SYSTEMS article.
  3. Disconnect the Black vacuum source hose from the vacuum reservoir which is mounted on the side of the fresh air inlet duct.
  4. Remove the one upper screw and two lower nuts from the fresh air inlet duct.
  5. Drain radiator and disconnect heater hoses at the heater core in the engine compartment.
  6. Remove ground strap attachment from heater core tube, if equipped.
  7. Remove instrument panel. See appropriate INSTRUMENT PANELS article.
  8. Disconnect blower motor resistor and temperature blend door actuator electrical harness connectors.
  9. Disconnect the vacuum harness connector.
  10. Remove nut from support bracket at left end of A/C evaporator housing assembly. (Scheme 21)
  11. Remove four nuts retaining A/C evaporator housing, located in the engine compartment. (Scheme 21)
  12. Carefully remove A/C evaporator housing assembly. To install, reverse removal procedure.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Note. When servicing heater core, and engine cooling system components, do not reuse constant tension (Mubea) hose clamps. Discard them and replace with suitable worm-gear type hose clamps.

  1. Disconnect battery ground cable.
  2. Drain engine coolant system.
  3. Remove cowl top vent panel for clearance.
  4. Disconnect heater water hoses from heater core inlet and outlet tubes in the engine compartment.
  5. Remove ground strap attachment (if present) from heater core tube
  6. Remove cassette box/center instrument panel support trim.
  7. Pull out and remove cup holder.
  8. Remove rear seat air flow duct.
  9. Disconnect keyless entry wiring harness, if equipped.
  10. Remove center instrument panel support brackets.
  11. Disconnect climate control vacuum line connector.
  12. Remove heater floor duct.
  13. Remove heater core cover retaining screws and remove heater core cover.
  14. Remove heater core. (Scheme 22)and (Scheme 23). To install, reverse removal procedure.

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23
  1. Remove heater core and A/C evaporator housing assembly. See «EVAPORATOR HOUSING»(ref-138026-S22211981512002031800000) and «HEATER CORE»(ref-138026-S29991192442002031800000) .
  2. Disconnect vacuum line connector from vacuum control motor.
  3. Remove four screws retaining recirculating air duct to heater core and A/C evaporator housing assembly.
  4. Remove duct.
  5. To install, reverse removal procedure.

For removal and installation of windshield defroster nozzle and demister, refer to illustrations. (Scheme 24)and (Scheme 25).

Scheme 24

Scheme 24: Removal & Installation
Scheme 24: Removal & Installation

Scheme 25

Scheme 25
Scheme 25
  1. Remove cassette storage box or lower console shelf assembly if equipped.
  2. Remove push-pin retaining rear seat air flow duct.
  3. Remove rear seat air flow duct.
  4. Remove screws attaching heater outlet floor duct to A/C evaporator housing assembly just below heater outlet floor duct.
  5. Pull heater outlet floor duct away from evaporator case.
  6. To install, reverse removal procedure. Make sure retainer at forward edge of heater outlet floor duct is inserted over edge of opening in A/C evaporator housing.
  1. Lift cowl top vent panel. (Scheme 20) Disconnect windshield washer hose from cowl top vent panel. Remove cowl top vent panel.
  2. Disconnect two vacuum hoses from vacuum reservoir on side of air inlet duct. (Scheme 26)
  3. Remove screw and two nuts from studs at dash.
  4. Remove air inlet duct. To install, reverse removal procedure.

Scheme 26

Scheme 26
Scheme 26
  1. Remove instrument panel. See appropriate INSTRUMENT PANELS article.
  2. Remove all retaining screws, including the screw retaining the instrument panel to the cross beam and bracket. (Scheme 27)
  3. Remove instrument panel duct assembly.
  4. To install, reverse removal procedure.

Scheme 27

Scheme 27
Scheme 27

Note. Three insert nuts are used to secure the blower motor to the housing and can be serviced. Tighten to 2 N-M (18 lb-in).

  1. Disconnect battery ground cable.
  2. Remove glove compartment door completely, and position it out of the way.
  3. Disconnect heater blower motor electrical connector.
  4. Remove blower motor vent tube from blower motor.
  5. Remove four heater blower motor assembly retaining screws.
  6. Remove blower motor assembly. (Scheme 28)or (Scheme 29).
  7. Carefully remove blower wheel retaining push-nut from blower motor shaft.
  8. Remove blower wheel from heater blower motor shaft.
  9. To install, reverse removal procedure.

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Note. The heater blower motor resistor and thermal limiter assembly are installed on the bottom passenger side of the heater case behind the glove compartment. Use only the specified heater blower motor resistor assembly for service replacement. Do not apply sealer to the resistor board mounting surface.

  1. Locate heater blower motor resistor assembly, under the passenger side of the instrument panel. (Scheme 30)
  2. Disconnect wire harness connector from heater blower motor resistor.
  3. Remove two retaining screws and remove heater blower motor resistor from A/C evaporator housing.
  4. To install, position heater blower motor resistor in A/C evaporator housing opening and install two retaining screws. Do not apply sealer to heater blower motor switch resistor assembly mounting surface.
  5. Connect wire harness connector to heater blower motor resistor.
  6. Check operation of blower motor.

Scheme 30

Scheme 30
Scheme 30

Note. It is necessary to replace the whole heater blower motor resistor when replacing heater blower motor thermal limiter. See HEATER BLOWER MOTOR RESISTOR ASSEMBLY .

Note. The heater air inlet duct door is integral to the air inlet duct, and is not serviced separately. See AIR INLET DUCT .

Note. The heater air damper door is integral to the heater case, and is not serviced separately. See EVAPORATOR HOUSING .

Note. The windshield defroster door is integral to the heater case, and is not serviced separately. See EVAPORATOR HOUSING .

  1. Disconnect vacuum hose connectors from vacuum control motor, Yellow hose from side of unit, Blue hose from end of unit.
  2. Remove push-pin from end of shaft. (Scheme 31)
  3. Remove two mounting screws and remove vacuum control motor. (Scheme 32)
  4. To install, reverse removal procedure.

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32
  1. Disconnect vacuum hose connectors, Red hose from side, Green hose from end of vacuum control motor.
  2. Remove two retaining screws from vacuum control motor.
  3. Rotate vacuum control motor until shaft is clear of retainer.
  4. Lift shaft off mounting pin and remove vacuum control motor.
  5. To install, reverse removal procedure.
  1. Disconnect Orange vacuum hose.
  2. Remove two screws retaining vacuum control motor.
  3. Rotate vacuum control motor until shaft is clear of retainer.
  4. Lift shaft off mounting pin and remove vacuum control motor.
  5. To install, reverse removal procedure.
  1. Remove instrument panel. See appropriate INSTRUMENT PANELS article.
  2. Remove each hose from the air duct (driver's side demister) and the demister elbow (passenger side) by carefully rotating and pulling outward and away.
  3. To install, reverse removal procedure.

Removal & Installation (3.0L)

  1. Drain the coolant from the cooling system.
  2. Loosen the clamps and remove the heater water hose from the vehicle. (Scheme 33)
  3. Route the heater water hose following route of original or removed hose exactly.
  4. Connect the heater water hose to the fittings, and tighten the clamps to 1.81-2.49 N-M (17-22 lb-in). DO NOT overtighten the hose clamps.
  5. Fill and bleed the cooling system. See appropriate COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article.
  6. Check for coolant leaks and for proper operation of the system.

Scheme 33

Scheme 33
Scheme 33

Removal (1998 3.8L)

DescriptionTool Number
Heater Hose Disconnect ToolT85T-18539-AH

SPECIAL SERVICE TOOL(S) REQUIRED

  1. Drain the coolant from the cooling system.
  2. Push the heater water hose toward the engine to fully expose the locking tabs.
  3. When compressing the White coupling retainer, the Heater Hose Disconnect Tool (T85T-18539-AH) must be perpendicular to and on the highest point of the coupling. See «SPECIAL TOOLS»(ref-138026-S13909532862002032200000).
  4. Pull the heater water hose away from the engine.
  5. Spread the retainer tabs apart and slide the retainer off the tube. Discard the retainer. (Scheme 34)
  6. Loosen the clamps at the remaining connections and remove the heater water hoses from the vehicle. Note routing for installation procedure.

Scheme 34

Scheme 34
Scheme 34

Installation

  1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube (E25Y-19553-A) or equivalent meeting Ford specification.
  2. Route the heater water hoses following route of original or removed hose exactly. (Scheme 36)
  3. Connect the heater water hose to the fittings and install clamps.
  4. Push the heater water hose with a quick disconnect coupling onto the tube. (Scheme 35) Make sure the coupling is fully engaged by lightly pulling on the heater water hose.
  5. Fill and bleed the cooling system. See appropriate COOLING SYSTEM SPECIFICATIONS & DRIVE BELT ROUTING article.
  6. Check for coolant leaks and for proper operation of the system.

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

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