Automatic A/c-Heater Systems: Removal & Installation Lincoln LS I

Programmable Module Installation (PMI)

Programmable Module Installation (PMI) method is used when a new programmable module is installed on vehicle. It is no longer necessary to command the diagnostic tool to download parameters from old module. NGS tester automatically obtains any available module option content information from old module during the vehicle ID routine that runs when scan tool is initially connected to vehicle. It is important that you connect WDS to the vehicle and allow it to identify the vehicle and obtain configuration data prior to removing any modules, if possible.

REMOVAL & INSTALLATION

Disconnect negative battery cable. A/C cycling switch is mounted on a Schrader valve. It is not necessary to discharge refrigerant system. Disconnect harness connector from A/C cycling switch. Remove A/C cycling switch. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil.

Disconnect negative battery cable. Raise vehicle on hoist. Remove lower radiator air deflector. Disconnect connector and remove A/C pressure cut-off switch. To install, reverse removal procedure.

Disconnect negative battery cable. Remove radiator sight shield. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Raise vehicle on hoist. Remove radiator air deflector. Remove A/C pressure relief valve from side of manifold and tube assembly. To install, reverse removal procedure. Use new "O" ring coated with clean refrigerant oil. Evacuate, charge, and leak test A/C system.

Disconnect negative battery cable. Remove ambient sensor bracket screws, disconnect harness connector and remove ambient air temperature sensor. To install, reverse removal procedure.

Disconnect negative battery cable. Remove passenger's side floor duct. Remove 3 screws from cover. Disconnect harness connector. Remove blower motor. To install, reverse removal procedure.

Remove evaporator core housing. See EVAPORATOR/HEATER CORE HOUSING . Disconnect blower motor speed control harness connector. Remove air inlet-to-evaporator housing screws. Remove blower motor speed control mounting screw. Disengage clip and separate air inlet and evaporator housings. Remove blower motor speed control. To install, reverse removal procedure.

Remove 2-piece pin retainers. Separate Velcro(R) attachment of rubber hinge cover to rear outboard corner of cowl vent screen. Pull up on cowl vent screen to release lower clips. Remove right side cowl vent screen. Push on right hand corner of air filter to release clip and remove filter. To install, reverse removal procedure.

Remove cabin air filter. See CABIN AIR FILTER . Remove 7 cross-vehicle support bolts. Remove 4 cabin air filter housing bolts and remove cabin air filter housing by lifting outboard side, then remove housing. Remove 2 bolts and remove plenum panel. To install, reverse removal procedure.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove accessory drive belt. Disconnect negative battery cable.
2. Raise vehicle on hoist. Remove sight shield. On models with 3.9L engine, remove and position power steering hose aside. On all models, remove A/C manifold and tube assembly bolt and position aside. Cap openings immediately. Disconnect A/C compressor clutch harness connector. Support compressor and remove compressor mounting bolts. Remove compressor.
3. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Measure and replace oil in new compressor. See COMPRESSOR OIL CHECKING article in GENERAL SERVICING. Evacuate, charge, and leak test A/C system.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect air outlet tube and position aside. Disconnect pressure transducer harness connector. Remove nut from peanut fitting and disconnect peanut fitting.
2. Raise vehicle on hoist. Remove left and right sight shields. Remove 5 screws and remove air deflector. Remove refrigerant line bracket bolt. Disconnect spring lock coupling. Loosen bolt and remove A/C compressor manifold and tube assembly (refrigerant line).
3. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Apply pipe sealant to manifold bolt. Evacuate, charge, and leak test A/C system.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect air outlet tube and position aside. Remove nut and disconnect peanut fitting from A/C discharge line.
2. Raise vehicle on hoist. Remove screws and remove left sight shield. Remove 5 air deflector screws and remove air deflector. Disconnect peanut fitting from receiver-drier. Plug all openings. Remove left condenser mounting bolt. Support condenser and remove right mounting bolt. Lower condenser core to remove.
3. To install, reverse removal procedure. Add one ounce of new refrigerant oil to condenser during installation. Use new "O" rings coated with clean refrigerant oil. Evacuate, charge, and leak test A/C system.

1. Disconnect negative battery cable. Remove ashtray finish panel. Using a mini-pick, insert it into center register and pull to remove register from instrument panel.
2. Remove 4 screws from DATC module and radio assembly and pull away from instrument panel. Disconnect harness connectors. Remove 4 screws from each side of control assembly and remove DATC module.
3. To install, reverse removal procedure. If installing a new DATC, it is necessary to configure the new DATC. See «DATC MODULE CONFIGURATION»(ref-96435-S23821327282001043000000) under PROGRAMMING.

Disconnect negative battery cable. Disconnect harness connector. Using a rocking motion, remove sensor. To avoid damage to sensor or housing, DO NOT twist sensor during removal. To install, reverse removal procedure.

Removal & Installation (Floor Duct Door)

Disconnect negative battery cable. Remove driver's side instrument panel insulator. Remove left side floor duct. Disconnect floor duct door harness connector. Remove 3 mounting screws and remove actuator. To install, reverse removal procedure. If reinstalling an actuator removed from vehicle, align arrow on actuator housing with line on actuator coupling. (Scheme 33)

Scheme 32

Removal & Installation (Cold Air By-Pass Door)

Disconnect negative battery cable. Remove driver's side instrument panel insulator. Disconnect harness connector Remove left side floor duct. Disconnect actuator harness connector. Remove 3 mounting screws and remove cold air by-pass door actuator. To install, reverse removal procedure. If reinstalling an actuator removed from vehicle, align arrow on actuator housing with line on actuator coupling. (Scheme 34)

Scheme 33

Removal & Installation (Defrost Door)

Remove instrument panel. See INSTRUMENT PANEL. Disconnect actuator harness connector. Remove 3 mounting screws. To install, reverse removal procedure. If installing an actuator removed from vehicle, align arrow on actuator housing with line on actuator coupling. (Scheme 35)

Scheme 34

Scheme 35

1. Disconnect negative battery cable. Remove instrument panel. See «INSTRUMENT PANEL»(ref-96435-S06684462502001042700000). Disconnect link end from center console door. Remove mounting screws and remove panel/floor console door actuator.
2. To install, reverse removal procedure. If reinstalling an actuator removed from vehicle, align arrow on actuator housing with line on actuator housing. see scheme 18 Position actuator and door fully open or fully closed. Manually position floor console door fully open or fully closed and then install the link. Verify door position by checking airflow to panel and floor console.

Remove evaporator/heater core housing. See EVAPORATOR/HEATER CORE HOUSING . Remove air inlet housing-to-evaporator housing screws. Disengage clip and separate housing. Remove gasket. Remove 9 screws and clip and separate evaporator/heater core housing. Remove evaporator core. Disconnect thermostatic expansion valve. To install, reverse removal procedure.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain coolant level to below heater core level. Disconnect heater hose assembly from heater core.
2. Disconnect manifold and tube assembly from thermostatic expansion valve. Remove instrument panel. See «INSTRUMENT PANEL»(ref-96435-S06684462502001042700000) . Disconnect harness connector at top of evaporator core housing. Remove cowl top attachment bolt.
3. From engine compartment, remove evaporator housing attachment bolt and 3 nut and washer assemblies retaining evaporator housing to bulkhead. Remove 2 push pins from rear seat floor ducts. Remove evaporator core housing. To install, reverse removal procedure.

Remove heater core housing. See EVAPORATOR/HEATER CORE HOUSING . Remove evaporator/heater core housing-to-air inlet housing screws. Disengage clip and separate evaporator core housing from air inlet housing. Remove blower motor speed control. Remove gasket. Remove 9 screws, disengage clip and separate housing. Disconnect air by-pass door harness connector and position harness aside. Remove screws and heater core. To install, reverse removal procedure.

Disconnect negative battery cable. Remove instrument cluster finish panel. Disconnect harness connector. Disconnect aspirator hose and remove in-car air temperature sensor. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Position steering wheel straight ahead. Remove driver's air bag. Remove floor console and console A/C duct. Remove automatic transmission selector lever assembly (if equipped). Remove 2 pin retainers and passenger's side instrument panel insulator. Disconnect courtesy light harness connector.
2. Remove driver's and passenger's scuff plates. Position door weatherstrips aside. Remove "A" pillar lower trim panels and windshield side garnish moldings. Remove instrument panel defrost opening grille assembly. Remove instrument panel cowl panel top screws. Loosen instrument panel upper reinforcement bolts.
3. Remove instrument panel side panels. Remove hood release handle assembly and place aside. Disconnect upper right hand bulkhead connector. Disconnect passenger's side harness connectors through instrument panel opening. Disconnect passenger's side tunnel harness connector.
4. Remove intermediate shaft pinch bolt and separate intermediate shaft from steering column. Move carpet aside and disconnect driver's side junction box harness connector. Disconnect driver's side harness connectors through instrument panel side opening.
5. Disconnect ignition shift interlock harness connector (if equipped). Move carpet aside and remove 4 instrument panel tunnel brace bolts. Remove driver's side outer instrument panel cowl side cover and reinforcement bolt. Remove driver's and passenger's side instrument panel cowl side bolts and nuts.
6. With an assistant, carefully remove instrument panel from vehicle. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-96435-S22123667782001041300000) .

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove pressure relief valve. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Evacuate, charge, and leak test A/C system.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Raise vehicle on hoist. Remove left side sight shield. Remove air deflector. Disconnect peanut fitting. Cap all openings.
2. Lower vehicle. Disconnect air outlet tube. Disconnect refrigerant line from top of receiver-drier. Cap all openings to keep moisture out. Remove receiver-drier bracket screw and move receiver-drier away from radiator. Disconnect receiver-drier from manifold.
3. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Add proper amount of new refrigerant oil to receiver-drier prior to installation. See COMPRESSOR OIL CHECKING article in GENERAL SERVICING. Evacuate, charge, and leak test A/C system.

Removal & Installation (3.0L Engine)

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect A/C discharge line peanut fitting. Disconnect peanut fitting from receiver-drier line. Remove nut at top of receiver-drier. Cap all openings.
2. Remove receiver drier mounting bracket clamp bolt. Move receiver drier away from fan shroud and remove receiver drier. Remove receiver-drier manifold assembly (refrigerant line).
3. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Apply pipe sealant to manifold bolt. Evacuate, charge, and leak test A/C system.

Removal & Installation (3.9L Engine)

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Raise vehicle on hoist. Disconnect high-side line peanut fitting. Remove 5 air deflector pan screws and remove air deflector pan. Remove 2 push-pin retainers and 4 side clip retainers and remove air deflector.
2. Disconnect low-side line peanut fitting. Lower vehicle. Remove air cleaner outlet tube. Remove nut from top of receiver-drier. Remove receiver-drier mounting bracket clamp bolt. Move receiver-drier away from fan shroud and remove receiver-drier. Remove receiver-drier manifold assembly (refrigerant line).
3. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Apply pipe sealant to manifold bolt. Evacuate, charge, and leak test A/C system.

Disconnect negative battery cable. Remove trim panel on upper right side of instrument panel. Disconnect harness connector. Remove sunload sensor. To install, reverse removal procedure.

Disconnect negative battery cable. Discharge A/C system, using approved recovery/recycling equipment. Remove evaporator core. See EVAPORATOR CORE . Disconnect thermostatic expansion valve fittings. Cap all openings. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove cabin air filter. See «CABIN AIR FILTER»(ref-96435-S28830987662001042700000) . Disconnect heater hoses from heater core.
2. Disconnect coolant recovery line. Remove forward heater hose mounting bolt at right front shock tower. Raise vehicle on hoist. Remove rear heater hose mounting bolt from body side and position heater hose assembly aside. Disconnect spring-lock coupling.
3. Remove nut and disconnect peanut fitting. Remove 2 refrigerant line bracket bolts. Remove refrigerant line bracket bolts and position bracket aside. Remove bolt at thermostatic expansion valve manifold and tube assembly. Remove manifold and tube assembly (refrigerant line)
4. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Apply pipe sealant to manifold and tube assembly bolt. Evacuate, charge, and leak test A/C system.

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove cabin air plenum. See «CABIN AIR PLENUM»(ref-96435-S37484376312001042700000) . Disconnect heater hoses from heater core.
2. Remove forward heater hose mounting bolt at right front shock tower. Raise vehicle on hoist. Remove rear heater hose mounting bolt from body side and position heater hose assembly aside. Disconnect spring-lock coupling. Remove nut at peanut fitting and disconnect peanut fitting.
3. Remove refrigerant line bracket bolt. Lower vehicle. Remove 2 power steering reservoir mounting bolts and move reservoir aside. Remove refrigerant line bracket bolts and position bracket aside. Remove refrigerant line bracket bolt. Disconnect coolant recovery line.
4. Disconnect vacuum hose and harness connector from Differential Pressure Feedback EGR (DFPE) sensor. Remove wiring harness retaining nuts and position harness aside. Remove 2 harness bracket retaining bolts and remove harness bracket. Disconnect manifold and tube assembly (refrigerant line) at thermostatic expansion valve.
5. To install, reverse removal procedure. Use new "O" rings coated with clean refrigerant oil. Apply pipe sealant to manifold and tube assembly bolt. Evacuate, charge, and leak test A/C system.