A/c-Heater System - Automatic: Removal & Installation Lincoln Mark I

REMOVAL

Discharge A/C system using approved refrigerant recovery/recycling equipment. Insert appropriate spring lock coupling clamp over fitting. (Scheme 4) Close clamp and push into cage to release female fitting from garter spring. After garter spring has expanded, pull coupling apart. Remove spring lock coupling clamp from line.

INSTALLATION

Ensure garter spring is in cage of male fitting. If garter spring is missing or damaged, install a new garter spring. Install new "O" rings and lubricate with clean refrigerant oil. Push fittings together until garter spring is over flared end of female fitting. Pull on female fitting and verify position of garter spring.

Scheme 4

REMOVAL & INSTALLATION INFORMATION

AMBIENT TEMPERATURE SENSOR R & I

Remove outside/recirculation air duct. (Scheme 5) Remove screws and ambient temperature sensor. To install, reverse removal procedure.

BLOWER MOTOR SPEED CONTROLLER R & I

Note. DO NOT operate ATC system with blower motor disconnected or damage to blower motor speed controller may occur.

1. Disengage glove box door stops and allow door to hang by hinge. Remove sound insulator behind glove box. Remove screw attaching lower end of instrument panel to side cowl panel.
2. Loosen floor console and move it rearward. Remove ATC control panel. Remove screws attaching instrument panel to floor pan. Working through glove box opening, unplug connector from blower motor speed controller. see scheme 3and (Scheme 5).
3. Remove screws attaching blower motor speed controller to evaporator case and remove controller. DO NOT touch controller fins as they may be HOT. To install, reverse removal procedure.

1. Disconnect negative battery cable. Remove sound insulator and glove box. Remove instrument panel right finish panel insert. Remove radio and set wiring and antenna lead aside.
2. Remove tripminder (4 screws). Remove shield over actuator and linkage (3 screws). Disconnect wiring harness from actuator. see scheme 3 Remove nut from actuator arm and disconnect link. Remove actuator.

1. Connect link and wiring harness to actuator. Connect negative battery cable. Start and warm engine to normal operating temperature. Turn engine off and place ignition switch in RUN position.
2. Ensure ambient temperature is 50-90°F (10-33°C). Ensure actuator attaching screws are loose. Set temperature on ATC control panel to 90°F setting.
3. Push OFF/AUTO and defrost buttons simultaneously. Within 2 seconds press VENT button. ATC control panel should display 88. Depress WARM button. ATC control panel is now locked for calibration. Ensure OFF/AUTO indicator is lit (automatic mode).
4. Measure discharge air temperature at driver's floor duct (in long thin slot, closest to dash panel). Slide actuator until temperature reading is 50-54°F (10-12°C). Allow 5 minutes for temperature to stabilize.
5. Tighten actuator screws and recheck temperature. With ATC control panel in automatic mode, set temperature to 60°F. Blend door should move to full A/C position.
6. Change temperature to 90°F. Ensure blend door moves to full heat position. Turn ignition off. To complete installation, reverse removal procedure.

BLOWER MOTOR R & I

Note. DO NOT operate ATC system with blower motor disconnected or damage to blower motor speed controller may occur.

1. Disconnect negative battery cable. Remove sound insulator and glove box. Remove side cowl trim panel. Disconnect wiring from motor. Remove instrument panel-to-lower right side cowl bolt.
2. Remove screw attaching support brace to top of air inlet duct. (Scheme 5) Remove 5 screws and outside/recirculation air duct. Remove 4 blower motor mounting screws.
3. Remove blower motor from housing. Detach blower wheel from motor shaft. To install, reverse removal procedure. Install blower wheel on blower shaft with push nut.

Scheme 5

COMPRESSOR R & I

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect A/C compressor clutch wiring. Disconnect refrigerant lines at compressor. Cap all openings to keep moisture out. Remove compressor drive belt. Remove 3 front A/C compressor mounting bolts.
2. Remove 2 rear A/C compressor mounting bolts. Remove A/C compressor and rear bracket from vehicle as an assembly. Remove rear bracket from A/C compressor. To install, reverse removal procedure. Evacuate, recharge and leak test A/C system.

CONDENSER R & I

Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect cables and remove battery. Disconnect refrigerant lines at condenser. (Scheme 4) Remove 4 bolts and condenser. To install, reverse removal procedure. Evacuate, recharge and leak test A/C system.

ATC CONTROL PANEL R & I

1. Disconnect negative battery cable. Pull ATC control panel trim insert from instrument panel (snap fit). Remove 4 control panel-to-instrument panel screws.
2. Slide control panel from instrument panel opening. Disconnect wiring harness from control panel. To install, reverse removal procedure.

EVAPORATOR CASE R & I

Note. Whenever evaporator case is removed, manufacturer recommends replacing receiver-drier. See RECEIVER-DRIER R & I in this article.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove intake air duct. Drain cooling system. Remove heater hoses from heater core. Disconnect wiring from A/C clutch cycling pressure switch on top of receiver-drier.
2. Disconnect refrigerant lines at evaporator core and cap all openings. Remove receiver-drier and set liquid lines aside. Remove 2 evaporator case retaining nuts (on engine compartment side of firewall).
3. Remove instrument panel. See INSTRUMENT PANEL R & I in this article. Disconnect wiring harness from blower motor and blower motor speed controller. Disconnect in-vehicle temperature sensor hose and elbow from evaporator case.
4. Disconnect wiring from ATC control panel. Disconnect radio antenna cable from strap on evaporator case. Detach rear seat duct adapter from floor duct. Remove 3 screws and evaporator case.
5. To install, reverse removal procedure. Evacuate, recharge and leak test system. Fill cooling system.

EVAPORATOR CORE R & I

Note. Whenever evaporator case is removed, manufacturer recommends replacing receiver-drier. See RECEIVER-DRIER under R & I in this article.

1. Remove instrument panel and evaporator case. See INSTRUMENT PANEL and EVAPORATOR CASE R & I in this article. Remove seal from evaporator core tubes. (Scheme 5) Drill 3/16" diameter holes in both upright tabs on top of evaporator case (1/4" down from notch in tabs).
2. Using small saw, cut through center of tabs (and drilled holes) following top seam of evaporator case. Cut along tab side and short sides of seam only. Fold cut-out flap back and remove evaporator core from case.

Install new seal on evaporator core. Install core and close cut-out cover. Use Caulking Cord (D9AZ-19560-A) to seal cut-out cover. Install lock-nuts and bolts through drilled holes in upright tabs. To complete installation, reverse removal procedure. Evacuate, recharge and leak test A/C system.

1. Disconnect negative battery cable. Remove sound insulator and glove box. Disconnect actuator wiring. see scheme 3 Remove side cowl trim panel. Remove instrument panel-to-lower right side cowl bolt.
2. Remove support brace-to-air inlet duct top screw. Remove 5 screws and recirculation air duct. Remove nut from actuator arm and disconnect link. Remove actuator.

1. To install, reverse removal procedure. Before installing glove box and sound insulator, connect negative battery cable and place ignition switch in RUN position.
2. Depress FLOOR button on ATC control panel. Actuator should move door to fresh air position. Depress OFF button on ATC control panel. Actuator should move door to recirculated air position.
3. Repeat step 2) several times to ensure correct actuator operation. Install glove box and sound insulator (short screws secure glove box, longer screws secure both insulator and box).

HEATER CORE R & I

Note. Whenever evaporator case is removed, manufacturer recommends replacing receiver-drier. See RECEIVER-DRIER R & I in this article.

1. Remove instrument panel and evaporator case. See INSTRUMENT PANEL and EVAPORATOR CASE R & I in this article. Remove 5 heater core cover-to-evaporator case screws. Remove heater core cover.
2. Lift heater core and seals from evaporator case. Remove 2 seals from heater core tubes. (Scheme 5) To install, reverse removal procedure. Evacuate, recharge and leak test A/C system. Fill cooling system.

INSTRUMENT PANEL R & I

1. Disconnect negative battery cable. Disconnect main wiring harness on engine compartment side. Disengage rubber grommet from firewall. Feed main wiring harness and connectors through opening into instrument panel area.
2. Remove steering column opening trim cover. Remove sound insulators panels from under instrument panel. Remove 5 steering column trim shroud screws. Remove steering column lower support. Disconnect wiring from steering column. Remove right and left side cowl panels.
3. Remove 4 steering column-to-brake pedal support nuts. Lower and rest steering column on front seat. Unsnap defroster grille tab from top of instrument panel. Remove floor console-to-instrument panel and floor screw. Move console rearward.
4. Remove 2 instrument panel-to-floor screws. Remove instrument panel-to-cowls screws. Remove instrument panel-to-parking brake support bracket bolt.
5. Disconnect main wiring harness at blower motor, right and left cowls, right side of steering column support and behind instrument cluster. Disconnect radio antenna and vacuum hoses attached to instrument panel.
6. Remove right and left side pillar trim covers. Remove 3 screws and instrument panel from firewall. To install, reverse removal procedure.

IN-VEHICLE TEMPERATURE SENSOR R & I

Disconnect negative battery cable. Remove instrument cluster finish panel. Carefully disconnect aspirator hose from in-vehicle temperature sensor elbow latch. (Scheme 5) Disconnect in-vehicle temperature sensor wiring. Remove screws and in-vehicle temperature sensor. To install, reverse removal procedure.

Disconnect negative battery cable. Loosen instrument panel and pull it back from cowl to expose panel/defrost duct, attached to instrument panel. Disconnect actuator wiring. Remove Black insulation cover from top of actuator. Remove nut from actuator arm and disconnect link. Remove actuator.

1. Install new tie strap and securely fasten both halves of actuator cover. Attach actuator to panel/defrost duct. Attach link to actuator arm and secure with nut. Plug in actuator connector.
2. Connect negative battery cable and place ignition switch in RUN position. Depress defrost button on ATC control panel. Actuator should move door to defrost position. Depress OFF button on ATC control panel. Actuator should move door to panel position.
3. Repeat step 2) several times to ensure correct actuator operation. Securely fasten top half of cover to actuator with new strap. To install, reverse removal procedure.

1. Disconnect negative battery cable. Loosen instrument panel and pull it back from cowl. Loosen evaporator assembly from firewall. Pull back evaporator assembly for access to floor/panel actuator (on driver's side). see scheme 3and (Scheme 5).
2. Disconnect wiring from actuator. Remove actuator cover screws and nut. Remove actuator arm nut and disconnect link. (Scheme 5) Note position of screws in slots for reassembly. Remove screws and actuator.

1. Loosely attach actuator to evaporator assembly. Attach link to actuator arm and secure with nut. Plug in actuator connector. Adjust actuator to same approximate position as when removed.
2. Connect negative battery cable and place ignition switch in RUN position. Depress FLOOR button on ATC control panel. Actuator should move door to floor position. There should be a minimum of 1/32" (.79 mm) compression in crank arm link. Depress PANEL button on ATC control panel. Actuator should move door to panel position. There should be a minimum of 1/32" (.79 mm) compression in crank arm link.
3. Repeat step 2) several times to ensure correct actuator operation. If there isn't a minimum of 1/32" (.79 mm) compression in crank arm link, adjust actuator position to obtain compression specification. Disconnect negative battery cable and attach actuator cover. To complete installation, reverse removal procedure.

RECEIVER-DRIER R & I

Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect suction line from compressor. Disconnect and remove inlet tube. Cap all openings. Disconnect wiring from clutch cycling pressure switch on receiver-drier. Remove screw and receiver-drier. To install, reverse removal procedure. Evacuate, recharge and leak test A/C system.

1991 Auto A/C-Heater Wiring Diagram (Mark VII). Scheme 6

1992 Auto A/C-Heater Wiring Diagram (Mark VII). Scheme 7