Climate Control Lincoln Zephyr US

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Air Conditioning

The refrigerant system components include the following

1. A/C compressor
2. A/C clutch assembly
3. A/C condenser core
4. A/C evaporator core
5. Receiver/drier cartridge
6. Connecting refrigerant lines
7. Thermostatic expansion valve (TXV)

The refrigerant system incorporates an A/C compressor controlled by the powertrain control module (PCM) through an A/C clutch relay. The climate control assembly sends an A/C request signal to the instrument cluster module, which relays the request to the PCM. An evaporator discharge air temperature sensor is used to disengage the A/C compressor clutch when the evaporator core temperature falls below an acceptable temperature.

The A/C compressor clutch will only be engaged by the PCM if all of the following conditions are met

1. The climate control assembly is set to a mode which provides an A/C request to the PCM via the instrument cluster module (ICM).
2. The evaporator discharge air temperature sensor is reading an acceptable temperature.
3. The A/C pressure transducer is reading an acceptable pressure in the high side of the refrigerant system.
4. The A/C compressor relay is switched to the closed position by the PCM.
5. The engine coolant temperature is not excessively high.
6. The PCM has not detected a wide open throttle (WOT) condition.

An A/C pressure relief valve is installed in the A/C compressor to protect the refrigerant system against excessively high refrigerant pressures.

Refrigerant flow into the evaporator core is metered by a TXV.

A/C Compressor and Clutch Assembly

Note. Internal A/C compressor components are not serviced separately. The A/C compressor is serviced only as an assembly. The clutch disc and hub, A/C compressor pulley and bearing and clutch field coil are serviceable.

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

The A/C compressor has the following characteristics

Scheme 1

1. A non-serviceable shaft seal
2. A pressure relief valve is installed in the rear of the compressor to protect the refrigerant system against excessively high refrigerant pressures
3. The A/C compressor uses PAG oil or equivalent. This oil contains special additives required for the A/C compressor
4. The A/C compressor oil may have some slightly dark-colored streaks while maintaining normal oil viscosity. This is normal for this A/C compressor because of break-in wear that can discolor the oil
5. Use standard oil matching procedures when installing new compressors

When battery voltage is applied to the A/C compressor clutch field coil, the clutch plate and hub assembly is drawn toward the A/C clutch pulley. The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. When battery voltage is removed from the A/C compressor clutch field coil, springs in the clutch plate and hub assembly move the clutch plate away from the A/C clutch pulley.

A/C Condenser/Power Steering Combo Cooler

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

The A/C condenser/power steering combo cooler is an aluminum fin-and-tube design heat exchanger located in front of the vehicle radiator. It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled.

The receiver/drier is incorporated onto the LH side of the condenser core. The receiver/drier cartridge is a separate component and can be removed and installed separately from the condenser core.

The top portion of the condenser/power steering combo cooler is partitioned from the refrigerant system and is used for power steering fluid cooling.

Evaporator Core

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

The evaporator core is an aluminum plate/fin type and is located in the heater core and evaporator core housing. A mixture of refrigerant and oil enters the bottom of the evaporator core through the evaporator core inlet tube and continues out of the evaporator core through the evaporator core outlet tube. Air from the blower motor is cooled and dehumidified as it flows through the evaporator core fins.

Thermostatic Expansion Valve

The thermostatic expansion valve (TXV) is located between the evaporator core lines and the thermostatic expansion valve manifold and tube assembly at the rear of the engine compartment. The TXV provides a restriction to the flow of refrigerant from the high-pressure side of the refrigerant system and separates the low-pressure and high-pressure sides of the refrigerant system. Refrigerant entering and exiting the evaporator core passes through the TXV through 2 separate flow paths. An internal temperature sensing bulb senses the temperature of the refrigerant flowing out of the evaporator core and adjusts an internal pin-type valve to meter the refrigerant flow into the evaporator core. The internal pin-type valve decreases the amount of refrigerant entering the evaporator core at lower temperatures and increases the amount of refrigerant entering the evaporator core at higher temperatures.

Receiver/Drier

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

The receiver/drier is integral to the A/C condenser/power steering combo cooler. It stores high-pressure liquid after it leaves the condenser core. A receiver/drier cartridge mounted inside the receiver/drier removes any retained moisture from the refrigerant. The receiver/drier cartridge is a separate component and can be removed and installed separately from the A/C condenser/power steering combo cooler.

Evaporator Discharge Air Temperature Sensor

The evaporator discharge air temperature sensor contains a thermistor which receives a reference voltage from the PCM. The thermistor then varies the resistance to the reference voltage based on the evaporator discharge air temperature. The resulting voltage is returned to the PCM where it is interpreted as an evaporator air discharge temperature reading.

The PCM maintains evaporator core temperature and prevents icing of the evaporator core, by disengaging the A/C compressor clutch when the evaporator discharge air temperature sensor reading falls below acceptable levels, and by engaging the A/C compressor clutch when the discharge air temperature rises above acceptable levels.

The evaporator discharge air temperature sensor is located inside of the heater core and evaporator core housing in the air-stream leaving the evaporator core.

A/C Pressure Transducer

The A/C pressure transducer monitors the compressor discharge pressure and communicates with the PCM. The PCM will interrupt A/C compressor operation in the event that the A/C pressure transducer indicates high system discharge pressures. It is also used to sense low charge conditions. If the pressure is below a predetermined value for a given ambient temperature, the PCM will not allow the clutch to engage.

Service Gauge Port Valves

The high-pressure service gauge port valve is located on the condenser-to-evaporator line.

The low-pressure service gauge port valve is located on the TXV manifold and tube assembly.

Scheme 2

The fitting is an integral part of the refrigeration line or component.

1. Special couplings are required for both the high-side and low-side service gauge ports.
2. A very small amount of leakage will always be detectable around the Schrader-type valve with the service gauge port valve cap removed, and is considered normal. A new Schrader-type valve core can be installed if the seal leaks excessively.
3. The service gauge port valve caps are used as primary seals in the refrigerant system to prevent leakage through the Schrader-type valves from reaching the atmosphere. Always install and tighten the A/C service gauge port valve caps to the correct torque after they are removed.

Refrigerant System Dye

Fluorescent refrigerant system dye is added to the refrigerant system at the factory to assist in refrigerant system leak diagnosis using a Rotunda approved ultraviolet blacklight. It is not necessary to add additional dye to the refrigerant system before diagnosing leaks, even if a significant amount of refrigerant has been removed from the system. Additional refrigerant system dye should only be added if more than 50% of the refrigerant system lubricant capacity has been lost due to a fitting separation, hose rupture, etc. Refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS .

Air Distribution and Filtering

Note. This vehicle is not equipped from the factory with a cabin air filter.

There are 2 sources of air available to the air distribution system

1. Outside air
2. Recirculated air

Recirculated air is always used when the climate control assembly is set to the MAX A/C mode on vehicles equipped with manual climate control. Vehicles equipped with electronic automatic temperature control (EATC) use recirculated air only when the RECIRC function is selected in any mode other than DEFROST, or when required by the EATC module in the AUTOMATIC mode.

Air distribution within the vehicle is determined by the function selector position (manual A/C), or the EATC system in the AUTOMATIC mode. The air distribution mode on vehicles equipped with EATC can be overridden by the driver if desired. Airflow mode control doors are used to direct airflow within the heater core and evaporator core housing. Electric mode door actuators are used to position these airflow mode doors.

Vehicles equipped with dual-zone EATC use 2 separate temperature blend doors. This allows individual temperature settings to be selected for the RH and LH air outlets. The airflow mode doors are not partitioned for separate RH and LH airflow positions. Therefore, the airflow mode will always remain similar for the RH and LH sides of the vehicle regardless of the temperatures selected.

Air enters the passenger compartment from the

1. Instrument panel registers.
2. Floor duct.
3. Windshield defroster.
4. Side window demisters.
5. Rear footwell duct (if equipped).

Passenger compartment air is exhausted from the vehicle through open windows or body air vents.

Electronic Manual Temperature Control

The electronic manual temperature control (EMTC) components are used to select

1. Air inlet source (outside or recirculated).
2. Blower motor speed.
3. Discharge air temperature (temperature blend).
4. Discharge air location (defrost, panel, floor).
5. A/C compressor operation.

Control System Inputs

The EMTC system has 2 system control inputs.

The climate control assembly integrates the temperature control, airflow mode selection, A/C request button, recirculated air request button and rear defog switch into a single unit.

The temperature control switch setting determines air temperature. Movement of the temperature display from COOL (blue) to WARM (red) causes a corresponding movement of the temperature blend door and determines the air discharge temperature that the air distribution system will maintain. The temperature control switch is an integral part of the climate control assembly and cannot be replaced separately.

The A/C request button determines A/C compressor operation, except when the function selected is in the OFF, MAX or DEFROST mode. The A/C request button is an integral part of the climate control assembly and cannot be replaced separately.

The recirculated air request button can select recirculated air in any mode except DEFROST, and fresh air in any mode except MAX A/C or OFF.

The rear defog button signals activation of the heated backlight. The rear defog button is an integral part of the climate control assembly and cannot be installed separately.

The EMTC module is not equipped with self-test capabilities.

Blower Motor Switch

The blower motor switch is mounted in the climate control assembly and controls blower motor speed by adding or bypassing resistors in the blower motor resistor in all modes except OFF.

Control System Outputs

The EMTC system has 3 system outputs.

Blower Motor Resistor

The blower motor resistor

1. Is located on the heater core and evaporator core housing near the blower motor.
2. Has 3 resistor elements mounted on the resistor board to provide 4 blower motor speeds.
3. Depending on the blower motor switch position, series resistance is added or bypassed in the blower motor circuit to decrease or increase blower motor speed.

Temperature Blend Door Actuator

The temperature blend door actuator

1. Is located on the heater core and evaporator core housing.
2. Moves the temperature blend door on command from the EMTC module.
3. Contains a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the temperature blend door.
4. Applies a 5-volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EMTC module and is matched with an expected wiper voltage value. The EMTC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EMTC module wiper voltage value.

Mode Door Actuator

The mode door actuator

1. Uses a cam setup to direct system airflow to the vehicle interior as determined by the climate control assembly.
2. Contains a reversible electric motor.
3. Contains a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the mode door.
4. Applies a 5-volt signal to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EMTC module and is matched with an expected wiper voltage value. The EMTC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EMTC module wiper voltage value.

Air Inlet Mode Door Actuator

The air inlet mode door actuator

1. Moves the air inlet door between the FRESH and RECIRC positions on command from the EMTC module.
2. Contains a reversible electric motor.
3. Automatically stops when it reaches the full FRESH or full RECIRC position and does not report its position back to the EMTC module.

Electronic Automatic Temperature Control

Two different electronic automatic temperature control systems are available

1. Single-zone EATC (Fusion/Milan)
2. Dual-zone EATC (Zephyr)

The electronic automatic temperature control (EATC) module analyzes input from the following major sources

1. Temperature, airflow direction, blower, A/C and RECIRC selection (made by the vehicle occupants)
2. In-vehicle temperature sensor
3. Ambient temperature sensor
4. Solar radiation sensor
5. Vehicle speed
6. Engine coolant temperature

Using these inputs, the dual-zone EATC module determines the correct conditions for the following outputs

1. A/C compressor operation
2. Blower speed
3. Temperature blend door position
4. DEFROST/PANEL/FLOOR door position
5. Air inlet door position

The dual-zone EATC system has 4 control system inputs.

EATC Module

The dual-zone EATC module

1. Is located in the instrument panel.
2. Has a vacuum fluorescent display for displaying set temperature, airflow direction, blower speed and diagnostic trouble codes (DTCs).
3. Utilizes an on-board diagnostic (OBD) feature to supply the technician with diagnostic trouble codes (DTCs). These DTCs direct the technician to the inoperative component.

In-Vehicle Temperature Sensor

The in-vehicle temperature sensor operates in the following manner

1. A thermistor in the in-vehicle temperature sensor measures air temperature inside the passenger compartment.
2. An aspirator hose and elbow is connected between the heater core and evaporator core housing and the in-vehicle temperature sensor.
3. The aspirator hose and elbow takes air from the heater core and evaporator core housing air stream to create a suction in the in-vehicle temperature sensor.
4. The suction draws in-vehicle air into the in-vehicle temperature sensor and across the thermistor.

Solar Radiation Sensor (Sunload Sensor)

The solar radiation sensor supplies information to the EATC module indicating sunload.

Ambient Temperature Sensor

The ambient temperature sensor signal is received by the EATC module and indicates the outside air temperature. The ambient temperature sensor is located in front of the radiator on the radiator support.

The EATC system has 3 control system outputs.

Blower Motor Speed Control

The blower speed control

1. Is located on the heater core and evaporator core housing near the blower motor.
2. Varies the blower motor speed and is controlled by the EATC module software.

Temperature Blend Door Actuator(s)

Single-zone EATC systems use one temperature blend door actuator. Dual-zone EATC systems use 2 separate temperature blend door actuators to control 2 separate temperature blend doors for the driver and passenger sides of the vehicle. The temperature blend door actuator(s)

1. Is/are located on the heater core and evaporator core housing.
2. Move the temperature blend door(s) on command from the dual-zone EATC module.
3. Each contain a reversible electric motor and a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the temperature blend doors.

A 5-volt signal is applied to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EATC module and is matched with an expected wiper voltage value. The EATC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EATC module wiper voltage value.

The mode door actuator

1. Uses a cam setup to position the 2 airflow mode doors to direct system airflow to the vehicle interior as determined by the EATC module settings.
2. Contains a reversible electric motor.
3. Contains a potentiometer. The potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to indicate the position of the mode door.

A 5-volt signal is applied to one end of the potentiometer and ground to the other. The voltage available at the wiper indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is sent to the EATC module and is matched with an expected wiper voltage value. The EATC module then drives the actuator motor in whichever direction is necessary to make the actuator wiper voltage agree with the expected EATC module wiper voltage value.

The air inlet mode door actuator

1. Moves the air inlet door between the FRESH and RECIRC positions on command from the EATC module.
2. Contains a reversible electric motor.
3. Automatically stops when it reaches the full FRESH or full RECIRC position and does not report its position back to the EATC module.

Heating and Ventilation

The heating and ventilation system has the following features

1. Controls the temperature and, during A/C operation, reduces the relative humidity of the air inside the vehicle
2. Delivers heated or cooled air to maintain the vehicle interior temperature and comfort level
3. Cooling or heating can be adjusted to maintain the desired temperature
4. Uses a reheat method to provide conditioned auto the passenger compartment
5. All airflow from the blower motor passes through the A/C evaporator core
6. Temperature blending is controlled by the temperature blend door(s), which regulate(s) the amount of air that flows through and around the heater core, where it is then mixed and distributed

Heater Core

The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer the heat to air passing through the plenum.

Blower Motor

The blower motor pulls air from the air inlet and forces it into the heater core and evaporator core housing where it is mixed and distributed.

Heater Core and Evaporator Core Housing

The heater core and evaporator core housing directs airflow from the blower motor through the evaporator core and heater core. All airflow from the blower motor passes through the evaporator core. The airflow is then directed through or around the heater core by the temperature blend door(s). Vehicles equipped with dual-zone electronic automatic temperature control (EATC) use a partitioned heater core and evaporator core housing with 2 electric actuator-positioned temperature blend doors. This allows for separate temperatures to be selected for the driver and passenger sides of the passenger compartment. Manual systems use a single electric actuator-positioned temperature blend door to direct airflow through or around the heater core.

Air Conditioning (A/C) Compressor - 2.3L

MATERIAL CHART

Scheme 3

Removal and Installation

Note. If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

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

1. If flushing of the A/C system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
3. Remove the lower engine splash shield.
4. Remove the drive belt from the A/C compressor pulley.
5. Disconnect the field coil electrical connector.
6. Remove the A/C compressor manifold bolt. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
7. Remove the 3 secondary air injection pump bolts and position the pump aside (if equipped). To install, tighten to 30 Nm (22 lb-ft).
8. Remove the 3 A/C compressor bolts. To install, tighten to 25 Nm (18 lb-ft).
9. Remove the A/C compressor.
10. 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»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__clutch-and-clutch-field-coil) . Install new gasket seals. If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
11. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Air Conditioning (A/C) Compressor - 3.0L

MATERIAL CHART

Scheme 4

Note. If installing a new A/C compressor, the A/C clutch disc and hub, A/C compressor pulley and A/C clutch field coil must be inspected and transferred from the old unit to the new unit if suitable for reuse.

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

1. If flushing of the A/C system has not been carried out, recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
3. Remove the lower engine splash shield (if equipped).
4. Remove the drive belt from the A/C compressor pulley.
5. Remove the A/C compressor manifold bolt. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
6. Disconnect the field coil electrical connector.
7. Remove the 3 A/C compressor bolts. To install, tighten to 25 Nm (18 lb-ft).
8. Remove the A/C compressor.
9. 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»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__clutch-and-clutch-field-coil) . Install new gasket seals. If filtering of the A/C system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
10. If filtering of the A/C system is not to be carried out, evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Scheme 5

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Detach the A/C evaporator discharge air temperature sensor.
3. Disconnect the A/C evaporator discharge air temperature sensor electrical connector.
4. Remove the evaporator discharge air temperature sensor.
5. To install, reverse the removal procedure.

Scheme 6

1. Remove the front bumper cover. For additional information, refer to «BUMPERS»(/lincoln/zephyr/us-2006-2006/remont/exterior-body-panels/#bumpers) .
2. Remove the radiator grille upper sight shield.
3. Disconnect the ambient air temperature sensor electrical connector.
4. Remove the ambient air temperature sensor.
5. To install, reverse the removal procedure.

Scheme 7

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

Scheme 8

1. Disconnect the blower motor resistor electrical connector.
2. Remove the blower motor resistor screw.
3. Remove the blower motor resistor.
4. To install, reverse the removal procedure.

Scheme 9

1. Remove the RH lower instrument panel insulator.
2. Disconnect the blower motor speed control electrical connector.
3. Remove the blower motor speed control screw.
4. Remove the blower motor speed control.
5. To install, reverse the removal procedure.

Scheme 10

1. Remove the climate control assembly. For additional information, refer to «CLIMATE CONTROL ASSEMBLY»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control) .
2. Pull and remove the blower motor switch knob.
3. Depress the tab and rotate the blower counterclockwise to remove.
4. To install, reverse the removal procedure.

Scheme 11

1. Remove the instrument panel lower center finish panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Remove the 4 climate control assembly screws.
3. Remove the climate control assembly.
4. To install, reverse the removal procedure.

Clutch and Clutch Field Coil

SPECIAL TOOL(S) CHART Holding Fixture, Compressor Clutch Disc and Hub 412-134

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__air-conditioning-ac-compressor-23l) or «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__air-conditioning-ac-compressor-30l) .
2. Remove the 3 screws and the A/C clutch shield (if equipped).
3. Remove the A/C clutch disc and hub bolt. Hold the A/C clutch disc and hub with the special tool. Remove the A/C clutch disc and hub bolt.
4. Remove the A/C clutch disc and hub.
5. Remove the A/C compressor pulley snap ring.
6. Remove the A/C compressor pulley.
7. Remove the A/C clutch field coil electrical connector clip screw.
8. Remove the A/C clutch field coil snap ring.
9. Remove the A/C clutch field coil.

Installation

Note. If installing a new A/C compressor, the A/C clutch components should be reused unless obvious signs of damage are found. If excessive grooving is found, a new A/C clutch disc and hub and A/C compressor pulley must be installed together. Otherwise, each component can be installed individually where needed.

Scheme 16

Scheme 17

Scheme 18

Scheme 19

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 A/C clutch field coil snap ring.
5. Install the A/C clutch field coil electrical connector clip screw.
6. Install the A/C clutch pulley.
7. Install the A/C clutch pulley snap ring.
8. Place one nominal thickness A/C clutch disc and hub spacer inside the clutch hub spline opening.
9. Install the A/C clutch disc and hub assembly.
10. Install the A/C clutch disc and hub bolt. Hold the A/C clutch disc and hub with the special tool. Install the A/C clutch disc and hub bolt. Tighten to 14 Nm (10 lb-ft).
11. Install the A/C clutch shield and the 3 screws.
12. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers.
13. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING (A/C) COMPRESSOR - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__air-conditioning-ac-compressor-23l) or «AIR CONDITIONING (A/C) COMPRESSOR - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__air-conditioning-ac-compressor-30l) .

Compressor Manifold and Tube Assembly - 2.3L

MATERIAL CHART

Scheme 20

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
3. Detach the 2 coolant reservoir hose retainers from the compressor manifold and tube assembly.
4. Remove the washer reservoir filler neck bolt. To install, tighten to 6 Nm (53 lb-in).
5. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. Discard the gasket seal. To install, tighten to 15 Nm (11 lb-ft).
6. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the gasket seal. To install, tighten to 15 Nm (11 lb-ft).
7. Remove the lower engine splash shield.
8. Remove the compressor manifold bolt and detach the manifold from the A/C compressor. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
9. Remove the 3 secondary air injection pump bolts and position the secondary air injection pump aside (if equipped). To install, tighten to 30 Nm (22 lb-ft).
10. Remove the compressor manifold and tube assembly.
11. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
12. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Compressor Manifold and Tube Assembly - 3.0L

MATERIAL CHART

Scheme 21

Note. Installation of a new A/C desiccant cartridge 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 A/C desiccant cartridge.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
3. Remove the lower engine splash shield (if equipped).
4. Remove the compressor manifold bolt and detach the manifold from the A/C compressor. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
5. Detach the 2 coolant reservoir hose retainers from the compressor manifold and tube assembly.
6. Remove the washer reservoir filler neck bolt. To install, tighten to 6 Nm (53 lb-in).
7. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. Discard the gasket seal. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the condenser inlet fitting nut and disconnect the fitting. Discard the gasket seal. To install, tighten to 15 Nm (11 lb-ft).
9. Remove the compressor manifold and tube assembly.
10. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
11. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Condenser Core

MATERIAL CHART

Scheme 22

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. With the vehicle in NEUTRAL position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
3. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the washer reservoir filler neck bolt.
5. Remove the 2 condenser fitting nuts and disconnect the fittings. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
6. Unclip the 2 radiator brackets from the radiator core support and position the cooling module rearward.
7. Remove the 2 radiator brackets.
8. Release the 2 power steering hose clamps at the condenser and disconnect the hoses.
9. Remove the condenser manifold pin-type retainer.
10. Release the 2 condenser clips at the radiator and detach the condenser from the radiator.
11. Remove the condenser core.
12. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
13. Fill the power steering system. For additional information, refer to «STEERING SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/manual-power-steering/#steering-system-general-information) .
14. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

MATERIAL CHART

Scheme 23

Note. If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle.

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

1. Remove the heater core and evaporator core housing. For additional information, refer to «HEATER CORE AND EVAPORATOR CORE HOUSING»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__heater-core-and-evaporator-core-housing) .
2. Detach the wire harness from the heater core and evaporator core housing.
3. Remove the 15 evaporator core cover screws.
4. Separate the 2 halves of the heater core and evaporator core housing.
5. Remove the dash panel seal.
6. Remove the evaporator core.
7. To install, reverse the removal procedure. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Scheme 24

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

1. Remove the heater core and evaporator core housing. For additional information, refer to «HEATER CORE AND EVAPORATOR CORE HOUSING»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control__heater-core-and-evaporator-core-housing) .
2. Detach the wire harness from the heater core cover.
3. Remove the 8 heater core cover screws.
4. Remove the heater core cover.
5. Remove the dash panel seal from the heater core tubes.
6. Remove the heater core.
7. To install, reverse the removal procedure.

MATERIAL CHART

Scheme 25

Scheme 26

1. Remove the lower cowl panel grille. For additional information, refer to «FRONT END BODY PANELS»(/lincoln/zephyr/us-2006-2006/remont/exterior-body-panels/#front-end-body-panels) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
3. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-panel-and-console) .
5. Disconnect the A/C pressure transducer electrical connector and detach the wire harness from the thermostatic expansion valve (TXV) stud.
6. Remove the TXV fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
7. Release the heater hoses clamps and disconnect the hoses from the heater core
8. Remove the 6 heater core and evaporator core housing nuts. To install, tighten to 9 Nm (80 lb-in).
9. Remove the heater core and evaporator core housing.
10. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
11. Fill the engine coolant level. For additional information, refer to «ENGINE COOLING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
12. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Scheme 27

1. Remove the lower steering column cover screws.
2. Remove the lower steering column shroud.
3. Disconnect the in-vehicle temperature sensor electrical connector.
4. Remove the in-vehicle temperature sensor.
5. To install, reverse the removal procedure.

Scheme 28

1. Lower the glove compartment.
2. Remove the RH instrument panel end panel.
3. Remove the glove compartment storage bin.
4. Disconnect the air inlet mode door actuator electrical connector.
5. Remove the air inlet mode door actuator.
6. To install, reverse the removal procedure.

Scheme 29

1. Remove the instrument panel. For additional information, refer to «INSTRUMENT PANEL AND CONSOLE»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-panel-and-console) .
2. Disconnect the LH temperature blend door actuator electrical connector.
3. Remove the 2 LH temperature blend door actuator screws.
4. Remove the LH temperature blend door actuator.
5. Disconnect the DEFROST/PANEL/FLOOR mode door actuator electrical connector.
6. Remove the 3 DEFROST/PANEL/FLOOR mode door actuator and cam assembly screws.
7. Remove the DEFROST/PANEL/FLOOR mode door actuator and cam assembly.
8. To install, reverse the removal procedure.

Receiver Drier

MATERIAL CHART

Note. Installation of a new A/C desiccant cartridge 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 A/C desiccant cartridge.

Scheme 30

Scheme 31

Scheme 32

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
3. Remove the lower radiator air deflector.
4. Unscrew and remove the plastic receiver/drier cap.
5. Remove the receiver/drier plug. Push the receiver/drier plug upwards and remove the snap ring. Install the bolt included with the A/C desiccant cartridge service kit in the center of the receiver drier plug and remove the plug.
6. Using a suitable tool, grasp the A/C desiccant cartridge grab handle and remove the A/C desiccant cartridge.
7. To install, reverse the removal procedure. Lubricate the receiver/drier plug O-ring seals using residual refrigerant oil from inside the receiver/drier. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Scheme 33

1. Remove the audio unit bezel.
2. Remove the 2 upper instrument panel storage bin screws.
3. Remove the upper instrument panel storage bin.
4. Release the 3 upper clips on each register and remove the 2 center instrument panel registers.
5. To install, reverse the removal procedure.

Scheme 34

Note. Passenger side register shown, driver side similar.

1. Remove the instrument panel end panel.
2. Working through the instrument panel end panel opening, release the 2 lower register clips and remove the driver or passenger side instrument panel register.
3. To install, reverse the removal procedure.

Scheme 35

Note. Center registers shown, outer registers similar.

Scheme 36

1. Open the register barrel vanes, grasp the inside of the register barrel and pull the register barrel straight out.
2. Release the 3 tabs and remove the register housing.
3. To install, reverse the removal procedure.

Scheme 37

Note. The LH temperature blend door actuator can be accessed from below the LH side of the instrument panel.

1. Disconnect the LH temperature blend door actuator.
2. Remove the 2 LH temperature blend door actuator screws.
3. Remove the LH temperature blend door actuator.
4. To install, reverse the removal procedure.

Scheme 38

1. Remove the passenger air bag module. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(/lincoln/zephyr/us-2006-2006/remont/airbag/#supplemental-restraint-system) .
2. Disconnect the RH temperature blend door actuator electrical connector.
3. Remove the 2 RH temperature blend door actuator bracket screws.
4. Detach the wire harness from the RH temperature blend door actuator bracket.
5. Remove the RH temperature blend door actuator.
6. To install, reverse the removal procedure.

MATERIAL CHART

Scheme 39

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. Disconnect the A/C pressure transducer electrical connector and detach the wire harness from the thermostatic expansion valve (TXV) stud.
3. Remove the TXV fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
4. Remove the 2 TXV bolts.
5. Remove the TXV. Discard the gasket seals.
6. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
7. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

Thermostatic Expansion Valve Manifold and Tube Assembly

MATERIAL CHART

Scheme 40

Note. Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.

Scheme 41

1. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
2. Remove the TXV manifold and tube bracket bolt. To install, tighten to 8 Nm (71 lb-in).
3. Detach the wire harness clip from the TXV manifold and tube assembly.
4. Remove the condenser-to-evaporator line fitting nut and disconnect the fitting. Discard the gasket seal. To install, tighten to 15 Nm (11 lb-ft).
5. Remove the compressor manifold and tube suction fitting nut and disconnect the fitting. Discard the gasket seal. To install, tighten to 15 Nm (11 lb-ft).
6. Disconnect the A/C pressure transducer electrical connector and detach the wire harness from the TXV manifold and tube.
7. Remove the TXV fitting nut and disconnect the fitting. Discard the gasket seals. To install, tighten to 15 Nm (11 lb-ft).
8. Remove the TXV manifold and tube assembly.
9. To install, reverse the removal procedure. Install new gasket seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .
10. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) .

See also:
• CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
• JACKING & LIFTING
• INSTRUMENT PANEL AND CONSOLE
• BUMPERS
• ENGINE COOLING
• STEERING SYSTEM-GENERAL INFORMATION
• FRONT END BODY PANELS
• SUPPLEMENTAL RESTRAINT SYSTEM
• CLUTCH AND CLUTCH FIELD COIL
• CLIMATE CONTROL ASSEMBLY
• AIR CONDITIONING (A/C) COMPRESSOR - 2.3L
• AIR CONDITIONING (A/C) COMPRESSOR - 3.0L
• HEATER CORE AND EVAPORATOR CORE HOUSING