Auxiliary HVAC Control System: Removal & Installation Mercury Montego III

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Recover the refrigerant. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233047) .
3. Remove the LH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-233049) .
4. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-233003) .
5. Remove the LH rear wheel and tire assembly.
6. Remove the LH rear wheel opening splash shield.
7. Release the auxiliary heater inlet hose clamp and disconnect the auxiliary heater inlet hose.
8. Release the auxiliary heater outlet hose clamp and disconnect the auxiliary heater outlet hose.
9. Remove the auxiliary evaporator outlet line fitting nut and disconnect the fitting. To install, tighten to 8 Nm (71 lb-in).
10. Remove the auxiliary evaporator inlet line fitting nut and disconnect the fitting. To install, tighten to 8 Nm (71 lb-in).
11. Remove the 2 floorpan bracket nuts. To install, tighten to 3 Nm (27 lb-in).
12. Remove the 2 auxiliary duct pin-type retainers and detach the auxiliary ducts.
13. Disconnect the 2 auxiliary climate control housing electrical connectors.
14. Detach the auxiliary blower motor relay pin-type retainer(s).
15. Remove the 3 auxiliary climate control housing bolts. To install, tighten to 6 Nm (53 lb-in).
16. Remove the auxiliary climate control housing.
17. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233047) .
18. Fill the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-233003) .
19. Evacuate, leak test and charge the refrigerant system. For additional information, refer to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION»(ref-233047) .

Scheme 25

1. Remove the LH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-233049) .
2. Disconnect the auxiliary blower motor electrical connector.
3. Remove the 3 auxiliary blower motor screws.
4. Remove the auxiliary blower motor.
5. Remove the auxiliary blower motor wheel clip.
6. Remove the auxiliary blower motor wheel.
7. To install, reverse the removal procedure.

Scheme 26

1. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-233003) .
2. Remove the LH quarter trim panel. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-233049) .
3. Remove the 9 auxiliary heater core cover screws.
4. Release the auxiliary heater core inlet hose clamp and disconnect the hose.
5. Release the auxiliary heater core outlet hose clamp and disconnect the hose.
6. Remove the auxiliary heater core.
7. To install, reverse the removal procedure.
8. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-233003) .

Scheme 27

Scheme 28

Note. The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing 2-piece lines for ease of installation.

Note. The following procedure can be used to remove and install one or both of the auxiliary heater inlet line and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.

Scheme 29

Scheme 30

1. Drain the engine coolant. For additional information, refer to «ENGINE COOLING»(ref-233003) .
2. Position a jack stand to support the muffler and tailpipe assembly.
3. Disconnect the resonator isolator.
4. Disconnect the underbody catalytic convertor and discard the gasket.
5. Disconnect the muffler front isolator.
6. Disconnect the muffler rear isolator.
7. Remove the muffler, resonator and underbody catalytic convertor assembly.
8. Remove the rear driveshaft. For additional information, refer to «DRIVESHAFT»(ref-233022) .
9. Remove the exhaust heat shield.
10. Remove the front auxiliary heater outlet line clamp and disconnect the line.
11. Remove the front auxiliary heater inlet line clamp and disconnect the line.
12. Remove the LH rear wheel.
13. Remove the LH rear quarter panel moulding. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(ref-233040) .
14. Remove the 3 outer LH rear quarter panel moulding bracket bolts.
15. Remove the 2 inner LH rear quarter panel moulding bracket bolts.
16. Remove the LH rear quarter panel moulding bracket. Detach the splash shield pin-type retainer.
17. Remove the 2 LH rear brake caliper bolts and position the caliper aside. To install, tighten to 35 Nm (26 lb-ft).
18. Remove the 2 parking brake cable bolts. To install, tighten to 12 Nm (9 lb-ft).
19. Remove the 4 rear subframe bracket bolts. To install, tighten to 63 Nm (46 lb-ft).
20. Remove the trailing arm-to-knuckle bolt. To install, tighten to 110 Nm (81 lb-ft).
21. Loosen the trailing arm-to-subframe bolt and position the trailing arm aside. To install, tighten to 110 Nm (81 lb-ft).
22. Remove the LH lower shock bolt. To install, tighten to 142 Nm (105 lb-ft) for AWD. To install, tighten to 110 Nm (81 lb-ft) for FWD.
23. Position a lifting table to support the rear subframe.
24. With a wax pencil, mark the relational alignment of the rear subframe to the underbody at the mounting locations.
25. Disconnect the 2 rear wheel speed sensor electrical connectors.
26. Loosen, but do not completely remove the 2 RH rear subframe bolts. To install, tighten to 115 Nm (85 lb-ft).
27. Remove the 2 LH rear subframe bolts. To install, tighten to 115 Nm (85 lb-ft).
28. Correctly support the fuel tank and remove the LH rear fuel tank strap bolt. To install, tighten to 35 Nm (26 lb-ft).
29. Remove the rear auxiliary heater outlet line clamp and disconnect the line.
30. Remove the front auxiliary heater outlet line clamp and disconnect the line.
31. Remove the 2 middle rear auxiliary line bracket bolts. To install, tighten to 5 Nm (44 lb-in).
32. Remove the 2 middle rear auxiliary line brackets.
33. Remove the 2 middle front auxiliary line bracket nuts. To install, tighten to 5 Nm (44 lb-in).
34. Remove the 2 middle front auxiliary line brackets.
35. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the middle fitting on the replacement line(s).
36. Remove the front auxiliary line bracket nut. To install, tighten to 5 Nm (44 lb-in).
37. Remove the front auxiliary line bracket.
38. Remove the front portion of the auxiliary heater outlet line and/or auxiliary heater inlet line.
39. Remove the rear auxiliary line bracket nut. To install, tighten to 5 Nm (44 lb-in).
40. Remove the rear auxiliary line bracket.
41. Remove the rear portion of the auxiliary heater outlet line and/or the auxiliary heater inlet line.
42. To install, reverse the removal procedure.
43. Fill the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-233003) .