Automatic A/c-Heater Systems: Removal & Installation Mercury Villager II

REMOVAL & INSTALLATION

A/C compressor cycling switch is mounted on Schrader valve, located on top of suction accumulator-drier. It is not necessary to discharge A/C system to replace switch. Tighten switch to 12-48 INCH lbs. (1.4-5.4 N.m).

Removal

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Disconnect inlet (high pressure) and outlet (low pressure) lines. Disconnect cycling clutch pressure switch connector. Remove speed (cruise) control servo. Remove coolant sensor. Remove suction accumulator-drier.

Installation

Ensure replacement suction accumulator-drier contains 2 ounces of new refrigerant oil. To complete installation, reverse removal procedure. Evacuate, charge, and leak test A/C system.

Removal & Installation (Auxiliary System)

1. Disconnect negative battery cable. Drain engine coolant. Discharge A/C-heater system, using approved refrigerant recovery/recycling equipment. Remove "C" pillar upper trim panel. Remove left quarter trim panel. See «QUARTER TRIM PANEL»(ref-91346-S22224162822001030900000) . Remove rear package tray brace bolts. Loosen blower motor housing bracket bolt. Remove upper duct from A/C-heater unit.
2. Disconnect blower motor connector and blower motor resistor connectors. Disconnect auxiliary system temperature blend door actuator motor connector and vent door actuator motor connector.
3. Disconnect A/C evaporator line from spring-lock coupling. Disconnect A/C evaporator lines from expansion valve. Disconnect drain hose.
4. Remove case attaching screws and remove blower motor and evaporator case assembly. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system. Fill cooling system. Check for leaks.

Removal & Installation (Main System)

1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Position power steering junction block aside. Disconnect refrigerant line spring-lock coupling from evaporator core. Remove instrument panel. See «INSTRUMENT PANEL»(ref-91346-S02691212922001030900000) . Remove lower instrument panel brace. Disconnect electrical connector and remove blower motor speed control.
2. Disconnect temperature/blend panel by-pass door connector. Disconnect blower motor to evaporator case cooling tube. Remove blower motor housing nut. Remove blower motor housing screws. Remove evaporator housing nuts. Remove evaporator/blower assembly. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system.

Clutch cycling pressure switch is mounted on Schrader valve, located on top of suction accumulator-drier. It is not necessary to discharge A/C system to replace switch. Tighten switch to 12-48 INCH lbs. (1.4-5.4 N.m).

1. Disconnect negative battery cable. Remove center seat. Remove auxiliary A/C-heater unit access panel from quarter trim panel. Disconnect auxiliary blower motor connector. Remove blower motor bolts and blower motor. Squeeze blower motor wheel retainer, and separate blower motor and blower motor wheel. To install, reverse removal procedure.

1. Disconnect negative battery cable. Remove glove box from instrument panel. Disconnect glove box striker plate catch connector. Remove instrument panel lower reinforcement.
2. Disconnect blower motor connector. Disconnect blower motor housing tube from blower motor and position aside. Remove blower speed controller screws, and position controller aside. Remove blower motor from main A/C-heater unit. Remove blower motor wheel retainer, and remove blower motor wheel and blower motor. To install, reverse removal procedure.

Locate Blower Speed Controller (BSC) on bottom of blower motor assembly. Remove BSC screws, and pull BSC forward to remove. Disconnect BSC connectors. To install, reverse removal procedure.

1. Disconnect negative battery cable. Remove auxiliary control panel by prying from quarter trim panel. Disconnect and remove auxiliary control panel connectors.
2. Disconnect auxiliary system fan switch connector. Remove fan switch screws and fan switch from auxiliary control panel. To install, reverse removal procedure.

Disconnect negative battery cable. Remove ashtray and cup holder assembly. Remove console cover. Remove 2 screws and instrument panel center finish panel. Remove 4 screws and climate control panel. Disconnect connectors from back of climate control panel. Remove control panel. To install, reverse removal procedure.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove manifold bolt, and move manifold aside. Remove drive belt, and disconnect compressor (magnetic) clutch connector.
2. Loosen upper compressor bolts. Remove lower compressor bolts. Remove upper bolts and remove compressor. Discard manifold "O" rings. Record amount of refrigerant oil in old compressor. If replacing compressor, replace suction accumulator-drier and fixed orifice tube.

1. Drain oil from new A/C compressor. Add new refrigerant oil to new compressor as follows. If amount drained from old compressor is 3-5 ounces, add same amount to new compressor. If amount drained is less than 3 ounces, add 3 ounces to new compressor. If amount drained is more than 5 ounces, add 5 ounces to new compressor.
2. Lubricate new "O" rings with clean refrigerant oil and install onto A/C compressor. Install compressor, and tighten bolts to 15 ft. lbs. (20 N.m). Connect compressor clutch connector. Install manifold, and tighten bolt to 19 ft. lbs. (26 N.m). Install drive belt, and check belt tension. Evacuate, charge, and leak test A/C system.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Disconnect suction and discharge lines. Remove manifold bolt. Remove manifold and tube from compressor. 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. Drain cooling system. Disconnect cooling fan connectors. Disconnect overflow tube, and remove coolant reservoir. Move center fuse panel aside. Disconnect both radiator hoses.
2. Remove fan and shroud assembly. Disconnect and plug transaxle oil cooler lines. Remove radiator. Disconnect inlet (high pressure) and outlet (low pressure) lines. Remove condenser.

1. Ensure replacement condenser contains 1.0-1.7 ounces of new refrigerant oil. To complete installation, reverse removal procedure. Evacuate, charge, and leak test A/C system.

Dual pressure switch is located on compressor manifold. Switch is mounted on a Schrader valve. It is not necessary to discharge A/C system to replace switch. Tighten switch to 60-108 INCH lbs. (6.8-12.2 N.m).

Remove auxiliary A/C-heater unit. See A/C-HEATER UNIT . Remove evaporator case bolts. Separate evaporator case and remove evaporator. To install, reverse removal procedure.

Remove evaporator/blower assembly. See A/C-HEATER UNIT . Remove evaporator/blower assembly screws, and separate case halves. Ensure replacement evaporator core contains 1.5-2.5 ounces of new refrigerant oil. To complete installation, reverse removal procedure. Evacuate, charge, and leak test A/C system.

1. Disconnect heater hoses. Remove A/C evaporator housing. See «EVAPORATOR»(ref-91346-S05566389812001030900000) . Remove front seats. Remove accelerator pedal stopper cover. Remove front door scuff plates. Remove cowl side trim panels.
2. Position carpet aside. Remove rear seat duct bolt and air ducts. Remove rear heater duct cover. Remove rear seat outlet duct. Remove 6 instrument panel center support bracket bolts. Remove center support brackets. Remove lower instrument panel center support bolts. Remove lower center support bracket.
3. Remove heater outlet floor duct. Disconnect electronic door actuator motor connector. Remove heater/ventilation intake duct bolts and duct. Remove upper heater case attaching nut. Remove lower heater case attaching nut. Remove heater case. Remove heater core foam grommet. Remove heater core attaching screws and support clip. Remove heater core. To install, reverse removal procedure.

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Disconnect negative battery cable. Remove 2 driver-side air bag module access covers from behind steering wheel. Remove steering wheel bottom cover. Disconnect air bag electrical connector. Remove module retaining bolts. Separate air bag module from steering wheel and disconnect horn pad switch. Remove driver-side air bag.
2. Remove 4 push-pins and CD changer/console compartment door on passenger side. Remove ashtray and cup holder assembly. Remove center instrument panel finish panel. Open glove box. Remove 4 screws and 4 bolts retaining passenger-side lower finish panel. Pull out finish panel enough to access electrical connectors. Remove finish panel. Disconnect passenger-side air bag electrical connector. Remove 4 retaining nuts and remove passenger-side air bag module.
3. Remove nuts and screws attaching instrument panel lower covers and remove lower covers. Disconnect footwell light electrical connectors. Remove climate control panel assembly. Remove radio/CD changer (if equipped). Reach through glove box opening and disconnect light sensor amplifier electrical connector. Remove instrument cluster finish panel.
4. Remove screws and push-pin retainers holding instrument panel steering column cover reinforcement, and remove reinforcement. Remove lower heater duct screw. Remove heater duct. Remove 4 nuts holding steering column, and lower steering column. Disconnect remote keyless entry electrical connector. Remove lower left side instrument panel reinforcement screw and nut. Remove center instrument panel screws.
5. Working through passenger-side air bag module opening, remove instrument panel attaching screw. Working through glove box opening, remove instrument panel attaching bolts. Remove lower right side instrument panel screw. Remove defroster opening grille. Disconnect electrical connectors through opening (if equipped).
6. Remove left and right side windshield garnish moldings. Remove instrument panel cowl top screws and nut. Remove instrument panel. To install, reverse removal procedure.

Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove high pressure relief valve from compressor manifold. Tighten pressure relief valve to 51-132 INCH lbs. (5.8-14.9 N.m). Evacuate, charge, and leak test A/C system.

1. Fixed orifice tube is located in condenser-to-evaporator line. Replacing fixed orifice tube requires replacement of condenser-to-evaporator line. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain engine coolant to a level below thermostat. Remove upper radiator hose and hose bracket.
2. Disconnect condenser-to-evaporator lines at evaporator near firewall. Remove condenser-to-evaporator line containing orifice tube and hold-down bracket. To install, reverse removal procedure. Evacuate, charge, and leak test A/C system.

Disconnect negative battery cable. Remove center seats. Move rear seat to center seat position. Remove 3 right rear seat belts. Remove hold-down net retainers. Remove liftgate scuff plate. Remove cargo shelf trim panel. Remove 2 trim screws and quarter trim panel. Disconnect electrical connector. To install, reverse removal procedure.