Werkstatthandbuch Book 2 · Seiten 301–400

36-00-1 Ventilating, Heating and Air Conditioning 36-00-1 GROUP Ventilating, Heating and 36 Air Conditioning PART TITLE PART NO. PART TITLE PART NO. Air Conditioning Basic Theory 36-31 Granada and Monarch Heater/Air Air Conditioning General Service - Conditioner System 36-40 Refrigerant Systems 36-32 Heated Rear Window System 36-86 Cougar and LTD II Heating System 36-12 Heating General Service 36-10 Cougar and LTD II Heater/Air

36-01-2 Ventilating Systems 36-01-2 DESCRIPTION AND OPERATION FRONT AIR VENTS Ford and Mercury register can be pivoted from side to side for horizontal The ventilation air ducts are located in the right and air distribution. The louvers can be closed by moving left cowl panels and are accessible for service by them upward. removing the cowl trim panels. The air vent grilles are The left register is a horizontally-mounted type withan integral part of the trim panels. vertical louvers that can be moved from side to side. When the vehicle is in motion, outside air enters the

36-01-3 Ventilating Systems36-01-3 NUT SCHEW RIGHT CONTROL VIEW C FORD VEHICLES ONLY FORD SHOWN MERCURY AND METEOR TYPICAL PARKINO BHAKC

au-v ‘--‘ RIGHT YCN ouct DUC VIEW B VIEW A / Ll&l6-2B VIEW C VIEW 6 System

36-0-5 ASSEMBLY REGISTER HOUSING SEE SECTIONAL VIEW E RETAINIt TAB 5ECTIOT’ht VIEW E REGISTER Ens LOUV

36-01-6 Ventilating Systems 36-01-6 FRONT or vEHICLE LEFT VENT LEFT DUCT ASSEMBLYN LEFT RIGHT VENT ---.. FRONT OF VEHICLE SEE VIEW A OFF POSITION REGISTER/FLOOR AIR AIR TO REGISTER IHIGHI %HMID POSITIONI 1 HIGH/LOW VIEW A 1 FIG. 5 High/Low Ventilation S

36-01-7 Ventilating Systems 36-01-7 FRONT OF VEHICLE 1.COWL TOP PANEL INSTRUMENT CLUSTER 5_. SCREW 12 REDO I LEFT AIR REGISTER LOUVER ASSEMBLY INSTRUMENT PANEL HI/LO I PRONTOFVEHICLE

36-01-8 Ventilating Systems 36-01-8 HEATER ASSEMRLY HEX WASHER I-lEAD SCREW-3B3936 RIGHT AIR REGISTER LOUVER ASSEMBLY INSTRUMENT PANEL DUCT A SS EM BLY SCREW 2 REOD ¶

36-01-9 Ventilating Systems 36-01-9 REMOVAL AND INSTALLATION MUSTANG II Vent Duct-Left 1. Disconnect the vent control from the instrument panel Fig. 7. 2. Remove the two vent-to-cowl top panel mounting screws, separate the vent assembly from the air duct and remove the vent assembly. 3. To remove the air duct, remove the air duct-to- instrument panel retaining screws. 4. If the air duct was removed, place it in position and instoll the two air duct-to-instrument panel LARGE retaining screws. Position the vent assembly in place and install the two vent assembly-to-cowl top panel retaining screws.

36-01-10 Ventilating Systems 36-01-10 Unlock the four tabs by pushing each one down and 3. Remove the three 3 duct-to-upper-cowl mounting inboard of the rectangular holes Fig. 12. stud nuts. 4. Separate the vent duct from the left register air duct and remove the vent duct assembly. 5. Install the assembly by reversing the above procedure. Right Vent Assembly Fig. 4

36-10-1 Heating System General Service 36-10-1 PART Heating System General Service 36-10 SUBJECT PAGE SUBJECT PAGE GENERAL INFORMATION TESTING Cont’d. Heater Cores 101 Blower Switch Test 10-5 Heating Systems and Control Doors 101 Heater Blower Motor Current Draw Test 10-5 Safety Precautions 10-1 Heater Core Tests 10-6 Heater Water Valve Tests 10-5 DIAGNOSIS

36-10-2 Heating System General Service 36-10-2 DIAGNOSIS COMPLAINT Insufficient, erratic, or not heat or defrost Poseible Cause Checks and Corrections Low radiator coolant due to: Check radiator cap pressure. Replace if below minimum pressure. * Coolant leaks Fill to level. Pressure test for engine cooling system and heater system leaks. Repair as required. * Engine overheating Remove bugs, leaves, etc. from radiator or condenser fins. Check for: Loose tan belt

36-10-3 Heating System General Service 36-10-3 COMPLAINT Insufficient, erratic, or no heat or defrost Possible Cause Checks and Corrections Sticking heater water valve if applicable Vacuum check with hand vacuum pump. Replace if required. Kinked, clogged, collapsed, soft, swollen, or Replace damaged hoses and backflush engine cooling system, decomposed en9ine cooliny system or heater then heater system, until all particles have been removed. system hoses Blocked air inlet Check cowl air inlet for leaves, foreign material, etc. Remove as required. Right vent open Close ve

36-10-4 Heating System General Service 36-104 CONDITION Air comes out of defroster outlet in any function control lever position. Possible Cause Checks and Corrections Vacuum system this indicates a very bad leak, Listen for vacuum system leak. Look for disconnected vacuum and is usually easy to locate hose connector. Use hand.operated vacuum pump, and check vacuum motors for diaphragm leak. Also check for leaking check valve, and leaking vacuum reservoir tank. Repair hoses, or replace components as required. CONDITION Cowl ventilation system leaks air Possible Cause

36-10-5 Heating System General Service 36-10-5 TESTING The following tests may be made on the heater: HEATER BLOWER MOTOR CURRENT DRAW burned out fuses, loose wire connections, damaged TEST wires, or collapsed hoses. Loose defroster ducts and air leaks in the body may be determined by visual This test will determine if the blower motor is inspection of the parts. operating properly. Connect a 0-10 ammeter as shown in Pig. 2. The blower motor will operate the control switch, and the current drawn by the motor will be DISCONNECT indicated

36-10-6 Heating System General Service 36-10-6 heater core is restricted. If a vacuum is observed, refer to the vehicle applications section on Vacuum Systems for corrective action. HEATER WATER VALVE VACUUM SWITCH Some applications use a water valve vacuum switch to send vacuum to the water valve vacuum motor to close the water valve. A plunger in the switch is actuated by the movement of the crank arm with the temperature control lever. HEATER WATER VALVE VACUUM SWITCH ADJUSTMENT ROTURDA 21-0012 1. Make sure that the temperature control cable connects the temperature control lever to the temperature blend door is properly adjusted. 2. Move the temperature control l

36-11-1 Ford, and Mercury Heating System 36-11-1 Ford and Mercury 36-11 Heating System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Control Assembly 11-1 Blower Motor and Wheel Assembly 11-4 Function Control Lever Operation 11-2 Control Assembly 11-4 Power Vent Feature 11-3 Control Switches and Vacuum Valve 114 System Operation and Control Doors 11-1 Defroster Nozzle 11-4 Temperature Control Lev

36-11-2 Ford, and Mercury Heating System 3647.2 TEMPERATURE CONTROL LEVER-1 SLOWER SPEED CONTROL SWTCH TO WATFP HEATER SUPPLY WATER VALVE FUNCTION CONTROL LEVER ACCESSORY SWITCH FORD AND MERcuRy

36-11-3 Ford, and Mercury Heating System 36-11-3 In the OFF position, the function control lever opens and the vertical vanes moved from right to left for air the system off-on switch to stop current flow to the deflection Fig. 3. The registers are closed by moving three-position blower speed control switch blower the vanes inboard. The Mercury left register can be stops. As soon as the lever is moved from OFF position pivoted from side to side and the horizontal vanes can to the right one detent position, it closes the off-on be moved up and down for air deflection. The registers switch to bring current to the blower speed control are closed by moving the vongs upword. switch whose sole function is to regulate blower speed

36-11-4 Ford, and Mercury Heating System 36-11-4 REMOVAL AND INSTALLATION CONTROL ASSEMBLY REGISTER LOUVER BARRELS 1. Disconnect the battery ground cable. Pry on the end pivot with a thin blade to separate 2. Remove the knobs from the blower speed control, the pivot from the pivot hole and putt the barrel function control and temperature control levers. If assembly out of the instrument panel as shown in Fig. so equipped, remove the knob from the accessory 5- switch control lever. The barrels con be installed in one way only because3. Remove the two mounting screws on the control

36-U-S Ford, and Mercury Heating 36-115 RjGHT1SIRDUCT NTRUENT PANEL VIEW B LLI AIR DULT VIE A RIGHT ALR DLCT U VIEW B $EE VIEW A CENTER AIR DUCT REGISTFP LEFT ASSEMBLY 555 ‘115W C LULIVER

36-11-6 Ford, and Mercury Heating System 36-11-6 TYPICAL-ALL LOuVERS SECTIONAL VIEW A REMOVED IN SAME MANNER LiBOl-IA 1- Ofl-4 FIG. S Register Louver Barrel FIG. 6 Heater Core Removal 10. Route the lead wire and the ground wire through the clip on the resistor; connec

36-11-7 Ford, and Mercury Heating System 36-11-7 DRILL DIMPLE SEE VIEWA DRILL 1"DIA.I-IOLE TANGENT TO CENTERLINE OF THE BEAD, AT DRILL DIMPLE WHICH IS LOCATED 1/2" FROM CENTERLINEOF BEAD ACCESS HOLE BEAD ON

36-11-8 Ford, and Mercury Heating System 36-11-8 SPECIFICATIONS Average Blower Motor Current Draw Current at 12.8 Volts Low -3 amps. Medium -5.5 amps. High -9 amps. Circuit Protection-15 amp. Fuse. "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowed without the express written permission of Ford Motor Company."

36-12-1 LTD II, Cougar, and Thunderbird Heating System 36-12-1 Cougar, LTD II and Thunderbird 3fl2 Heating System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Cont’d. Air Flow 12-1 Heater Assembly 12-3 Control Assembly 12-1 Heater Blower Motor and Wheel ADJUSTMENTS Assembly 12.4 Function Control Cable 12-2 Heater Control Assembly 12-3 Temperature Control Cable

36-12-2 LTD II, Cougar, and Thunderbird Heating System 36-12-2 KNOB SCREW ASSEMBLY FRONT FACE TRIM OF CONTROL BEZEL CONTROL "COOL WARM LEVER FRONT OF VEHICLE 18578- TEMPERATuRE CONTROL CABLE ASSEMBLY / 18548- FUNCTIONAL CONTROL CABLE ASSEMBLY PART OF 14401 WIRING

36-12-3 LTD II, Cougar, and Thunderbird Heating System 36-12-3 HEAT-DErROST 7 DOOR CONTROL CAB VIEW B L1554-2D FIG. 3 Heater Assembly REMOVAL AND INSTALLATION HEATER CONTROL ASSEMBLY 5. Carefully remove the nozzle assembly upward through the opening in the instrument panel. 1. Disconnect the battery ground cable. 2. Remove the knobs from the function, temperature HEATER ASSEMBLY and blower switch control levers. 3. Disconnect the cable end at each control lever one Rem

36-12-4 LTD II, Cougar, and Thunderbird Heating System - 36-12-4 V OUTLET N, LEFT OUTLET-.. N N - DEFROSTER NOZZLE N ASSEMBLY N N - N

36-12-5 LTD II, Cougar, and Thunderbird Heating System 36-12-5 SPECIFICATIONS HEATING SYSTEM SPECIFICATIONS Blower Motor Current Draw at 12.8 Volts - - - - ito 9 Amps on I-ugh Blower Control Illumination Protection Device LTD II, Cougar and Thunderbird One 1 CP No, 161 Bulb LTD II, Cougar and Thunderbird 20 Amp Fuse in Fuse Panel CL15562G "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or

333333 333555 36-13-1 Fairmont and Zephyr Heating System 36-13-1 Fairmont and Zephyr PART 36-13 Heating System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Heater System 13-3 Blower Assembly 13-16 Air Distribution 13-3 Blower Switch Assembly 13-14 Air Flow 13-3 Blower Wheel 13-11 Blower Fan Control 13-5 Control Asse

36-13-2 Fairmont and Zephyr Heating System 36-13-2 DESCRIPTION AND OPERATION on the register outlet of theHIGH/LOW VENTILATION SYSTEM FIG. 1 polyurethane foam gasket left ventilator assembly prevents air leakage at the left Two openings in the upper cowl force or ram the register duct and limits the amount of air leakage outside air, from the forword motion of the vehicle, into behind the instrument panel. the top of the left and right ventilator assemblies Fig. 2. The omount of air flow may be increased by opening Left Register Duct the side ventilation louvers if so equippe

36-13-3 Fairmont and Zephyr Heating System 36-13-3 Right Outside Air Inlet Duct OUTSIDE Mn The right outside air inlet duct Fig. 29 is secured to the top af the blower housing portion of the heater case assembly with two retaining screws. A OUTS’ DE - MR polyurethane foam gasket,

36-13-4 Fairmont and Zephyr Heating System 36- 13-4 VENTILATION SYSTEM PASSE NC EEl SI UEJ CABLE OPERATED FIND F U FWO MID POSITION

36-13-S Fairmont and Zephyr Heating System 36-13-5 BLOWER FAN CONTROL 5. Turn the ignition switch to the ON position. System ON-OFF Switch 6. With a fully charged battery, blower voltage should be within the specified range for each blower Power to the blower motor is provided by a system switch position as indicated in the blower switch ON-OFF slide switch, located an the back of the chart of the electrical wiring diagram Fig. 6.Function Control Lever Fig. 16. The switch contacts close

36-13-6 Fairmont and Zephyr Heating System 36-13-6 ID IJEFROSTERS J--- ,-_l --OFF-. OUTSIDE AIR TO FLOOR TO DEFROSTERS - HEAT - WARM POSITION AIR

__ 36-13-7 Fairmont and Zephyr Heating System 36-13-7 SAT EHY DASH PANE L 4 V CL LOW IGNITION SoIl OH GREY W/Lr El DE STRIPE 15 A I 261A ORANDE WIELACK STRIPE FIlER BR OW II V -Ti QH A NO E

36-13-8 Fairmont and Zephyr Heating System 36-13-8 12583-2A FIG. 7 Blower Motor Voltage and Current Draw Test Connections ADJUSTMENTS 1-INCHCONTROL CABLES INITIAL POSITION APPROX. Function and/or Temperature Control Cables CONTROL WIRE OFPORRE-ADJUSTMENTINS

36-13-9 Fairmont and Zephyr Heating System 36-13-9 3. Move the control levers to the top of the slot LEFT AND RIG HT VENTILATOR CONTROL temperature WARM-function DEF to position the CABLES self-adjustIng clip. The left and right ventilator control cables are non- 4. Check far proper control operation. adjustable. REMOVAL AND INSTALLATION DUCT BRACKETLEFT OR RIGHT VENTILATOR CONTROL RETAINING SCREW Ill

36-13-10 Fairmant and Zephyr Heating System 36-13-10 grHle from the bottom of the ventilator assembly as shown in Fig. 1 2, for access to the lower right ventilator assembly retaining screw. LEFT VENTILATOR 5. Remove right register duct and register assembly DOOR - 5401 B63 refer to procedures for access to the upper right ventilator retaining screw. Use’ long extension

36-13-11 Fairmont and Zephyr Heating System 36-13-11 I / RIGHT REGISTER DUCT -540 1878- RIGHT VENTILATOR -19409- RIGHT - a = S- CONTROL 0

36-13-12 Fairmont and Zephyr Heating System 36-13-12 the retaining tab pivot clears the hole in the register opening. 2. Pull the register assembly end out from the housing only enough to prevent the pivot from going back into the pivot hole. 3. Repeat Step 1 for the other retaining tab and pull RIGHT

36-13-13 Fairmant and Zephyr Heating System 36-13-13 THE PLENUM DOORS MAY OCCUR, top edge of the right instrument panel trim RESULTING IN CASE ASSEMBLY REMOVAL applique, above the glove box. AND DISASSEMBLY FOR PROBLEM 5, Loosely install the left side instrument panel pad CORRECTION. retaining screws 2 in the retaining tab slot 5. Raise the overhanging brow edge of the instrument apenings in the upper right and left corners of the panel pad, to clear the retaining tabs, and pull instrument panel cluster area. rearward to remove from the top of the instrument 6. Secure the instrument panel pad in position by panel.

36-13-14 Fairmont and Zephyr Heating System 36-13-14 4. Disconnect the blower speed switch, system on-off Installation switch and the contral illumination wire harness 1. Align the Function Control Lever tab with the slot connectors. of the system on-off switch and position the system 5. Remove the control assembly with the control on-off switch assembly an the locator pins of the cables. Control Assembly Fig. 16. 2. Install the system on-off switch retaining screws 2 6. Depress the lacking tang white on the end of the function contral cable hou

36-13-15 Fairmont and Zephyr Heating System 36-13-15 INETR IJMENT CLUSTER TRIM PANEL CONTRR I ASSEIv1BLY RETAINING 1

36-13-16 Fairmont and Zephyr Heating System 36-13-16 HEAT-DEFROST DOOR TEMPERATURE BLEND ODOR CRANK ARM CLIP-ISBEBI- A FUNCTION CONTROL TEMPERATURE CABLE ASSEMBLY CONTROL CABLE -1 8C592- ASSEMBLV-180306- -j N SELF ADJUSTING

36-13-17 Fairmont and Zephyr Heating System 36-13-17 12504-lA L2595-IA FIG. 8 Resistor Assembly Removal FIG. 19 Blower Motor and Wheel Assembly Removal BLOWER WHEEL Removal 1. Remove the right ventilator assembly. Refer ta procedure and Fig. 11. 2. Remove the hub clamp spring from the wheel hub. Refer to Fig. 20. Note: Hose clamp pliers for flat spring type clomps will simplify this operation. 3. Slide the blower wheel from the motor shaft. Installation 1. Align the flat surface on the ID of the blower wheel hub with the flat surfac

36-13-18 Fairmont and Zephyr Heating System 36-13-18 Installation HEATER CASE ASSEMBLY 1. Align heater core with the heater case opening Removal with core tubes on top and slide the heater core 1. Remove right register assembly, register duct and into the heater case assembly Fig. 21. right ventilator assembly. Refer to removal 2. Position the heater core cover onto the opening of procedures and Figs. 11 and 13. the case assembly and install core cover retaining 2. Remove the floor heat duct assembly from heater screws 4. Tighten cover retaining screw

36-13-19 Fairmont and Zephyr Heating System 36-13-19 9. Remove the radiator cap, open the radiator drain 5. Tighten the heater case assembly.to-dash panel cock and partially drain the engine coolant to drain mounting stud nuts 3 to specification. the heater core. Close the radiator drain cock. 6. Connect heater hoses to core tubes and tighten 10. Loosen heater hose clamps and disconnect the hose clamps to specification Figs. 26, 27 or 28. heater hoses from the heater core tubes. Cap the 7. Refill cooling system with specified coolant to core tubes to prevent the spilling of coolant in the proper coolant level and install the radiator cap. passenger compartment.

36-13-20 Fairmont and Zephyr Heating System 36-13-20 15. Test the heater system for proper operation. 4. Remove the defroster nozzle from under the instrument panel. - FLOOR HEAT DISTRIBUTION DUCT InstallationASSEMBLY 1. Position the defroster nozzle assembly under the Removal instrument panel onto the outkt openings at the Remove the retaining screw 1 securing the right instrument panel Fig. 24. half of the floor heat distributi

36-13-21 Fairmont and Zephyr Heating System 36-13.21 L2599-1A FIG. 23 Floor Heat Distribution Duct Assembly Removal L2600-2A FIG. 24 Defroster Nozzle Removal "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material is allowe

36-13-22 Fairmont and Zephyr Heating System 36-13-22 HEATER CORE SUPPORT BRACKET 12601-IA FIG. 25 Temperature Blend Door Removal L2602-2A FIG. 26 Heater Hose Routing-2.3L 1-4 Engine "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction

36-13-23 Fairmont and Zephyr Heating System 36-13-23 12602- 24 FIG. 27 Heater Hose Routing-3.3L 200 CID 1-6 Engine L2604-2A FIG. 28 Heater Hose Routing-5.OL 302 CID V-B Engine "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Company. No further reproduction or distribution of the Ford Motor Company material

36-13-24 Fairmont and Zephyr Heating System 36-13-24 DISASSEMBLY AND ASSEMBLY HEATER CASE ASSEMBLY 3. Install the Temperature Blend Door in the front case half, with the straight shaft end inserted into the Disassembly bearing journal. 1. Remove the retaining screws 2 securing the 4. Insert the blower power and ground wire leads outside air inlet duct to the heater case assembly, through the blower housin9 opening in the front and remove the duct from the heater case assembly case half. Position the blower mounting flange onto Fig. 29.

36-13-25 Fairmant and Zephyr Heating System 36-13-25 OUTSIDE AIR IN LET DUCT - 19408 FRONT CASE HALE - 18A532 RETENTION

36-14-1 Mustang II, Pinto and Bobcat Heating System 36-14-1 Mustang II, Pinto and Bobcat PART 36-14 Heating System SUBJECT PAGE SUBJECT PAGE OESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Air Flow 14-1 Blower Motor Resistor 14-5 Control Assembly 14-1 Blower Motor and Wheel Assembly 14-4 Function Control Lever Operation 14-1 Control Assembly 14-3 Temperature Control Lever Operation 14-1 Control Cables

36-14-2 Mustang II, Pinto and Bobcat Heating System 36-14-2 MOUNTING UPACKET AND CLIP TEMPERATURE BLERD DOOR CRANK ARM SEE VIEW A INSTRUMENT PANEL COIL MUST EXTEND

36-14-3 Mustang II, Pinto and Bobcat Heating System 36-14-3 that connects the cable to the 5 door, and pull the 3. Disconnect the electrical connectors from the cable out. blower switch, system off switch and illumination 4. When installing, first connect the cabless to the bulb harness. control assembly, push the cables through the 4. Disconnect the electrical connectors from the opening and install the control assembly to the defogger switch and warning lamp, if so equipped. instrument panel. Then connect the cables to the 5. Disconnect the function control cable and 5 and/or 7 door. Adjust the cable as outlined temperature control cable from the control head

36-14-4 Mustang II, Pinto and Bobcat Heating System 36-14-4 L1514-2F FIG. 4 Heating System-Pinto and Bobcat Shown the heater case away from the dash panel. At the same time, pull the two heater hoses in through the HEATER ASSY. FRONT CASE dash panel. Then, disconnect the hoses from the heater core tubes, and remove the heater case

36-14-5 Mustang II, Pinto and Bobcat Heating System 36-14-5 HEATEN BLOWER MOTOR RESISTOR The resistor is mounted on the lower part of the heater case just above the passenger’s feet Fig. 6. To replace, disconnect two push-on connectors and remove VIEW A two retaining screws. VIEW B 19834 SEEVIEWO I-ISIS-Ic FIG. 6 Blower Motor and Wheel Assembly SPECIFICATIONS Blower Motor Curre

36-16-1 Granada and Monarch Heating System 36-16-1 Granada and Monarch PART 36-16 Heating System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Air Flow 16-1 Blower Motor and Wheel Assembly 16-4 Function Control Lever Operation 16-1 Control Assembly 16-3 Temperature Control Lever Operation 16-1 Defroster Nozzle 16-4 ADJUSTMENTS Heater Assembly 16-

36-16-2 Granada and Monarch Heating System 36-16-2 TO DEFROSTERS 013151DB AIR I EMILIIAflOL WAIIM UU PB QMT TOFLOOR HEATDEFROST IMODEI000R TEMPERATURE CABLE CONTROLLED RLENDDOOR CABLE CO

36-16-3 Granada and Monarch Heating System 36-16-3 ADJUSTMENTS TEMPERATURE CONTROL CABLE FUNCTION CONTROL CABLE Adjust the Temperature Control Cable in the Adjust the Function Control Cable in the following following manner; manner: 1. With the cable housing to heater attaching screw 1. With the cable housing to heater attaching screw loose, rotate the temperature door to the full loose Fig. 2, rotate the Heat-Defrost Door crank clockwise left position Fig. 2. arm to the full clockwise left position. 2. Push the Temperature Control Lever to the WARM

36-16-4 Granada and Monarch Heating System 36-16-4 18519 KNOB ASSEMBLY 18C622 4 REO’D REAR DEFOG WARNING LAMP ASSEMBLY I 5549 CONTROL ASSEMBLY 18541 ILLUMINATION BULB AND

36-31-1 Air Conditioning Basic Theory 36-31-1 PART Air Conditioning Basic Theory 36-31 SUBJECT PAGE SUBJECT PACE BASIC PRINCIPLES DIAGNOSIS 31-3 Effect of Pressure on Boiling or Condensation 31-2 Heat Transfer 31-1 Latent Heat of Vaporization 31-1 C12341-ZB BASIC PRINCIPLES Cor Air Conditioning is the cooling or refrigeration of heat that the water absorbs from th

36-31-2 Air Conditioning Basic Theory 36-31-2 from the higher temperature water to the lower 1. Dispose of the heat in the vapor. temperature milk. The milk would be heated rather than 2. Convert the vapor back to liquid for re-use.cooled, because the boiling point of water is too high. 3. Return the liquid to the starting point in the In order to make practical use of the heat transfer refrigeration cycle. that takes place when a liquid boils, we must choose a liquid with a law boiling point. Refrigerant 12 is the The compressor Fig. 1 performs these functions. It liquid mo

36-31-3 Air Conditioning Basic Theory 36-31-3 Or CHECK TEMP CONTROL LEVER FOR STICKING OR BINDING. CHECK BLEND DOOR TO INSURE COM PLETE TRAVEL OF DOOR FROM MINIMUM TO MAXI MUM POSITIONS OF CONTROL LEVER. NOt OK ADJUST BOWDEN CABLE CK3435-2B "This publication contains material that is reproduced and distributed under a licen

36-32-1 A/C General Service-Refrigerant Systems 36-32-1 PART - A/C General Service 36-32 Refrigerant Systems SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REFRIGERANT SYSTEM Compressor Unit 32-4 Charging From Small Containers 32-17 Condenser 32-5 Charging the System 32-16 Combination V

36-32-2 A/C General Service-Refrigerant Systems 36-32-2 SUCTION SERVICE ACCESS HIGH PRESSURE SERVICE ACCESS SUCTION GAUGE PORT VALVE L171B 2D FIG. 1 Expansion Valve and Suction Throttling Valve FRONT VIEW

36-32-3 A/C General Service-Refrigerant Systems 36-32-3 PROPER ‘ORING USE PLIERS HERE TO EVAPORATOR PRESSURE GAUGE PORT 0 RING SEAL III -387262 S O RING SEALS 121 387 195-5- CAP EVAPORATOR -387 195-S 9 VALVE BODY 190878

36-32-4 A/C General Service-Refrigerant Systems 36-32-4 REAR VIEW FRONT VIEW EVAPORATOR MA Np E OLD PLATE EVAPORATOR MANIFOLD PLATE STV HOUSING MANIFOLD- 10-EXPANSION VALVE ATTACHING SCREWS SOCKET HEAD

36-32-5 A/C General Service-Refrigerant Systems 36-32-5 CONDENSER The air conditioning condenser, located in front of the radiator, receives heated and compressed refrigerant gas from the compressor. As the refrigerant gas flows down through the condenser, it is cooled by air passing between the sections of the condenser. The cooled, compressed refrigerant gas condenses to liquid refrigerant which then flows into the receiver. MAGNETIC CLUTCH AND AMBIENT TEMPERATURE SWITCH The compressor clutch and the compressor are off when the system selector lever is in the OFF, ECONOMY VENT, HI-LO except ATC or HEAT positions. In all other positions of the system selector 1121-IA lever, the clutch will be engaged or diseng

36-32-6 A/C General Service-Refrigerant Systems 36-32-6 GAUGE PORT OR VALVE OPEN PRESSURE LINE MAN POLO GAUGE HOSE ASSEMBLY L1613-1° FIG. S Gauge Set Connected to Service Access Gouge Port Valve "This publication contains material that is

36-32-7 A/C General Service-Refrigerant Systems 36-32-7 DIAGNOSIS SUCTION GAUGE READING TOO LOW DISCHARGE PRESSURE GAUGE READING TOO LOW ENGINE AND TEST FOR REFRIGERANT LEAK rSTOP NOT OK OK SERVICE OR REPLACE LEAKING REFRIGERANT DISCHARGE SYSTEM. PERFORM COMPRESSOR L SYSTEMCOMPONENTS OILLEVELCHECK I NOT OK OK ADD OR REPLACE OIL TO SPECIFIED LEVEL EVACUATE AND CHARGE REFRIGERANT 5Th-

_______________ 36-32-8 A/C General Service-Refrigerant Systems 36-32-8 HIGH EVAPORATOR PRESSURE I 1 COMPRESSOR DISCHARGE PRSSSURE 1 1 COMPRESSOR NOISY AND/OR COMPRESSOR SUCTION PRESSURE AND/OR LOW COMPRESSOR GAUGE READING SUCTION PRESSURE BOUNCES 3 TO 4 PSI CONDITION OF INSUFFICIENT LIQUID BLEED LINE COLD. CHECK ENGINE COOLING COOLING AT HI

_ _ 36-32-9 A/C General Service-Refrigerant Systems 36-32-9 HIGH REGISTER AIR RATURE ETIQN THRQTT LE VA ND SUCTION HO - WARMER THAN EVAPORATOR COLD INLET TUBE CHECK FOR RESTRICTION LIQUID BLEED LINE FROSTED. LINE HOSE FROM CONDENSER TO EXPANSION VALVE- COLD OR FROSTED SPOT CHECK EXPANSION V

36-32-10 A/C General Service-Refrigerant Systems 36-32-10 A/C SYSTEM NEEDS FREQUENT CHARGING OR SHOWS SIGNS OF LEAKING 1 PERFORM A/C SYSTEM LEAK TEST. NOT OK OK ‘I, SERVICE OR REPLACE A/C COMPONENTS PERFORM REFRIGERANT SYSTEM ANALYSIS TESTS CAUSING LEAK CONDITION. REFER TO APPROPRIATE REFRIGERANT SYSTEMI.

__ 36-32-11 A/C General Service-Refrigerant Systems 36-32-11 MAGNETIC CLUTCH INOPERATIVE OR IS ERRATIC Fl VERIFY THE CONDITION I TURN IGNITION SWITCH TO ACCESSORY POSITION. I I MOVE FUNCTIONAL CONTROL LEVER TO MAX OR I FRESH A/C OR PANEL POSITION. MOVE I TEMPERATURE CONTROL LEVER TO COOL POSITION. LISTEN

36-32-12 A/C General Service-Refrigerant Systems 36-32-12 HAS EXCESSIVE VIBRATION OR NOISE*_I _COMPRESSOR LIFY CHECK FOR MISSING OR DAMAGED THE1COMPRESSORCONDITIONMOUNTING BOLTS. CHECK FOR BROKEN OR CRACKED BRACKETS OR BRACES. CHECK MOUNTING BOLTS TO MAKE SURE THEY ARE TORQUED TO SPECIFICATION. NOT 1 OK OK SERVICE OR REPLACE BRACKETS OR BRACES CHECK ALL DRIVE BELTS FOR ADJUSTMENT, WEAR IF REQUIRED. REPLACE MISS

36-32-13 A/C General Service-Refrigerant Systems 36-32-13 COMPRESSOR HAS EXCESSIVE VIBRATION OR NOISE - Continued 1 1 CONTINUED FROMpREVIOUS PACE I CHECK CLUTCH FOR LOOSENESS OR PLAY ON COMPRESSOR SHAFT. REMOVE CLUTCH AND INSPECT TAPER 2 CYL. COMPRESSOR AND KEYWAY IF LOOSENESS IS SUSPECTED. ..1 NOT OK

36-32-14 A/C General Service-Refrigerant Systems 36-32-14 TESTING ATTACHING THE MANIFOLD GAUGE SET EU RN S P When performing any of the various tests, test equipment must be connected to the system. If charge statIon-type eqUipment is used, follow the instructions of the manufactUrer, SEARCH DETECTOR HOSE UNIT To attach a monifold gauge set to the system proceed as follows: ROTUNDA 1. Remove the caps from the high and low pressure TOOL - c

36-32-15 A/C General Service-Refrigerant Systems 36-32-15 AIR CONDITIONER PERFORMANCE TEST idle speed and a surrounding air temperature of 110 degrees F, the high pressure may go as high The pressures developed on the high pressure as 300 pounds or more. discharge and low pressure suction side of the If it becomes necessary to operate the air conditionercompressor indicate whether or not the system is under these conditions, keep the high pressure downoperating properly. with a fan directed at the condenser and radiator.

36-32-16 A/C General Service-Refrigerant Systems 36-32-16 2. Perform the air conditioner performance test as RECEIVER DRYER TEST outlined in the foregoing procedure. Make any repairs indicated by the test. The receiver-dryer should be replaced if it has been 3. After operating the system for 10 to 15 minutes, damaged in an accident, leaks, or has become restricted be sure that normal operating pressures are or clogged. Do not attempt to repair the receiver-dryer. indicating on the manifold gauge set low pressure It is a refrigerant storage area, filter, and a moisture gauge 10 to 20 psi and high pressure gauge collecting device. If there is any indication of moisture 1

3642-17 A/C General Service-Refrigerant Systems 36-32-17 4. Set the high pressure discharge manifold gouge 13. After satisfactory operation has been achieved, valve at the full clockwise or closed position. disconnect the manifold gauge set high and low pressure hoses from the charging valves.5. Open the Refrigerant-12 tank valve to allow refrigerant to enter the system, and observe the 14. Install caps on the gauge ports and the manifold gauges. When both gauges reach 60 to 80 pounds gauge set lines. at approximately 75 degrees F, shut off the tank valve. CHARGING FROM SMALL CONTAINERS 6. Perform the leak test with the leak detector. 7. Set th

36-34-1 Six-Cylinder Compressor 36-34-1 PART - Six Cylinder Compressor 36-34 SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 34-1 MAJOR REPAIR OPERATIONS Compressor Assembly 34-12 MAINTENANCE Adding Oil 34-1 Compressor Disassembly 34-11 - External REMOVAL AND INSTALLATION

36-34-2 Six-Cylinder Compressor 36-34-2 4. If the oil drained from the removed compressor Oil should be added to replacement components as measured less than 4 ounces, replace 6 ounces of follows: new oil in the replacement compressor. Evaporator: Add 3 fluid ounces. 5. If the oil drained from the removed compressor measured between 4 and 6 ounces, the oil is Condenser: Add 1 fluid ounce. properly distributed throughout the system. Simply Receiver: Add 1 fluid ounce. replace an equal amount of new oil in the replacement compressor. Condenser and Receiver Assembly: Add 2 fluid

36-34-3 Six-Cylinder Compressor 36-34-3 5. Loosen the three belt tension adjusting screws Fig. CLUTCH ASSEMBLY 1, and rotate the compressor and bracket assembly in the front slot to disengage the belt. HUB AND DRIVEN PLATE 6. While supporting the weight of the compressor, Removal remove the three belt tension adjusting screws they 1. Remove the compressor from the vehicle as outlined are also mounting screws. in the preceding procedure. 7. Lower the compressor and then carefully lift the

36-34-4 Six-Cylinder Compressor 36-34-4 wall 9/16.inch socket, remo"e hub and driven plate assembly lock nut from shaft Fig. 2. PLATE REMOVER4. Remove hub and driven plate assembly retainer HUB DRIVEN a’ ring, using standard snap ring pliers. Remove spacer Fig. 4. 4.5. Screw the threaded hub puller 171P-19703-E into the hub of the driven plate. Hold the main body of the tool with the wrench and turn the forcing screw clockwise to remove the driven plate Fig. 5.

36-34-5 Six-Cylinder Compressor 36-34-5 11. Remove the compressor and clutch assembly from the holding fixture. After the compressor is installed, the engine at idle and the system is operating satisfactorily, cycle the clutch by turning air conditioning off and on at least 20 times at approximately one-second intervals PLATE to SEAT or RUN-IN th

36-34-6 Six-Cylinder Compressor 36-34-6 1. When replacing a new ball bearing assembly into BEARING RETAINER RING the pulley, use T71 P.i9703D pulley bearing installer Fig. 13. PULLEY RETAINING RINU 2. Replace the pulley assembly wire retainer ring in the pulley Fig. 9. ..,BEARING 3. Press or tap the pulley and bearing assembly on the

36-34-7 Six.Cylinder Compressor 36-34-7 DRIVEN PLATE 0.. ,_, DRIVE PLATE *tI - Ii B/S SCORING OF DRIVE PLATE AND DRIVEN PLATE IS NORMAL- DO NOT REPLACE FOR TIllS CONDITION

36-34-8 Six-Cylinder Compressor 36-34-8 CLLIT H GIL ‘I 190555 KIT WI RE CA IjLI E O20-3173 CLEARANCE II I I-V NI’ BE HIN 9 EEI5L STRAIGHT EDGE ISCALE i 1E’EI9 / ,EAL IS H1 15 P NAP RING / I I

36-34-9 Six-Cylinder Compressor 36-34-9 seat with Tool T71P-19703-M Fig. 16; and push it into place so as not to disturb the 0-ring. Remove the tools. SEAL ASSEMBLY REMOVER AND REPLACER 4. Using standard Tool T71 P-19703-T or Snap-On T71 P-19703-G snap-ring pliers PRA25, install the new s

36-34-10 Six-Cylinder Compressor 36-34-10 PRESSURE TEST PLATE TOOL-T7IP-197D3-O HIGH PRESSURE GAUGE LOW ADAPTERS TOOL-T7 1 P-i 9703-R&S L16fl-25 FIG. 19 Leak testing Compressor Shaft Seal c. Open the oil plug fitting in the compressor housing toward the top of the compressor. With a small and allow air t

36-34-11 Six-Cylinder Compressor 36-34-11 FIG 20 Compressor Shaft and Seal, Absorbent Sleeve and Retainer MAJOR REPAIR OPERATIONS COMPRESSOR remove the gears. Identifying marks are to assure that the gears, if reused, will be installed in Disassembly identical position. 1. Remove the compressor from the car and the clutch 8. Remove and discard the rear head-to-shell 0-ring. assembly from the compressor as described under 9. Carefully remove the rear discharge valve plate Removal and Installation. assembly. Use two small screwdrivers under the 2. Remove

36-34-12 Six-Cylinder Compressor 36-34-12 OIL PUMP CAVITY REAR DISCHARGE PLATE SUCTION CAVITY ASSEMBLY -VALVE19G656 FRONT- 190659SUCTION REEG FRONTPLATE ASSEMBLYDISCHARGE- VALVE190656 REAR SUCTION REED 0-RING - - 190659 DOWEL PINS P15 10 IN S FRONT HEAD--

36-34-13 Six-Cylinder Compressor 36-34-13 COMPRESSOR FRONT DISCHARGE VALVE PLATE SHELL TODL-TJ1P-19703-C J - OIL PICK-UP TUBE 0-RING I REED VALVE L 1- FRONT HEAD

36-34-14 Six-Cylinder Compressor 36-34-14 FRONT HEAD PR AN T VALVE PLATE RECESS LARGE HOLE ASSEMBLY PINS O0O HEAR DISCHARGE FRONT DISCHARGE VALVE PLATE VALVE PLATE CYLINDER AND SHAFT ASSEMBLY VIEW VIEW A

36-34-15 Six-Cylinder Compressor 36-34-15 PRESSURE TEST PLATE PRESSURE TESTVLATE TI1P-19703-Q HIGH PRESSURE T7IP’197O3-O GAUGE LOW PRESSURE GAUGE AOAPTERS T?1P-19702.R& TO REFRIGERANT SUPPLY TANK

36-34-16 ‘ Six-Cylinder Compressor , 36-34-16 TOOL NUMBER DESCRIPTION TOOL NUMBER DESCRIPTION 171 F-’ 19703-’9 PULLEY PULLER 171 -P19703--L ‘‘0’’ RING AND SNAP RING REPLACER 171 P- 19703-C ‘O’’RINO REMOVER T7IP- 9703--V CE RAMIC SEAL REMOVER AND T7IP-197O3-D BEARING AND PULLEY REPLACER ASSEMBLY np-LACER AND BEARING REMOVER T7IP-19703-N FELT SLEEVE RETAINER

3645-1 Two-Cylinder Compressor 36-35-1 PART - Two Cylinder Compressor 36-35 SUBJECT PAGE SUBJECT PAGE TESTING REMOVAL AND INSTALLATION Cont’d. Compressor Oil Level Check 35-2 Clutch Bearing 35-8 Crankshaft Seal Leak Test 351 Compressor 35-3 Oil Leakage Past Carbon Ring 35-1 Crankshaft Seal 35-5 Oil Leakage Through 0-Ring 35-1 Valve Plate and Gasket