Werkstatthandbuch Book 2 · Seiten 401–500

36-35-2 Two-Cylinder Compressor 36-35-2 I ECUMtE H L1826-2A FIG. 2 Oil Leakage Paths Compressor Oil Seal 3. Remove the oil filler plug from the compressor. wipe all the oil away from the seat area before using Insert a flattened 1/8-inch diameter rod Fig. 3 in the leak detector, because the oil may contain the oil filler hole until it bottoms. The rod or dipstick refrigerant which would give erroneous readings. If fashioned for the particular compressor Figs. 4 or refrigerant leakage at the seal exceeds

34354 Two-Cylinder Compressor 36-35-3 RUBBER TUBING METAL COMPRESSOR TO VACUU-’ PUMP EACH END THIS END FOR VERTICAL MOUNT OIL TO BE CHECKED WITH COMPRESSOR KEYWAV IN SHAFT FACING

36-35-4 Two-Cylinder Compressor 36-35-4 PLUGInstallation SHIPPING CAP-. .__SHIPPING Before installing the compressor, carefully remove SUCTION SCREEN any burrs or dirt that may be on the compressor shaft. The shaft must be dry and brightly polished. SERVICE VALVE 1. Mount the clutch on the shaft and install the I 0-RING

36-35-5 Two-Cylinder Compressor 36-35-5 SHIPPING CAP 1. Discharge the system Part 36-32. Loosen and SUCTION SCREEN remove the belt. CYLINDER HEAD 2. Remove the clutch see Clutch Removal in this Part MOUNTING and remove the Woodruff key. Carefully remove the secondary dust shield so as to avoid marring CYLFNDER the shaft. HEAD GASKET 3. Carefully remove al

36-35-6 Two-Cylinder Compressor 36-35-6 and out on the shaft a few times to insure a good CLUTCH DRIVE BEARING seal between the seal and the shaft. PLATE ASSEMBLY EXTERNALRETAINER 3. Push the seal all-the.way on the shaft. BEARING FIELD COIL INTERNAL4. Place the carbon ring Fig. 6 over the shaft and in RETAINER the seal ring retainer. The polished surface of the carbon ring must face o

36-35-7 Twa-Cylinder Compressar 36-35-7 drive plate to make certain that there is free 5. Install the clutch assembly an the compressor shaft. rotation and there is not looseness of the assembly before installing the clutch onto the compressor. A DJUSTMENTS 0 RIVE BELT Adjust the belt by repositioning the idler pulley if so from the engine until the specified belt tension is eq uipped. Otherwise, follow this procedure. obtained. Remove the gauge. Tighten the 1. Loosen the alternator-to-brackets attaching bolts. alternator bolts. Install the tension gauge and check the belt tension.2. Install the tension gauge an the compressor clutch

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

"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."

36-41-1 Ford and Mercury Heater-Air Conditioner System 36-41-1 Ford and Mercury PART 36-41 - Heater Air Conditioner System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Cont’d. Split Case Assembly 41-1 Compressor Mounting 41.15 System Components 41-4 Condenser and Receiver 41-9 System Operation 41-1 Control Assembly 41-9 ADJUSTMENTS Defros

36-41-2 Ford and Mercury Heater-Air Conditioner System 36-41-2 TEMPERATURE CONTROL LEVER COOL TEMPERATURE WARM R ECONOMV A SLOWER SPEED - N OFF VENT A/C HI-b HEAT * DEFROST ACCESSORYDWITCH CONTROL FUNCTIONAL CONTROL LEVER TO OUT-SIDE AIR DOOR 1 PULL ISLDE

36-41-3 Ford and Mercury Heater-Air Conditioner System 36-41-3 comes out the panel registers, except for a slight floor In DEFROST position, the A/C-Heat and heat- bleed. defrost doors are in defrost position no vacuum and air is discharged through the defrasters with some bleed In the HI-La position, the partial A/C-Heat and full air to the floor. Heat-Defrost doors in the plenum chamber are open vacuum and air is discharged through the air A four position blower switch and resistor assembly conditioning registers and also through the air outlets provides four blower speeds to control air volume. The in the lower plenum to the floor ar

36-41-4 Ford and Mercury Heater-Air Conditioner System 36-41-4 feature gives the operator additional options for cooled The water valve is located in the engine compartment air discharge other than the panel registers. in the heater core inlet water hose near the dash panel A six-cylinder compressor is now used on bath car Fig. 3. The heater core outlet hose connects to the lines Figs. 19 and 20. water pump. The ambient air temperoture switch closes on use Evaporator Case above 50SF and opens at 35rF. mm. and closes at T

WATER VALVE UPPER COWL TEMPERATURE BLEND DOOR CABLE CONTROLLED ITE HEAT DOOR MOTOR MOTOR VIEW A YELLOW R EO BLUE

______ _________ 36-41-6 Ford and Mercury Heater-Air Conditioner System 36-41-6 PV - PARTIAL vAcuuM NV - NO VACUUM V - VACUUM VACUUM MAN IFOLD- CHECK VALVE -19A566- VACUUM OUTSIDE AIR DOOR DASH PANEL GROMMET RED PARTIAL YELLOW BLUE FUNCTION SELECTOR SWITCH ELECTRICAL BLACK

36-41-7 Ford and Mercury Heater-Air Conditioner System 36-41-7 The Pressure Differential Valve is a Schrader type 4. The compressor suction draws the vaporized valve that has been calibrated to open at a pressure refrigerant out of the top of the evaporator at the range of 10 to 20 psi. Its function is to by-pass oil laden outlet top tube where it passes, and the refrigerant around the restriction formed when the STY temperature is transferred to the bulb of the is closed due to reduced heat load on the A/C system capillary tube which is clamped tightly on the tube. and thereby provide an assured oil return to the 5. Gas pressure in the capillary tube drops when compressor. Under high heat loads this valve is closed, coo

36-41-8 Ford and Mercury Heater-Air Conditioner System 36-41-8 ball and plate assembly. The expansion valve diaphragm. As the cool refrigerant passes through spring forces the boll onto the slotted tapered seat the evaporator outlet tube, the temperature is and the liquid refrigerant flow is reduced. As the transferred to the bulb of the capillary tube and the pressure is reduced, due to the restricted refrigerant gas above the diaphragm will contract and allow flaw, the diaphragm flexes downward again the expansion valve spring to close the expansion opening the expansion valve to provide the valve. When heat from the passenger compartment required controlled pressure and refrigerant flow is absorbe

36-41-9 Ford and Mercury Heater-Air Conditioner System 36-41-9 ADJUSTMENTS TEMPERATURE CONTROL CABLE ADJUSTMENT 1. Loosen the cable housing attaching screw at the 3. Adjust the cable at bracket on plenum by sliding plenum bracket. cable flag in bracket groove until the temperature 2. Move the temperature control lever to maximum door crank arm is in the full right position. Tighten COOL position. the cable screw at the plenum bracket. REMOVAL AND INSTALLATION PLENUM CHAMBER the motors. Refer to Fig. 9 for removing vacuum and electrical connectors. The plenum chamber

iCE AIR DAM1’R JOOR SEL LOC P.T cON COWL VIE1 A OUTSIDE AIR DAMPER ooQR ASSEMOLY I: OPEN NO VACUJI!’ EXPLODED VIEW CRD SECTION Dp OOO C - 711 - 12 REOOI

36-41-11 Ford and Mercury Heater-Air Conditioner System 36-41-11 STEEL VACUUM PORT MOTOR DNLV POSI-GRIP VACUUM HOSE RETAINER REMOVAL PROCEDURE VACUUM VACUUM PORT HOSE METHOD 2 FOR PLASTIC VACUUM PORT VACUUM MOTORS FOR STEEL VACUUM PORT VACUUM ONLY

36-41-12 Ford and Mercury Heater-Air Conditioner System 36-41-12 5B928S2 BRACKET LEFT AIR UUCT 7 P500. CLOSE /4 LEFT REGISTER LOUVER ASSY. ClOSE ..4 LEFT GNT CENTER 1+. C LU SE CENTERHa REGISTER CENTER AIfI LOUVER ASSEMBLY DISTRIBUTION DUCT 38427552 CLOSE

36-41-13 Ford and Mercury Heater-Air Conditioner System 36-41-13 6. Move air door assembly inboard and rotate door 7. Remove four 4 right to left cover flange screws. and frame assembly carefully to clear opening in 8. Remove five 5 cover to case mounting screws from cowl top panel. left inboard cover and remove cover. Installation NOTE: A bead of rope sealer between the two 1. Carefully insert air door and frame assembly into Covers must be replaced during installatian. position in cowl tap panel. 9. Remove five 5 cover to case mounting screws from 2. Install motor shaft on door crank arm as shown in rig

36-41-14 Ford and Mercury Heater-Air Conditioner System 36-41-14 SUCTION THROTTLING VALVE EVAPORATOR CORE COVER L EPT EVAPORATOR CORE - -fl COVER RIOHTI POPE SEALER VALVE

36-41-15 Ford and Mercury Heater-Air Conditioner System 36-41-15 SCREW? REOUIflD -$1 COVER CLIP GASKET INLET HEATER CORE. OUTLET CDRE MOUNTING GASKET-LOWER EVAPORATOR CASE HEATER CORE RETENTION CLIP L2045-1D FIG. 17 Blower Motor and Wheel

36-41-16 Ford and Mercury Heater-Air Conditioner System 36-41-16 112 DRILL DIMPLE SEE VIEW A DRILL 1" DIA. HO LE TANGENT TO CENTERLINE OF THE BEAD, AT DRILL

36-41-17 Ford and Mercury Heater-Air Conditioner System 36-41-17 190629-COMPRESSOR AND CLUTCH ASSEMBLY FIG. 19 Compressor lnstallation-5.0/5.8L 302/351W CID Engines COMPRESSOR MANIFOLD 19DB95 -- BRACE i9D624- BRACKET 19N5B6 - BRACKET 84617- IDLER PULLEY FOR 3Bi649 - BELT BELT ADJUSTMENT

36-41-18 Ford and Mercury Heater-Air Conditioner System 36-41-18 SCREW - 370600 SCREW 384834 WIRING ASSV

36-41-19 Ford and Mercury Heater-Air Conditioner System 36-41-19 SPECIFICATIONS FORD AND MERCURY MANUAL A/c-HEATER Protective Device - 35 amp. fuse blower located in fuse panel. Blower Motor Current Draw p3 12.8 Volts - - 20 amp, fuse clutch located in fuse panel. Low 6.0 amps. Contr& Illumination - One I OP 161 bulb. Medium Low 12.0 amps. Medium 1-ugh 16.0 amps, Rear Defog Jewel Lamp - One .5 CP - 03A6.18C622-AA Lamp and Wiring Assembly High 24.0 amps.

36-43-1 Fairmont and Zephyr Heater-Air Conditioner System 36-43-1 PART - Fairmont and Zephyr Heater 36-43 Air Conditioner System SUBJECT PAGE SUBJECT PAGE ADJUSTMENTS REMOVAL AND INSTALLATION Compressor Drive Belt 43-19 Air Inlet Duct 43-25 Temperature Control Cable 43-19 A/C-Defrost Door 43-33 A/C-Defrost Door Vacuum

36-43-2 Fairmont and Zephyr Heater-Air Conditioner System 36-43-2 DESCRIPTION AND OPERATION SYSTEM OPERATION TEMPERATURE lever, is forced through and/or around the heater core into the plenum. The air is then directed to the floor, defroster nozzles or the instrument panel The Manual A/C-Heater System is shown in Fig. 1. registers depending on the position of the functkn During system operation, air is drawn directly into the control lever. system by the blower motor and wheel from the cowl The volume of air flow through Ehe system is air intake, independent of the temperature lever controlled by a four position

36-43-3 Fairmont and Zephyr Heater-Air Conditioner System 36-43-3 PARTIAL TOP] BLUE RESTR]CTOR DOOR MOTOR LOCATED INSIDE CASE] DUTSLDE AIM TO DEFROSTER OUTSIDE/RECIRC DOOM j @ A/C DEFROST DOOR NV - NO VACUUM MN PLENUM CHAMBERI - - PV - PARTIAL VACU

36-43-4 Fairmont and Zephyr Heater-Air Conditioner System 36-43-4 AIR DISTRIBUTION When the temperature lever is moved to Range 2 shown in Fig. 2, the restrictor door is open allowing air The distribution of air inside the vehicle is dependent flow through the heater core. Air flow is directedon the position of the function control lever. Air can be through and around the heater core for the desireddistributed through the floor outlets, through the floor temperature, depending on the position of theoutlets and instrument panel registers, through the

36-43-5 Fairmont and Zephyr Heater-Air Conditioner System 36-43-5 TO FLOOM - OFF TO DEFROSTER -‘- - NOZZLES TO PANEL REGISTERS MAXIMUM A/c *FULL cOOLING *REcIRc AIR HI-LO MEDIUM WARMiNG NV - NO VACUUM

36-43-6 Fairmont and Zephyr Heater-Air Conditioner System 36-43-6 TO FLOOR H EAT FULL HEATING TO DEFROSTER NOZZLES TO PANEL1LIREGISTERS H EAT MEDIUM HEATING LI HEAT MINIMUM HEATING DEFROST FULL H

____________ 36-43-7 Fairmont and Zephyr Heater-Air Conditioner System 36-43-7 AMB CUT.OFF SAITCH SATTE H V -19618- A.C CLUTCH 7EOA 751 752 2BIA 35 AMP RESISTUR ASSY T0R SCHEMATIC TH

36-43-8 Fairmont and Zephyr Heater-Air Conditioner System 36-43-8 oER LEFT RE GIST ER DUCT EVAPORATOR ASSEMBLY BLOVEH MOTOR AND WHEEL ASSEMBLY

36-43-9 Fairmont and Zephyr Heater-Air Conditioner System 36-43-9 about half travel of the motor arm. If vacuum is applied REFRIGERANT SYSTEM to the side port only, motor operation is minimal. If the The A/C-heater refrigerant system uses a By-pass vacuum hoses to this motor are reversed, the vacuum orifice combination valve and a two cylinder motor will not operate properly when the function compressor. The combination valve differs from the control lever is in the HI-LO position Fig 2. combination valve used on other systems in that it does not have a separate evaporator manifold plate. The

36-43-10 Fairmont and Zephyr Heater-Air Conditioner System 36-43-10 0 EVAPORATOR CORE TUOES 0-RING - 380979 0-RING - 380977 DEFLECTOR- 19C675 VALVE EXPANSION

36-43-li Fairmont and Zephyr Heater-Air Conditioner System 36-43-il HIGH PRESSURE LINE COMBINATION VALVE HIGH PRESSURE SERVICE ACCESS GAUGE PORT VALVE SUCTION LINE EVAPORATOR SERVICE ACCESS GAUGE PORT VALVE LIOUIO RECEIVER

36-43-12 Fairmont and Zephyr Heater-Air Conditioner System 36-43-12 REAR VIEW FRONT VIEW SUCTION LINE CONNECTION 5TV HOUSING MANIFOLD TO EXPANSION VALVE ATTACHING SCREWS IALLEN HEADI EVAPORATOR INLET

36-43-13 Fairmont and Zephyr Heater-Air Conditioner System 36-43-13 PRESSURE DIFFERENTIAL VALVE The manifold is attached to the expansion valve with twa socket head ALLEN screws tightened to 4 to 6 ft-lb The pressure differential valve is a Schrader type torque. valve that is calibrated to open at a pressure range of 10 to 20 psi. Its function is to by-pass oil laden CONDENSER AND RECEIVER-DRIER refrigerant around the restriction formed when the STY ASSEMBLY is closed due to reduced heat load on the A/C system and thereby provide an assured oil return to the The condenser and receiver.drier assembly is compressor. This valve is closed under high heat loads mounted to the radiator support in fr

36-43-14 Fairmont and Zephyr Heater-Air Conditioner System 36-43-14 R2168-1A FIG. 17 A/C Compressor Installation-2.3L FIG. 19 A/C Compressor Installation-3.3L 200 Engine-49 States With Standard CID Engine Transmission and California With Standard and Auto Transmission FIELD ASSEMBLY - 2987 CLUTCH AS

36-43-15 Fairmont and Zephyr Heater-Air Conditioner System 36-43-15 DIAGNOSIS AND TESTING BLOWER MOTOR VOLTAGE TEST 3. Place the TEMPERATURE Control Lever in the mid- position and the Function Control Lever in the HEAT 1. Fabricate a short iumper wire with a male spade position to turn the blower ON. connector on one end and a female spade connector on the other end. Strip any insulation 4. Turn the ignition switch to the ON position. from the female connector. 5. With a fully charged battery, the blower motor current draws amps should be approximate

______ ______ 36-43-16 Fairmont and Zephyr Heater-Air Conditioner System 36-43-16 VACUUM TO VACLOM MANIFOLD GREEN DASH PANEL FLIOR ® HEAT DEFROST 0 DOOR

36-43-17 Fairmont and Zephyr Heater-Air Conditioner System 36-43-17 shown in Fig. 2 gives the vacuum motors applied for If the conditional requirements are not satisfied, the each position of the function and temperature control pressure readings will not be accurate and could levers along with an air flow diagram of the system. The indicate that a normal system is not functioning air flow diagram shows the position of each door when properly. If the conditional requirements cannot be vacuum is applied and, their no vacuum position. With satisfied, the pressure readings will not be accurate but this chart, air flow for each position of the control can be used to determine what is causing the problem assembly con be determined. If a vacuum motor fails

36-43-18 Fairmont and Zephyr Heater-Air Conditioner System 36-43-18 PROBLEM REFRIGERANT SYSTEM PRESSURE EVALUATION For Systems Without Low Pressure Suction Service ACCESS Gouge Port Valve NQT E; NoEmal system conditional requirements must be mai nt,iirted to properly evaluate refrigerant system pressures, Refer tO Chart applicable to system under test. HIGH PRESSURE EVAPORATOR POSSIBLE @ LIQUID LINE @ COMPRESSOR PRESSURE PROBLEM/COMPONENT ENGINE OVERHEATING / HIGH HIGH HIGH EXPANSION VALVE SENSING

36-43-19 Fairmont and Zephyr Heater-Air Conditioner System 36-43-19 ADJUSTMENTS TEMPERATURE CONTROL CABLE 4. Check total lever travel. A space of approximately ADJUSTMENT 1/4 inch should exist, between the control lever and the ends of the slot, at both ends of the slot. The temperature control cable is self-adjusting with the movement of the temperature control lever to the COMPRESSOR DRIVE BELT ADJUSTMENT top of the slot in the bezel face of the control head. 3.31 200 CID Engine 1. Insert the end of a small pocket screwdriver in the end loop of the temperature control cable, at the 1. Check the belt

36-43-20 Fairmont and Zephyr Heater-Air Conditioner System 36-43-20 5. Install the pulley and clutch drive assembly on the 4. Disconnect the two refrigerant lines at the fittings compressor shaft. Connect the clutch field coil wire on the right side of the radiator Fig. 27. at the connector and energize the clutch. Then, 5. Remove four bolts attaching the condenser to the tighten the clutch retaining bolt to specification. radiator support and remove the condenser and 6. Install the drive belt on the compressor clutch pulley receiver-drier from the vehicle. and tighten the belt to specification following the 6. Disconnect the refrigerant lines from the receiver- procedure under Compressor Drive Belt Adjustment.

36-43-21 Fairmont and Zephyr Heater-Air Conditioner System 36-43-21 6. Install and connect the battery. REFRIGERANT LINES 7. Leaktest, evacuate and charge the refrigerant 1. Discharge the refrigerant from the A/C system at system following the recommended procedures and the service access gauge port valve located on the safety precautions. underside of the combination valve. Observe all RECEIVER-DRIER safety precautions. 2.

36-43-22 Fairmont and Zephyr Heater-Air Conditioner System 36-43-22 R 21O 2A FIG. 29 Refrigerant Lines and Heater Hose Routings-3.3L 200 CID 1-6 Engine R2I81-2A FIG. 30 Refrigerant Lines and Heater Hose Rautings-5.OL 302 CID V-8 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

36-43-23 Fairmont and Zephyr Heater-Air Conditioner System 36-43-23 4. Remove one screw attaching the support bracket INSTALLATION to the underside of the combination valve and Use new 0-rings dipped in refrigeration oil during remove the combination valve. assembly and installation of the STY. 5 Remove two Allen head cap screws attaching the 1. Install the STY in the expansion valve using a new STY housing manifold to the expansion valve Fig. 0-ring dipped in refrigeration oil. 15. Remove the STY housing manifold from the

36-43-24 Fairmont and Zephyr Heater-Air Conditioner System 36-43-24 !NCTRC/MflJT CLLISTFR TRIM PANEL HETAINING SCREWS R21f22A FIG. 31 Manual A/C-Heater System Control Head Assembly-Removal BLOWER FAN SWITCH 4. Install the instrument cluster trim panel. Then, push the blower switch knob on the fan switch

36-43-25 Fairmont and Zephyr Heater-Air Conditioner System 36-43-25 CABLE DOWN fiziBa-ZA FIG. 32 Temperature Control Cable-Removal 5. Install the instrument cluster trim panel. ASSEMBLY6. Connect the self-adjusting clip to the blend door REGISTER LOUVER crank. Then, connect the cable to the cable bracket

36-43-26 Fairmont and Zephyr Heater-Air Conditioner System 36-43-26 4. Remove the nut retaining the blower housing lower 8. Connect the blower motor ground wire to the cowl support bracket to the evaporator case Fig. 34. side panel with the ground screw. 5. Remove the side cowl trim panel and remove the 9. Install the instrument panel lower right side blower ground wire screw. attaching bolt. Then, install the right cowl side trim 6. Remove one screw attaching the top of the air inlet panel. duct to the evaporator case Fig. 34. BLOWER MOTOR RESISTOR 7. Move the air inlet duct and blower housing assembly down and away from the evaporator

36-43-27 Fairmont and Zephyr Heater-Air Conditioner System 36-43-27 BLOWER GASKET - MOTOR 01807 -19805 AIR INLET DUCT - VACUUM MOTOR - I 8A3 I S WHEEL

36-43-28 Fairmont and Zephyr Heater-Air Conditioner System 36-43-28 INSTRUMENT PANEL 12. Remove one screw attaching each end of the instrument panel to the cowl side panels.REMOVAL 13. Move the instrument panel rearward and 1. Disconnect the ground cable from the battery. disconnect the speedometer cable from the 2. Remove the instrument panel pad following the speedometer and any wires that will not allow the procedure under Instrument Panel Pad removal. instrument panel to lay on the front seat. Use care 3. Remove two screws attaching the steering colum

36-43-29 Fairmont and Zephyr Heater-Air Conditioner System 36-43-29 10. Position the steering column opening cover to the 8. Install the instrument panel following the procedure instrument panel and install the two attaching under Instrument Panel Installation. screws. il. Install the instrument panel pad and connect the EVAPORATOR CASE ground cable to the battery. REMOVAL 12. Connect the temperature control cable to the 1. Remove the instrument panel and lay it on the front temperature blend door crank arm. seat following the procedures under Instrument Panel Removal. REGISTER DUCTS AND/OR DEFROSTER 2. Discharge the re

36-43-30 Fairmont and Zephyr Heater-Air Conditioner System 36-43-30 5. Connect the blower motor ground wire to ground 7. Install the heater core with new caulking cord and the harness to the resistor and blower motor between the core and the evaporator case. Then, lead. install the heater core access cover, 6. Connect the black vacuum supply hose to the 8. Install the air inlet duct and blower housing vacuum check valve in the engine compartment. assembly on the evaporator case. 7. Connect the high and low pressure refrigerant hoses 9. Install the evaporator case in the vehicle following to the combination valve using new 0-rings dipped the procedure

36-43-31 Fairmont and Zephyr Heater-Air Conditioner System 36-43-31 DOOR SHAFT SEAL -18C676- DOOR SHAFT -18A293- RESTRICTOR DOOR -19A555 COMBINATION

36-43-32 Fairmant and Zephyr Heater-Air Conditioner System 36-43-32 FLOOR AIR DISTRIBUTION DUCT RESTRICTOR DOOR VACUUM MOTOR 1. Remove two screws attaching the duct to the 1. Remove the heater core following the procedure for evaporator case assembly just below the A/C-Heat Heater Core Replacement. distribution duct Fig. 7. 2. Remove two nuts retaining the vacuum motor to the 2. Pull the floor air distribution duct away from the mounting bracket Fig. 38. evaporator case. 3. Disengage the vacuum motor from the mounting 3. To install, position the duct to the evaporator case. bracket and the restrictor door. Make sure the retainer at the

36-43-33 Fairmont and Zephyr Heater-Air Conditioner System 36-43-33 2. Remove the screw retaining the heat-defrost door 3. Install a new spring nut Part No. 383358-S to the door shaft Fig. 38. to retain the vacuum motor arm on the 3. Slide the door off the shaft and remove the door heat-defrost door shaft. from the evaporator case. 4. Position the A/C-defrost distribution duct to the center register duct and the evaporator case. Then,INSTALLATION install the four attaching screws. L Position the heat-defrost door in the evaporator

36-43-34 Fairmont and Zephyr Heater-Air Conditioner System 36-43-34 SPECIFICATIONS REFRIGERANT -- - TYPE Refrigerant 12 A-12 Dichiorodifluorometliarie CC L2F? ... FORD SPECIFICATION ESAM17B2A FORD PART NUMBER D3AZ-19B519-A CAPACITY 3Lb.BOz, -440z -0 Oz. REFRIGER

36-44-1 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-1 Mustang II, Pinto and Bobcat 36-44 - Heater Air Conditioner System SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Cont’d. Independent Case Assembly Condenser and Receiver Assembly - - Blower Upstream 44-2 Pinto and Bobcat 44-15 - Mustang II 44-15 Refrigerant

36-44-2 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-2 to outside air position and the water valve remains proportionate to the setting of the temperature blend closed. Moving the lever one inch away from the door that controls the warm and cool air as it enters the maximum cool position opens the water valve. With the air distribution plenum duct. function control lever in OFF position the blower is off In HEAT position, the Heat-Defrost door restricts air and the outside recirc. air door is closed to outside air, to the registers full vacuum, and diverts the air to the open to recirc. air vacuum, the water

_______ CC SSO TEMPERATURE CONTROL LEVER coni TEMPERATURE WARM p 0 F A ECONOMY A0FBLOWER N OFF VENT A/C HI LO HEAT * DEFROST 0SWITCH SWITCH UNCTION CONTROL LEVER 18495 OUTSIDF- AIR OUTSIDE RECIRC ID DI/FROSTFRS

MANUAL A/C-HEATER SYSTEM VACUUM MOTOR TEST CHART VACUUM MOTORS APPLIED WITH VACUUM FUNCTION TEMPERATURE HEAT-DEFROST CONTROL LEVER WNTROL LEVER OUTSIDE- WATER A/C- C POSITION POSITION RECIRC. VALVE DEFROST PARTIAL FULL En‘-4 0 OFF Any Position 1-2 4 -

36-44-5 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-5 MODS DOOR MOTOR SEE VIEW B TEMPERATURE CONTROL CABLE INLINE CONNECTOR VIEWS - VIEW C Li 884-24 FIG. 3 Independent Case, Manual A/C-Hea

36-44-6 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-6 PV - PARTIAL VACUUM NV-NO VACUUM V-VACUUM VACUUM MAN FOLD CHECK VAI ye RESERVOIR DC® UROMMET 190670- WATER VALVE SUE ENOIO BLACK TEMPERATURE OONTROL CABLE RED -t9C734

36-44-7 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-7 AMBIENT CUT OFF SWITCH A/CCLUTCH& COMPRESSOR 260A 54 752 261 A RESISTOR SCHEMATIC BLOWER

36-44-0 Mustang II, Prnto and Bobcat Heater-A/C System 36-44-8 EVAPORATOR SERVICE ACCESS GAUGE PORT VALVE CROSSOVER COMBINATION TUBE VALVE ASSEMBLY 1 -----:- r SUCTION LINE FROM

36-44-9 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-9 HIGH PRESSURE SERVICE ACCESS GAUGE PORT VALVE 1344S29 FIG. 7 Mustang II A/C and Heater Hose Routings-2.8L Engines "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.

36-44-10 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-10 CONDENSER -197 12- K3449-20 FIG. 8 Mustang II A/C and Heater Hose Routings-5.OL 302 CID Engines "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 e

36-44-11 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-11 EVAPORATOR SERVICE ACCESS GAUGE PORT VALVE CROSSOVER TUBE COMBINATION VALVE ASSEMBLY SUCTION LINE FROM INTAKE MAN IEU LU

36-44-12 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-12 EVAPDRATDR SERVICP ACCESS GAUGE ROOT VALVE FRE-PORMED HEATFR HOSE HEATER 1 8G429- WATERVALVE -18405- A/C HOSE AND ACCUMULATOR ASS* -12C9T3- A/C LICUID LINE -19635- PR B-FOR ME D HEATER HOSE SUCT

36-44-13 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-13 PROPER C RING LOCATIONS HEX HEAD SCREHIS EVAPORATOR SERVIcE ACCESS GAUGE PORT 386924-S SUCtION THROTTLING VALVE ISTVI 190 5RD 387195P-S STV MANIFOLD HOUSING 190734

INSTALLED AFTER NOZZLE IS IN PLACE DEFROSTER 1 NDZZI E A/C DEFROST DOOR MOTOR 1 A/C IPANELE - DEEESOST AIR LEFT AIR DUCT DISTRIBUTION DUCT ASSY.

36-44-15 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-15 REMOVAL AND INSTALLATION COMBINATION VALVE ASSEMBLY FIG. 11 CONDENSER AND RECEIVER ASSEMBLY- MUSTANG II SEE FIG. 14 Observe the Safety Precautions outlined in Part 36- 31. Observe the safety precautions outlined in Part 36- Removal 31. 1. Discharge the refrigerant system. 1. Discharge the refrigerant system. 2. Remove the battery cables, battery and battery 2. Remove the lower hood lock and vertical support heat shield for access to the Combination Valve brace. assembly.

‘3 a C C -v 0

36-44-17 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-17 Center Air Duct 1. Remave the two center register louver assemblies. 2. Remove the radio. 3. Remove the one retaining screw at the left center register louver opening and the two retaining screws at the right center register louver opening.

36-44-18 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-18 SEAL 8 REOO/ 0-RING II 383844-S EVAPORATOR CORE

36-44-19 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-19 Pinto and Bobcat See Fig. 13 24. Remove 4 instrument panel retaining bolts and 1. Remove the glove box. remove the instrument panel. 2. Remove the A/C-Defrost plenum right and center 25. Disconnect the heater hoses from the heater core air ducts. tubes in the engine compartment. 3. Straighten the four defroster to instrument panel 26. Remove the two hex head screws attaching the flange tabs, lower the nozzle toward the right and evaporator manifold plate to the expansion valve remove it from below the instrument panel. body. 4. To install, reverse the preceding procedure. Be

36-44-20 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-20 19. Connect the 5 connectors at the left cowl panel. 16. Rotate the evaporator assembly down and away 20. Connect the radio antenna lead to the radio if so from dash panel and out from under the instrument equipped. panel. 21. Install the bottom bolt-center shake brace-to- 17. To install, reverse the above procedure. Make sure instrument panel. to follow the nate on installation in Steps 3 and 12. Evacuate and charge the refrigerant system Part22. Connect the accelerator control cables 2 and install the accelerator pedal assembly.

36-44-21 Mustang II, Pinto and Bobcat Heater-A/C System 36-44-21 BLOWER MOTOR AND WHEEL VACUUM MOTORS The blower motor and wheel is integrally located 1. The outsjde-recirc. door vacuum motor is accessiblewithin the scroll portion of the evaporator assembly on for service by removing the glove box.the right side of the evaporator case. To remove the blower motor and wheel, remove the glove box and 2. The A/C-defrost door motor and Heat-Defrost door remove the four screws retaining the blower motor and motor can be serviced from

36-45-1 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-1 LTD II, Cougar and Thunderbird PART 36-45 Manual A/C-Heater System SUBJECT PAGE SUBJECT PAGE DESCRIPTION 45-I SYSTEM COMPONENTS Cont’d. OPERATION Vacuum Motors 45-6 System Air Flow 45-2 Water Valve 45-4 SYSTEM COMPONENTS REMOVAL AND INSTALLATION Blower Motor Housing Assembly 35-5 Air Distribution Ducts

36-45-2 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-2 RECEIVER-DRYER CON DE N5EP SUCTION ACCUMULATOR EVAPORATOR CASE ASSEMBLY 2-CYLINDER COMPRESSOR DEFROSTER NOZZLE ASSEMBLY AIR DUCTS CENTER AIR S-

36-45-3 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-3 V - vACuIA NV-- NO VACUUM PV - PARTIAL veCulaq FUNCTION CONTF. U TEMPERATURE CONTROL LEVER LEVER BLOWER

36-45-4 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-4 EVAPORATOR CASE OUTSIDE AIR INLET DUCT AIR ASSEMBLY 8

36-45-S LTD ii, Cougar and Thunderbird Manual A/C-Heater System 36-45-5 BATTERY AMBIENT -19618- AJC CLUTCH & CUTOFF SWITCH CIRCUIT WIRE COLOR COMPRESSOR NO 347 Black/YellOw Hash 57P BI.ck 26 IA

36-45-6 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-6 A/C-heat doors, and heat-defrost door. The center air CONDENSER AND RECEIVER ASSEMBLY distribution duct containing air mix baffles, seats firmly over the rectangular opening in the plenum chamber The condenser and receiver assembly is located and distributes air directly to the center panel registers forward of the radiator and is mounted to the radiator and to the left and right registers through rigid air ducts. support in four places. Clearance for removal is See Fig. 9. provided by removing the upper radiator mounts and tilting the radiator rearward. DEFROSTER NOZZLES