Werkstatthandbuch Book 2 · Seiten 501–600

36-45-7 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-7 L231i2-2A FIG. 8 Evaporator Assembly Installation ‘S PANEL REGISTER L2363-25 FIG. 9 Air Distribution Ducts-LTD II, Thunderbird and Cougar REMOVAL AND INSTALLATION CONTROL ASSEMBLY 1. Remove A/C control knobs and accessory switch 3. Remove two 2 upper control assembly attaching

36-45-8 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-8 5. Disconnect vacuum harness from vacuum selector valve. 6. Disconnect electrical wiring connectors from blower switch. 7. Remove control head from rear of instrument panel. To install reverse the above procedure. Adiust the temperature cable for proper output. K EVAPORATOR CASE AND CORE 1. Discharge the A/C System at the STV observe safety precautions. 2. Raise the vehicle and remove the right front wheel. 3. Drill a 1.50 inch service hole in the fender apron. DRILL’ 1/2 INCH See Fig. 10. A drill dimple is provided for proper HOLE AT DIMPLE location of the hole. 4. Drain engine coolant a

36-45-9 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-9 4. Remove heater care by lifting upward. See Fig. 11. 190629AND CLUTCHCOMPRESSORASSEMBLY 5. Replace heater core and seals. Carefully install the new heater assembly. Verify that the seals on the sides of the core fit against their respective metal support brackets in the evaporator housing. Press down an the heater care and tip it rearward so that the notch on seal is aligned with the flange on the evoparatar housing. 6. Clean off old sealer from the heater cover plate and evaporator housing. Apply rope sealer, ESB M4G32-A, in the farmed depression and sides of the heater cover plate. 7. Install cover plate 4 screws. 8. Check far air leaks by placing the A/C control

36-45-10 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-10 TEMPERATURE CONTROL CABLE the temperature control lever and right end of the ADJUSTMENT lever slot to insure maximum heat position before tightening cable screw at plenum bracket. 1. Move the temperature control lever to maximum WARM position. CONDENSER 2- Adlust the cable at the bracket on the bottom of The condenser assembly is serviced by removing four the plenum by sliding cable flag in bracket groove nuts at the isolation mounts, one screw at the liquid line until the temperature door crank arm is in the full to condenser br

36-45-11 LTD II, Cougar and Thunderbird Manual A/C-Heater System 36-45-11 SPECIFICATIONS MANUAL A/C.HEATEH SYSTEM - LTD II, Cougar and Thunderbird Protection Device 20 amp fuse in clutch circuit Compressor Contd. 35 amp fuse in blower circuit Refrigerant Capacity 4-1/4 lbs. + 1/4 lb. Control Illumination One ICP, No. 161 bulb RefrigeraRt Type A-U Blower Motor Current Oil Specitication ESA-M2C31-A Ford Part No. Amps. and Voltage Low 6 amps 5 Volts CYAZ-19577-A

36-71-1 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-1 Ford, Mercury and P 36-71 Lincoln Continental ATC SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION 71-1 REMOVAL AND INSTALLATION Cont’d. Heat-Defrost Door Vacuum Motor 71-33 TESTS 7112 Neater Core 11-43 High Blower Relay 71-35 ADJUSTMENTS 7 1-19 Instrument Panel Pad 71

36-71-2 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-2 RECEIVER OIlIER ASSEMBLY HIGH BLOWER RELAY LINCOLN ONLYI PLENUM ASSEMBLY CONTROL ASSEMBLY SE NSOR ASSEMBLY L2609-2A FIG. 1 ATC System Overall Schematic -1978 Ford, Mercury and Lincoln Continental AUTOMATIC TEMPERATURE CONTROL The electrical and air flow schematics and vacuum The modulated vacuum from the senso

____________ 36-11-3 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-3 TEMPERATURE CONTROL LEVER BLOWER SWITCH FUNCTION CONTROL V - VACUUM LEVER NV NO VACUUM PV PARTIAL vACUU’ SUCTION THROTTLING VALVE 5FULL VACUUM N_I RED SIDE ,ç-PARTIAL VACUUM YELLOW ITOPI TO FLOOR REGISEERS

36-71-4 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-4 VACUUM .19A566- RESERVOIR TO VACUUM MANIFOLD -19A563- IN-LINE CHECK VALVE -190919- FUNCTION CONTROL VACUUM SELECTOR VALVE ID PORTI FUNCTION_SELECTOR VALVE LEVER POSITIONS HOSE PORT FUNCTION OFF ECONOMY A/C HI-LO HEAT 7 EFROS COLOR VENT EF I OutsIde- Recj,c V Tog To I Wh,te 1-2 2 Partial A/C- Heal

36-71-5 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-5 ENGINE TEMPERATURE SENDER CLOSED BELOW 100 F. OPEN ABOVE 120 F. TO INSTRUMENT CLUSTER TEMP GAUGç/LIGHT 348 347 A/C CLUTCH & BATTERY LTG/PH COMPR ESSOR TERMINAL DASH PANEL B LOW! B MOTOR

36-71-6 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-6 ENGINE TEMPERATURE SENDER CLOSED BELOW 1UO II OPEN ABOVE 120 TO INSTRUMENT CLUSTER TEMP GAUGF,&IGHT BLOWER MO FER -19805- FV RELAY 190671 - 749 C OK AlT GAS DK.B!LT.GIR.S

36-71-7 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-7 SYSTEM AIR FLOW HI-LO POSITIONS Figures 2 and 3 contain system vaCuum schematics Operation is similar to that described in the A/C and vacuum motor charts which illustrate vacuum roUt position paragraphs, except that airflow is divided ings and air flaw dUring the various system conditions. between the panel registers and floor ducts. The system Figures 4 and 5 show the system electrical wiring dia will not recirculate interior air for maximum cooling. gram including ContinUity test information. HEAT POSITION - MAXIMUM HEATING With the function control le

36-71-8 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-8 Thus, the modulated vacuum output is the result of the THERMAL LIMITER RESISTOR ASSEMBLY effects of the control bias and the temperature of the The blower motor thermal limiter resistor assemblyair across the bi-metallic sensor. is located on the evaporator assembly in the engine The sensor assembly also includes an aspirator am compartment. There are three resistance elements venturi as it is called in previous ATC systems. The mounted on the resistor board to provide four blower aspirator provides a very small vacuum to draw a speeds. Depending

36-71.9 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-9 operation. The ambient switch will open and close between 35 0 F 2 0 C minimum. . and 50 G F 10 0 C maximum with a minimum difference of 3°F between opening and closing temperatures. The ambient switch is lo cated in the airflow path behind the radiator grille. An internally equalized By-Pass Orifice Expansion Val

36-71-10 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-10 SUCTION THROTTLING VALVE STV The Suction Throttling Valve STV is the same used cause of a change in pressure inside the evaporator. in current model refrigerant systems, except the Refer to the normal Pressure/Altitude Chart in Fig.14. equalizer line connection has been removed Fig. B. Suction "throttling" starts when the compressor suc Its purpose is to control suction pressure in the tion pressure decreases below the pressure setting 0f evaporator to prevent ice or frost from blocking the the valve. Compr

36-71-11 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-11 REFPIGEnANTfAI_H,lI[ NON.REGIJLATED SUCTION TIIROTTLINO VALVE ICOMPRCSSOR suciIONI REFRIGERANT_FLOW REGULATED REFRIGERANT PRESSURE IEVAPORAT0RI PRESSURE DIrVERENTIAL VALVE STARTS TO OPEN 10 P.S

36-71-12 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-12 10. Gas in the capillary tube bulb produces the re- When heat from the passenger compartment is quired pressure on the top 0f the pressure sensing absorbed by the refrigerant, it will cause the gas diaphragm. Asthe cool refrigerant passesthrough in the capillary tube to expand and the pvsh pins the evaporator outlet tube, the temperature is will again force the expansion valve to open, transferred to the bulb of the capillary tube and allowing more refrigerant to flow so that more the gas above the diaphragm will contact and heat can be absorbed. allow the expansion valve spring to close the ex pansion valve. TESTS ELECTRICAL

36-71-13 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-13 CHART 1 HISSING ATC VACUUM SYSTEM OR CONTROL ASSEMBLY SELECTOR VALVE CHECK IN-LINE AND CONTROL AS SEMBLY MULTIPLE CONNECTORS FOR PROPER INSTALLATION HISS CONTINUES HISS TOPS 4, MOVE FUNCTION LEVER TO DETERMINE WHAT SELECTOR VALVE POSITIONS ARE LEAKING. RECHECK SYSTEM FOR PROPER OPERATION. SOME LEAK BUT NOT ALL ALL LEAK

36-71-14 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-14 CHART 2 HISSING ATC VACUUM SYSTEM OR CONTROL ASSEMBLY SELECTOR VALVE CONTINUED FROM CHART 1 ALL FUNCTION SELECTOR VALVE POSITIONS LEAK MOVE TEMPERATURE CONTROL LEVER FROM 65 TO 85 HISS CONTINUES t 11155 STOPS AT SOME SE11’INGS CHECK VACUUM SOURCE TUBE BLACK FROM RESERVOIR TO CONTROL ASSEMBLY FOR CUT

36-71-15 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-15 CHART 3 HISSING ATC VACUUM SYSTEM OR CONTROL ASSEMBLY SELECTOR VALVE L CONTINUED FROM CHART 2 SOME TEMPERATURE CONTROL LEVER POSITIONS LEAK ‘I, PINCH OFF SOURCE TUBE BLACK AT DIVERTER VALVE HISS CONTINUES HISS STOPS

36-71-16 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-16 50 45 ,CENTER REGISTER DISCHARGE AIR TEMPERATURES F. 40 35 NOTE - CONDITIONAL REQUIREMENTS MUST BE MAINTAINED FOR SYSTEM BEING TESTED 30 F AMBIENT TEMPERATURES F. 60 70 60 90 100 CL-2621-2AFIG. 13 Normal Center Register Discharge Air Temperatures

36.71-17 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-17 NORMAL STV/BPO REFRIGERANT SYSTEM PRESSURES 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 30 20 10 0 -10 60 70 80 90 100 AMBIENT TEMPERATURES °F CL2623-2A FIG. 15 Normal STV/BPO Refrigerant System Pressures "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford

36-71-18 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-18 PROBLEM REFRIGERANT SYSTEM PRESSURE EVALUATION For All STy and STV/BPO Systems with Low Pressure Suction Service Access Gauge Port Valves NOTE: Normal system conditional requirements must be maintained to properly evaluate refrigerant system pressures. Refer to chart applicable to system under test. HIGH PRESSURE LOW EVAPORATOR POSSIBLE @ LIQUID LINE @ COMPRESSOR PRESSURE PRESSURE PROBLEM/COMPONENT HIGH HIGH HIGH HIGH ENGINE OVERHEATING/EXPANSION VALVE SENSING BULB - Poor Contact, Inadequa

36.71-19 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-19 ADJUSTMENTS SENSOR CALIBRATION 1. Remove the instrument panel pad and visually the calibration notch. Loosen the cable housing- determine which direction to rotate the sensor to-sensor attaching screw, move the temperature calibration locking pin Fig. 17. control lever the desired amount and retighten the attaching screw Fig. 17.2. While moving the temperature control lever, ro tate the calibration locking pin into the calibra NOTE: Move the temperature control lever HIGHER tion notch of the sensor control arm. to DECREASE and LOWER to INCREASE the 3. Che

36-71-20 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-20 1. Check the belt tension with lool T631-8620-A or equivalent. The belt tension should be with spe cifications. 2. If the belt tension is not within specification, loosen the two idler pulley arm attaching bolts until they are just snug Figs. 19, 20, and 21.

36-71-21 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-21 COMPRESSOR - 19703 BRACE --19089, - 1991653 BRACKET - 19N506 BRACE- 190894 I K3655-2A FIG. 20 Compressor instgllgtion - 5.71. 35-M CID and 6.61. 400 CID Engi

36-71-22 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-22 BRACKET - 2883 - 2882 FIG. 22 Compressor Installation - Lincoln Continental with 7.51 460 CID Engine K3658-1A - Ford and Mercury with FIG. 23 Compressor Installation 7.5L 460 CID Engine "This publication contains material that is reproduced and distributed under a license to Detroit Iron from Ford Motor Compa

36-71-23 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-23 REMOVAL AND INSTALLATION CONTROL ASSEMBLY Removal 1. Remove the radio knobs 4 from the radio 11. Remove the retaining screw 1 securing the tem 2. Remove the retaining screws 2 securing the right perature control cable assembly to the control instrument cluster trim panel to the instrument assembly and remove the control assembly. panel. Installation 3. Pull the lower edge of the right instrument cluster trim panel away from the instrument panel and 1. Position the control assembly near the instrument disengage the top right instrument cluster trim panel opening and slip the wire coil

36-71-24 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-24 9. Position the ash tray support bracket, install and Installation tighten the ash tray-to-instrument panel retaining 1. Align the function lever slot with the pin on the screws 3. function control vacuum selector valve, position 10. Insert the ash tray into the guide tracks of the ash the alignment pins of the control assemblywith the tray support bracket and install the ash tray. alignment holes on the selector valve body and 11. Test the ATC system for proper operation. install the function control vacuum selector va

36-71-25 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-25 InstallatIon 5. Remove the instrument panel attaching bolts and lay the instrument panel back on the seat. Discon The pivots on each end of the register assembly are nect wires, vacuum hoses, speedometer cable anddifferent diameters and therefore determine the in other components as necessary to lay the instrustalled position of the register assembly. ment panel on the front seat. 1. Position the register assembly into the op

36-71-26 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-26 LEFT DUCT LEFT REGISTER LOUVER ASSY. I RIGHT REGISTER DUCT C LOSE RIGHT REGISTER CENTER REGISTER LOUVER ASSY’S. 364275.52 2 REQ’S. K36622A FIG. 27 1978 Mercury and Lincoln

36-71-27 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71.27 RIGHT DEFROSTER NOZZLE- 18A565 LEFT DEFROSTER - RIGHT DEFROSTER NUZZLE DUCT-’ 18A43b LEFT DEFROSTER PLENUM DUCT- 18A435 ASSEMBLY

36-71-28 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-28 Installation 2. Using a magnet or locking tang-type phillips screwdriver, loosely install the upper finish panel 1. Carefully position the instrument panel pad and upper finish panel assembly onto the instrument retaining screws 2 in the retaining screw holes of the defroster outlet openings. panel Fig. 29. 2. Using a magnet or locking tang-type phillips CAUTION: CARE SHOULD BE TAKEN TO PRE screwdriver, loosely install the upper finish panel

36-71-29 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-29 SERVO ASSEMBLY Removal MOUNTING BRACKET LINCOLN CONTINENTAL 1. Remove the Center A/C Distribution Duct for pre liminary access to the Servo Motor Arm-to- Temperature Blend Door connecting pin. 2. Disconnect the blue and orange vacuum hoses from the full blue and partial orange A/C-Heat

36-71-30 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71.30 VACUUM DIVE RTER PUWUH SERVO PLENUM CHAMBER ASSEMBLY EV RELAY K 3665-2 A PI

36-71-31 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-31 EVAPORATOR CASE ASSEMBLY - 19850 RIGHT DEFROSTER DUCT 18A435 NUT AND WASHER 2 REOD.I - 45333 J, NUTS 2 REO’DJ

36-71-32 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-32 COWL TOP PANEL OUTSIDE AIR DAMPER DOOR ASSEMBLY LOCATION 7/ VIEW A fl CLOSED OUTSIDE AIR DAMPER DOOR ASSEMBLY £1 OPEN NO vACUuMI CROSS SECTION OF DOOR VIEW C

36-71-33 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-33 RECIRCULATING AIR DOOR VACUUM MOTOR Removal InstallatIon 1. Remove the sill plate from the right front door 1. Position the motor to the vent assembly and install the opening. two attaching screws. 2. Remove the right cowl side trim panel Fig 36. 2. Connect the vacuum motor arm to the vent assembly 3. Remove the push nut retaining the vacuum motor door and install a new push nut. arm to the cowl vent assembly. 3. Connect the vacuum hose to the vacuum motor and 4. Disconnect the vacuum hose from the vacuum install the

36-71-34 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-34 WATER VALVE 2. Position the cover plate over the access opening Removal and drill eight 8 ‘Is-inch holes in the apron, using the 8 holes in the cover as a template. Protect 1. Loosen the radiator cap, open the radiator drain the evaporator case with a metal shield during the cock and partially drain the coolant from the en drilling operation to prevent damage to the case. gine cooling system. Close the radiatordrain cock. 3. Apply rope sealerto the motor mounting plate and 2. Disconnect the vacuum hose green from the vac in

36-71.35 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-35 NOTE: Hose clamp pliers for flat spring type 2. Dkconnect the vacuum hose from the outside air clamps will simplify this operation. door vacuum motor. 3. Slide the blower wheel from the motor shaft. 3. Remove two 2 vacuum motor mounting plate. screws Fig. 35. Installation 4. Remove two 2 air door to cowl top panel mount- 1. Align the flat surface on the ID. of the blower ing screws. wheel hub with the flat surface of the motor shaft. 5

36-71-36 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-36 SUCTION THROTTLING VALVE STV 12. Disconnect the SW from the evaporator core. 13. Remove the right cover from the core.Removal 14. Disconnect the expansion valve from the1. Discharge the refrigerant system following the evaporator core tube. recommended procedures and safety preca utions. 15. Remove the core mounting gasket2. Disconnect the suction line from the Sly and cap the suction line Fig. 41. Ins

36-71-37 Ford Mercury and Lincoln Continental Automatic Temperature Control 36-71-37 DRILL DIMPLE SEE VIEW A DRILL 1 WA. HOLE TANGENT TO CENTERLINE OF THE BEAD AT DRILL DIMPLE WHICH IS LDCATEOI/2 FROM

36-71.38 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-38 EVAPORATOR CASE ASSY. 19850 4 REOD. K3692-iA FIG. 38 Blower Motor and Wheel-Disassembled EVAPORATOR CASE ASSEMBLY MULTIPI E CONNECTOR SLOWER

36-71-39 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-39 STRAP 382987-S 14401 WIRING ASSY. SLOWER MOTOR 1A39BWIF4ING ASSY RESISTOR

36-71-40 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-40 WATER VIEW B VALVE - SUCTION LINE 18495 - 19D850 HIGH PRESSURE LINE - 190850 TO

36.71-41 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-41 SUCTION WATER LINE VALVE -190850 -- I 8495 SERVICE ACCESS GAUGE PORT VALVE HIGH PRESSURE

36-71-42 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-42 SUCTION LINE -190850 VACUUM RESERVOIR - 19A556

36-71-43 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-43 LI OU ID LINE - 19836 HIGH PRESSURE HOSE - 190850 K3675-2A FIG. 46 Refrigerant Lines and Heater Hose Routings - Lincoln with 7.5L 460 C.l.D. Engine HEATER CORE Removal 1. Loosen the radiator cap, open the radiator drain 3. Place the heater core cover plate gasket and cover cock and drain the engine coolant. plate over the core tubes and align the retaining 2. Close the radiator drain cock. screw holes.

36-71-44 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-44 COVER PLATE ...SCREWI7REOUlREOI_.af_ 12. Remove one case mounting stud nut under the instrument panel on the right side of the plenum chamber mounting flange Fig. 34. COVER GASKET 13. Remove three case-to--dash panel mounting screws and two stud mounting nuts. 14. Move the case assembly forward to clear three studs, lift the case upward t

36-71-45 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-45 CONDENSER RECEIVER-DRIER-FORD & MERCURY Removal Removal 1. Discharge the refrigerant from the system observ 1. Discharge the refrigerant from the system at the ing all safety precautions. service access gauge port valve on the STy. ob 2. Drain the coolant from the radiator in a clean serve all safety precautions. container. 2. Working under the vehicle, disconnect the two 3. Remove the radiator hoses and the transmission refrigerant lines at the fittings on the bottom of the cooler lines from the radiator

36.71-46 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-46 N SNAP LOCK CONNECTOR AMBIENT CUT-OF F ITCH - I 9618 K3673-2A FIG. 49 Ambient Cut-off Switch Removal - Ford, Mercury and Lincoln Continental COMPRESSOR Removal

36-71-47 Ford, Mercury and Lincoln Continental Automatic Temperature Control 36-71-47 SPECIFICATIONS ELECTRICAL System Protection Clutch Accessory Circuit 20 Amp Fuse in Panel Blower Circuit 35 Amp Fuse is-i Panel Blower Motor Current Draw Switch Setting Amps Volts Low 6 5 Medium Low 70 7 Medium High 17 10

36-72-1 Granada and Monarch Automatic Temperature Control 36-72-1 PART Granada and Monarch A.T.C. 36-72 SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Automatic Temperature Control 72-1 Compressor 72-13 Control Lever 72-1 Control Head Assembly 12-13 System Air Flow 72-5 Electro Vacuum Relay 72-13 Resistor Assembly 7213

36-72-2 Granada and Monarch Automatic Temperature Control 36-72-2 BLOWER SWITCH FUNCTION CONTROL LEVER OUTSIDE - HECIRC AIR ODOR AUTOMATIC TEMPERATURE CONTROL SYSTEM VACUUM MOTOR TEST CHART VACUUM MOTORS APPLIED WITH VACUUM FUNCTION HEAT-DEFROST CONTROL LEVER ATC OUTSIDE- WATER TEMP A/C- POSITION REQUIREMENT RECIAC VALVE* * OLEND + DEFROST PA

36-72-3 Granada and Monarch Automatic Temperature Control 36-72-3 -19A 566- VACUUM RESERVOIR -18495- WATER VALVE - PV PARTIAL VACUUM TO

36-72-4 Granada and Monarch Automatic Temperature Control 36-72-4 COLD ENGINE LOC <OUT DC 1IO0F SWITCH CC 1l00F A/C CLUTCH & COMPRESSOR INTERNAL GROUND BLOWER MOTOR

36-72-5 Granada and Monarch Automatic Temperature Control 36-72-5 the sensor assembly. The air flows through the aspirator operation, and to switch the system to recirculating air which draws vehicle interior air Over the in-car bimetal. Until the engine coolant warms-up to about 115°F. This combined air is then exhausted from the sensor underneath the instrument panel where it will not be felt Control Head Assembly Figs. 5. 6 and 1 by the passengers or driver. The control head consists of three main parts: 1 the The modulated vacuum from the sensor is directly function selector-a nine port vacuum selector valve connected to the large calibrated vawum motor portion combined with two cam operated electrical switches; 2 of the servo assembly. The

T1 Cporncz - fl-up 0> a >C HC 0n1 00 Q0 2’-I C p IC rn

36-72-7 Granada and Monarch Automatic Temperature Control 36-72-7 and the temperature blend door and water valve temperature lever setting, the blend door moves to assume a position depending on the modulated vacuum admit more cooled air and tess heated air. If the in-car form the sensor to the power servo. temperature drops below the setting, the blend door NOTE: A modulated vacuum is produced n ALL moves to admit more heated air and less cooled air. function control lever positions and is entirely Hi-Lo Positiondependent on the temperature lever setting and existing in-vehicle temperature conditions. Operation is similar to that described in the A/C position paragraphs, except that

FUNCTION SELECTOR LEVER CONTROL READ ASSEMBLY 19C642 - BLOWER SPEED SWITCH - 19A642 9a 00a

36-72-9 Granada and Monarch Automatic Temperature Control 36-72-9 Defrost Position floor. The temperature blend door modulates in this position but maximum heat can be obtained by moving When the function lever is in the DEFROST position, the temperature lever to the highest temperaturethe A/C-Defrost and Heat-Defrost doors ore in the full position. The A/C clutch also operates in this positiondefrost no vacuum position so that all incoming air is to dehumidify

36-72-10 Granada and Monarch Automatic Temperature Control 36-72-10 HEATER CORE AND SEAL - 198539 AICSFNSOA AIR SCGOP TUBE OUTLET - 19D882 EVAPORATOR CASE UPPER HALF - 19C974 OLOWER REStSTOR

36-72-11 Granada and Monarch Automatic Temperature Control 36-72-11 ADJUSTMENTS SENSOR CALIBRATION FIG. 9 sensor calibration as descilbed in the above procedure. If O.K., use the following procedure: 1. Remove the instrument panel pad and visually determine which direction to rotate the sensor 1. Establish the customer’s preference and the calibration locking pin. difference between the present and desired comfort 2. While moving the temperature control lever, rotate level setting. the calibration locking pin into the 75°F calibration 2. Determine the direction of change. notch of

36-72-12 Granada and Monarch Automatic Temperature Control 36-72.12 CDNENSER ASSY - 19fl 2

36-72-13 Granada and Monarch Automatic Temperature Control 36-72-13 ELECTRO VACUUM RELAY EVR 3. Remove two 2 upper control assembly attacHng screws. 1. Remove EVR mounting screw from bracket on plenum assembly. 4. Remove temperature control cable from control head 1 screw.2. D;sconnect the vacuum connector and electrical connector. 5. Disconnect multiple vacuum harness connector from the 9-port vacuum selector valve.3. Reverse this procedure to install.

36-73-1 Versailles Automatic Temperature Control 36-73-1 Versailles Automatic PART 36-73 Temperature Control SUBJECT PAGE SUBJECT PAGE DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION Cont’d. Automatic Temperature Control 73-3 Condenser and/or Receiver-Drier 73-35 Components 13-6 Control Assembly 73-21 Control Lever Operation 73-2 Defroster Nozzle 73-30 Refrigerant System 13-1 Electro Vacuum Relay {EVR

36-73-2 Versailles Automatic Temperature Control 36-73-2 nozzles, or the instrument panel A/C registers accord operate, a calibrated temperature control lev

36-73-3 Versailles Automatic Temperature Control 36-73-3 IN-CAR MOUNTING AIR PATH HOLE BIMETALLIC SENSOR FOAM SEAL TO PANEL MOUNTINC HOLE AIR DISCHARGE MODULATED VACUUM TO SERVO MOTOR L1808’2E FIG. 3 Sensor Assembly ‘AUTOMATIC TEMPERATURE CONTROL high vehicle interior temperatures produce high sensor outp

36-73-4 Versailles Automatic Temperature Control 36-73-4 BLOWER SWITCH - VACUUM FUNCTION CONTROL .13405. COMBINATION NV- NO VACUUM LEV ER HEATER PV- PARTIAL VACUUM

36-73-5 Versailles Automatic Temperature Control 36-73-5 ENGINE TEMPERATURE SENDER CLOSED BELOW 100 F. OPEN ABOVE 120 F. TO INSTRUMENT CLUSTER ENGINE TEMP. LIGHT 347 34E BK/V H A/C CLUTCH & BATTERy LT.G/PH COMPRESSOR P OR C TERMINAL DASH PANEL 1OA

36-73-6 Versailles Automatic Temperature Control 36-73-6 ECONOMY-VENT POSITION leaving the evaporator core is directed through the In ECONOMY-VENT position, outside air is directed heater core. Blended air the mixture of outside air through the panel A/C registers with automatic con and heater air then is directed into the car interior. The A/C clutch does not operate in the HEAT position.trol of discharge air temperatures and water valve actuation. However, refrigerated cooling is not avail DEFOG I’ POSITION able. ECONOMY-VENT and HEAT positions provide the most economical operations because the compres In DEFOG Y operation is the same as the HEAT sor does not ope

36.73-7 Versailles Automatic Temperature Control 36-73-7 ELECTRO-VACUUM RELAY E.V. RELAY Located on the plenum assembly below the A/C- Defrost door vacuum motor, the E.V. Relay is a combi nation normally closed vacuum solenoid valve and a single pole single throw normally closed electrical relay, both actuated by one electrical coil. The EV. Relay is used during cold engine operation, in the HEATfunction lever position, to lock-out blower opera tion, and to switch the system to recirculating air until the engine coolant warms up to about 1200 F 49°C. CONTROL ASSEMBLY The control assembly consists of three main parts: 1 the function selector - a nine-port vacuum selector valve combined with two cam operated electrical THERMAL UMITER

36-73-8 Versailles Automatic Temperature Control 36-73-8 An internally equalized By-Pass Orifice BPO The By-Pass Orifice BPO Combination Valve is an Combination Valve assembly is used to control refri assembly which combines the Expansion Valve and the gerant system pressures. Suction Throttling Valve into one integral unit. It also has an evaporator manifold plate assembly for at Refer to the Normal System Operation Charts and tachment to the inlet and outlet evaporator core tubes,the Problem Refrigerant System Pressure Evaluation as well as an SW housing m

36-73-9 Versailles Automatic Temperature Control 36-73-9 BY-PASS ORIFICE BPO EXPANSION VALVE It is attached to the evaporator manfold plate with two 2 hex-head screws which are torqued 4to 8 lbs. ft. The By-Pass Orifice Expansion Valve is the H-block type similar to that used on earlier refrigerant systems, The By-Pass Orifice SPO Expansion Valve must except that the tapered ball seat is slotted to prevent regulate the flow of liquid refrigerant during cool- complete sealing of the lisuid refrigerant inlet to the down while the car interior and evaporator core are evaporator. It is machined to accommodate the instal cooling down. As the evaporator co

36-73-10 Versailles Automatic Temperature Control 36-73-10 PRESSURE DIFFERENTIAL CALIPRATED EVAPORATOR PRESSURE VALVE FOR OIL RETURN GAUGE PORT NEEDLE SUCTION LINE CONNECTION STV HOUSING MANIFOLD AND TUBE ASSEMBLY

36-73-11 Versailles Automatic Temperature Control 36-73-11 S. The liquid bleed line circuit parallels the suction REFRIGERANT SYSTEM throttling valve. The pressure differential valve in the circuit no replacement part available starts to Refer to the normal system operation charts in Fig. 14 open when the suction pressure in the STV housing tor normal center register discharge air temperatures, Fig. is 10 psi less than the evaporator pressure. It will 15 for normal evaporator pressure gauge readings vs. fully open when the suction pressure is 20 psi less altitude and Fig. 16 for normal STV/BPO refrigerant than the evaporator pressure. system pressures. Also refer to the

36-73-12 Versailles Automatic Temperature Control 36-73-12 -I 9A 566- VACUUM RESERVOIR .18495. WATER VALVE TO VACUUM MANIFOLD EVAPORATOR PVNV -- PARTIALNO VACUUMVACUUM CHECK VALVE V - VACUUM OUTSIDE AIR

36-73-13 Versailles Automatic Temperature Control 3&73-13 CHART 1 HISSING ATC VACUUM SYSTEM OR CONTROL ASSEMBLY SELECTOR VALVE II CHECK IN-LINE AND CONTROL AS SEMBLY MULTIPLE CONNECTORS FOR PROPER INSTALLATION 1 HISS CONTINUES 1118$ TOPS ‘I MOVE FUNCTION LEVER TO DETERMINE WHAT

36-73-14 Versailles Automatic Temperature Control 36-73-14 CHART 2 HISSING ATC VACUUM SYSTEM OR CONTROL ASSEMBLY SELECTOR VALVE CONTINUED FROM CHART I ALL FUNCTION SELECTOR VALVE POSITIONS LEAK MOVE TEMPERATURE CONTROL LEVER FROM 65 TO 85 HISS CONTINUES 1 HISS STOPS AT SOME SETTINGS CHECK VACUUM SOURCE TUBE BLACK FROM RESERVOIR TO CONTROL ASSEMBLY FOR CUT

36-73-15 Versailles Automatic Temperature Control 36-73-15 CHART 3 HISSING ATC VACUUM SYSTEM OR CONTROL ASSEMBLY SELECTOR VALVE CONTINUED FROM CHART 2 SOME TEMPERATURE CONTROL LEVER POSITIONS LEAK -J 4 PINCH OFF SOURCE TUBE BLACK AT DIVERTER VALVE HISS CONTINUES HISS STOPS 3

36-73-16 Versailles Automatic Temperature Control 36-73-16 50 45 40 35 30 60 70 80 90 100 AMBIENT TEMPERATURES °F. CL2621-2A FIG. 14 Normal Center Register Discharge Temperatures "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 Co

36-73-17 Versailles Automatic Temperature Control 36-73-17 35 IIIIIIIIII ---------- - 34 - - CONDITIONAL REQUIREMENTS * StabIlIzed Pressures - * Stabilized In Car Temperatures @ 70 to 80SF 33 * Maxhnum A/C RecirculatIng Air * Medium Blower Speed * 1500 Engine RPM Compressor Clutch Engaged

36-73-18 Versailles Automatic Temperature Control 36-73-18 NORMAL STV/BPO REFRIGERANT SYSTEM PRESSURES 240 230 220 210 200 190 180 170 160 150 140 130 120 110 100 30 20 10 0 -10 60 70 80 90 100 AMBIENT TEMPERATURES °F CL2G23-2A FIG. 16 Normal STV/BPO Refrigerant System Pressures "This publication contains material that is reproduced and distri

36-73-19 Versailles Automatic Temperature Control 36-73-19 REFRIGERANT SYSTEM PRESSURE EVALUATION For Systems Without Low Pressure Suction Service Accesa Gauge Port Volvo NOTE: Normal system conditional requirements must be maintained to properly evaluate refrigerant system pressures. Refer to chart applicable to system under test HIGH PRESSURE EVAPORATOR POSSIBLE @ LIQUID LINE @ COMPRESSOR PRESSURE PROBLEM/COMPONE?IT ENGINE OVERHEATING / HIGH HIGH HIGH

36-73.20 Versailles Automatic Temperature Control 36-73-20 ADJUSTMENTS SENSOR CALIBRATION 1. Remove the instrument panel pad and visually 1. Establish the customers preference and the differ determine which direction to rotate the sensor ence between the present and desired comfort calibration locking pin. Refer to Fig. 18. level setting. 2. While moving the temperature control lever, ro 2. Determine the direction of change. tate the calibration locking pin into the calibra 3. b decrease or increase, adjust the temperature tion notch of the sensor control arm. control lever position with the sensor arm locked in 3. Check the position of the temperature contro

36-73-21 Versailles Automatic Temperature Control 36-73-21 COMPRESSOR DRIVE BELT TENSION TEMPERATURE CONTROL CABLE Removal 1. Check the belt tension with Tool T63L-8620-A or 1. Remove the instrument panel pad assembly. Refer equivalent. The belt tension should be within to the procedure. specifications. 2. Remove the retaining bolts 2 securing the Instru ment Panel-to-Cowl Brace and remove the brace. 2. If the belt tension is not within specification, 3. Remove the seat belt chime mounting screws 2 loosen the two idler pulley arm attaching bolts

36-73-22 Versailles Automatic Temperature Control 36-73-22 BLOWER SWITCH FUNCTION CONTROL VACUUM SELECTOR VALVE Removal Removal 1. Disconnect the negative ground battery cable. 2. Remove the steering column opening cover located 1. Perform steps 1 thru 6 of the Control Assembly below the steering column. Removal Procedure. 2. Disconnect the multiple vacuum connectorfrom the3. Depress the spring and pull the knob from the blower switch shaft. function control vacuum selector valve. 4. Remove one screw atta

36-73-23 Versailles Automatic Temperature Control 36-73-23 HEATER CORE TUBE HEATER CORE AND EA L SEAL EVAPORATOR CASE UPPER HALF THERMAL LIMITER EVAPORATOR BLOWER RESISTOR PLENUM ASSY ASS?. TUBE MANIFOLD

36-73-24 Versailles Automatic Temperature Control 36-73-24 ELECTRO VACUUM RELAY EVR 2. Remove the retaining screws 3 securing the in strument panel pad to the instrument panel, The LV. Relay is located on the left end of the above the glove box door. evaporator case below the A/C-defrost door vacuum 3. Remove the retaining screws 3 securing the in motor. strument panel pad to the instrument panel, Removal above the top of the instrument cluster. 1. Remove one screw attaching the E.V. relay to the 4. Raise the brow edgethe instrument panel pad and mounti

36-73-25 Versailles Automatic Temperature Control 36-73-25 ATC SENSOR ASSEMBLY OUTSIDE AIR/RECIRC MOTOR MOTOR VACUUM FRONT OF CAR K3458-2c FIG. 22 Rear View at Instrument Panel-ATC INSTRUMENT PANEL REGISTER DUCTS 14. Remove one screw and washer assembly attaching each lower end of the instrument panel to the side Removal cowl Fig. 23. 1. Disconnect the ground cable from

36-73-26 Versailles Automatic Temperature Control 36-73-26 BRACE - 660459R NUT 55736-S7 VIEW fl FIG. 23 Instrument Panel Installation DEFROSTER NOZZLE INSTALLATION L2056.2A FIG. 24 Duct

36-73-27 Versailles Automatic Temperature Control 36-73-27 11. Install the screw to attach the instrument panel at 15. Install the right and left cowl side trim panels. the steering column opening to the brake pedal Then, tighten the front door sill plate attaching support. screws. 12. Position the steering column to the brake pedal 16. Install the instrument panel lower finish panel. support and install the clamp. 17. Connect the ground cable to the battery. 13. Install the steering column opening cover panel. 14. Install the hood latch release handle and bracket on the lower edge of the instrument panel. SENSOR ASSEMBLY Removal 1. Remove the instrumen

36-73-28 Versailles Automatic Temperature Control 36-73-28 OUTSIDE - RECIRCULATING AIR DOOR 1. Position the register assembly into the opening VACUUM MOTOR with the largest diameter pivot near the largest pivot hole. Removal 2. Depress the retaining tabs, push the register as 1. Disconnect the vacuum hose white from the vac sembly into the register opening and engage the uum motor. retaining tab pivots in the pivot holes. 2. Remove the attaching screws 2 securing the vac

36-73-29 Versailles Automatic Temperature Control 36-73-29 8. Install the lower finish plate on the instrument 9. Connect the negative ground cable to the bat panel. tery. HEATER CORE AND SEAL EVAPORATOR CASE ASSEMBLY RETAINING SERVO SCREWS

36-73-30 Versailles Automatic Temperature Control 36-73-30 6. Connect the vacuum harness connector to the E.V. Installation relay and install the retaining nut. 1. Position the floor distribution duct on the plenum 7. Connect the yellow vacuum hose to the A/C-defrost opening. door vacuum motor. 2. Install the retaining screw 1 securing the floor 8. Connect the blue vacuum hose to the end of the distribution duct to the evaporator case. heat-defrost door vacuum motor and the red vac 3. Install the clip se

36-73-31 Versailles Automatic Temperature Control 36-73-31 Installation A/C-DEFROST DOOR VACUUM MOTOR 1. Position the door onto the crank arm loop and Removal loosely install the door retaining screw. 1. Remove the retaining bolts 2 securing the Instru 2. Move the door to the maximum no vacuum position ment Panel-to-Dash Panel brace and remove the and tighten the retaining screw to specification. brace. Move the door back and forth to assure freedom of 2. Removethefloordistribution duct assembly. Refer movement and readjust if necessary.

36-73-32 Versailles Automatic Temperature Control 36-73-32 CAUTION: NEVER MANUALLY OPERATE ANY EVAPORATOR CASE VACUUM MOTOR OR VACUUM MOTOR CONTROLLED DOOR WHEN CONNECTED TO THE VACUUM Removal MOTOR - THIS MAY CAUSE INTER NAL DAMAGE TO THE VACUUM 1. Disconnect the ground cable from the battery and MOTOR DiAPHRAGM. partially drain the cooling system. Alternate Removal 2. Remove the air cleaner assembly from the engine compartment. Remove the retaining screws 2 securing the vac

DEFROSTER NOZZLE EVAPORATOR CASE LEFT AIR DUCT ASSEMBLY CENTER AIR DISTRIBUTION DUCT RIGHT Al FLOOR DUCT BLOWER WHEEL ORANGE WIRE

36-73-34 Versailles Automatic Temperature Control 36-73-34 Installation 3. Remove four screws and remove the blower motor and wheel from the blower housing. 1. Position the evaporator case to the dash panel 4. Remove three screws inside the blower housing and the plenum assembly. Install the Iwo screws and one screw outside the blower housing and and two clips to retain the plenum to the separate the blower housing from the evaporator evaporator case.

36-73-35 Versailles Automatic Temperature Control 36-73-35 7. Remove the SW 0-ring seal from the Expansion 4. Refill the engine cooling system to proper Valve body. level with a 50-50 mix of coolant and water. Installation 5. Move the function control lever to HEAT 1. Lubricate and install 3 new 0-rings, two on the and start the engine to refill the heater SW to seal the SW Housing Manifold and one in core and hoses. the STV opening of the By-Pass Orifice BPO Ex