Thursday, February 10, 2011

2006 ford taurus heater core replacement complete disassembly.?

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for at least 1 minute for the SRS or air bag module to deplete its energy.

  3. Place the front wheels in the straight-ahead position.
  4. Lock the steering column.
  5. Remove or disconnect the following:

    SRS bolt covers from both sides of the steering wheel
    SRS module-to-steering wheel bolts
    SRS module and disconnect the electrical connector
    Steering wheel bolt and discard it

  6. Press the steering wheel from the steering column.

    Lower steering column shaft bolt
    2 lower instrument panel cover-to-instrument panel screws and unsnap the lower cover from the instrument panel

  7. Turn ignition switch to the RUN position
  8. Insert a 1 / 8 in. (3mm) wire or pin punch in the lower steering column shroud hole, under the ignition switch; then, press on the pin while pulling out on the ignition switch lock cylinder and remove it from the steering column lock cylinder housing.
  9. Remove or disconnect the following:

    3 steering column shroud screws and the shrouds
    Shift control selector lever boot
    Gearshift lever pin from the manual control lever and remove the lever
    Wiring connector at the bottom of the steering column and remove the wiring from the column, (if equipped with an overdrive lockout switch on the manual control lever)
    Electrical connectors
    Multi-function switch screws and move it aside
    Shift indicator cable from the shifter tube
    Shifter indicator-to-column adjustment cable screw
    Interlock cable and actuator (if equipped with a column shift)
    4 steering column-to-instrument panel bracket nuts and steering column
    Push pins and the lower instrument cover from the instrument panel reinforcement (at the passenger-s side)
    Console finish panel

  10. Under the steering column, 2 instrument panel brace screws, the courtesy lamp socket, the 2 Diagnostic Link Connector (DLC) screws and the instrument panel brace.
  11. If not equipped with an Electronic Automatic Temperature Control (EATC), disconnect the electrical connectors and the vacuum harness from the evaporator housing and the blower motor.
  12. If equipped with an Electronic Automatic Temperature Control (EATC), remove the sensor hose/elbow and disconnect the electrical harness connectors and the vacuum hose harness from the evaporator housing.
  13. Insert the Radio Removing tools 415-001 into the integrated control panel faceplate; then, push the tools in approximately 1 1 / 2 in. (38mm) to release the retaining clips. Spread the tools slightly and pull the integrated control panel from the instrument panel.
  14. Remove or disconnect the following:

    Electrical connectors and the automatic temperature control sensor hose and elbow, if equipped
    6 console center finish panel screws and the panel, (if equipped with a floor shift)
    4 instrument panel finish panel screws and panel, located at the right side of the steering column, (if equipped with a column shift)
    Instrument cluster finish panel-to-instrument panel clips and pull the finish panel straight out
    4 instrument cluster-to-instrument panel screws, the electrical connectors and the instrument cluster
    Upper finish panel (located at the top of the instrument panel)
    Light sensor amplifier connector, (if equipped with an autolamp)
    Instrument panel finish end panels on both sides of the instrument panel
    Front scuff plates and pull the door weatherstrip away from the instrument panel (on both sides of the instrument panel)
    3 instrument panel-to-upper cowl top panel screws
    2 screws at each end of the instrument panel
    Instrument panel electrical connectors and the parking brake switch
    Instrument panel

  15. Drain the cooling system into a clean container for reuse
  16. Remove or disconnect the following:
    WARNING
    Do not attempt to bend any part of the lever, for it is brittle and will break.



    Heater hoses from the heater core and plug the openings
    4 air conditioning electronic blend door actuator-to-heater/air conditioning housing assembly screws and the actuator
    Metal cover, disengage the spring from the heater core cover and from the lever
    Gently, depress the locking ramp and remove the lever from the secondary air temperature control door end

  17. Rotate the primary air conditioning air temperature control door shaft downward, swing the metal link counterclockwise and remove it from the pin.
  18. Remove the 3 heater core cover-to-heater/air conditioning housing assembly screws, the cover and the seal.
  19. Press on the heater core tubes and remove the heater core from the heater/air conditioning housing assembly.

    Click image to see an enlarged view

    Fig. Remove the instrument panel insulator from the instrument panel reinforcement



    Click image to see an enlarged view

    Fig. Manual air conditioning/heater equipped vehicles disconnection points



    Click image to see an enlarged view

    Fig. EATC equipped vehicles disconnection points



    Click image to see an enlarged view

    Fig. On floor shift vehicles, remove the console center finish panel



    Click image to see an enlarged view

    Fig. On floor shift vehicles, remove the finish panel from around the integrated control panel



    Click image to see an enlarged view

    Fig. If equipped with autolamps, detach the light sensor amplifier



    Click image to see an enlarged view

    Fig. Unsnap the upper finish panel from the instrument panel



    Click image to see an enlarged view

    Fig. Remove the instrument panel finish end panel



    Click image to see an enlarged view

    Fig. Detach the electrical connectors



    Click image to see an enlarged view

    Fig. Instrument panel-to-cowl panel mounting



    Click image to see an enlarged view

    Fig. Remove the 4 blend door actuator retaining screws



    Click image to see an enlarged view

    Fig. Secondary air temperature door connections



    Click image to see an enlarged view

    Fig. Exploded view of the SRS module and the steering wheel assembly



    Click image to see an enlarged view

    Fig. View of the integrated control panel



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel



    Click image to see an enlarged view

    Fig. View of the temperature control mechanism



    Click image to see an enlarged view

    Fig. Exploded view of the heater core


To install:

  1. Install or connect the following:
    WARNING
    Do not use excessive force when installing the radio, the retaining clips can become damaged.



    Heater core to the heater/air conditioning housing assembly
    Heater core cover, the seal and the 3 heater core cover-to-heater/air conditioning housing assembly screws
    Lever to the secondary air conditioning air temperature control door end
    Spring to the lever, engage the spring to the heater core cover and install the metal cover
    Air conditioning electronic blend door actuator and the 4 actuator-to-heater/air conditioning housing assembly screws
    Heater hoses to the heater core
    Instrument panel with the help of an assistant
    Instrument panel electrical connectors and the parking brake switch
    2 screws at each end of the instrument panel with the help of an assistant
    3 instrument panel-to-upper cowl top panel screws
    Front scuff plates and the door weatherstrip (on both sides of the instrument panel)
    Instrument panel finish end panels (on both sides of the instrument panel)
    Electrical connector to the light sensor amplifier (if equipped with an autolamp)
    Upper finish panel (at the top of the instrument panel)
    Instrument cluster, electrical connectors and the 4 instrument cluster-to-instrument panel screws
    Instrument cluster finish panel and engage the finish panel-to-instrument panel clips
    Instrument panel finish panel and 4 panel screws, located at the right side of the steering column (if equipped with a column shift)
    Console center finish panel and the 6 panel screws (if equipped with a floor shift)
    Electrical connectors and the automatic temperature control sensor hose and elbow, if equipped
    Integrated control panel faceplate



    Sensor hose/elbow, the electrical harness connectors and the vacuum hose harness to the evaporator housing (if equipped with an Electronic Automatic Temperature Control (EATC)
    Connect the electrical connectors and the vacuum harness to the evaporator housing and the blower motor (if not equipped with an EATC)
    Instrument panel brace and the 2 Diagnostic Link Connector (DLC) screws
    Courtesy lamp socket and install the 2 instrument panel brace screws
    Console finish panel (if equipped with a floor shift)
    Lower instrument cover to the instrument panel reinforcement (located on the passenger-s side)
    Steering column and torque the 4 steering column-to-instrument panel bracket nuts to 10-13 ft. lbs. (13-17 Nm)
    Interlock cable and actuator (if equipped with a column shift)
    Shifter indicator-to-column adjustment cable screw
    Shift indicator cable to the shifter tube
    Multi-function switch and the screws
    Electrical connectors
    Wiring connector at the bottom of the steering column and install the wiring to the column (if equipped with an overdrive lockout switch on the manual control lever)
    Gearshift lever and the lever pin to the manual control lever
    3 steering column shroud screws and the shrouds
    Ignition switch to the steering column lock cylinder housing
    Lower instrument panel cover and the 2 lower cover-to-instrument panel screws
    Lower steering column shaft bolt and torque it to 17-20 ft. lbs. (22-26 Nm)
    Steering wheel to the steering column
    New steering wheel bolt and torque it to 26-33 ft. lbs. (34-46 Nm)
    SRS module and connect the electrical connector
    SRS module-to-steering wheel bolts and torque the bolts to 89-123 inch lbs. (10-14 Nm)
    SRS bolt covers
    Negative battery cable

  2. Fill the cooling system.
  3. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.