Tuesday, June 14, 2011

how to remove blend door actuator on 2003 Mercury Grand Marquis?


Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove the instrument panel.
  4. Disconnect the electrical connector from the blend door motor/actuator.
  5. Remove the four screws holding the blend door actuator to the plenum.
  6. Remove the temperature blend door actuator.

    Click image to see an enlarged view

    Fig. Blend door actuator electrical connector



    Click image to see an enlarged view

    Fig. Blend door actuator mounting to plenum


To install:

Installation is reverse of removal.


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Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Disengage the wire harness connectors from the retainer.
  4. Disconnect the blower motor electrical connector.
  5. Remove the motor cooling hose.
  6. Remove the screws and remove the blower motor.
    NOTE
    Prior to removing a wheel that is to be reused, clean any corrosion from the blower motor shaft to prevent damage to the wheel mounting shaft.

  7. Remove the wheel from the blower motor as follows:

    Remove the push clip.
    Remove the wheel from the blower motor.

    Click image to see an enlarged view

    Fig. Blower motor cooling hose



    Click image to see an enlarged view

    Fig. Blower motor mounting plate



To install:

  1. Install or connect the following:

    Wheel to the blower motor, if removed.
    Blower motor and securely tighten the screws.
    Motor cooling hose
    Blower motor electrical connector
    Wire harness retainers

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Removal & Installation

CAUTION
Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system:
    NOTE
    Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator.



    If A/C flushing equipment is available, carry out the flushing of the air conditioning system prior to installing a new air conditioning compressor.
    If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed.
    Install a new evaporator core orifice (19D990) as directed by the A/C flushing or filtering procedure.
    Install a new suction accumulator (19C836) as directed by the A/C flushing or filtering procedure.

  4. If flushing of the air conditioning system has not been carried out, recover the refrigerant.
  5. Remove the drive belt from the A/C compressor pulley.
  6. Disconnect the field coil electrical connector.
  7. Loosen the bolt and detach the compressor manifold and tube assembly from the A/C compressor.
  8. Discard the O-ring seals.
  9. Raise the vehicle.
  10. Disconnect the crank sensor electrical connector.
  11. Remove the nut and detach the wiring harness clips.
  12. Remove the studs and the A/C compressor.

    Click image to see an enlarged view

    Fig. A/C compressor field coil connector



    Click image to see an enlarged view

    Fig. A/C compressor manifold and tube assembly



    Click image to see an enlarged view

    Fig. A/C compressor studs and nuts


To install:

  1. Install new O-ring seals lubricated in clean PAG oil.
  2. If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.
  3. If filtering of the refrigerant system is not to be carried out, evacuate, charge and leak test the refrigerant system.
  4. Install or connect the following:

    A/C compressor studs and torque to 18 ft. lbs. (25 Nm)
    A/C compressor
    Crank sensor electrical connector
    Compressor manifold and tube assembly to A/C compressor and torque the bolt to 15 ft. lbs. (21 Nm)
    A/C compressor field coil electrical connector
    Accessory drive belt

  5. Partially refill the system and check for leaks.
  6. If no leaks are present, complete refrigerant charging.
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Electronic Automatic Temperature Control



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove or disconnect the following:

    Finish panel
    Control head electrical connectors
    Control head vacuum harness
    Automatic temperature control (EATC) module from the instrument panel

    Click image to see an enlarged view

    Fig. EATC mounting



    Click image to see an enlarged view

    Fig. EATC electrical and vacuum harness



To install:

Installation is reverse of removal.

Manual Control



  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove or disconnect the following:

    Finish panel
    Control head electrical connectors
    Control head vacuum line
    Climate control head

    Click image to see an enlarged view

    Fig. Control panel mounting.



    Click image to see an enlarged view

    Fig. Control panel electrical connectors and vacuum line.



To install:

Installation is reverse of removal.

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No air from defrost:---

Vehicle air conditioning is the cooling r refrigeration of the air in the passenger compartment. Refrigeration I accomplished by making practical use of the laws of nature. HEAT GOES TO LESS HEAT. All this means is that heat transfers. If two substances of different temperature are placed near each other, the heat in the warmer substance will always travel to the colder substance until both are of equal temperature.

As a fail-safe, the air handling system is designed to provide defrost when no vacuum is applied to any of the vacuum control motors. This is done to prevent a situation where defrost cannot be obtained due to a system vacuum leak. Instead, a leak in the vacuum control circuit will send all airflow to the defroster outlets. This condition may occur during acceleration (slow vacuum leak), may exist at all times (large vacuum leak), and may happen only when certain specific functions are selected, indicating a leak in that portion of the circuit.

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Heater Core:-- FOR town car and mercury is similar for heater code replacing procedure.

Removal & Installation


  1. If equipped, turn the air suspension service switch to the OFF position before raising the vehicle.
  2. Drain the cooling system.
  3. Remove or disconnect the following:

    Negative battery cable
    Front seats
    Carpeting
    Rear airflow duct
    Heater hoses

  4. Remove the driver-s side air bag module by removing or disconnect the following:

    SRS module-to-steering wheel bolts, from both sides of the steering wheel.
    SRS module and disconnect the electrical connector
    Horn switch electrical connector

  5. Remove the passenger-s side SRS module by removing or disconnecting the following:

    Open the glove box and disconnect the glove compartment isolator
    Push inward on the 2 glove box door tabs and lower it
    SRS module-s electrical connector
    SRS module-to-instrument panel bolts and the module

  6. Remove the instrument panel by removing or disconnecting the following:

    Speed control servo nuts and move the servo aside
    Bolt and disconnect the left side bulkhead connector
    Left side bulkhead connector from the dash panel
    Windshield washer fluid reservoir screw, and position the reservoir aside
    Blower motor electrical connector
    Air conditioning pressure cut-off switch electrical connector
    In-line electrical harness connector
    Electronic Automatic Temperature Control (EATC) variable blower motor controller electrical connector
    Right front wheel
    Right front fender splash shield bolts and move the shield away from the cowl
    Wiring harness from the evaporator case
    Wiring harness from the cowl
    Right side instrument panel lower insulator pushpins, disconnect the power point electrical connector, remove the courtesy lamp from the socket and remove the insulator
    Unseat the wiring grommet and feed the wiring harness through the cowl
    Cowl side trim panels and the windshield side garnish moldings from both sides
    Locking clip and the Electronic Crash Sensor (ECS) module electrical connector
    Antenna connector
    Ground wire bolts from the right side
    EATC hose at the evaporator housing
    Bolt and disconnect the bulkhead connector from the right side
    Pull the door weatherstrip seals away from the instrument panel on both sides
    Tunnel brace trim cover
    Climate control head vacuum harness connector
    Instrument panel tunnel brace nuts and the brace
    Ground wire bolts from the left side
    Wiring harness connectors from the left side
    Parking brake switch electrical connector

    1. Pry out the instrument panel defroster opening grille, disconnect the electrical connectors and the remove the grille.

  7. Remove or disconnect the following:

    3 upper instrument panel screws
    Instrument panel cowl side nut from both sides
    Instrument panel cowl side bolt from the left side
    Instrument panel
    Windshield wiper mounting arm and the pivot shaft
    Electrical connector and remove the upper cowl extension screw and the extension
    Vacuum hoses and the wire harness connector from the evaporative emissions canister purge valve
    Evaporative emissions purge valve nuts and the valve
    Cowl side nut
    Right side rear fender apron screws and reposition the apron
    Evaporator housing nut and screw
    Vacuum hoses and the wiring harness connectors
    Plenum chamber-s lower flange nuts
    Plenum chamber-s upper flange nut and the plenum chamber
    Heater core cover-to-heater plenum chamber screws and the cover
    Seal and the heater core

    Click image to see an enlarged view

    Fig. View of the instrument panel finish panels



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Crown Victoria and Grand Marquis



    Click image to see an enlarged view

    Fig. Exploded view of the heater air plenum chamber, the evaporator housing and the air inlet duct



    Click image to see an enlarged view

    Fig. View of the heater core



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Town Car



To install:

  1. Install or connect the following:

    Seal and the heater core
    Heater core cover and the cover-to-heater plenum chamber screws
    Plenum chamber and the plenum chamber-s upper flange nut
    Plenum chamber-s lower flange nuts
    Vacuum hoses and the wiring harness connectors
    Evaporator housing nut and screw
    Right side rear fender apron and the apron screws
    Cowl side nut
    Evaporative emissions purge valve and the valve nuts
    Vacuum hoses and the wire harness connector to the evaporative emissions canister purge valve
    Electrical connector; then, install the upper cowl extension screw and the extension
    Windshield wiper mounting arm and the pivot shaft

  2. Install the instrument panel by installing or connecting the following:

    Instrument panel
    At the left side, install the instrument panel cowl side bolt
    Instrument panel cowl side nut on both sides
    3 upper instrument panel screws
    Electrical connectors and the install the instrument panel defroster opening grille
    Parking brake switch electrical connector
    Wiring harness connectors on the left side
    Ground wire bolts on the left side
    Instrument panel tunnel brace and the brace nuts
    Climate control head vacuum harness connector
    Install the tunnel brace trim cover.
    Door weatherstrip seals to the instrument panel on both sides
    Bulkhead connector and tighten the bolt on both sides
    EATC hose at the evaporator housing
    Ground wire bolts on the right side
    Antenna connector
    ECS module electrical connector and the locking clip
    Cowl side trim panels and the windshield side garnish moldings on both sides
    Feed the wiring harness through the cowl and seat the wiring grommet
    Right side instrument panel lower insulator, connect the power point electrical connector, install the courtesy lamp to the socket and secure the insulator with pushpins
    Wiring harness from the cowl
    Wiring harness to the evaporator case
    Right front fender splash shield and the shield bolts
    Right front wheel
    EATC variable blower motor controller electrical connector
    In-line electrical harness connector
    Air conditioning pressure cut-off switch electrical connector
    Blower motor electrical connector
    Windshield washer fluid reservoir and the reservoir screw
    Left side bulkhead connector to the dash panel
    Left side bulkhead connector and tighten the bolt
    Speed control servo and the servo nuts
    Right SRS module and torque the module-to-instrument panel bolts to 62-97 inch lbs. (7-11 Nm)
    Right SRS module electrical connector
    Glove compartment isolator
    Glove box door
    Horn switch electrical connector
    Electrical connector and install the left SRS module
    Left SRS module-to-steering wheel bolts on both sides of the wheel, and torque the bolts to 90-122 inch lbs. (10-14 Nm)
    Rear airflow duct
    Carpeting
    Front seats
    Heater hoses

  3. Refill the cooling system.
  4. Connect the negative battery cable.
  5. Operate the engine to normal operating temperature. Check the climate control operation and check for leaks.

Town Car



  1. Disconnect the negative battery cable.
  2. Drain the cooling system and disconnect the heater hoses from the heater core tubes. Plug the hoses and the heater core tubes to prevent coolant leakage.
  3. Remove the 3 nuts located below the windshield wiper motor attaching the left end of the plenum to the dash panel. Remove the 1 nut retaining the upper left corner of the evaporator case to the dash panel.
  4. Disconnect the vacuum supply hose(s) from the vacuum source. Push the grommet and vacuum supply hose(s) into the passenger compartment.
  5. Remove the right and left lower instrument panel insulators.
  6. On 1988-93 vehicles:
    1. Remove the 3 glove compartment hinge screws, disconnect the check arms and remove the glove compartment. Loosen the right door sill plate and remove the right side cowl trim panel. Remove the bolt attaching the lower right end of the instrument panel to the side cowl. Remove the instrument panel pad as follows:
    2. Remove the 2 screws attaching the pad to the instrument panel at each defroster opening. Be careful not to drop the screws into the defroster openings.
    3. Remove the one (shouldered) screw attaching each outboard end of the pad to the instrument panel.
    4. Remove the line of screws attaching the lower edge of the pad to the instrument panel. Pull the instrument panel pad rearward and remove it from the vehicle.

  7. On 1988-89 vehicles:
    1. Remove all instrument panel mounting screws and pull the instrument panel back as far as it will go without disconnecting any wiring harnesses.
    2. Make sure the nuts attaching the instrument panel braces to the dash panel are removed.
    3. Loosen the right door sill plate and remove the right side cowl trim panel.
    4. Disconnect the temperature control cable from the ATC sensor. Disconnect the vacuum harness line connector from the ATC sensor harness and disconnect the electrical connector from the ATC servo connector.

  8. On 1990-00 vehicles:
    1. Remove the cross body brace and disconnect the wiring harness from the temperature blend door actuator.
    2. Disconnect the ATC sensor tube from the evaporator case connector.

  9. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
  10. Remove the 2 hush panels.
  11. Remove 1 plastic push fastener retaining the floor air distribution duct to the left end of the plenum. Remove the left screw and loosen the right screw on the rear face of the plenum and remove the floor air distribution duct.
  12. Remove the 2 nuts from the 2 studs along the lower flange of the plenum.
  13. Carefully move the plenum rearward to allow the heater core tubes and the stud at the top of the plenum to clear the holes in the dash panel. Remove the plenum from the vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull the lower edge of the instrument panel rearward, as necessary, while rolling the plenum from behind the instrument panel.
  14. On 1988-1989 vehicles, remove the ATC servo from the plenum.
  15. Remove the 4 retaining screws from the heater core cover and remove the cover from the plenum assembly. Pull the heater core and seal assembly from the plenum assembly.

To install:

  1. Carefully install the heater core and seal assembly into the plenum assembly. Visually check to ensure that the core seal is properly positioned. Position the heater core cover and install the 4 retaining screws.
  2. On 1988-1989 vehicles, install the ATC servo on the plenum.
  3. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
  4. Position the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the evaporator case.
  5. Install the 3 nuts on the studs along the lower flange and one on the upper flange of the plenum. Install the 3 nuts below the windshield wiper motor to attach the left end of the plenum to the dash panel and the one nut to retain the upper left corner of the evaporator case to the dash panel.
  6. Position the floor air distribution duct on the plenum. Install the 2 screws and plastic push fastener. If removed, position the panel door vacuum motor to the mounting bracket and install the 2 attaching screws.
  7. Connect the white vacuum hose to the outside-recirculating door vacuum motor. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install the floor duct.
  8. If equipped with manual air conditioning, connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable.
  9. If equipped with ATC, proceed as follows:
  10. Connect the temperature control cable to the ATC sensor and adjust the cable. Route and connect the vacuum harness connector to the ATC sensor and connect the electrical connector to the ATC servo connector. Do not block the sensor aspirator exhaust port with the excess vacuum harness. Install the ATC sensor tube between the sensor and the evaporator connector.
  11. On 1990-00vehicles:
    1. Connect the ATC sensor tube to the evaporator case connector.
    2. Install the cross body brace and connect the wiring harness to the blend door actuator.
    3. Install the bolt to attach the lower right end of the instrument panel to the side cowl. Install the right side cowl trim panel and tighten the right door sill plate attaching screws.

  12. On 1988-1989 vehicles install the instrument panel pad and the glove compartment door.
  13. On 1990-99 vehicles, push the instrument panel back into position and install all instrument panel mounting screws. Install the right and left lower instrument panel insulators.
  14. Connect the vacuum supply hose(s) to the vacuum source.
  15. Install the right and left lower instrument panel insulators and install the 2 hush panels.
  16. Unplug the heater core tubes and the heater hoses and connect the heater hoses to the heater core tubes. Fill the cooling system.
  17. Connect the negative battery cable and check the system for proper operation.


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