Friday, March 16, 2012

How to Replace Heater Core On Ford F Series Trucks And Lincoln Mark?


The procedure is similar for both ford and Lincoln car models:-----

Removal & Installation Of heater core for ford F series truck and Lincoln Mark vehicles:----

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. If equipped with adjustable pedals, move the pedals to the full forward position.
  3. If equipped with a floor console:
    1. Remove the 3 floor trim panel push pins.
    2. Remove the 2 floor trim panels.
    3. Remove the shifter trim panel. 

      image
      Fig. Instrument panel exploded view-F-150 and Mark LT

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      Fig. Heater/Evaporator housing-F-150 and Mark LT


      Click image to see an enlarged view
      Fig. Floor console-F-150 and Mark LT


      Click image to see an enlarged view
      Fig. Driver-s air bag module-F-150 and Mark LT


      Click image to see an enlarged view
      Fig. Suction accumulator-F-150 and Mark LT


      Click image to see an enlarged view
      Fig. Heater core removal-F-150 and Mark LT


      Click image to see an enlarged view
      Fig. Clockspring-F-150 and Mark LT
    4. Disconnect the shifter cable.
    5. Disconnect the floor console electrical connector.
    6. Remove the 4 floor console bolts.
    7. Remove the floor console.
      CAUTION
      To reduce the risk of serious personal injury, read and follow all warnings, cautions, notes and instructions in the supplemental restraint system (SRS) deactivation/reactivation procedure.
  4. De-power the supplemental restraint system (SRS). For additional information, refer to Steering.
  5. Position the left and right door weatherstrip seals aside.
  6. Remove the A-pillar trim panels and right cowl side trim panel.
  7. Remove the left and right instrument panel side finish panels.
  8. Remove the 2 steering column opening trim screws.
  9. Remove the steering column opening trim.
    WARNING
    Removing the steering wheel without using a puller can damage the column bearings.


    WARNING
    Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and re-centered.
  10. Place the steering wheel in the straight-ahead position and turn the ignition switch to the OFF position.
    CAUTION
    Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.


    CAUTION
    Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.


    CAUTION
    Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment.


    CAUTION
    After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards.


    CAUTION
    Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.


    CAUTION
    Air bag modules with discolored or damaged trim covers must be replaced, not repainted.


    CAUTION
    To reduce the risk of personal injury, do not use any memory saver devices.


    NOTE
    The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.


    NOTE
    The SRS must be fully operational and free of faults before releasing the vehicle to the customer.


    NOTE
    Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.
  11. Remove the 2 steering wheel back cover plugs.
  12. Remove the 2 driver-s air bag module bolts.
  13. Partially remove the driver-s air bag module from the steering wheel.
    WARNING
    The clockspring electrical connectors are unique and cannot be reversed when connected to the driver-s air bag module. Match the electrical connector key to the keyway in the driver-s air bag module. Do not force the electrical connectors into the driver-s air bag module during installation.
  14. Disconnect the driver-s air bag module electrical connectors.
  15. Disconnect the horn switch electrical connector and remove the driver-s air bag module.
    NOTE
    Do not remove the bolt until the steering wheel has been separated from the column.
  16. Loosen the steering wheel bolt.
  17. Using a puller, separate the steering wheel from the steering column assembly.
  18. Remove the steering wheel bolt and the steering wheel.
  19. Remove the lower steering column cover screw.
  20. Remove the lower steering column cover.
  21. Remove the 2 upper steering column cover screws.
  22. Remove the upper steering column cover.
  23. Remove the instrument cluster finish panel.
  24. Remove the instrument panel center finish panel.
  25. Remove the instrument cluster center finish panel.
  26. Remove the parking brake release handle bolt.
  27. Position aside the parking brake release handle. Remove the parking brake release handle pin-type retainer.
  28. Remove the hood release handle bolt.
  29. Position aside the hood release handle.
  30. Loosen the electrical connector screw and disconnect the bulkhead electrical connector.
  31. Remove the ground bolt.
  32. Disconnect the electrical connectors.
  33. Position aside the front carpet.
  34. Remove the 4 left center brace bolts.
  35. Remove the left center brace.
  36. If equipped, disconnect the transmission range indicator cable and position aside.
    WARNING
    To avoid damage to the clockspring, do not allow the steering column shaft to rotate while the intermediate shaft is disconnected.
  37. Remove the steering column pinch bolt and disconnect the steering column intermediate shaft.
  38. Disconnect the steering column electrical connector.
  39. Remove the ground bolt.
  40. Disconnect the radio antenna.
  41. Disconnect the 4 PDB (B1, B2, L1 and L2) electrical connectors.
  42. Disconnect the ETAC electrical connector.
  43. Disconnect the instrument panel electrical connectors.
  44. Position aside the front carpet.
  45. Remove the 4 right center brace bolts.
  46. Remove the right center brace.
    NOTE
    If equipped with a floor console, remove the third center brace.
  47. If equipped, remove the 4 third center brace bolts.
  48. If equipped, remove the third center brace.
  49. Remove the 2 defrost grilles.
  50. Disconnect the wiring harness pin-type retainer.
    WARNING
    To avoid damage to the instrument panel, an assistant is required to support the panel before carrying out this step.
  51. Remove the 9 instrument panel bolts.
    WARNING
    Before removing the instrument panel, make sure all electrical connector wiring is free and not hindered.
  52. Remove the instrument panel.
    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.
  53. Recover the refrigerant.
  54. Remove the powertrain control module (PCM).
  55. Remove the battery and battery tray.
  56. Remove the PCM bracket.
  57. Remove the suction accumulator outlet fitting nut and disconnect the fitting.
  58. Discard the O-ring seal.
  59. Disconnect the suction accumulator inlet fitting. Discard the O-ring seals.
  60. Remove the 2 suction accumulator bracket nuts.
  61. Remove the suction accumulator.
  62. Disconnect the evaporator core spring lock coupling. Discard the O-ring seals.
  63. Clamp off and disconnect the 2 heater core quick disconnect fittings.
  64. Remove the 3 heater core and evaporator core housing nuts.
  65. Disconnect the 2 harness electrical connectors.
  66. Remove the air inlet duct bracket nut.
  67. Remove the bolt and position the junction box aside.
  68. Loosen the nut and remove the heater core and evaporator core housing.
  69. Remove the dash panel seal from the heater core tubes.
  70. Position the temperature blend door actuator aside.
  71. Remove the heater core cover.
  72. Remove the heater core.
    NOTE
    The heater core seal must be correctly installed to prevent airflow from bypassing the heater core.


    CAUTION
    Incorrect centralization may result in premature component failure. If in doubt when centralizing the clockspring, repeat the centralizing procedure. Failure to follow this instruction may result in personal injury.


    WARNING
    Make sure the road wheels are in the straight-ahead position.
  73. If the vehicle's clockspring has rotated out of center, follow these steps to center the clockspring.
    1. Hold the clockspring outer housing stationary.
      WARNING
      Overturning will destroy the clockspring. The internal ribbon wire acts as the stop and can be broken from its internal connection.
    2. While turning the rotor counterclockwise, carefully feel for the ribbon wire to run out of length and for a slight resistance. Stop turning at this point.
    3. Turn the clockspring clockwise approximately 3 turns. This is the center point of the clockspring. Do not allow the rotor to turn from this position. To prevent accidental rotation until the clockspring is installed, 2 pieces of tape may be applied to the clockspring.
      NOTE
      Slight turning of the clockspring rotor is allowable for alignment purposes to the steering column.
    4. With the flats of the clockspring aligned to the flats of the steering column, slide the clockspring onto the steering column. For vehicles receiving a new clockspring, remove the retaining pin. For vehicles reusing the clockspring that was removed, remove the tape.
  74. To install, reverse the removal procedure. Evacuate, charge and leak test the system. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil.
  75. Observe the following torques:

    Heater core nut: 62 inch lbs. (7 Nm)
    Air inlet duct bracket: 62 inch lbs. (7 Nm)
    Heater core and evaporator core housing nuts: 80 inch lbs. (9 Nm)
    Suction accumulator bracket nuts: 53 inch lbs. (6 Nm)
    Suction accumulator outlet fitting nut: 71 inch lbs. (8 Nm)
    PCM bracket: 89 inch lbs. (10 Nm)
    Instrument panel bolts: 15 ft. lbs. (20 Nm)
    Steering column pinch bolt: 30 ft. lbs. (40 Nm)
    Steering wheel bolt and the steering wheel: 30 ft. lbs. (40 Nm)
    Driver-s air bag module bolts: 89 inch lbs. (10 Nm)
  76. Fill the engine cooling system.
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Clamp off and disconnect the heater water hoses from the heater core.
  3. Disengage the stops and lower the glove compartment door.
    NOTE
    Do not attempt to bend any part of the panel/floor door lever. It is brittle and will break.
  4. Remove the panel/floor door vacuum control motor.
  5. Remove the electronic blend door actuator and bracket assembly.
  6. Remove the core cover screws.
    NOTE
    The heater core cover must be raised vertically before removal to avoid damage to the heater core housing.



    Click image to see an enlarged view
    Fig. Remove the heater core cover-F-250 and F-350


    Click image to see an enlarged view
    Fig. Remove the heater core-F-250 and F-350
  7. Raise the heater core cover.
  8. Remove the heater core cover.
  9. Remove the heater core.
    NOTE
    Position the temperature blend door manually to correctly align the actuator and the door. Do not power the actuator electrically. If it is not engaged with the temperature blend door, damage to the actuator can occur.


    NOTE
    Add gasket between housing and cover before installing cover.
  10. To install, reverse the removal procedure.
  11. Fill the engine cooling system.


These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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