1With the heater unit removed from the
vehicle, remove the two securing screws and
withdraw the heater matrix from the casing
(see illustrations).
2Cut the heater casing gasket in line with the
casing joint, then use two suitable
screwdrivers to prise off the retaining clips
and separate the casing halves. Withdraw the
lower part of the casing to the side.
3Remove the air flap valves, then press the
control levers from the casing. Note that the
“up/down” control lever can only be removed
when the marks are aligned as shown (see
illustration).
4Clean all components and hose through the
matrix to remove any debris. If necessary usea chemical cleaner to clear the inner passage
of the matrix. Renew the components as
necessary.
5Reassembly is a reversal of dismantling.
Removal
1Disconnect the battery negative lead.
2Where necessary, unclip the brake servo
vacuum hose for improved access.
3On models from 1987, unclip the
windscreen washer hoses and wiring from the
motor cover, and secure them to the
bodywork out of the way.
4Unscrew the two securing bolts from the
motor cover, pull off the rubber moulding,
then withdraw the cover (see illustration).
5Disconnect the wiring from the motor, and
detach the earth lead from its bracket. 6Unscrew the two motor securing nuts, and
withdraw the motor assembly (see illustration).
7Unclip the casing halves, then prise open
the motor retaining strap using a screwdriver,
or if necessary a drift.
8Detach the wiring from the motor, then
remove the motor and fan wheels from the
casing. Refitting
9Refitting is a reversal of removal.
1Only those items which can be renewed
without discharging the system are described
here(see illustration).Other items must be
dealt with by a Ford dealer or air conditioning
specialist.
21Air conditioning system -
component renewal
20Heater motor - removal and
refitting
19Heater unit - overhaul
3•10Cooling, heating and air conditioning systems
19.1a Remove the securing screws . . .19.3 Heater “up/down” control lever must
be aligned as shown before removal
Note that the cross marks are for right-hand
drive vehicles
1 De-ice thermostat
2 Evaporator
3 Expansion valve
4 Compressor
5 Compressor clutch6 Pressure switch
7 Sight glass
8 Dehydrator/collector
9 Cooling fan
10 Condenser
21.1 Layout of air conditioning system components
20.6 Heater motor and wiring
20.4 Unscrew the securing bolts and
withdraw the heater motor cover
19.1b . . . and withdraw the heater matrix
Compressor drivebelt
2Disconnect the battery negative lead.
3On SOHC models, remove the thermo-
viscous cooling fan.
4Slacken the compressor mounting and
pivot bolts, move the compressor towards the
engine and remove the old drivebelt (see
illustration).
5Fit the new drivebelt, position the
compressor to achieve the correct belt
tension, then tighten the mounting and pivot
bolts.
6On SOHC models, refit the thermo-viscous
cooling fan.
7Reconnect the battery negative lead.
Condenser fan and motor
Models up to 1987
8Disconnect the battery negative lead, and
remove the radiator grille. On Ghia models,
remove the front bumper.9Disconnect the fan wiring connector at the
side of the condenser.
10Remove the three securing bolts and
withdraw the fan assembly. Turn the frame to
position the fan wiring on the dehydrator side
to avoid damaging the wiring. Take care also
not to damage the condenser fins or tube.
11To remove the fan blades from the motor,
remove the retaining nut and circlip. The nut
has a left-hand thread, ie, it is undone in a
clockwise direction.
12With the blades removed, the motor can
be unscrewed from the frame.
13Reassemble and refit in the reverse order
of dismantling and removal.
Models from 1987
14Disconnect the battery negative lead.
15Remove the bonnet lock.
16Unclip the guard from the fan frame.
17Disconnect the fan wiring connector (see
illustration).
18Apply the handbrake, jack up the front of
the vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
19Unscrew the two lower condenser
securing bolts and disengage the condenser
from the top of the radiator by releasing the
three clips.
20Unscrew the four securing bolts and
detach the fan assembly from the condenser.
Withdraw the fan assembly from underneath
the vehicle.
21Proceed as described in paragraphs 11 to
13 inclusive.
De-ice thermostat
22Disconnect and remove the battery.23Disconnect any vacuum hoses,
windscreen washer hoses and electrical
wiring as necessary, then unscrew the four
securing bolts and on models up to 1987 the
single nut, and remove the right-hand plenum
chamber cover plate from the bulkhead.
24Disconnect the thermostat from the
evaporator casing and withdraw it. Also
withdraw the thermostat probe from the
casing.
25Refitting is a reversal of removal.
Heating/air conditioning controls
26The procedure is similar to that described
for the heater controls but additionally the
vacuum hoses must be disconnected from
the control unit vacuum valve during removal,
and reconnected when refitting.
Cooling, heating and air conditioning systems 3•11
3
21.17 Air conditioning condenser fan
wiring connector location (arrowed) -
models from 198721.4 Typical air conditioning compressor
mounting and pivot bolts (arrowed)
