Service Guide Heater with Air Conditioning E-Series Ford Aeromaster Contents Blower Motor...2 Plenum Removal...3 Control Module...6 Servo Motors...8 Coolant Valve and Servo Motor...8 Evaporator Recirculation Servo Motor...11 Evaporator Assembly...12 Evaporator and Heater Cores...14 Plenum Installation...18 Condensor...24 Dryer...24 Trinary Switch...25 1
Blower Motor 1. Remove the six screws to replace the blower motor. NOTE: The blower wheel can be reused or replaced. Screw Hose Vent Tube Blower Motor Blower Wheel Adapter Vent Tube Blower Housing Foam Gasket Ring Blower motor assembly 2
WARNING: Utilimaster recommends the only a licensed/certified automotive technician services the vehicle's air-conditioning system. WARNING: Always wear safety glasses and other proper protective equipment (gloves, hearing protection, etc.) as appropriate to the process. WARNING: Batteries that are improperly connected can potentially explode and discharge acid, causing vehicle damage and personal injury. Refer to the chassis manufacturer s instructions. Battery posts and related accessories may contain lead and lead compounds. Wash hands after handling. Always wear proper protective equipment when working around batteries. CAUTION: Keep all fasteners for reinstallation unless otherwise noted. Plenum Removal NOTE: This process does not require opening the engine coolant system or evacuating the HVAC system. NOTE: This document does NOT address removing work tables, cup holders, or other optional equipment to gain access to the plenum. NOTE: Keep all fasteners for reinstallation unless noted otherwise. 1. Read and understand all the instructions before starting the repair. 2. Turn ignition switch off and remove the keys. 3. Disconnect the vehicle Negative (BLACK) battery cable(s). 4. Secure the battery cable(s) away from the terminal to prevent accidental contact. 3
5. Use a 9/16" socket wrench to remove (4) nuts and washers connecting the heater plenum studs to the cowl. Cowl fasteners under hood 6. Remove fasteners from the dash cover, instrument panel and fuse cover. Dash fasteners 7. Remove fasteners from the right-hand defrost duct. Pull away from transition duct and set aside. Defrost duct fasteners 4
8. Remove the transition duct from the plenum-cowl area. Transition duct 9. Note or label wire connections before removal. 10. Disconnect (2) thermostatic switch connectors and the blower motor resistor connector from the top, outboard side of the evaporator assembly. Thermostatic switch and blower motor resistor connectors 11. Note or label the hose configuration before removal. 12. Remove (3) duct hoses from plenum. Release clamp attaching foot dump hose to plenum. Plenum duct hoses 5
Control Module 13. Carefully cut wire ties securing wire harness connectors and control module. 14. Unplug (2) connectors from the main dash wire harness to the plenum harness. Plenum wire harness connectors 15. Unplug (3) connectors to the control module harness. NOTE: Leave the HVAC control module wire harness connected to the module. HVAC control module 16. Disconnect the blower motor power supply. Blower motor power supply 6
17. Disconnect the recirculating servo motor connector located between the engine cover and the evaporator unit. Recirculating servo motor connector 18. Remove the heater plenum unit with blower motor from the vehicle. 7
Servo Motors NOTE: There are three servo motors on the plenum that can be replaced. Armature Dash Vents Driver s Feet Servo motor locations Defrost 1. Remove the three nuts securing the motor. 2. Pull the motor straight out away from the plenum. 3. Disconnect the wire harness. Coolant Valve and Servo Motor NOTE: The heater valve servo motor is mounted on the radiator shroud. Heater valve on radiator shroud 8
1. Move all heater controls to the OFF or COLD positions. 2. Place a catch pan under the vehicle for any coolant leakage. 3. Remove enough of the quick ties, P-clamps, and protective convoluted tubing to allow access to the hose clamps and to remove the heater valve. Position the hose far enough into the clamp jaws so that leading edges of the clamp do NOT bite into the hose 4. To minimize the loss of coolant when the system is opened, clamp both hoses to and from the valve. Be careful not to nick, cut, or otherwise damage the hoses when clamping. 5. Loosen the hose clamps and disconnect the hoses from the valve. 6. Remove only the (2) UPPER Hex-head fasteners that release the assembly from the mounting bracket. Hex-head fasteners shown on the shroud-mounted assembly 9
7. Disconnect the wire harness. 8. Install the replacement valve or servo motor. 9. Connect the harness to the replacement motor. 10. Attach the hoses and secure the hose clamps to 36 44 in-lbs. 11. Release the locking pliers. 12. Clean up any coolant spill. 13. Start the engine and check the heater controls for full operation. 14. Check for coolant leaks. 15. Read the chassis provided owner s manual on how to check the coolant level and for proper replacement requirements. Loss of engine coolant should be minimal, but it is IMPORTANT to check and refill as necessary. 10
Evaporator Recirculation Servo Motor 1. Remove the screws securing the cover and remove the cover. 2. Remove the three nuts securing the motor. 3. Pull the motor straight out away from the plenum. 4. Disconnect the wire harness. Servo Motor Recirculation servo motor evaporator 11
Evaporator Assembly Removal 1. Remove the fresh intake duct. Fresh intake duct 2. Remove the foam around the expansion valve, the tubes of the heater core, and the four evaporator assembly studs. 3. Remove the four evaporator assembly studs. Evaporator assembly under the hood 12
Installation 1. Install the four evaporator studs. 2. Place foam around the expansion valve, the tubes of the heater core, and the four evaporator assembly studs. 3. Install the fresh intake duct. Evaporator assembly under the hood Fresh intake duct 13
Evaporator and Heater Cores Evaporator assembly CAUTION: The capillary tube is filled with gas and very fragile. Use caution when removing. Removal NOTE: The evaporator assembly housing must be removed from the vehicle before the evaporator or heater core can be removed. 1. Drain the air-conditioning system of all refrigerant and disconnect air-conditioning hoses from the expansion valve located under the hood on the firewall. 2. Remove screws along the top and sides of the evaporator assembly housing. 3. Remove screws holding the thermostat to the top plate. 14
4. Remove the top plate from the evaporator assembly housing. Top plate removed 5. Remove screws from the front plate and remove the front plate. 6. Remove the foam covering the screws on the bottom plate. 7. Remove the screws holding the bottom plate to the evaporator. 8. Remove the foam around the inlet and outlets of the heater and evaporator cores. 9. Disconnect the orifice tube from the clip on the evaporator outlet and hold the orifice's as you remove the core. Remove foam 15
10. Unscrew the expansion valve from the evaporator inlet. 11. Carefully remove the evaporator or heater core from the evaporator assembly housing. Installation Evaporator core Heater core 1. Carefully insert the evaporator or heater core into the evaporator assembly housing. Evaporator core Heater core 16
2. Connect the expansion valve to the evaporator inlet. 3. Connect the orifice tube to the evaporator outlet. 4. Place the foam around the inlet and outlets of the heater and evaporator cores. Replace foam 5. Place the bottom plate on the evaporator assembly housing and insert screws. 6. Place the foam around the screws. 7. Attach the servo switch cover. 8. Secure the front plate on the evaporator assembly housing with screws. 9. Secure the top plate onto the evaporator assembly housing with screws. 10. Attach the thermostat to the top plate. 11. Insert screws into the top and sides of the evaporator assembly housing. Thermostat 17
Plenum Installation CAUTION: Plenum spacers vary for top and bottom studs on some models. Be sure to install spacers in the same location on the replacement plenum. NOTE: The blower motor, foot dump hose adaptor, and plenum spacers can be reused on the replacement plenum. 1. Remove (6) fasteners, (3) fasteners per side, that join the blower motor to the plenum and install on replacement plenum. Blower motor fasteners Plenum Prep 2. Remove fasteners from driver foot dump (part varies between chassis), remove the cap plug, and install on replacement plenum. Driver foot dump and cap plug 18
NOTE: Driver foot dump will vary with chassis. 3. Use pliers to remove (4) retaining clips from the plenum spacers. Plenum spaceres and fasteners 4. Remove spacers from plenum studs and install on replacement plenum using new clips. 5. Carefully place the plenum assembly on the evaporator assembly and engine cover, and insert studs through cowl. NOTE: Make sure to seat the blower motor foam gasket against the top of the evaporator assembly. Cowl fasteners 19
6. Secure to the cowl using (4) nuts and washers. 7. Connect blower motor power supply. Blower motor power supply 8. Connect thermostatic switches and the blower motor resistor. Thermostatic switch connectors 9. Attach (2) plenum harness connectors to the main wire harness. Plenum harness connectors 20
10. Secure (3) connectors to control module harness. HVAC control module 11. Connect duct hoses to the plenum. Tighten clamp that connects hose to the foot dump. Duct hoses 12. Connect the Negative (BLACK) battery cable(s). 21
Test System 1. Start engine to test system functions. Confirm all vents operate correctly. Turn AC controls to max setting to confirm compressor operation. 2. Secure all harnesses and the HVAC control module with wire ties. 3. Install the transition duct. AC controls Transition duct 4. Install the defrost duct on the transition duct and secure to the cowl. Defrost duct installation 22
5. Secure the dash cover, instrument panel and the fuse cover. Dash cover installation Dash fasteners 23
Condensor Dryer NOTE: The condenser is a Ford chassis component. Refer to the Ford service information or your local dealer. NOTE: It is strongly recommended that the dryer be replaced whenever the system is opened for service. NOTE: It is strongly recommended that the expansion valve be replaced when along with the dryer. 1. Evacuate the air-conditioning system of all refrigerant. 2. Disconnect air-conditioning hoses from dryer. 3. Remove trinary switch. 4. Remove two screws from dryer mounting bracket and set aside. Dryer location under the hood 24
Trinary Switch The trinary switch is located on the dryer. The switch has three functions: high pressure cut-out, low pressure cut-out, and condenser fan operation. Removal 1. Disconnect wire harness. 2. Remove switch by turning counterclockwise and set aside. Installation 1. Lubricate rubber seal inside switch with mineral oil. 2. Secure switch by turning clockwise. 3. Connect wire harness. Trinary switch on dryer 25
Dryer Installation NOTE: It is strongly recommended that the expansion valve be replaced when along with the dryer. 1. Install trinary switch. 2. Lubricate two new #6 O-rings and attach to dryer. 3. Secure dryer hoses. 4. Secure dryer with two screws. 5. Charge air-conditioning system with 35 ounces of refrigerant. 6. Start vehicle and check air-conditioning performance. Dryer location under the hood Utilimaster Customer Service 574-848-2200 Email: Parts@Utilimaster.com Heating with Air Conditioning E-Series Ford Aeromaster Document Part Number 03103436-A10003 March 2015 Utilimaster Corp., 603 Earthway Boulevard, Bristol, Indiana 46507 USA 26