AutoZone 2006 Lexus Truck GX470 4.7L SFI DOHC 8cyl | Repair Guides | Heating & Air Conditioning | Heater Core | Removal & Installation 2 | AutoZone.com

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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Removal & Installation 2

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    1998-01 Ford Windstar



    Removal & Installation
    Front System
    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Remove the cowl top vent panel for clearance.
    6.  
    7. Disconnect the heater hoses from the heater core inlet and outlet tubes in the engine compartment.
    8.  
    9. Remove the cassette box/center instrument support trim.
    10.  
    11. Pull out and remove the ashtray cup holder by depressing the service lever.
    12.  
    13. Remove the floor/rear seat lower air duct.
    14.  
    15. Disconnect the keyless entry wiring harness, if equipped.
    16.  
    17. Remove the center instrument panel support brackets.
    18.  
    19. Disconnect the climate control vacuum harness connector.
    20.  
    21. Remove the heater floor/rear seat upper air duct.
    22.  
    23. Remove the heater core cover retaining screws and remove the heater core cover.
    24.  
    25. Remove the heater core.
    26.  
    27. Remove the seal from the heater core tubes and discard.

      Click image to see an enlarged view

      Fig. Front heater housing assembly-Ford Windstar



      Click image to see an enlarged view

      Fig. Be careful when removing the hoses from the heater core, as the tubes are easily damaged-Ford Windstar



      Click image to see an enlarged view

      Fig. The center instrument panel is attached using special plastic screws-Ford Windstar



      Click image to see an enlarged view

      Fig. The rear seat airflow duct carries air to the rear of the passenger compartment-Ford Windstar



      Click image to see an enlarged view

      Fig. The instrument panel support bracket must be removed to lower the heater core-Ford Windstar



      Click image to see an enlarged view

      Fig. The heater outlet floor duct is attached to the bottom of the housing core-Ford Windstar



      Click image to see an enlarged view

      Fig. The heater core is located in a box at the bottom of the housing core-Ford Windstar



      Click image to see an enlarged view

      Fig. A foam liner is used to cushion the heater core-Ford Windstar

    28.  

    To install:

    1. Install the seal to the heater core tubes and discard.
    2.  
    3. Install the heater core.
    4.  
    5. Install the heater core cover and the heater core cover retaining screws.
    6.  
    7. Install the heater floor/rear seat upper air duct.
    8.  
    9. Connect the climate control vacuum harness connector.
    10.  
    11. Install the center instrument panel support brackets.
    12.  
    13. Connect the keyless entry wiring harness, if equipped.
    14.  
    15. Install the floor/rear seat lower air duct.
    16.  
    17. Install the ashtray cup holder by depressing the service lever.
    18.  
    19. Install the cassette box/center instrument support trim.
    20.  
    21. Connect the heater hoses to the heater core inlet and outlet tubes in the engine compartment.
    22.  
    23. Install the cowl top vent panel for clearance.
    24.  
    25. Refill the cooling system.
    26.  
    27. Connect the negative battery cable.
    28.  
    29. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    30.  

    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Remove the cowl top vent panel for clearance.
    6.  
    7. Disconnect the heater hoses from the heater core inlet and outlet tubes in the engine compartment.
    8.  
    9. Remove the cassette box/center instrument support trim.
    10.  
    11. Pull out and remove the ashtray cup holder by depressing the service lever.
    12.  
    13. Remove the floor/rear seat lower air duct.
    14.  
    15. Disconnect the keyless entry wiring harness, if equipped.
    16.  
    17. Remove the center instrument panel support brackets.
    18.  
    19. Disconnect the climate control vacuum harness connector.
    20.  
    21. Remove the heater floor/rear seat upper air duct.
    22.  
    23. Remove the heater core cover retaining screws and remove the heater core cover.
    24.  
    25. Remove the heater core.
    26.  
    27. Remove the seal from the heater core tubes and discard.

      Click image to see an enlarged view

      Fig. Front heater housing assembly-Ford Windstar



      Click image to see an enlarged view

      Fig. Be careful when removing the hoses from the heater core, as the tubes are easily damaged-Ford Windstar



      Click image to see an enlarged view

      Fig. The center instrument panel is attached using special plastic screws-Ford Windstar



      Click image to see an enlarged view

      Fig. The rear seat airflow duct carries air to the rear of the passenger compartment-Ford Windstar



      Click image to see an enlarged view

      Fig. The instrument panel support bracket must be removed to lower the heater core-Ford Windstar



      Click image to see an enlarged view

      Fig. The heater outlet floor duct is attached to the bottom of the housing core-Ford Windstar



      Click image to see an enlarged view

      Fig. The heater core is located in a box at the bottom of the housing core-Ford Windstar



      Click image to see an enlarged view

      Fig. A foam liner is used to cushion the heater core-Ford Windstar

    28.  

    To install:

    1. Install the seal to the heater core tubes and discard.
    2.  
    3. Install the heater core.
    4.  
    5. Install the heater core cover and the heater core cover retaining screws.
    6.  
    7. Install the heater floor/rear seat upper air duct.
    8.  
    9. Connect the climate control vacuum harness connector.
    10.  
    11. Install the center instrument panel support brackets.
    12.  
    13. Connect the keyless entry wiring harness, if equipped.
    14.  
    15. Install the floor/rear seat lower air duct.
    16.  
    17. Install the ashtray cup holder by depressing the service lever.
    18.  
    19. Install the cassette box/center instrument support trim.
    20.  
    21. Connect the heater hoses to the heater core inlet and outlet tubes in the engine compartment.
    22.  
    23. Install the cowl top vent panel for clearance.
    24.  
    25. Refill the cooling system.
    26.  
    27. Connect the negative battery cable.
    28.  
    29. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    30.  

    Rear Auxiliary System
    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Discharge and recover the rear auxiliary air conditioning refrigerant.
    6.  
    7. Raise and support the vehicle safely.
    8.  
    9. Place a drain pan under the heater water hose connections for the rear heater assembly.
    10.  
    11. Drain and recycle the engine coolant from the auxiliary heater core and hoses.
    12.  
    13. Disconnect the 2 air conditioning spring lock couplings using a quick disconnect coupling tool.
    14.  
    15. Lower the vehicle.
    16.  
    17. Remove all rear passenger-s seating.
    18.  
    19. Remove the 3 push pin retainers from the lower edge of the auxiliary heater and air conditioning service cover.
    20.  
    21. Lift the service cover outward and upward to remove.
    22.  
    23. Label and disconnect the electrical harnesses.
    24.  
    25. Label and disconnect the vacuum lines.
    26.  
    27. Remove the body side trim panels.
    28.  
    29. Disconnect and plug all air conditioning refrigerant lines.
      NOTE
      It is extremely important that the air conditioning lines be plugged to prevent the entry of dirt or moisture.

    30.  
    31. Remove the lower air conditioning recirculation air duct and heater extension air duct.
    32.  
    33. Remove the auxiliary heater and air conditioning assembly.
    34.  
    35. Remove the housing cover screws and the cover.
    36.  
    37. Remove the heater core and the heater core case seal.

      Click image to see an enlarged view

      Fig. Rear heater and air conditioning assembly-Ford Windstar



      Click image to see an enlarged view

      Fig. Rear heater housing assembly-Ford Windstar

    38.  

    To install:

    1. Install the heater core and the heater core case seal.
    2.  
    3. Install the housing cover and screws.
    4.  
    5. Position the auxiliary heater and air conditioning assembly in the vehicle. Guide the heater water hoses through the floor grommet. Tighten the retaining screws to 16-23 inch lbs. (2-3 Nm).
    6.  
    7. Connect all air conditioning refrigerant lines.
    8.  
    9. Install the lower air conditioning recirculation air duct and heater extension air duct. Tighten the retaining screws to 16-23 inch lbs. (2-3 Nm).
    10.  
    11. Install the body side trim panels.
    12.  
    13. Connect the vacuum lines.
    14.  
    15. Connect the electrical harnesses.
    16.  
    17. Install the auxiliary heater and air conditioning service cover and secure with 3 push pin retainers.
    18.  
    19. Install all rear passenger-s seating.
    20.  
    21. Raise and support the vehicle safely.
    22.  
    23. Connect the heater water hoses to the heater core tubes.
    24.  
    25. Lower the vehicle.
    26.  
    27. Refill the cooling system.
    28.  
    29. Connect the negative battery cable.
    30.  
    31. Evacuate and charge the rear auxiliary air conditioning refrigerant.
    32.  
    33. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    34.  

    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Discharge and recover the rear auxiliary air conditioning refrigerant.
    6.  
    7. Raise and support the vehicle safely.
    8.  
    9. Place a drain pan under the heater water hose connections for the rear heater assembly.
    10.  
    11. Drain and recycle the engine coolant from the auxiliary heater core and hoses.
    12.  
    13. Disconnect the 2 air conditioning spring lock couplings using a quick disconnect coupling tool.
    14.  
    15. Lower the vehicle.
    16.  
    17. Remove all rear passenger-s seating.
    18.  
    19. Remove the 3 push pin retainers from the lower edge of the auxiliary heater and air conditioning service cover.
    20.  
    21. Lift the service cover outward and upward to remove.
    22.  
    23. Label and disconnect the electrical harnesses.
    24.  
    25. Label and disconnect the vacuum lines.
    26.  
    27. Remove the body side trim panels.
    28.  
    29. Disconnect and plug all air conditioning refrigerant lines.
      NOTE
      It is extremely important that the air conditioning lines be plugged to prevent the entry of dirt or moisture.

    30.  
    31. Remove the lower air conditioning recirculation air duct and heater extension air duct.
    32.  
    33. Remove the auxiliary heater and air conditioning assembly.
    34.  
    35. Remove the housing cover screws and the cover.
    36.  
    37. Remove the heater core and the heater core case seal.

      Click image to see an enlarged view

      Fig. Rear heater and air conditioning assembly-Ford Windstar



      Click image to see an enlarged view

      Fig. Rear heater housing assembly-Ford Windstar

    38.  

    To install:

    1. Install the heater core and the heater core case seal.
    2.  
    3. Install the housing cover and screws.
    4.  
    5. Position the auxiliary heater and air conditioning assembly in the vehicle. Guide the heater water hoses through the floor grommet. Tighten the retaining screws to 16-23 inch lbs. (2-3 Nm).
    6.  
    7. Connect all air conditioning refrigerant lines.
    8.  
    9. Install the lower air conditioning recirculation air duct and heater extension air duct. Tighten the retaining screws to 16-23 inch lbs. (2-3 Nm).
    10.  
    11. Install the body side trim panels.
    12.  
    13. Connect the vacuum lines.
    14.  
    15. Connect the electrical harnesses.
    16.  
    17. Install the auxiliary heater and air conditioning service cover and secure with 3 push pin retainers.
    18.  
    19. Install all rear passenger-s seating.
    20.  
    21. Raise and support the vehicle safely.
    22.  
    23. Connect the heater water hoses to the heater core tubes.
    24.  
    25. Lower the vehicle.
    26.  
    27. Refill the cooling system.
    28.  
    29. Connect the negative battery cable.
    30.  
    31. Evacuate and charge the rear auxiliary air conditioning refrigerant.
    32.  
    33. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    34.  

     
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