Ford Falcon. Manual - part 304

412-02-20 Heating 

and 

Ventilation 412-02-20

REMOVAL AND INSTALLATION

Blower Fan Assembly

HVAC Assembly

Removal

Removal

1.  Disconnect electrical connector.

1.  Recover refrigerant from the A/C system. Refer to

2.  Undo three screws.

Section 412-03.

3.  Lower the Blower Fan assembly and remove.

2.  Drain engine coolant. Refer to Section 303-03.
3.  Disconnect A/C tubes, Refer to Section 412-03.

 CAUTION: Evaporator O-rings and tube

ends should be capped to prevent damage

and contamination.

4.  Disconnect Heater hoses.

 CAUTION: Cap the heater tube ends to

prevent coolant spillage onto the vehicle

interior.

5.  Remove Instrument Panel, Refer to Section

501-12.

6. Disconnect 

blower 

harness.

7.  Disconnect HIM main harness (power)
8.  Disconnect HIM main harness (control).

Item

Description

1

Electrical Connector

2

3  Screws

Installation
1.  Refit components in reverse order.

 CAUTION: Ensure correct alignment of

cooling air guide.

Item

Description

1

HIM Main power harness

2

Evaporator sensor elec connector

3

HIM Main control harness

9.  Undo the four nuts and two bolts used to retain

the HVAC Assembly mountings to the firewall.

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412-02-21 Heating 

and 

Ventilation 412-02-21

REMOVAL AND INSTALLATION (Continued)

10. Carefully work the firewall insulation off and over

Installation

each speed nut with a screw driver.

1.  Refit components in reverse order.

NOTE: A small amount of firewall insulation

around the mounting points may be damaged at

HVAC Case Scroll

removal stage, but this is not deemed to be a

problem.

Removal
1.  Undo one Screw (HIM).

11. Carefully remove the HVAC assembly from the

passenger side of the vehicle.
NOTE: On removal of the HVAC, if a large

section of firewall insulation is damaged, repair

before re-installing the HVAC Assembly.

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412-02-22 Heating 

and 

Ventilation 412-02-22

REMOVAL AND INSTALLATION (Continued)

2.  Remove two screws used to retain the tube shield

2.  Undo one Screw (Heater Tubes).

to HVAC.

3.  Undo five Screws (Case-Scroll).

3.  Remove shield-heater tubes.

4.  Remove Case Scroll.

4.  Slide out the Heater Core.

 CAUTION: Care should be taken when

withdrawing heater core to prevent bending of

pipes (High stress may result at joint between

tank and pipe if end of pipes used as

"handles")

Installation
1.  Refit all previously removed components in

reverse order.

 CAUTION: When inserting heater core

ensure that core "bottoms out" before fitting

shield heater tube. Also ensure that foam seal

is not distorted or damaged so as to affect

integrity of air seal between case and core.

Installation
1.  Refit components in reverse order.

Case Assy — Recirc Door Complete

 CAUTION: Ensure correct alignment

Removal

between tongue and groove of mating parts.

1.  Remove the HVAC Assembly.

Heater Core Assembly

Removal
1.  Remove HVAC Assembly, as outlined in the

Removal and Installation procedure in this

section.

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412-02-23 Heating 

and 

Ventilation 412-02-23

REMOVAL AND INSTALLATION (Continued)

2.  Remove Seal-A/C Tubes.

6.  Undo five Screws retaining the recirc door

housing to the HVAC Assembly.

3.  Remove one Screw from the A/C tube retaining

plate.

7.  Push in HIM Recirc Lever.

 CAUTION: Beware not to disengage slider

block from HIM recirc lever and ensure part is

greased when reassembled (see specifications

in this chapter).

Item

Description

1

Screw

2

AC tube retaining plate

4.  Remove Plate-A/C Tubes.

8. Remove 

Case-Recirc.

5.  Remove Mesh Filter and Cover Assembly or

Particle Filter as outlined in this section.

Installation
1.  Refit components in reverse order.

 CAUTION: Ensure correct alignment

between tongue and groove of mating parts.

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