VENTILATING SYSTEM AND HEATER - Mustang - ventilation.pdf · heater case assembly to service ma- ature door in the heater housing jor components of the heater assem- from minimum

PAGE16-20

PART 16-1VENTILATING SYSTEM AND

HEATER PART 16-2

AIR CONDITIONING-FORD .16-10

PAGE PART 16-3AIR CONDITIONING-SELECTAIRE

PART 16-4RADIO. . . . . . . . . . . . . . . . . . . . . .

PART 16-5SPECIFICATIONS

.16-1

16-26

16-29

SYSTEM AND HEATERVENTILATING

PageHeater Hose Routing 16-7Heater Hose Replacement. . . . . . . . . . . . . . .16-7Bleeding Air From Heater Core. . . . . . . .. .16-7

4 Removal and Installation. . . . . . . . . . . . . . . . . .16-7Heater-Mustang 16-7Heater Core-Mustang 16-8Heater Control Assembly-Fairlane .16-8Heater Control Assembly-Falcon. . . . . . . . . .16-8Heater Control Assembly-Comet .16-8Discharge Air Registers .16-8Defroster Nozzles-Comet, Falcon and

Fairlane 16-8Heater Core Assembly-Comet,

Falcon and Fairlane 16-8Blower Motor and Wheel Assembly-

Comet, Falcon and Fairlane "... .16-8Heater Blower-Mustang .16-8Defroster Nozzles-Mustang .16-9Blower Switch-Mustang. . . . . . . . . . . . . . . . . . 16-9

Section Page1 Description and Operation. . . . . . . . . . . . . . . . .16-1

Ventilating and Heating System-Comet,Falcon and Fairlane 16-1

Ventilating and Heating System-Mustang. . . .16-22 Diagnosis and Testing 16-6

Ventilating and Heating Trouble DiagnosisGuide 16-6

Heater Current Draw Test. . . . . . . . . . . . . . . . .16-6Loose Motor Fan Test 16-6Blower Switch Test 16-6Plugged Heater Core Test. . . . . . . . . . . . . . . . . . 16-6

3 Common Adjustments and Repairs .16-6Ventilating System 16-6Heating System 16-6

Control Adjustments-Mustang. . . . . . . . . . .16-6Bowden Cable Adjustments-Comet,

Falcon and Fairlane 16-7Blower Motor Electrical Circuit-

Comet. Falcon and Fairlane . . . . . . . . . .. ..~ .

Section

1 {;- 7

DESCRIPTION AND OPERATION-VENTILATING AND HEATING discharge air register or defrosterSYSTEM-COMET, FALCON outlets (Fig. 2).AND FAIRLANE The air temperature is controlled

The 1966 heater is a blend air by the position of the temperaturesystem connected to an opening in air valve, or door, located betweenthe right vent air duct. The entire the blower and heater core in theheater assembly is located under the heater housing. As the temperatureinstrument panel and it is necessary lever is moved from LOW to HIGH;to remove the right air vent duct and a Bowden cable moves the temper-heater case assembly to service ma- ature door in the heater housingjor components of the heater assem- from minimum heat to full heat po-bly (Fig. 1). sition to modulate the air flow

Outside air is drawn into the ve- through and/ or around the heaterhicle from the cowl through the core. The air through the core andright air duct, into the blower hous- the air through the bypass chambering, forced through and/ or around is then mixed as it enters the plenumthe heater core, mixed, and then dis- chamber.charged through the outlets in the A heater air valve, referred to as

the heat-defrost door, is located inthe plenum chamber to control thedischarge air between heat and de-frost, and close off all air in the OFFposition. The heat-defrost lever ac-tuates a Bowden cable connected tothe heater air valve in the plenumchamber. Air flow through the ple-num is directed, as required by theoperator, through the discharge airoutlets in the plenum, in the heatposition; or up to the windshield inthe defrost position. The air flowcan also be modulated by setting thecontrols in any position betweenheat and defrost.

A single defroster nozzle leads to

16-2 GROUP 16 VENTilATING, HEATING, AND ACCESSORIES

DEFR.QSTER ~OZZLE FORFAIRLANE AND FALCON

~A '~ .-= A :;::::;;..:.t~~~-~

~~@ / ---

REFER TO FIGURE 6VIEW 6 FOR (:OMETNOZZLE ~.: -

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II

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~ /Ii ~ -{.1~

HEATER TEMPERATURE

CAS:, DOOR~~AN~(~~M,",,;' ,'HEAi.DEF~;OS¥

CRANK ARM

--A LIGN CRANK AR'M ~!WITH DAR:f'f,DR'HEAT PDSITION

, 'SEE FIGURi 6VIEW A K1644-A

l-Heater Assembly-Comet, Falcon and Fairlane

DEFROSTI:R DUTLeTtBLOWER MOTOR

rB~27kEAT.DEFR~T, bOOR

"'-"

~~~:;;..,- ~~~d~', ~

",;~

vers and the blower switch (Fig. 4).The Comet heater controls are lo-

cated to the left of the steering col-umn in the lower instrument panelarea. The dial for the Caliente andCyclone models are illuminated withone bulb; the Capri and 202 modeldoes not have an illuminated dial(Fig. 5).

In order to provide adequate airdistribution on all vehicles, two airdistribution register assemblies areprovided. All vehicles equipped withconsoles or economy air condition-ing is equipped with a register thatdistributes the air to the left andright of the tunnel area. The registerfor standard vehicles has air outletsacross the face of the register and asmall outlet on the lower left end(View A, Fig. 9).

--'\~~r ' ~\\\a~<~""C..<t)

VENTILATING AND HEATINGSYSTEM-MUST ANG

VENTILATING SYSTEM

Two manually operated doors 10-

- ,BY.PASS HEATER- CHAMBER CORE-I8476

HEAT.DEFRQST TEMPERATURE OOOR1>1SCHARGE CRANK ARM CRANK ARMREGISTER K1643.A

FIG. 2-Heater Air Flow (Modulated)-Comet, Falcon and Fairlane

two slots in the forward instrument The nomenclature for the Fairlane

panel crash pad. heater controls is located on the

Three speeds are provided for the lower right side of the instrument

blower fan with a four position cluster, and the horizontal control

switch in the control assembly and a levers are directly below on the low-

resistor assembly located to the right er lip of the instrument panel (Fig.

of the heater core in the heater 3).

housing. The resistor in the blower The Falcon control, located on

motor circuit controls the low and the right side of the cluster assem-

medium blower soeeds. blv. contains two vertical slide le-

PART 16-1 VENTILATING SYSTEM AND HEATER 16-3

only when the HEAT lever is in the

up position. The position of the fresh

air doors deflects the air as desired.

FIG. 3-Heater Controls-Fairlane

HEATING SYSTEM

The fresh air heater is designed to

function in conjunction with the

right duct of the fresh air ventilating

system. The heater assembly couples

to an outlet provided in the right

cowl assembly. A door in the duct

and two doors in the heater housing

are operated by controls located on

the instrument panel, allowing the

selection of outside air for ventila-

tion or heating (Figs. 6 and 7).

The defroster control lever oper-

ates a valve in the heater plenum

chamber. Push the lever downward

for proportionately more air to the

defroster registers.

The PUSH FOR TEMP lever op-

erates the blend-air valve in the

heater blower housing. The blend-air

door controls the amount of air flow

through the heater core. Any inter-

mediate position of the blend-air

door allows both cool and heated air

to be mixed in the plenum chamber

for lower than maximum tempera-

tures.

The PUSH FOR HTR lever oper-

ates a door in the right incoming air

duct. When the lever is in the up po-

sition air from the cowl grille enters

the passenger compartment throughan opening under the right side of

the instrument panel. A manually

operated door closes the opening, or

deflects air as desired. Pushing the

lever downward allows air to enter

the heater blower inlet duct.

To opeJ;ate the blower motor,

move the top lever from the center

OFF position. Moving the lever to

the left will give high speed opera-

tion, and moving it to the right will

give low speed operation (Fig. 8).the passenger compartment. Theri2ht door is open to the cowl inlet

16-4 GROUP 16 - VENTILATING, HEATING, AND ACCESSORIES

A~ ~

~K1648.A

FIG. 8-Heater Controls-Mustang

FIG. 6-Heater System-Mustang

DIAGNOSIS AND TESTING

VENTILATING AND HEATING TROUBLE DIAGNOSIS GUIDE

INSUFFICIENT OR NOHEAT

6. Improperly connected heaterhoses.

7. Plugged heater core, or airoutlet.

8. Improperly installed or defec-tive engine thermostat.

9. Incorrectly installed and ad-justed control cables.

10. Air leaks in the body.

1. Burned out fuse or loose wiresto the heater blower.

2. Defective motor ground, or de-fective blower motor.

3. Fan loose on motor shaft, ormotor stalled.

4. Defective heater blower switch.5. A kinked, clogged, or collapsed

water hose.

INSUFFICIENT OR NODEFROSTING

zle, or obstructed defroster openingsat windshield.

4. Defroster hoses not properlyattached at plenum.

1. Improperly adjusted defrostercontrol cable, or disconnected de-froster hose.

2. Binding defroster valve.3. Plugged or loose defroster noz-

1. Incorrectly adjusted blend-airvalve.TOO MUCH HEAT

Current draw should be to specifica-tion.

LOOSE MOTOR FAN TESTTurn on the heater switch, and

listen for the sound of the motor. Ifonly a hum is heard, the fan is looseon the motor shaft.

BLOWER SWITCH TESTSubstitute a known good blower

switch for the suspected switch.

PLUGGED HEATER CORETEST

Start the engine and temporarilyremove the outlet hose from theheater core (the hose that leads tothe water pump). Very little or noflow of water from the core outletindicates that the core is plugged.Make certain that water is being sup-plied to the core inlet.

TESTINGRefer to Wiring Diagram Manual

Form 7795P-66 for locations of wir-ing harnesses. Schematics are shownin Group 2 of this manual.

The following tests may be madeon the heater: Burned out fuses,loose wire connections, defectivewires, collapsed hoses, loose defros-ter hoses and air leaks in the bodymay be determined by visual inspec-tion of the parts.

REA TER CURRENTDRAW TEST

This test will determine if theblower motor is defective. Connecta 0-50 ammeter as shown in Fig. 10.The blower motor will operate in-dependently of the control switch,and the current drawn by the motorwill be indicated on the ammeter.

COMMON ADJUSTMENTS AND REPAIRS

HEATING SYSTEMVENTILATING SYSTEM

Bowden cable operated vents andair inlets are adjusted so that thevents are tightly closed when thecontrol knobs are all the way in.Loosen the Bowden cable retainingscrew at the vent control arm, movethe cable housing back and forth un-til the vent is closed when the knobis 1/16 to VB inch from the in position,then ti2hten the retainin2 screw.

CONTROL ADJUSTMENTS-MUSTANG

To assure maximum temperaturethe following temperature controladjustments should be used.

1. Insert a VB -inch spacer be-tween the temperature control lever(center lever) and the bottom of theslot. Move the lever down until it is

seated against the spacer.2. Loosen the control cable re-

taining clip (at either end of thecable).

3. With the temperature controldamper crank (heater assembly)held tightly in the full heat position,tighten the control cable retainingclip screw.

4. Remove the spacer from thecontrol head and check the lever

FIG. 10-Heater Motor CurrentDraw Test

PART 16-1 VENTILATING SYSTEM AND HEATER 16-7

K1651-A

FIG. 11-Blower Motor Circuit-Comet, Falcon and Fairlane

HEATER HOSE REPLACEMENTTo replace a heater hose, drain

the coolant, remove the hose, cut anew hose to the same length as theold hose, install the hose, and replacethe coolant. Make certain that theheater hoses do not come in contactwith any part of the exhaust system.

After the coolant has been re-placed, bleed the air from the heatercore.

travel. All overtravel (spring back)should appear at the bottom of thelever travel.

BLEEDING AIR FROMHEATER CORE

Remove the hose at the outletconnection of the heater core (hosethat leads to the water pump). Al-low any trapped air to flow out.When a continuous flow of coolantis obtained, connect the hose to thecore.

the locating dart directly below thecrank arm on the case. With thecrank arm in this position, the heat-defrost door is in a horizontal posi-tion for maximum heat.

The Bowden cables can also beadjusted at the control assembly(Figs. 4, 5 and 9).

BLOWER MOTOR ELECTRICALCIRCUIT-COMET, FALCONANDFAIRLANE

For the blower motor circuit wir-ing diagram refer to Figure 11 orthe Wiring Diagram Manual Form7795P-66.

HEATER HOSE ROUTINGCare must be taken when servic-

ing the hoses to insure a smooth kinkfree installation for maximum heat-ing (Fig. 12).

BOWDEN CABLEADJUSTMENTS-COMET,FALCON AND FAIRLANE

TemperatureAdjust the temperature Bowden

cable at the heater case (Figs. 1 or2), with the temperature door crankarm in the far left position and thetemperature control lever on HI.Provide approximately YB inch clear-ance between the lever and edge ofthe slot for proper adjustment.

Heat and DefrostAdjust the heat-defrost Bowden

cable at the heater case by aligningthe crank arm (Figs. 1 or 2), with

REMOVAL AND INSTAllATION

5. Disconnect the heater hoses atthe water pump and the carburetorheater. Remove the heater hosesfrom the retaining clips. On 8-cylin-der models remove the hose fromthe choke clip (Fig. 12).

6. Disconnect the wires at theheater motor and remove theground-wire-to-dash panel retainingscrew.

7. Remove the heater and motorassembly retaining nuts from thedash panel.

8. Disconnect the fresh air inletrubber boot, pull the heater assem-bly from the dash panel and lay theheater assembly on the floor.

INSTALLATION1. Position the heater assembly to

the dash panel and install the retain-ing nuts.

2. Connect the heater motor wiresto the wiring harness, and connectthe heater motor ground wire to thedash panel with the retaining screw.

3. Connect the heater hoses andinstall the hose retaining clips.

4. Connect the fresh air inletboot.

S. Connect the defroster hoses tothe heater plenum.

6. Connect and adjust the threecables to the heater, and install theglove box.

HEATER-MUSTANGMost of the heater repairs can be

performed with the heater assemblylying on the car floor. Therefore,the following procedure will not re-move the heater assembly from thecar. The heater core or plenum re-placement procedures contain theadditional required steps to removethe heater assembly from the car.

REMOVAL, 1. Drain the cooling system.

1. Remove the glove box.3. Disconnect the three control

cables.4. Disconnect the defroster hoses

at the heater plenum.


removed from the heater assemblyif necessary (View A, Fig. 9).

DEFROSTER NOZZLES-COMET,FALCON AND FAIRLANE

The Fairlane and Falcon have acommon type nozzle; the nozzle forthe Comet is unique due to the wid-er space between the two openingsin the instrument panel.

1. Remove the glove box.2. Remove the defroster nozzle

retaining clip screw (Figs. 2 and 3).3. Remove the defroster nozzle

retaining nuts; two on the Fairlaneand Falcon, and four on the Comet.

4. Lower the nozzle down andout from under the panel on theFairlane and Falcon; remove theComet nozzle through the glove boxopening.

---

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gj//'1- ,/;

, =-- v;?~~~~!~~~:~~~~ "'-" )"/ "-~-~~;, ~~o C.I.D. ENGINE @ /J

FIG. 1 2-Heater Hose Routings-Six and Eight Cylinder Engines

HEATER CORE ASSEMBLY-COMET, FALCON ANDFAIRLANE

The heater core is mounted in theheater case in a diagonal position inthe center of the case and is servicedthrough an opening in the back plate.With the heater assembly out of thevehicle, simply remove four screwsfrom the cover plate and pull thecore from the housing (Fig. 13).The core is mounted in the heaterhousing with butyl rubber pads oneach end to insure a snug fit.

K1649-A

7. Fill the cooling system, andcheck the system for leaks.

8. Bleed the system.

el, then lower the control from un-der the panel and disconnect theBowden cables.

The blower switch is located tothe left of the two control levers andretained with one screw in the faceof the lower instrument panel (Fig.4).

BLOWER MOTOR AND WHEELASSEMBLY-COMET, FALCONAND FAIRLANE

To remove the blower motor andwheel assembly, it is necessary to re-move the right air vent duct and theheater case assembly. The blowermotor and wheel assembly ismounted to the forward right side ofthe heater case in the blower scrolland attached with four screws to theback plate (Fig. 13).

HEATER CONTROL ASSEMBLY-FALCON

To service the controls, removethe three knobs, remove two upperscrews in the control bezel and twolower mounting nuts behind the in-strument cluster. Lower the controlassembly and disconnect the twoBowden cables and blower switchwiring (Fig. 5).

HEATER CONTROL ASSEMBLY-COMET

To remove the control assembly,remove the knobs and spanner nutsfrom the headlight and wiperswitches and lower the control as-sembly from under the instrumentpanel, then disconnect the Bowdencables, light bulb, and wiring.

HEATER CORE-MUSTANG1. Remove the heater assex:nbly

and lay the assembly on the carfloor.

2. Remove the clips retaining theheater housing halves together andseparate the halves.

3. Lift the heater core from theheater housing chamber. On consoleequipped cars it may be necessary toremove the heater from the car.

4. Position the heater core in theforward half of the heater housing,assemble the housing, and install theretaining clips. If a 2-inch core isused, transfer the adapter from theold core to the new core.

5. Position the assembly on thecar floor.

6. Install the heater assembly.7. Refill and bleed the cooling

system and check for leaks.

HEATER CONTROL ASSEMBLY-FAIRLANE

To remove the control assembly,remove the three control knobs andremove two control mounting screwsfrom the face of the instrument pan-

DISCHARGE AIR REGISTERSThe discharge air registers can be

HEATER BLOWER MOTOR-MUSTANG

1. Remove the heater assemblyand lay the assembly on the carfloor.

2. Remove the blower motor andbracket to the blower housing retain-ing screws and remove the blowerassembly.

3. Loosen the blower cage setscrew and remove the blower cagefrom the motor.

4. Remove the b lower motormountinsz plate from the motor.

VENTILATING SYSTEM AND HEATER 16-9PART 16-1

5. Install the b lower motormounting plate to the new motor.

6. Install the blower cage andtighten the set screw.

7. Install the heater motor andbracket to the blower housing.

8. Install the heater assemblv.

DEFROSTER NOZZLES-MUSTANG

1. Remove the defroster outletregister retaining screws and removethe register.

2. Disconnect the defroster hoseat the plenum.

3. Remove the defroster nozzleretaining clips and remove the nozzleassembly.

4. Tr!i~Sfer the retaining clips tothe new froster nozzle assembly.

5. Instal the defroster nozzle tothe instrumenv panel.

6. Install th'e defroster outlet reg-ister.

7. Connect the hoses to plenum.

K1650-A

BLOWER SWITCH-MUSTANG

1. Loosen the screw in the knob.2. Disconnect the wiring.3. Remove one screw holding the

blower switch to the control head as-semblv. and remove the switch.

FIG. 13-Heater Blower Motor and Core Assemblies-Comet, Falconnnrl ~nirlnn~

16-10

AIR CONDITIONING-FORD

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Section1 Description and Operation... . . . . . . . .

Receiver Unit. . . . . . . . . . . . . . . . . . . . . .Evaporator Unit Expansion Valve Compressor Unit Liquid Sight Glass Magnetic Clutch , Thermostatic Switch Service Valves. . . . . . . . . . . . . . . . . . . . . .

2 Diagnosis and Testing Air Conditioning Diagnosis Guide. . . . .

Checking For Leaks ".",."...Use of Sight Glass ,..Checking System Pressures. . . . . . . . . . .Interpreting Abnormal System PressuresThermostatic Switch Test. . . . . . . . . . . .Magnetic Clutch Blower Motor ,

Expansion Valve """"""""""Compressor Volumetric Efficiency Test.

3 Common Adjustments and Repairs. . . .Safetv Precautions. . . . . . . . . . . . . . . . . .

SectionDischarging the System Evacuating the System. . . . . . . . .

Making a Partial Charge. . . . . . .Making a Complete Charge. . . . .Charging From Small ContainersCompressor Oil Level Check. . .Isolating The Compressor. . . . . .

4 Removal and Installation. . . . . . .Evaporator. . . . . . . . . . . . . . . . . .Condenser. . . . . . . . . . . . . . . . . . .Compressor ."'..."".."".Compressor Components Valve Plate. . . . . . . . . . . . . . . . . .

Crankshaft Seal Expansion Valve ",.,...,.",.

Thermostatic Switch. . . . . . . . . . .Air Conditioner Blower Motor. .Belt. .. . . ... .. .. .. .. .. .. .. ..Clutch. . . . . . . . . . . . . . . . . . . . . .

5 Cleaning and Inspection. . . . . . . .Compressor

DESCRIPTION AND OPERATION

cooling system. Besides these majorcooling components there is a liquidsight glass, an oil separator (integralwith the compressor), a cooling unitthermostatic switch, and a blowerassembly.

Refer to Wiring Diagram ManualForm 7795P-66 for locations of wir-ing harnesses. Schematics are shownin Group 22 of this manual.

The Ford air conditioner is usedon the Falcon and Fairlane (Fig. 1).

liquid Refrigerant-12 under pressurein a combination receiver and dehy-drator (Pig. 2). The pressure in thereceiver normally varies from about80 to 300 psi, depending on the sur-rounding air temperature and com-pressor speed.

The dehydrator serves the purposeof removing any traces of moisturethat may have accumulated in thesystem. Even small amounts of mois-ture will cause an air cooling unit tomalfunction. A fusible plug isscrewed into the receiver. This willrelease the refrigerant before therefrigerant temperature exceeds212°P.

~6 ;;~i4 [

,;' oj,

~ 4~~~~~ i

/4

K1559-A

FIG. 1-Ford Air Conditioner

The Mercury air conditioner is usedon the Comet. The Selectaire isavailable on the Fairlane. All unitsuse a receiver, an expansion valve,an evaporator, a compressor, and acondenser. These parts are the stand-ard units which are used in any air

EVAPORATOR UNIT

When the cooling system is in op-eration, the liquid Refrigerant-12flows from the combination receiverand dehydrator unit through a flexi-ble hose to the evaporator (Fig. 2)where it is allowed to evaporate ata reduced pressure, to cool the evap-orator.

Passenger compartment air isblown through the evaporator finsand is thus cooled by the evaporator.

Fig. 2 shows an air conditioningsystem in schematic form. Arrowsindicate the direction of refrigerantflow.

RECEIVER UNITThe air cooling system stores the

16-11PART 16-2 AIR CONDITIONING-FORD

~ APORt.; TOR~ HIGH PRESSURE LIQUID

~ LOW PRESSURE LIQUID

~ HIGH PRESSURE GAS

~ LOW PRESSURE GAS

~~3 J~- ,'00

'",0 : 0

00' ( 0

°Oqo 0~~

CONDENSOR

EXPANSION VALVE( ~. .

~TO CONDENSOR ~ .

J~OUT TO COMPRESSOR

jJ;) /-- TOCONDENSOR

TO EXPANSION VALVEAND EVAPORATOR

. RECEIVER

,...

~ ~

OUT TO RECEIVER~K1231-B

FIG. 2-Air Conditioning System

compressor is electrically cut in andout of operation by the use of amagnetic clutch pulley mounted onthe compressor crankshaft (Fig. 2).The magnetic clutch is controlled bya thermostatic switch which has itstemperature sensing tube inserted inthe fins of the evaporator core.

THERMOSTATIC SWITCHThe thermostatic switch controls

the operation of the compressor bycontrolling the compressor magneticclutch. The temperature sensing tubeof the switch is placed in contactwith the evaporator fins. When thetemperature of the evaporator be-comes too cold, the thermostaticswitch opens the magnetic clutchelectrical circuit, disconnecting thecompressor from the engine. Whenthe temperature of the evaporatorrises to the upper limit at which thethermostatic switch is set, the ther-mostatic switch closes and energizesthe magnetic clutch. This connectsthe compressor to the engine, andcooling action begins again.

When the ignition switch is off orthe cooling control thermostaticswitch is in the off position, the mag-netic clutch is not energized, and thecompressor can not operate.

When the ignition switch is on(engine running), and the coolingcontrol is in the cooling range, themagnetic clutch is energized, thecompressor is connected to the en-gine and the cooling system is in op-eration.

The thermostatic switch may beadjusted to maintain an averageevaporator temperature of from30°-60°F. The thermostatic switchoperating differential temperature atanyone setting is 6°F.

EXPANSION VALVEThe rate of refrigerant evapora-

tion is controlled by an expansionvalve (Fig. 2) which allows onlyenough refrigerant to flow into theevaporator to keep the evaporatoroperating efficiently, depending onits heat load.

The expansion valve consists ofthe valve and a temperature sensingcapillary tube and bulb. The bulb isclamped to the outlet pipe of theevaporator. Thus the valve is con-trolled by evaporator outlet temper-ature.

The restricting effect of the ex-pansion valve at the evaporatorcauses a low pressure on the lowpressure side of the system of 12 to50 psi, depending on the surroundingair temperature and compressorspeed.

FIG. 3-Compressor Installed

through the condenser, it is cooledby air passing between the sectionsof the condenser. The cooled, com-pressed refrigerant gas condenses toliquid refrigerant which then flowsinto the receiver.

LIQUID SIGHT GLASSA liquid sight glass is mounted in

the high pressure refrigerant line be-tween the receiver and the expansionvalve (Fig. 2). The sight glass isused to check whether there isenough liquid refrigerant in the sys-tem.

SERVICE VALVESThe service valves on the com-

pressor are used to test and servicethe cooling system (Figs. 4 and 5).The high pressure service valve,mounted at the outlet to the com-pressor, allows access to the highpressure side of the system for at-taching a pressure gauge, or a serv-icing hose.

The low pressure valve, mountedat the inlet to the compressor, allowsaccess to the low pressure side of thesystem for attaching a pressuregauge or a servicing hose.

Both service valves may be usedto shut off the rest of the systemfrom the compressor during com-pressor service.

MAGNETIC CLUTCHIt is necessary to control the

amount of cooling that the systemproduces. To accomplish this, the

COMPRESSOR UNITThe evaporated refrigerant leav-

ing the evaporator (now in the formof a gas) at a pressure of 12 to 50psi is pumped by the compressor, lo-cated on the engine (Fig. 3), intothe top of the condenser, located infront of the radiator.

The compressor maintains a pres-sure on its high pressure side of from.SO to 300 psi, depending on the sur-rounding air temperature and com-pressor speed.

As the now heated and com-pressed refrigerant gas flows down

16-12 GROUP 16 - VENTILATING, HEATING, AND ACCESSORIES

FIG. 5-High Pressure ServiceValve Gauge Port

FIG. 4-Low Pressure ServiceValve Gauge Port

EJ DIAGNOSIS AND TESTINGAIR CONDITIONING-DIAGNOSIS GUIDE

INSUFFICIENT ORNO COOLING

7. Compressor defective, or looseor broken compressor belt.

8. A/C thermostat defective.9. Clutch lead disconnected or

broken.10. Expansion valve inoperative

-stays open or closed.11. Plugs left in compressor under

service valve (both gauges indicatethe same pressure).

12.. Moisture in system.

1. Inoperative magnetic clutch.2. Inoperative blower, motor, or

switch.3. Obstructed air passages.4. Complete loss of charge (No

foam in sight glass at system start-up).

5. Partial loss of charge (Contin-uous foam in sight glass after start-up).

6. Service valves improperly set(should be maximum counterclock-wise).

NOISY COMPRESSOR parts in compressor.4. Compressor loose on bracket.

1. Loose, torn or misaligned belt.2. Loose or slipping clutch.3. Foreign material or damaged

1. Brokenbracket.

or loose mounting 2. Loose clutch.3. Loose belt.

COMPRESSOR VIBRATION

a flame type leak detector (Fig. 7).Follow the directions with the leakdetector. The smaller the flame themore sensitive it is to leaks. There-fore, to insure accurate leak indica-tion keep the flame as small as possi-ble. The copper element must be redhot. If it is burned away, replace theelement. Hold the open end of thehose at each suspected leak point fortwo or three seconds (Fig. 8). Theflame will normally be almost color-

TESTINGObstructed air passages, broken

belts, disconnected or broken wires,loose clutch, loose or broken mount-ing brackets may be determined byvisual inspection of the parts.

CHECKING FOR LEAKSAttach the manifold gauge set

(Fig. 6). Leave both manifold gaugevalves at the maximum clockwisenn~itinn ~pt hnth ~PTVice v~lve~ ~t

the center position. Both gaugesshould now show approximately 60to 80 pounds pressure at 75°P. Ifvery little or no pressure is indi-cated, leave the vacuum pump valveclosed, open the Refrigerant-12 tankvalve, and set the low pressure mani-fold gauge valve to the counterclock-wise position. This opens the systemto tank pressure.

Check all connections, and thecomDTeSSOT shaft seal fOT leaks. usio2

16-13PART 16-2 AIR CONDITIONING-FORD

set and hoses for leaks as well asthe rest of the system.

If the surrounding air is contami-nated with refrigerant gas the leakdetector will indicate this gas all thetime. Good ventilation is necessaryto prevent this situation. A fan, evenin a well ventilated area, is veryhelpful in removing small traces ofrefrigerant vapor.

K1548-A

FIG. 7 -Flame Type leakDetector

~

figures given are for an ambient(surrounding air) temperature of75°P., 50% relative humidity.

The low pressure gauge should in-dicate a pressure of from 12 to 50pounds. The high pressure gaugeshould indicate a pressure of six orseven times the low pressure or 80to 300 pounds.

At idle speed and a surroundingair temperature of 1000 to 1100F.,the high pressure may go as high as300 pounds or more. If it becomesnecessary to operate the air condi-tioner under these conditions, keepthe high pressure down with a fandirected at the condenser and radi-ator.

INTERPRETING ABNORMALSYSTEM PRESSURES

Low Pressure Below Normal,High Pressure NormalThese pressures indicate a restric-

tion between the receiver and theexpansion valve or between the ex-pansion valve and the low pressureservice valve. If the low pressure isactually a vacuum, the expansionvalve is probably closed tightly. Shutthe system down and allow it towarm to room temperature. Startthe engine and if the evaporator willnow become cool, the expansionvalve was frozen because of mois-ture in the system. Release the re-frigerant, replace the dryer-receiverassembly, check for leaks, then evac-uate and charge the system.

Whenever the system has beenopened three times the receiver dry-er should be replaced as a precau-tion against internal icing of the ex-pansion valve.

Check the system between the re-ceiver outlet and the low pressureservice valve for restrictions, by feel-ing all of the connections and com-ponents. Any portion that is cold tothe touch or that frosts up, with thepressures as indicated here, is re-stricting the refrigerant flow.

Low Pressure Above Normal,High Pressure NormalObserve both pressure gauges. If

the low pressure is above normal(12 to 50 pounds) and the high pres-sure is at or near normal (80 to 300pounds), the expansion valve is notoperating properly. This conditionmay cause the compressor to receiveslugs of liquid and thus to be verynoisy. Also, the suction side of thecompressor and the crankcase andhead will be colder than normal andwill frost UP.

USE OF SIGHT GLASSWhen observing the sight glass for

foam, run the engine at 1500 rpmwith the thermostatic switch controllever set for maximum cooling, andthe blower on high. Foam in thesight glass indicates an underchargeof refrigerant. Check the system forleaks, repair if necessary and chargethe system with the proper amountof Refrigerant-12.

No foam in the sight glass will in-dicate either a full charge or a com-plete loss of refrigerant. Clean thesight glass. If the system is fullycharged, the sight glass will be per-fectly clear. If the system is com-pletely empty of refrigerant, the sightglass will look oily and will not beas clear as when refrigerant is flow-ing through it.

When the compressor is not op-erating and when the system is com-pletely charged, an occasional largebubble of Refrigerant-12 vapor willnormally be seen in the sight glass.

Under conditions of extremelyhigh temperatures occasional foamor bubbles may appear.

CHECKING SYSTEMPRESSURES

The pressures developed on thehigh pressure and low pressure sideof the compressor indicate whetherthe system is operating properly.

Attach the manifold gauge set(Fig. 6). It will not be necessary toattach the Refrigerant-12 tank un-less refrigerant is to be added to thesystem. Set both manifold gaugevalves at the maximum clockwise orclosed position. Set both servicevalves at the center position.

Check the system pressures withthe engine running at 1500 rpm, allcontrols set for maximum cooling,and the front of the car at least fivefeet from any wall.

The actual pressures indicated onthe gauge will depend on the tem-perature of the surrounding air andthe humidity. High air temperaturesalong with low humidity, will givehigher system pressures. The lowest

r.c-, K1554-A

FIG. 8-Checking for leaks

less. The slightest leak will be indi-cated by a bright color to the flame.Be sure to check the manifold gauge

16-14 GROUP 16 - VENTilATING, HEATING, AND ACCESSORIES

its charge and the expansion valvemust be replaced.

or an ohmmeter connected to theswitch leads to check whether or notthe switch is closed. Release theswitch arm. The switch should beopen.

MAGNETIC CLUTCHDisconnect the magnetic clutch

wire at the bullet connector, andconnect it to the negative lead of anammeter. Connect the positive leadof the ammeter to the battery posi-tive terminal. The magnetic clutchshould pull in with a distinct clickand the current reading on the am-meter should be to specification.Make certain that the brushes andbrush slip rings are clean and free ofoil or grease.

BLOWER MOTORDisconnect the blower motor wire

at the bullet connector, and connectit to the negative lead of an amme-ter. Connect the positive lead of theammeter to the battery positive ter-minal. The motor should operate andthe reading on the ammeter shouldbe to specification.

EXPANSION VALVERemove the expansion valve from

the evaporator. Connect the Refrig-erant-12 supply hose to the expan-sion valve inlet with a suitable adapt-er. Open the refrigerant supply valveslightly. Refrigerant gas should come

The expansion valve will allowtoo much liquid refrigerant to flowto the compressor if it is defectiveor, if the temperature sensing ele-ment is not making close contactwith the evaporator outlet pipe.Make sure that the element is se-curely clamped to the outlet pipe,and properly covered.

High Pressure Below Normal,Low Pressure Above NormalIf the two pressures are equal or

within 30 pounds of each other, thecompressor may be defective. Per-form a compressor volumetric effi-ciency test. Repair or replace thecompressor as needed.

High Pressure Above NormalHigh compressor head pressures

are caused by an overcharge of re-frigerant, condenser air passagesclogged, a restriction between thecondenser inlet and the receiver, orhigh surrounding air temperatures.High head pressures are generallyevidenced by a noisy compressor.

Discharge excess refrigerant untilfoam is seen in the sight glass (sys-tem operating at 1500 engine rpm),then add V2 pound of refrigerant.

l1IERMOSTATIC SWITCHTEST

The switch must be removed forthis test. Move the switch arm to thecoldest temperature setting by hold-ing the arm against the stop nearest

LOWPRESSURE"SERVICE

VALVE CAPREMOVED

K1332.B

COMPRESSOR VOLUMETRICEFFICffiNCY TEST

Malfunction of the compressorcan be isolated by checking the com-pressor volumetric efficiency with aspecial tool. Make the test with thecar in a clean dry atmosphere.

Run the engine at 1500 rpm withall controls at maximum cooling forat least 10 minutes. Adjust the en-gine idle with a tachometer to ex-actly 515 rpm with the compressorclutch engaged. Turn the engine offand set the cooling control to theOFF position. Isolate the compres-sor, then remove both high and lowpressure service valve gauge portcaps, allowing the gas in the com-pressor to escape.

Attach the special tool (calibratedorifice with gauge attached) to thehigh pressure service valve gaugeport (Fig. 9). Start the engine. En-gage the magnetic clutch for 15 sec-ond intervals, by moving the coolingcontrol from the OFF position tothe maximum cooling position, andobserve the maximum gauge pres-sure at the end of each 15 secondinterval. Be sure to allow the gaugepressure to drop to zero between the15 second intervals. Stop the engine.

A good compressor will bring thepressure to 200 psi in 15 seconds. Ifthe pressure does not come up to200 psi, in 15 seconds, clean thecompressor intake screen. If the in-take screen is clean, remove and in-spect the valve plate. Most of thefailures to come up to the 200 psispecification will be caused by smallforeign particles under the valveplate leaves or a defective valveplate. Clean the valve plate and as-semble it to the compressor usingnew gaskets. If this does not effecta cure, replace the valve plate or thecompressor as required.

If no further work is to be doneon the system after making the vol-umetric efficiency test, disconnectthe orifice tool and gauge, evacuatethe compressor and connect it backinto the system.

FIG. 9-Voltmetric Efficiency Test

to the vacuum actuator. At roomtemperature the switch should beclosed. Use a self powered test light

out of the expansion valve outlet. Ifno gas comes out of the outlet, thetemperature sensing element has lost


conditioner system is Refrigerant-12.Refrigerant-12 is nonexplosive. non-

inflammable, noncorrosive, has prac-tically no odor. and is heavier than

SAFETY PRECAUTIONSThe refrigerant used in the air

PART 16-2 - AIR CONDITIONING-FORD 16-15

fumes from the leak detector. Makecertain that Refrigerant-12 is bothstored and installed in accordancewith all state and local ordinances.

When admitting Refrigerant-12gas into the cooling unit, alwayskeep the tank in an upright position.If the tank is on its side or upsidedown, liquid Refrigerant-12 will en-ter the system and damage the com-pressor. In surrounding air tempera-tures above 90°F., prolonged engineidle will result in excessively highcompressor pressures.

DISCHARGING THE SYSTEMDischarge the refrigerant from the

system before replacing any part ofthe system, except the compressor.

To discharge the system, connectthe manifold gauge set to the system(Fig. 10). Do not connect the mani-fold center connection hoses to the

HOSE FROM EVAPORATORHOSE TO cnNDENSER LOW PRE

""Gauge

-- ,-Low Pressure Gouge ..

TO REFRIGERANT SUPPLY AND VACUUM PUMP K1557-A

FIG. 1 a-Charging the Air Conditioning System

(Fig. 10). Open both manifoldvalves. Close the vacuum pumpvalve. Open the Refrigerant-12 tankvalve. Purge the air from the highpressure hose by loosening the highpressure hose at -the service valve,for a few seconds. Tighten the con-nection and set the high pressuremanifold gauge valve at the maxi-mum clockwise position. Loosen thelow pressure gauge hose slightly atthe low pressure service valve, for a

air. Although it is classified as a saferefrigerant, certain precautions mustbe observed to protect the parts in-volved and the person who is work-ing on the unit. Use only Refriger-ant-12.

Liquid Refrigerant-l 2, at normalatmospheric pressure and tempera-tures, evaporates so quickly that ittends to freeze anything that it con-tacts. For this reason, extreme caremust be taken to prevent any liquidrefrigerant from coming in contactwith the skin and especially the eyes.

Refrigerant-12 is readily absorbedby most types of oil. It is thereforerecommended that a bottle of sterilemineral oil and a quantity of weakboric acid solution be kept nearbywhen servicing the air conditioningsystem. Should any liquid refrigerantget into the eyes, use a few drops ofmineral oil to wash them out, thenwash the eyes clean with the weakboric acid solution. Seek a doctor'said immediately even though irrita-tion may have ceased.

Always wear safety goggles whenservicing any part of the refrigerat-ing system.

The Refrigerant-12 in the systemis always under pressure. Becausethe system is tightly sealed, heatapplied to any part would cause thispressure to build up excessively.

To avoid a dangerous explosion,never weld, use a blow torch, solder,steam clean, bake body finishes, oruse any excessive amount of heat on,or in the immediate area of, any partof the air cooling system or refriger-ant supply tank, while they areclosed to the atmosphere whetherfilled with refrigerant or not.

The liquid refrigerant evaporatesso rapidly that the resulting refriger-ant gas will displace the air sur-rounding the area where the refrig-erant is released. To prevent possi-ble suffocation in enclosed areas, al-ways discharge the refrigerant froman air cooling system into the gar-age exhaust collector. Always main-tain good ventilation surrounding thework area. If the car is to be under-coated, make certain that the under-coating does not plug the evaporatordrain tubes.

Although Refrigerant-12 gas, un-der normal conditions, is non-poison-ous, the discharge of refrigerant gasnear an open flame can produce avery poisonous gas. This gas will alsoattack all bright metal surfaces. Thispoisonous gas is generated in smallquantities when the flame-type leakdetector is used. Avoid inhaling the

Refrigerant-12 tank, or vacuumpump. Place the open end of thesehoses in a garage exhaust outlet. Setthe high pressure manifold gaugevalve at the maximum counterclock-wise or open position. Open the highpressure service valve a slightamount (Fig. 5), and allow the re-frigerant to discharge slowly fromthe system.

Do not allow the refrigerant torush out, as the oil in the compres-

sor will be forced out along with it.

EVACUATING THE SYSTEMAttach the manifold gauge set, a

tank of Refrigerant-12 and a vacu-um pump to the system (Fig. 10).Make certain that the Refrigerant-12 tank valve is tightly closed. Setboth service valves to the mid-posi-tion. Open both manifold valves. Re-lease any pressure in the system.Open the vacuum pump valve andrun the pump until the low pressuregauge reads at least 25 inches, andas close to 30 inches of vacuum aspossible. Continue vacuum pump op-eration for 20 to 30 minutes to boilany moisture out of the system.Close the pump valve. Turn off thepump.

MAKING A PARTIAL CHARGEAttach the manifold gauge set

HIGH PRESSURE SERVICE VALVE

.SURE SERVICE VALVE

16-16 GROUP 16 - VENTilATING, HEATING, AND ACCESSORIES

K1S44-A

FIG. 11-0il Level Check

few seconds, to purge the air fromthe hose. Tighten the connection. Setboth service valves at the center po-sition (Pig. 10).

Run the engine at 1500 rpm withan controls at the maximum coldposition. Charge the system until anfoam disappears from the sight glass,and then add 1/4 pound of Refriger-ant-12. Shut the Refrigerant-12 tankvalve.

It may be necessary to place theRefrigerant-12 tank in a containerof hot water at about 150oP. toforce the gas from the tank duringcharging.

Never heat the Refrigerant-12tank with a torch. A dangerous ex-plosion may result.

Set both service valves at themaximum counterclockwise position.Remove the gauge set, and cap theservice valve gauge ports and valvestems.

if these small containers are used in-stead of a tank.

Attach the hose, that would nor-mally attach to the large tank (Fig.10), to the special valve that is pro-vided for the small cans. Close thevalve (maximum clockwise position)and follow the procedure for leaktesting, evacuating and charging thesystem as previously given.

For charging, attach a one-poundcan of Refrigerant-12 to the specialvalve, and open the valve. Keep thecan in an upright position. When thecan is empty (no frost showing),close the valve, remove the emptycan, attach a new one, and open thevalve again.

Charge the system until the sightglass clears of foam then add an ad-ditional 1/4 pound of refrigerant. Es-timate the 1/4 pound weight by ob-serving the frost line on the one-pound can.

Check the system pressures, setboth service valves at the maximumcounterclockwise position. Removethe gauge set, and cap the servicevalve gauge ports and valve stems.

shaft. If additional oil is needed inthe compressor, add Suniso 5 orCapella E refrigerator compressoroil, or equivalent.

If more than 7/8 inch of oil is in-dicated, as might happen if a newcompressor is installed and oil al-ready in the system is pumped backto the compressor, draw out the ex-cess oil until the proper quantity isindicated.

Replace the oil filler plug, thenevacuate and connect the compressorback into the system. Be sure tocheck the compressor filler openingfor leaks.

COMPRESSOR OILLEVEL CHECK

Under normal conditions whenthe air cooling system is operatingsatisfactorily the compressor oil lev-el need not be checked. There is noplace for the oil to go except insidethe sealed system. When the car isfirst started some of the oil will bepumped into the rest of the system.After 15 minutes of operation, mostof the oil is returned to the compres-sor crankcase.

Check the compressor oil levelonly if a portion of the refrigerantsystem is being replaced or if therewas a leak in the system and the re-frigerant is being replaced.

Check the oil after the system hasbeen charged and has been operatingat an engine speed of 1500 rpm for15 minutes in 60oP. surrounding airtemperature or above. Turn off theengine, and isolate the compressor.Remove the oil filler plug from thecompressor, insert a flattened 1/8-inch diameter rod (Pig. 11), in theoil filler hole until it bottoms. Therod should show 'V8 inch of oil onTecumseh compressors and 3/4 inchof oil on York compressors. This isequivalent to 11 ounces on Tecum-seh and 10 ounces on York. It maybe necessary to rotate the compres-sor crankshaft slightly (by hand) sothat the dip rod will clear the crank-

MAKING A COMPLETECHARGE

Check for leaks first, release thepressure, then evacuate the system.Leave both service valves at themid-position and the vacuum pumpvalve closed. Leave the low pressuremanifold gauge valve at the maxi-mum counterclockwise or open po-sition. Set the high pressure manifoldgauge valve at the maximum clock-wise or closed position. Set all con-trols to the maximum cold position.

Open the Refrigerant-l 2 tankvalve. Run the engine at 1500 rpm.Charge the system until the sightglass is clear of foam, then add anadditional 1/4 pound of refrigerant.

During the charging, the highpressure may build up to an exces-sive value. This can be caused by anovercharge of refrigerant, or anoverheated engine, in combinationwith high surrounding temperatures.Never allow the high pressure to ex-ceed 240 pounds while charging.Stop' the engine, determine thecause, and correct it.

After the proper charge has beenmade, close the Refrigerant-12 tankvalve, and check the system pres-sures for proper operation. Set bothservice valves at the maximum coun-terclockwise position. Remove thegauge set, and cap the service valvegauge ports and valve stems.

ISOLATING THE COMPRESSORThis procedure is used when check-

ing the compressor oil level andwhen it is desired to replace the com-pressor without losing the refriger-ant charge.

To isolate the compressor from thesystem, turn both the high and thelow pressure service valves to theextreme clockwise position. Loosenthe cap on the high pressure servicevalve gauge port, and allow the gasto escape until the compressor is re-lieved of refrigerant pressure.

Loosen the cap a small amountonly, and do not remove it until thepressure is completely relieved.

To connect the compressor backinto the system, evacuate the com-pressor at the high pressure servicevalve gauge port, close the vacuumpump valve, turn both service valvesto the maximum counterclockwiseposition, and cap the high pressureservice valve gauge port and servicevalve stems.

CHARGING FROM SMALLCONTAINERS

Refrigerant-12 is available in one-pound cans. A scale is not necessary

PART 16-2 AIR CONDITIONING-FORD 16-17


plugs, attach the refrigerant lines andinstall the grille to radiator supportbracket and hood latch.

5. Check for leaks, evacuate andcharge the system.

COMPRESSOR

REMOVAL1. Isolate the compressor (see

Common Adjustments and Repairs inthis part). Disconnect the two servicevalves and hoses from the compres-sor (Fig. 12). Energize the clutchand loosen and remove the clutchmounting bolt.

1. Install a 5/8 -11 bolt in the clutchdrive shaft hole. With the clutch stillenergized, tighten the bolt to loosenthe clutch from the shaft. Disconnect

gize the clutch and torque the clutchmounting bolt to specification. If thenew compressor was shipped with abolt and washer in the end of thecrankshaft, remove and discard thebolt and use a bolt with a nylon insertin it. Install and adjust the drive belt.

3. Making sure that the protectiverubber plugs have been removed, in-stall the service valves on the com-pressor using new seals. Tighten theservice valve nuts to specification.Do not over-tighten the nuts. TheROTO-LOK service valves can berotated slightly on their seat withoutbreaking the high pressure seal. Thisis not an indication of a loose valve.Leak test the compressor, then evac-uate it and connect it back into thesystem.

4. Check the oil level in the com,.pressor and add or remove oil ifnecessary.

EVAPORATOR

REMOVAL.1. Discharge the refrigerant from

the system.2. Disconnect the two wires from

the unit, demount the evaporator as-sembly, and set the unit on the carfloor.

3. Disconnect the refrigeranthoses. On some models it may benecessary to remove the assemblyfrom the car before going further.

4. Remove the front panel, coversand the expansion valve from theunit. (See Expansion Valve Removaland Installation.)

5. Remove the thermostatic switchtemperature sensing tube from be-tween the evaporator fins, remove theevaporator-to-base mounting screwsand remove the evaporator from thebase.

INSTALLATION1. Attach the old expansion valve

to the n~w evaporator and leak testthe connection by capping the outletof the evaporator and using a suit-able reducing connector from thevalve inlet to a tank of Refrigerant-12.

'"'K1549-A

FIG. 12-Compressor-ServiceValves Removed

the clutch wire at the bullet con-nector.

3. Loosen the belt, remove thebelt and the clutch, and then removethe mounting bolts and the compres-sor.

4. With the compressor on thework bench, remove the key fromthe shaft.

INSTALLATIONBefore installing the compressor,

see Cleaning and Inspection in thispart.

1. Mount the clutch on the shaftand install the mounting screw andwasher finger-tight. Place the com-pressor on the mounting bracket andinstall the four mounting bolts.

2. Connect the clutch wire. ener-

COMPRESSOR COMPONENTSAll compressor removal and instal-

lation operations, except belt replace-ment, can be performed only afterthe unit has been isolated from therest of the system. (See CommonAdjustments and Repairs in this part.)

VALVE PLATE

Removal1. Isolate the compressor and dis-

connect the service valves. Removethe 12 head bolts.

2. Remove the cylinder head andvalve plate from the top of the com-pressor body (Fig. 13). Do not tap orhit the head with any hard tool, asdamage could result (York compres-sors are made of aluminum).

3. Remove and discard all gaskets,and be sure to clean gasket shredsfrom all gasket surfaces. Examine thecylinders and top of the pistons, par-ticularly in case of valve breakage.If there are score marks, replace thecompressor assembly.

4. If the cylinders and pistons arein good condition, check the valveplate and valve reeds for damage.If the valve assembly is in good con-dition, it can be used again. If thevalve plate is damaged, install theentire replacement kit which includesthe valve plate, valve reeds, and thetwo gaskets (Fig. 13).

5. When the valve plate assembly.is re-used, wash it in clean solventand dry in dry air. Check the oil fordirt. If the system is not clean, re-place the oil.

2. Position the evaporator on thebase and install the two evaporator-to-base mounting screws.

3. Push the thermostatic switchsensing tube into the same relativeposition at about the center of theevaporator, but if the same core isbeing used position the sensing tubebetween the next two fins for goodtemperature conduction. Install thecovers and front panel.

4. Attach the refrigerant lines andleak test the connections.

5. Mount the assembly, connectthe two wires, leak test, evacuateand charge the system.

CONDENSER1. Discharge the refrigerant from

the system.2. Remove the front grille to radi-

ator support bracket, and the hoodlatch.

3. Disconnect the refrigerant linesfrom the condenser and receiver.Remove the condenser mountingscrews and remove the condenser re-ceiver assembly. On the Mustang aspecial arrangement is used wherethe radiator retaining studs are partof the condenser.

4. Position and mount the newcondenser. remove the protective


3. Torque the bolts to specifica-tion.

4. Make certain that there are noburrs or dirt on the compressor shaft.Then install the key, and the clutch.

5. If the compressor was moved,reposition it and tighten the mount-ing bolts, then install the belt andadjust the tension.

6. Check the oil level (see Com-mon Adjustments and Repairs).

GUIDE PIN

CRANKCASE BODY

WOODRUFF KEY/

/"::/'

EXPANSION VALVE

REMOVAL1. Discharge the refrigerant from

the system. Disconnect the two wiresfrom the unit, demount the evapo-rator assembly, and set the unit onthe car floor. Disconnect the refrig-erant hoses. On some models, it maybe necessary to remove the assem-bly from the car before going further.

2. Remove the expansion valveprotection shield.

3. Carefully slit the insulation cov-ering the temperature bulb and re-move the temperature bulb clamp.Then disconnect the valve from theinlet pipe and remove the valve.

S'M'"~BASE PLATE GASKET

""CAP SCREW~,

LOCK WASHER

v~'.'aY !-- CAP SCREW

INSTALLATION1. Connect the new valve to the

inlet pipe, and leak test the connec-tion by capping the outlet end of theevaporator and using a suitable re-ducing connector from the valve in-let to a tank of Refrigerant-12. Po-sition the temperature bulb to theoutlet pipe, and install the bulbclamp. Be sure that the bulb, pipe,and clamp are clean and that theclamp is tight. Go over these partswith fine sandpaper to assure this.

2. Wrap the insulating materialaround the temperature bulb, pipe,and valve, and position the rubberseal over the pipe connections.

3. Install the expansion valve pro-tection shield.

4. Connect the refrigerant hosesand leak test the connections.

5. Mount the assembly, connectthe wires, leak test, evacuate andcharge the system.

THERMOSTATIC SWITCHThe thermostatic switch is mounted

to the air conditioner front register.Remove the three register to evapo-rator case screws. Pull the registerfrom the case and pull the sensingtube from the evaporator fins. Re-move the wires and the knob fromthe switch and remove the switch.

/" .SEAL COVER PLATE"'" GASKET / -

BASE PLATE K 1139-E

FIG. 13-York Cylinder Head and Valve Assembly

Installation 3. Carefully remove all accumu-1. Starting with the valve plate lated dirt and foreign material from

gasket, assemble the parts in the or- the seal plate and surrounding areader shown in Fig. 13. Insert the cylin- of the compressor, and position ader head bolts carefully to avoid small drain pan beneath the sealdamaging the gaskets. Before as- plate.sembly apply a film of new refrigera- 4. Remove the seal plate bolts,tion oil to both sides of both gaskets. and remove the plate and gasket. Do

2. Tighten all bolts finger-tight not mar the sealing surfaces, or thethen torque the bolts 1/4 turn at ~ polished shaft surface.time to specification. Then tighten the 5. Remove the carbon seal ringremaining bolts in a sequence so that and seal housing assembly from thethose diagonally opposite are evenly crankshaft. A disassembled view oftightened to the required torque. the cra.nks~aft seal assembly is in-

3. Connect the compressor into cluded m Fig. 13.the system. Check the oil level in the 6. Clean all old gasket materialcompressor, and add or remove oil from the seal plate and the compres-if necessary. (See Cleaning and In- sor. Make certain that the shaft, thespection.) seal plate and the compressor gasket

surfaces are completely clean beforeCRANKSHAFT SEAL installing the new seal.

REMOVAL INSTALLATION1. Lubricate the new shaft seal

1. Isolate the compressor, loosen parts in clean compressor oil, andand remove the belt. position the seal assembly on the

2. Remove the clutch and remove crankshaft, with the carbon ring~he Wood~uff .key (o~ som.e si~ cyl- toward the seal plate.mder engIne Installations It will be 2. Position the new gasket on thenecess~ry to loosen the compressor compressor, center the crankshaft inmountIng bolts and slide the com- the seal plate and install the sealpressor back sli2htlv). Dlate.

PART 16-2 AIR CONDITIONING-FORD 16-19

BELT

8-CYLINDER1. Loosen the idler pulley, then

remove the belt.2. Place the new belt in position,

and slide the compressor toward theoutside of the car and carefullyalign the belt. Then tighten the fourmounting bolts.

3. Adjust the belt tension to spec-ification, using the idler pulley.

6-CYLINDER1. Loosen the alternator mounting

and adjusting screws, and swing thealternator toward the center of thecar until the old belt can be removed.

2. Install the new belt and adjustto specification.

3. Tighten the alternator mount-ing and adjusting screws. Some en-gines have a means of adjusting thebelt with a vertical lock screw.

AIR CONDITIONER BLOWERMOTOR

REMOVAL1. Disconnect the battery ground

cable.2. Remove one screw and the

shield from the right hand lowerside of the evaporator case.

3. Remove the cover plate mount-ing screw and the cover plate at theleft hand side of the evaporator case.

4. Remove the mounting screwsfrom the register panel, and removethe panel from the evaporator case.

Care should be taken not to dam-age the temperature sensing tubewhen drawing it from between thefins of the evaporator.

5. Remove the bolts which retainthe evaporator case to the lower in-strument panel, and lower the evapo-rator to the floor.

6. Remove the mounting bracketfrom each side of the evaporator,and remove the ground wire fromthe left hand side.

7. Remove the clips which con-nect the upper and lower halves ofthe evaporator case, and lift off theupper half of the case.

8. Disconnect the blower wire atthe connector.

9. Remove the blower retainingscrews and remove the blower motorassembly from the evaporator case.(It will be necessary to lift the evap-orator core slightly to allow removalof the blower motor wire.)

10. Remove the blower cages,mounting bracket, and the insulatorpad.

INSTALLATION1. Install the blower cages,

mounting bracket and insulator pad.2. Lift the evaporator core slightly

to allow positioning of the blowermotor wire, and position the blowerin the evaporator case.

3. Connect the blower wire at theconnector.

4. Position the two halves of theevaporator case, and install the con-necting clips.

5. Install the mounting bracket toeach side of the evaporator, and in-stall the ground wire on the left handside.

6. Position the evaporator to thelower instrument panel and installthe mounting bolts.

7. Position the register panel nearthe evaporator and insert the sensingtube between the fins of the evapo-rator. For best results the sensingtube should be inserted in betweenthe next two fins from where it wasoriginally withdrawn. This assures amore positive contact and more exacttransfer of temperature changes. In-stall the mounting screws.

8. Position the cover plate to theleft hand side of the evaporatorcase and install the mounting screw.

9. Position the shield to the lowerright hand side of the' evaporatorcase and install the retaining screw.

10. Connect the battery groundcable.

It may be necessary in the case ofconsole equipped cars to remove theevaporator assembly from the cal' inorder to remove the blower motor.

CLUTCH1. Loosen the belt.2. Energize the clutch and loosen

and remove the clutch mounting bolt.3. Install a 5/8-11 bolt in the clutch

drive shaft hole. With the clutchstill energized, tighten the bolt toloosen the clutch from the shaft,then remove the magnetic clutch.For clearance on some installations,it is necessary to loosen the compres-sor mounting bolts and slide the com-pressor back slightly.

4. Install the clutch, the clutchmounting bolt, and the washer.

5. Energize the clutch, and torquethe bolt to specification.

CLEANING AND INSPECTION

COMPRESSOR

On compressor clutch installa-tions, carefully remove any burrs ordirt that may be on the compressorshaft. The shaft must be dry and

brightly polished. Then install thekey in the shaft.

When the compressor is disassem-bled, completely clean all surfaces ofgasket shreds and foreign objects.

If the compressor shaft seal is

being replaced, inspect the compres-sor internally and clean out dirt orchips as required.

When installing a new controlassembly or parts, inspect for dirtand foreiu;n objects.

16-20

AIR CONDITIONING-SELECTAIRE

Page16-20

Page16-2416-2416-2416-2416-2516-2516-2516-25

Section1 Description and Operation. . . . . . . . . . . . . . . .

Cornet, Falcon and Fairlane SelectAire AirConditioning and Heating System. . . . . .

Controls Air Velocity. . . . . . . . . . . . . . . . . . . . . . . . . . .

DischargeAir AjC-Heater Electrical System. . . . . . . . . . . .

2 Removal and Installation. . . . . . . . . . . . . . . . .

SectionHeater Air Conditioner Assembly. . . .EvaporatorCore Heater Core. . . . . . . . . . . . . . . . . . . . . . .

ExpansionValve Blower Motor Switch. . . . . . . . . . . . . . .

BlowerMotor AjC-Heat Door Vacuum Actuator. . .

Heat-Defrost Door Vacuum Actuator

DESCRIPTION AND OPERATION

COMET, FALCON ANDFAIRLANE SELECTAIRE AIRCONDITIONING ANDHEATING SYSTEM

The SelectAire air conditioningand heating assembly is containedentirely in one case under the instru-ment panel.

Outside air is drawn in from thecowl through the outside air doorinto the right vent duct, into theblower scroll, forced through the eva-porator core, through and/ or aroundthe heater core then mixed and dis-charged through either the A/C airduct or through the heat-defrostplenum air outlet, depending on theposition on the control setting (Figs.1 and 2).

The temperature door is located tothe left of the evaporator core and tothe rear of the heater core in the leftside of the case.

The A/C-heat door is located inthe left rear corner of the case, andthe heat-defrost door is in the plenumchamber attached to the rear face ofthe case assembly.

A single defroster nozzle leadingto two openings in the instrumentpanel is attached directly in theplenum chamber with a clip. TheComet defroster nozzle is unique indesign; the Fairlane and Falcon arethe same.

The A/C registers located in thelower instrument panel are located;one to the far left; one to the farright; and a double register in thecenter.

The Fairlane and Falcon registersare barrel type registers that can bemoved up and down and the verticalvanes are positioned by movine: aFIG. 2-Comet, Falcon and Fairlane A/C-Heater Air Flow-HEAT

16-2016-2116-2116-2216-2216-24

PART 16-3 AIR CONDITIONING SElECTAIRE 16-21

CONTROL ASSEMBLY. 19980

I TEMPERAffi~EAtR.,... BLENOLEVER

-=;

YELLOW -f?-BLOWER MOTOR

SWITCH

horizontal wheel within the assem-bly. The Comet registers are posi-tioned by moving a swivel knob orlever in the center of the registersthat control both horizontal and ver-tical vanes in the assembly.

The blower motor and wheel as-sembly is located in the blower scrollimmediately forward of the rightvent duct assembly. The evaporatorcore is located in a diagonal positionin the center of the case; and theheater core in a diagonal position inthe left side of the case.

Vacuum actuators that operate thenormal-recirc door in the right vent,and the A/C-heat door, are con-trolled by a vacuum selector on thecontrol head assemblv.

,.",.

;! X/:~ ~~.~<;' j w.,"" .-- .., HITE

"~- REDAI A~K BLUE

,\ A/C.HEATER-

, AIR DISTRIBUTIONCONTROL LEVER

K 1814-A

FIG. 3-Comet A/C-Heater Control Assembly

CONTROLSThe air temperature is controlled

by the location of the temperature airblend lever in the control assembly(Figs. 3, 4 and 5). As the lever ismoved from cool to warm, a Bow-den cable moves the (temperatureblend door) from maximum coolingposition to minimum cooling posi-tion. A vacuum switch on the controlassembly is actuated to supply vac-uum to close the water valve whenthe temperature lever is in the maxi-mum cool setting and the A/C-heat-er, air distribution control lever is ineither A/C position. See the A/C-Heater Control Setting Chart, Table1, and the Vacuum Schematic inFig. 6.

Air distribution is controlled bythe A/C-heater lever in the controlpanel assembly and the blower switchsetting. The lever actuates a vacuumselector switch on the control assem-bly which in turn operates vacuumactuators at the outside or recirculat-ing air door in the right vent duct;the A/C-heat air-blend door in thecase, and the heat-defrost door in theplenum chamber.

The blower switch must be on toengage the compressor clutch for airconditioning. With the A/C-heatercontrol lever in either air condition-ing position, the air conditioner heatdoor is in the air conditioning posi-tion (vacuum) and pressure is appliedto the compressor clutch switch toclose the circuit and engage theclutch.

AIR VELOCITY

lllree speeds are provided for theblower fan with a four positionswitch in the control assembly and aresistor assembly located in the blow-

K 1850- A

FIG. 4-Falcon A/C-Heater Controls

EATER-~IBUTION"LEVER

1 6-22 GROUP 16 VENTILATING, HEATING, AND ACCESSORIES

over the tunnel or to the windshielddefroster nozzle, depending on thelocation on the heat-defrost doorwithin the plenum.

AfC-HEATER ELECTRICALSYSTEM

The A/C heater electrical circuitis protected by a 25 ampere circuitbreaker and consists of the blowerswitch on the control assembly,blower motor, blower motor resistor,A/C thermostatic switch, clutchswitch and compressor clutch sole-noid (Fig. 7).

K 1851

FIG. 5-Fairlane A/C-Heater Controls

er housing. The resistor in the blowermotor circuit controls the low andmedium blower motor speeds.

DISCHARGE AIRAn AI C floor cooler tube located

at the lower rear corner of the ductis used to discharge cold air to thecenter of the left front floor area. Adeflector on the tube can be posi-tioned manually for driver comfort.

The two outboard registers can be

closed by a push-pull knob and leverthat actuates the balanced door be-hind the registers. On the Fairlaneand Falcon the knob is located belowthe registers on the lower lip of theinstrument panel. The Comet controlknob is located in the instrumentpanel at the inboard side of each out-board register.

The plenum chamber located onthe left rear face of the case assem-bly distributes heated air to the floor

K 1852 - A

FIG. 6-Comet, Falcon and Fairlane AfC-Heater Vacuum Schematic

PART 16-3 - AIR CONDITIONINGSELECTAIRE 16-23

TABLE 1 .SELECTAIRE CONTROL SETTING CHART

FUNCTIONAL CONTROL LEVER POSITIONA7C 1ii:if"

NORMOR

HEAT

DEFOR

DEFROST

OFF

OPEN TORECIRC

V

OPEN TO OUTSIDENY

AIR

D00R

OUTSIDERECIRC

AfCHEAT

HEATDEFROST

NV

HEATPOSITION

NVNV

.CLUTCHSWITCH

BLOWERSWITCH

ONSEE WIRING DIAGRAM

ON-L-M-H

OFF

OFFON-RECIRCCONDITION

I _9_N.::~-_~-~.-I OFF-RAM AIR

OPEN

ON-L-M-HOFF-RAM AIR

WATERVALVE

VACUUMI SWITCH

COOLMODWARMCOOLMODWARM

COOL

VACUUM SWITCH BY-PASSEDBY SELECTOR SWITCH CIRCUIT

NVCLOSED

~UOPEN I

V

NV

SELECTOR SWITCH CIRCUITOPENS WATER VALVE BY

CLOSING OFF VACUUM

WATERVALVE

TEMp

D00R

NY

ALL COLD "AIR BY-PASSESHEATER CORE

COLD AIR PASSESTHRU AND AROUND

HEATER CORE THEN MIXEDMOD

ALL COLD AIR PASSESTHRU HEATER COREWARM

L-LOWM-MEDIUMH-HI~H

V-VACUUMNV-NO VACUUM

MOD-MODULATED

FIG. 7-Comet, Falcon and Fairlane A/C-Heater Wiring Diagram

16-24 GROUP 16 VENTILATING, HEATING, AND ACCESSORIES


INSTALLATION1. Position the assembly under the

instrument panel resting it on thefloor.

2. Connect the thermostatic switchwire (left top of plenum).

3. Connect and adjust (as shownin Fig. 8), the temperature-blenddoor Bowden cable.

ADJUSTING NUTS

K 180S-A

FIG. 8-Temperature-Blend DoorBowden Cable Adjustment-ExceptMustang

HEATER AIR CONDITIONERASSEMBLY

REMOVAL1. Partially drain the cooling sys-

tem.2. Discharge the air conditioning

system.3. Disconnect the heater hoses at

the dash and remove the weatherseal pads:

4. Unwrap the insulation from thesensing bulb and unclamp the bulb.Disconnect the receiver to evapora-tor hose at the dash panel. Leave theexpansion valve attached to the hose.Remove the weatherseal at the dash.

5. Disconnect the evaporator tocompressor hose at the dash panel.

6. Remove the glove box liner.7. Remove the right hand fresh

air duct from the cowl upper panel.Remove the vacuum line from thevacuum actuator and remove theactuator.

8. Disconnect the wires from theresistor block and thermostaticswitch.

9. Disconnect the three plenum toinstrument panel air ducts from theplenum and position them out ofthe way.

10. Disconnect the vacuum linefrom the heat-defrost door vacuumactuator.

11. Remove the defroster plenumand vacuum actuator as an assembly.

U. Remove the instrument panelupper and lower support and removethe speaker grille.

13. Remove the speaker retainingscrews and position the speaker outof the way.

14. Remove the defroster nozzle.15. Remove the evaporator case

drain hose clamp and drain hose atthe dash.

16. Cover the floor mats and re-move the 4 nuts retaining the heaterair conditioner assembly to the dash.Pull the assembly from the dash andrest it on the car floor.

17. Disconnect the wire from thethermostatic switch.

18. Disconnect the temperature-blend door actuating Bowden cableand the vacuum line at the A/C-heatdoor vacuum actuator.

19. Position the front seat all theway back, turn the bottom of the as-sembly toward the rear of the carand remove the assembly from thecar.

stall the expansion valve temperaturesensing bulb.

15. Connect the receiver to eva-porator hose at the dash and installthe seal and temperature bulb insula-tion.

16. Fill the cooling system.17. Leak test, evacuate and charge

the air conditioning system.18. Check the operation of the

system.

EVAPORATOR CORE1. Remove the heater air-condi-

tioner assembly (in this section), andplace it on a bench.

2. Remove the thermostatic switchfrom the evaporator.

3. Separate the heater housingfrom the plenum.

4. Remove the evaporator corefrom the housing.

5. Transfer the mounting bracketand rubber pad to the new evapor-ator.

6. Install the evaporator in theplenum.

7. Position the plenum to thehousing and install the mountingscrews, clips, resistor block wiresand seal and retainer.

8. Install the heater-air condi-tioner assembly (in this section).

HEATER CORE1. Remove the heater air condi-

tioner assembly (in this section), andplace it on a bench.

2. Separate the heater housingfrom the plenum.

3. Slip the heater core out of theplenum.

4. Transfer the heater core sealfrom the old core to the new core.

5. Slip the new core with seal intothe plenum.

6. Install the plenum to the heaterhousing. Connect the wires at theresistor block, and install the sealand retainer at the evaporator tubes.

7. Install the heater-air condi-tioner assembly (in this section).

EXPANSION VALVE1. Discharge the air conditioning

system.2. Remove the insulation and re-

move the sensing bulb from the com-pressor to evaporator line.

3. Disconnect the expansion valvefrom the evaporator and disconnectthe valve from the valve to con-denser line.

4. Connect the vacuum line at theA/C-heat door vacuum actuator.

5. Position the heater-air condi-tioner assembly to the dash and in-stall the mounting nuts.

6. Install the defroster nozzle, thespeaker and speaker grille.

7. Install the instrument panelupper and lower supports.

8. Install the defroster plenumand connect the red vacuum line tothe heat-defrost door vacuum actu-ator.

9. Connect the wires to the resistorblock and thermostatic switch.

10. Install the right hand fresh airduct and the vacuum actuator and in-stall the white vacuum line to theactuator.

11. Install the glove box liner andinstall the 3 plenum to instrumentpanel air ducts.

12. Position the rubber seals andconnect the heater hoses.

13. Install the evaporator casedrain hose.

14. Connect the compressor-to-evaDorator hose at the dash and in-

1 6-25PART 16-3 - AIR CONDITIONING - SELECTAIRE

4. Position and connect the newvalve to the evaporator.

5. Connect the condenser to valveline to the valve.

6. Install and insulate the sens-ing bulb.

7. Leak test, evacuate and chargethe system. Check the system opera-tion.

sembly. Disconnect the vacuum linefrom the actuator and position it outof the way.

3. Disconnect the plug from theresistor block and remove the resis-tor block.

4. Remove the blower motorcover and remove the motor andblower wheel.

5. Remove the blower wheel andinstall it on the new motor.

6. Install the motor and wheeland ground wire in the heater case.Install the blower cover.

7. Install the resistor blo;;k tothe plenum and connect the wires.Check the blower operation.

8. Install the fresh air duct andvacuum actuator.

9. Install the glove box.

6. Disconnect the A/C plenum toright hand register air duct at theplenum and position it out of theway.

7. Disconnect the vacuum linefrom the actuator, remove the act-uator mounting screws, disconnectthe actuator to door lever arm at thelever and remove the actuator.

8. Install the new vacuum actua-tor and connect the actuator armand vacuum line.

9. Connect the right hand regis-ter air duct.

10. Position and install the de-frost~r nozzl~.

11. Install the speaker and speakergrille.

12. Install the instrument panelupper and lower support.

13. Connect the red vacuum lineto heat-defrost door vacuum actua-tor.

AfC-HEAT DOOR VACUUMACTUATOR

1. Remove the glove box liner.2. Remove the vacuum line at the

actuator, and remove the defrosterplenum chamber.

3. Remove the instrument panellower and upper support.

4. Remove the speaker grille, thespeaker mounting screws, and posi-tion the speaker out of the way.

5. Remove the defroster nozzle.

14. Install the glove box liner.

HEAT-DEFROST DOORVACUUM ACTUATOR

The defrost door vacuum actuatormay be replaced after first removingthe defroster plenum from the heat-er assembly.

After installing the new actuator,check its operation for full travelof the air door.

BLOWER MOTOR SWITCH1. Remove the air conditioning

plenum to center register air duct.Disconnect the plenum to right regis-ter air duct at the plenum and posi-tion it out of the way.

2. Remove the switch knob. Re-move the switch mounting screw re-taining the switch to the controlassembly and lower the switch.

3. Disconnect the wires from theswitch and remove the switch.

4. Connect the wires to the newswitch and install it in the controlassembly.

S. Install the two air ducts.6. Install the switch knob and

check the operation of the switch.

BLOWER MOTOR

1. Remove the glove box.2. Remove the right hand fresh

air duct and vacuum actuator as-

16-26

RADIO

Page. . .16-26. . .16-26. . .16-26. . .16-26. . .16-27

Section1 Description and Operation. . . . . . . . . . . . .

Cars and Radio Types 2 Diagnosis and Testing. . . . . . . . . . . . . . . .

Radio Diagnosis Guide. . . . . . . . . . . . . . ,3 Common Adjustments and Repairs. . . . .

Push Button Adjustment-Comet, Falconand Fairlane

Section Page4 Removal and Installation. . . . . . . . . . . . . . . . .16-27

Radio Receiver 16-27Antenna-Comet, Falcon, and Fairlane .16-27Front Speaker-Falcon and Fairlane .16-28Rear Speaker 16-28Interference Suppression. . . . . . . . . . . . . . . . .16-28.16-27

II DESCRIPTION AND OPERATIONCARS AND RADIO TYPES On the Comet and Mustang, a

band selector switch is provided forselection of either the AM or the FMbroadcast band. The five push but-tons can be preset to select five AMstations or five FM stations or anycombination thereof, however, thepush buttons cannot be used tochange from one broadcast band tothe other. The band selector switchmust first be positioned to the de-sired band before selecting stationswith the push buttons. When select-ing stations with the manual tuningcontrol, the band (AM or FM) inuse is controlled by the band selectorswitch, if the band selector switch isset to AM, the manual tuning con-trol (right hand knob) will selectAM stations.

ModelNo.

Manufacturerand Type

Car

6TPEF6TBG

Philco AMBendix AM-FM

Comet

6TPDPhilco AMFalcon

6TPOPhilco AMPairlane

6TPZPhilco AMMustang

On all cars except the Comet the pushbuttons on the AM-FM radio may bedivided between AM and FM sta-tions.

The antenna is mounted on theright fender. A rear seat speaker isavailable. The radios have push but-ton tuning as well as manual tuning.

EJ DIAGNOSIS AND TESTINGRADIO DIAGNOSIS GUIDE

NO RECEPTION substitute a known good antenna andspeaker.Be sure to turn off the radio re-ceiver before removing or installingthe speaker.

If the radio still will not play, re-move the receiver for a major repair.

1. Burned out fuse.2. Defective antenna.3. Shorted speaker lead or defec-

tive speaker.4. Reversed battery polarity.Make certain that voltage is avail-

able at the A lead (12 volts), then

NOISY OR ERRATICRECEPTION

NOISY RECEPTION-ENGINENOT RUNNING

1. Loose connections.

NOISY RECEPTION-ENGINE-RUNNING

1. Defective suppression equip-ment.

2. Suppression condensers notproperly grounded.

3. Receiver not properly groundedto the instrument panel.

NOISY RECEPTION-CAR INMOTION

1. Loose or broken lead-in cable.2. Loose or defective radio an-

tenna.3. Defective wheel static collector.

CONTINUED ON NEXT PAGE

PART 16-4 RADIO 16-27

RADIO DIAr:Nn~l~ r:llln~_Il'ft"+:""ArI'

the car outside of the garage. Plugthe antenna lead into the antennasocket in the radi9, and extend theantenna wand through the openwindow of the car.

it will not be necessary to removethe suspected antenna or speaker.Disconnect the antenna or speakerat the radio and plug in the knowngood unit. Check the antenna with

TESTINGTests for any of the components

in the radio system may be made bysubstituting known good parts. Inthe case of an antenna or speaker,


button to be set to unlock the pushbutton mechanism. The letters PMmust appear at the top of the pushbutton face. If the letters AM ap-pear, pull the push button out ap-proximately 1ho inch further untilthe push button is free to rotate androtate the push button 1800 to thePM position. Carefully tune in thedesired PM station with the manualtuning knob. After the station isclearly tuned in, push the buttonstraight in until it stops and then re-lease it. Repeat this procedure forthe remaining buttons.

PUSH BUTTON ADJUSTMENT-COMET, FALCON ANDFAIRLANE

Turn the radio on, and allow it towarm up for 15 minUtes. Extend theantenna to a height of approximately33 inches.

AM PUSH BUTTONSPlace the band selector switch to

the AM position. Pullout the pushbutton to be set to unlock the pushbutton mechanism. The letters AMmust appear at the top of the pushbutton face. If the letters FM appear,

pull the push button out approxi-mately 1110 inch further until the pushbutton is free to rotate and rotatethe push button 1800 to the AM po-sition. Carefully tune in the desiredAM station with the manual tuningknob. After the station is clearlytuned in, push the button straight inuntil it stops and then release it. Re-peat this procedure for the remain-ing buttons.

FM PUSH BUTTONSPlace the band selector switch to

the PM position. Pullout the push


6. Install the radio control knobs.7. Check the radio operation.

6. Remove the radio assemblyfrom the instrument panel.

INSTALLATION1. Position the radio to the instru-

ment panel, and then install thewashers and retaining nuts at theknob shafts. Be sure that the radiomounting stud enters the supportbracket.

2. Install the radio supportbracket retaining nut. Torque allmounting nuts to specification.

3. Connect the antenna lead tothe radio.

4. Connect the radio speaker lead.5. Connect the radio power lead

and the pilot light lead.

RADIO RECEIVER

REMOVALTo remove the radio receiver,

proceed as follows:1. Pull the radio control knobs

off and remove the nuts and washersretaining the radio to the instrumentpanel.

2. Disconnect the antenna lead atthe right side of the radio (at theback of the AM-PM radio).

3. Disconnect the speaker lead.4. Disconnect the radio lead wire

and the pilot light wire from thequick disconnects.

5. Remove the. radio supportbracket to radio retaining nut.

ANTENNA-COMET, FALCONAND FAIRLANE

1. Disconnect the antenna leadfrom the side of the radio receiver(at the back of the AM-FM radio).Tie a string to the end of the an-tenna lead.

2. Remove the antenna cap, fourscrews, and remove the antenna as-sembly.

3. Tie the string to the new an-tenna lead.

4. Position the antenna assembly

16-28 GROUP 16 VENTilATING. HEATING. AND ACCESSORIES

denser is an internal part of the al-terference suppression items used ondenser, and wheel static collectorsare also used. A constant voltageregulator choke and a hood bondingclip are used on the Comet only. In-terference suppression items used onthe Fairlane are shown in Fig. 2.

in the opening, put the spacer inposition on the antenna and installthe antenna.

5. Pull the antenna lead throughthe opening and route the lead un-der the glove box and connect thelead to the radio.

compartment. On the station wagonthe speaker is mounted on the leftrear trim panel. Remove the trimpanel to replace the speaker.

INTERFERENCE SUPPRESSIONInterference suppression items are

shown in Fig. 1. An alternator con-

FRONT SPEAKER-FALCONAND FAIRLANE

1. Disconnect the speaker wiresfrom the radio receiver.

2. Remove the glove box.3. Remove the speaker retaining

nuts and remove the speaker throughthe glove box opening.

4. Install the new speaker throughthe glove box to the instrumentpanel and secure it with retainingnuts.

5. Connect the speaker leads tothe radio and check the radio opera-tion.

6. Install the I!love box.

K 1494.CREAR SPEAKERThe rear seat speaker is accessible

for replacement from the luggage FIG. l-Radio Interference Suppression-Except Fairlane

(:,..,"ii

\ii\'

BEND COTTER KEY AWAY FRC».\

SPINOLe'CENT ER HOLE 50 ITWILL!NOT INTERFERE WITH

5TAT1C COLLECTOR '-

&:

LOCATIONOFR,H. HOOD".30 BONDING STRAPL.H. SYM.OPP.

CONDENSER. 18832. A

~'10 \'-_\ SPRING ASSEMBLY. WHEEL

STATIC COLLECTOR 18938: A ~~~\~i'I '

!

Iip,i'I

<9 i1

~

INSTAllATION OF RADIO CONDENSER I"ON BOTTOM OF VOL TAGE REGULA TOR ASSEMB~Y

FOR 6 & 8 CYLINDER ENGINES

\~---INST ALLA TIONOF ST A TIC COLLECTOR

.;

6 & 8 CYLINOER CYL. ENGINESKl560-C

FIG. 2-Fairlane Radio Int~rf~r~nl'" ~llnnr,.cci"n

16-29

SPECIFICATIONS

AIR CONDITIONER COMPRESSORAir

ConditionerHeaterTorque (ft-lbs)

YorkLocation

Blower MotorCurrent Drawat 12 Volts

High Speed

Medium Speed

low Speed

6-8 Amps

4-6 Amps

2-4 Amps

6.5-7.5 Amps

4.5-5.5 Amps

3.0-4.0 Amps

Cylinder Head

Front Seal Plate

Service Valves IRotolock)

Mounting Bolts

Oil Filler Plug

Clutch Mounting Bolt

Base Plate

Back Plate

14.18

13-17

35-Max.

14-17

18-22

15.22

7.11

7-10

SFE 14 Fuse

Fuse Panel

3AG 15 Fuse

In Line

CIRCUITPROTECTION

Location

RADIO CURRENT DRAW

Amp Max. at 12 Volts Oil Capacity_3/4 inch 00 ounces)Use Suniso #5, or Capella E

MOUNTING TORQUE (in-lbs)

DRIVEN BELT TENSION

MAGNETIC CLUTCH CURRENT DRAW

~2 Amperes at 12 Volts I

VENTILATING SYSTEM AND HEATER - Mustang - ventilation.pdf · heater case assembly to service ma- ature door in the heater housing jor components of the heater assem- from minimum

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