Technical Car Experts Answers everything you need: how to remove blend door actuator on 2003 Mercury Grand Marquis?

Air Mix Mode Actuator Blend Door

Removal & Installation

Before servicing the vehicle, refer to the Precautions section.

Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.

Remove the instrument panel.

Disconnect the electrical connector from the blend door motor/actuator.

Remove the four screws holding the blend door actuator to the plenum.

Remove the temperature blend door actuator.

Fig. Blend door actuator electrical connector

Fig. Blend door actuator mounting to plenum

To install:

Installation is reverse of removal.

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Blower Motor

Removal & Installation

Before servicing the vehicle, refer to the Precautions section.

Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.

Disengage the wire harness connectors from the retainer.

Disconnect the blower motor electrical connector.

Remove the motor cooling hose.

Remove the screws and remove the blower motor.
NOTE
Prior to removing a wheel that is to be reused, clean any corrosion from the blower motor shaft to prevent damage to the wheel mounting shaft.

Remove the wheel from the blower motor as follows:

Remove the push clip.

Remove the wheel from the blower motor.

Fig. Blower motor cooling hose

Fig. Blower motor mounting plate

To install:

Install or connect the following:

Wheel to the blower motor, if removed.

Blower motor and securely tighten the screws.

Motor cooling hose

Blower motor electrical connector

Wire harness retainers

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Compressor:--

Removal & Installation

CAUTION

Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

Before servicing the vehicle, refer to the Precautions section.

Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.

If installing a new air conditioning compressor due to an internal failure of the old unit, you must carry out the following procedures to remove contamination from the air conditioning system:
NOTE
Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator.

If A/C flushing equipment is available, carry out the flushing of the air conditioning system prior to installing a new air conditioning compressor.

If A/C flushing equipment is not available, carry out filtering of the air conditioning system after a new air conditioning compressor has been installed.

Install a new evaporator core orifice (19D990) as directed by the A/C flushing or filtering procedure.

Install a new suction accumulator (19C836) as directed by the A/C flushing or filtering procedure.

If flushing of the air conditioning system has not been carried out, recover the refrigerant.

Remove the drive belt from the A/C compressor pulley.

Disconnect the field coil electrical connector.

Loosen the bolt and detach the compressor manifold and tube assembly from the A/C compressor.

Discard the O-ring seals.

Raise the vehicle.

Disconnect the crank sensor electrical connector.

Remove the nut and detach the wiring harness clips.

Remove the studs and the A/C compressor.

Fig. A/C compressor field coil connector

Fig. A/C compressor manifold and tube assembly

Fig. A/C compressor studs and nuts

To install:

Install new O-ring seals lubricated in clean PAG oil.

If filtering of the refrigerant system is not to be carried out, lubricate the refrigerant system with the correct amount of clean PAG oil.

If filtering of the refrigerant system is not to be carried out, evacuate, charge and leak test the refrigerant system.

Install or connect the following:

A/C compressor studs and torque to 18 ft. lbs. (25 Nm)

A/C compressor

Crank sensor electrical connector

Compressor manifold and tube assembly to A/C compressor and torque the bolt to 15 ft. lbs. (21 Nm)

A/C compressor field coil electrical connector

Accessory drive belt

Partially refill the system and check for leaks.

If no leaks are present, complete refrigerant charging.

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Control Panel:--

Removal & Installation

Electronic Automatic Temperature Control

Before servicing the vehicle, refer to the Precautions section.

Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.

Remove or disconnect the following:

Finish panel

Control head electrical connectors

Control head vacuum harness

Automatic temperature control (EATC) module from the instrument panel

Fig. EATC mounting

Fig. EATC electrical and vacuum harness

To install:

Installation is reverse of removal.

Manual Control

Before servicing the vehicle, refer to the Precautions section.

Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.

Remove or disconnect the following:

Finish panel

Control head electrical connectors

Control head vacuum line

Climate control head

Fig. Control panel mounting.

Fig. Control panel electrical connectors and vacuum line.

To install:

Installation is reverse of removal.

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No air from defrost:---

Vehicle air conditioning is the cooling r refrigeration of the air in the passenger compartment. Refrigeration I accomplished by making practical use of the laws of nature. HEAT GOES TO LESS HEAT. All this means is that heat transfers. If two substances of different temperature are placed near each other, the heat in the warmer substance will always travel to the colder substance until both are of equal temperature.

As a fail-safe, the air handling system is designed to provide defrost when no vacuum is applied to any of the vacuum control motors. This is done to prevent a situation where defrost cannot be obtained due to a system vacuum leak. Instead, a leak in the vacuum control circuit will send all airflow to the defroster outlets. This condition may occur during acceleration (slow vacuum leak), may exist at all times (large vacuum leak), and may happen only when certain specific functions are selected, indicating a leak in that portion of the circuit.

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Heater Core:-- FOR town car and mercury is similar for heater code replacing procedure.

Removal & Installation

If equipped, turn the air suspension service switch to the OFF position before raising the vehicle.

Drain the cooling system.

Remove or disconnect the following:

Negative battery cable

Front seats

Carpeting

Rear airflow duct

Heater hoses

Remove the driver-s side air bag module by removing or disconnect the following:

SRS module-to-steering wheel bolts, from both sides of the steering wheel.

SRS module and disconnect the electrical connector

Horn switch electrical connector

Remove the passenger-s side SRS module by removing or disconnecting the following:

Open the glove box and disconnect the glove compartment isolator

Push inward on the 2 glove box door tabs and lower it

SRS module-s electrical connector

SRS module-to-instrument panel bolts and the module

Remove the instrument panel by removing or disconnecting the following:

Speed control servo nuts and move the servo aside

Bolt and disconnect the left side bulkhead connector

Left side bulkhead connector from the dash panel

Windshield washer fluid reservoir screw, and position the reservoir aside

Blower motor electrical connector

Air conditioning pressure cut-off switch electrical connector

In-line electrical harness connector

Electronic Automatic Temperature Control (EATC) variable blower motor controller electrical connector

Right front wheel

Right front fender splash shield bolts and move the shield away from the cowl

Wiring harness from the evaporator case

Wiring harness from the cowl

Right side instrument panel lower insulator pushpins, disconnect the power point electrical connector, remove the courtesy lamp from the socket and remove the insulator

Unseat the wiring grommet and feed the wiring harness through the cowl

Cowl side trim panels and the windshield side garnish moldings from both sides

Locking clip and the Electronic Crash Sensor (ECS) module electrical connector

Antenna connector

Ground wire bolts from the right side

EATC hose at the evaporator housing

Bolt and disconnect the bulkhead connector from the right side

Pull the door weatherstrip seals away from the instrument panel on both sides

Tunnel brace trim cover

Climate control head vacuum harness connector

Instrument panel tunnel brace nuts and the brace

Ground wire bolts from the left side

Wiring harness connectors from the left side

Parking brake switch electrical connector
1. Pry out the instrument panel defroster opening grille, disconnect the electrical connectors and the remove the grille.

Remove or disconnect the following:

3 upper instrument panel screws

Instrument panel cowl side nut from both sides

Instrument panel cowl side bolt from the left side

Instrument panel

Windshield wiper mounting arm and the pivot shaft

Electrical connector and remove the upper cowl extension screw and the extension

Vacuum hoses and the wire harness connector from the evaporative emissions canister purge valve

Evaporative emissions purge valve nuts and the valve

Cowl side nut

Right side rear fender apron screws and reposition the apron

Evaporator housing nut and screw

Vacuum hoses and the wiring harness connectors

Plenum chamber-s lower flange nuts

Plenum chamber-s upper flange nut and the plenum chamber

Heater core cover-to-heater plenum chamber screws and the cover

Seal and the heater core

Fig. View of the instrument panel finish panels

Fig. Exploded view of the instrument panel-Crown Victoria and Grand Marquis

Fig. Exploded view of the heater air plenum chamber, the evaporator housing and the air inlet duct

Fig. View of the heater core

Fig. Exploded view of the instrument panel-Town Car

To install:

Install or connect the following:

Seal and the heater core

Heater core cover and the cover-to-heater plenum chamber screws

Plenum chamber and the plenum chamber-s upper flange nut

Plenum chamber-s lower flange nuts

Vacuum hoses and the wiring harness connectors

Evaporator housing nut and screw

Right side rear fender apron and the apron screws

Cowl side nut

Evaporative emissions purge valve and the valve nuts

Vacuum hoses and the wire harness connector to the evaporative emissions canister purge valve

Electrical connector; then, install the upper cowl extension screw and the extension

Windshield wiper mounting arm and the pivot shaft

Install the instrument panel by installing or connecting the following:

Instrument panel

At the left side, install the instrument panel cowl side bolt

Instrument panel cowl side nut on both sides

3 upper instrument panel screws

Electrical connectors and the install the instrument panel defroster opening grille

Parking brake switch electrical connector

Wiring harness connectors on the left side

Ground wire bolts on the left side

Instrument panel tunnel brace and the brace nuts

Climate control head vacuum harness connector

Install the tunnel brace trim cover.

Door weatherstrip seals to the instrument panel on both sides

Bulkhead connector and tighten the bolt on both sides

EATC hose at the evaporator housing

Ground wire bolts on the right side

Antenna connector

ECS module electrical connector and the locking clip

Cowl side trim panels and the windshield side garnish moldings on both sides

Feed the wiring harness through the cowl and seat the wiring grommet

Right side instrument panel lower insulator, connect the power point electrical connector, install the courtesy lamp to the socket and secure the insulator with pushpins

Wiring harness from the cowl

Wiring harness to the evaporator case

Right front fender splash shield and the shield bolts

Right front wheel

EATC variable blower motor controller electrical connector

In-line electrical harness connector

Air conditioning pressure cut-off switch electrical connector

Blower motor electrical connector

Windshield washer fluid reservoir and the reservoir screw

Left side bulkhead connector to the dash panel

Left side bulkhead connector and tighten the bolt

Speed control servo and the servo nuts

Right SRS module and torque the module-to-instrument panel bolts to 62-97 inch lbs. (7-11 Nm)

Right SRS module electrical connector

Glove compartment isolator

Glove box door

Horn switch electrical connector

Electrical connector and install the left SRS module

Left SRS module-to-steering wheel bolts on both sides of the wheel, and torque the bolts to 90-122 inch lbs. (10-14 Nm)

Rear airflow duct

Carpeting

Front seats

Heater hoses

Refill the cooling system.

Connect the negative battery cable.

Operate the engine to normal operating temperature. Check the climate control operation and check for leaks.

Town Car

Disconnect the negative battery cable.

Drain the cooling system and disconnect the heater hoses from the heater core tubes. Plug the hoses and the heater core tubes to prevent coolant leakage.

Remove the 3 nuts located below the windshield wiper motor attaching the left end of the plenum to the dash panel. Remove the 1 nut retaining the upper left corner of the evaporator case to the dash panel.

Disconnect the vacuum supply hose(s) from the vacuum source. Push the grommet and vacuum supply hose(s) into the passenger compartment.

Remove the right and left lower instrument panel insulators.

On 1988-93 vehicles:
1. Remove the 3 glove compartment hinge screws, disconnect the check arms and remove the glove compartment. Loosen the right door sill plate and remove the right side cowl trim panel. Remove the bolt attaching the lower right end of the instrument panel to the side cowl. Remove the instrument panel pad as follows:
2. Remove the 2 screws attaching the pad to the instrument panel at each defroster opening. Be careful not to drop the screws into the defroster openings.
3. Remove the one (shouldered) screw attaching each outboard end of the pad to the instrument panel.
4. Remove the line of screws attaching the lower edge of the pad to the instrument panel. Pull the instrument panel pad rearward and remove it from the vehicle.

On 1988-89 vehicles:
1. Remove all instrument panel mounting screws and pull the instrument panel back as far as it will go without disconnecting any wiring harnesses.
2. Make sure the nuts attaching the instrument panel braces to the dash panel are removed.
3. Loosen the right door sill plate and remove the right side cowl trim panel.
4. Disconnect the temperature control cable from the ATC sensor. Disconnect the vacuum harness line connector from the ATC sensor harness and disconnect the electrical connector from the ATC servo connector.

On 1990-00 vehicles:
1. Remove the cross body brace and disconnect the wiring harness from the temperature blend door actuator.
2. Disconnect the ATC sensor tube from the evaporator case connector.

Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.

Remove the 2 hush panels.

Remove 1 plastic push fastener retaining the floor air distribution duct to the left end of the plenum. Remove the left screw and loosen the right screw on the rear face of the plenum and remove the floor air distribution duct.

Remove the 2 nuts from the 2 studs along the lower flange of the plenum.

Carefully move the plenum rearward to allow the heater core tubes and the stud at the top of the plenum to clear the holes in the dash panel. Remove the plenum from the vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull the lower edge of the instrument panel rearward, as necessary, while rolling the plenum from behind the instrument panel.

On 1988-1989 vehicles, remove the ATC servo from the plenum.

Remove the 4 retaining screws from the heater core cover and remove the cover from the plenum assembly. Pull the heater core and seal assembly from the plenum assembly.

To install:

Carefully install the heater core and seal assembly into the plenum assembly. Visually check to ensure that the core seal is properly positioned. Position the heater core cover and install the 4 retaining screws.

On 1988-1989 vehicles, install the ATC servo on the plenum.

Route the vacuum supply hose through the dash panel and seat the grommet in the opening.

Position the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the evaporator case.

Install the 3 nuts on the studs along the lower flange and one on the upper flange of the plenum. Install the 3 nuts below the windshield wiper motor to attach the left end of the plenum to the dash panel and the one nut to retain the upper left corner of the evaporator case to the dash panel.

Position the floor air distribution duct on the plenum. Install the 2 screws and plastic push fastener. If removed, position the panel door vacuum motor to the mounting bracket and install the 2 attaching screws.

Connect the white vacuum hose to the outside-recirculating door vacuum motor. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install the floor duct.

If equipped with manual air conditioning, connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable.

If equipped with ATC, proceed as follows:

Connect the temperature control cable to the ATC sensor and adjust the cable. Route and connect the vacuum harness connector to the ATC sensor and connect the electrical connector to the ATC servo connector. Do not block the sensor aspirator exhaust port with the excess vacuum harness. Install the ATC sensor tube between the sensor and the evaporator connector.

On 1990-00vehicles:
1. Connect the ATC sensor tube to the evaporator case connector.
2. Install the cross body brace and connect the wiring harness to the blend door actuator.
3. Install the bolt to attach the lower right end of the instrument panel to the side cowl. Install the right side cowl trim panel and tighten the right door sill plate attaching screws.

On 1988-1989 vehicles install the instrument panel pad and the glove compartment door.

On 1990-99 vehicles, push the instrument panel back into position and install all instrument panel mounting screws. Install the right and left lower instrument panel insulators.