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A/C Installation -- Introduction and Parts
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Bruce Bonebrake installs an air-conditioning system on a work-truck that was purchased with "no frills." In order to perform this installation, a number of parts need to be removed. A new a/c system -- that came as an after-market kit -- is then installed to outfit this work vehicle with cold air.
The problem: Our project vehicle, a Ford work-truck, was purchased originally without many comfort options -- including air conditioning. Fortunately, it is possible to retrofit many such options on many vehicles later on.
Parts Inventory
Parts Inventory
Following are some of the major components included in the a/c kit used in our instalation.
A new decal for installation on the dash panel and an a/c-compressor switch (figure A).
New hoses and evaporator assembly (figure B). The evaporator takes the place of the existing blower-motor that is currently on the truck.
The receiver dryer (figure C) serves to remove moisture from the system as the a/c operates.
The compressor assembly (figure D) is the heart of the a/c system, and comes complete with a clutch and a bracket for mounting the assembly onto the engine. It also comes with all the necessary fasteners, a belt-tensioner, and belt.
The condenser assembly (figure E) resembles a small radiator, and contains the refrigerant. This part becomes extremely hot during operation, and is mounted near the truck's front-grill.
The condenser in our kit is a universal design, and is made with a series of pre-drilled holes down both sides for installation. Several mounting brackets (figure F) are included in the kit also. The brackets you use will depend on your vehicle. Check the directions that come with your kit to identify the proper mounts for your vehicle.
The existing fan-guard on the truck will be replaced with a fan-shroud as part of the a/c upgrade.
Condenser Installation
To provide greater access, we removed the hood from the truck before beginning the installation (figure G). This step may not be necessary in all cases.
You'll need to remove a few items before the condenser can be installed. In our case, that meant disconnecting the coolant recovery hose and removing the front-grill cover (figure H).
Tip: The grill and associated trim pieces may be secured onto the vehicle using plastic fasteners. If this is the case, be very careful in removing them so as to avoid damaging them.
With the grill-cover removed, loosen and remove the bolts holding the fan-guard in place (figure I). In our case, there were only two of these bolts and they were easy to access.
The next step is to remove the radiator. Two bolts anchor it to the core support at the top. Loosen and remove the bolts and carefully lift the radiator off of its lower mounts and tilt it toward the engine (figure J).
The condenser is mounted between the radiator and grill, and is held in place by clips (provided with the kit) that snap into factory-manufactured holes (figure K).
Slide the condenser into position (figure L), and bolt it on securely according to the manufacturer's directions.
Secure the condenser at the bottom by installing the provided lower-brackets (figure M).
With the condenser unit installed, reinstall the radiator by reversing the earlier steps used to remove it.
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Click on the thumbnails to see larger images.
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A/C Installation -- Wiring and Refrigerant
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Model : |
Ford, Explorer
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Category : |
Engine - Cooling System
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... The green a/c wire from our kit connects to the purple wire on this plug. A test-light is used in order to ensure that this wire is still functional (figure J). Since the test-light comes on when the a/c switch is turned on inside the cab, the wire is found to be OK. [PICTUREID=10LEFT] - The green a/c wire is connected to the factory-installed purple wire using a crimp connection (figure ...
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Posted : |
16 November 2004
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Author : |
From "Weekend Mechanic" - episode WKM-211
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A/C Installation -- Compressor and Blower-Motor
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Model : |
Ford, Explorer
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Category : |
Engine - Cooling System
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... The replacement will include a new blower-box that includes an evaporator. In our case, we first had to unbolt and remove the vacuum solenoid (figure F) to gain access to the blower assembly. [PICTUREID=7LEFT] Next, disconnect the blower motor and remove it from the box (figure G). This part will be re-installed later, so it's a good idea to inspect it and clean it of any dirt or debris that ...
(more)
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Posted : |
16 November 2004
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Author : |
From "Weekend Mechanic" episode WKM-211
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A/C Installation -- Receiver-Dryer and Hoses
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Model : |
Ford, Explorer
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Category : |
Engine - Cooling System
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... you will be using in your a/c-system. The same is true of the lubricant that is used in installing the O-rings. Check the manufacturer's instructions to ensure that you are using the proper parts to prevent refrigerant leaks. [PICTUREID=6LEFT] Before making the final two connections to the receiver dryer, the capillary tube of the expansion valve (figure G) needs to be fastened properly. The ...
(more)
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Posted : |
16 November 2004
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Author : |
From "Weekend Mechanic" episode WKM-211
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Cooling fan manual switch install
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Model : |
Ford, Mustang
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Category : |
Engine - Cooling System
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... spot, the connector has numbers for each pin. NOTES FOR 4.6L SOHC and DOHC Hook into pin#46 on the PCM, that is located behind the passenger side kickpanel. Once you tie into that pin all you do is run it to the toggle switch, and run the other side of the switch to ground. Next you will have to TAP a wire to #17, don't CUT THE #17 WIRE !!!, you could use a scotchlock connector to tap into it, ...
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Posted : |
19 May 2005
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Griffin Radiator Install
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Model : |
Ford, Mustang
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Category : |
Engine - Cooling System
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... not want to take the chance of damaging the AC line that runs directly above the radiator location. It was very easy with the car Jacked up and on jack stands. 8. Now remove the hoses from the thermostat housing and remove the two bolts holding the housing to the upper intake. Once this is done CLEAN the housing and the intake VERY well. I use a screwdriver to scratch most of the old gasket and ...
(more)
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Posted : |
19 May 2005
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