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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 573 (Auxiliary HVAC Control System) >> Removal And Installation >> Auxiliary Heater Outlet and Inlet Line >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: It is necessary to cut the underbody auxiliary line(s) being serviced into sections to facilitate removal. Make sure to correctly identify the line(s) being serviced before carrying out any cutting of the line(s).
NOTE:
  • The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing 2-piece lines for ease of installation.
  • The following procedure can be used to remove and install one or both of the auxiliary heater inlet line and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.

    All vehicles 

  1. Drain the engine coolant. For additional information, refer to DRAINING .
  2. Position a jack stand to support the muffler and tailpipe assembly.
    Fig 1: Supporting Exhaust System Using Suitable Jack
    G03957576Courtesy of FORD MOTOR CO.
    3. NOTE: Inspect the isolator and install a new one if necessary.
  3. Disconnect the resonator isolator.
    4. CAUTION: Do not strike the catalytic converter or subject it to any force impacts (i.e. hammer blows). Doing so will damage the catalyst material.
    Fig 2: Disconnecting Underbody Catalytic Convertor & Discarding Gasket
    G04658071Courtesy of FORD MOTOR CO.
  4. Disconnect the underbody catalytic convertor and discard the gasket.
    5. NOTE: Inspect the isolator and install a new one if necessary.
    Fig 3: Disconnecting Muffler Front Isolator
    G04658072Courtesy of FORD MOTOR CO.
  5. Disconnect the muffler front isolator.
    6. NOTE: Inspect the isolator and install a new one if necessary.
    Fig 4: Disconnecting Muffler Rear Isolator
    G04658073Courtesy of FORD MOTOR CO.
  6. Disconnect the muffler rear isolator.
  7. Remove the muffler, resonator and underbody catalytic convertor assembly.

    8. AWD vehicles 

  8. Remove the rear driveshaft. For additional information, refer to REMOVAL AND INSTALLATION .

    9. All vehicles 

  9. Remove the exhaust heat shield.
  10. Remove the front auxiliary heater outlet line clamp and disconnect the line.
  11. Remove the front auxiliary heater inlet line clamp and disconnect the line.
  12. Remove the LH rear wheel.
  13. Remove the LH rear quarter panel molding. For additional information, refer to REMOVAL AND INSTALLATION .
  14. Remove the 3 outer LH rear quarter panel molding bracket bolts.
  15. Remove the 2 inner LH rear quarter panel molding bracket bolts.
  16. Remove the LH rear quarter panel molding bracket.
    • Detach the splash shield pin-type retainer.
  17. Remove the 2 LH rear brake caliper bolts and position the caliper aside.
    • To install, tighten to 35 N.m (26 lb-ft).
  18. Remove the 2 parking brake cable bolts.
    • To install, tighten to 12 N.m (9 lb-ft).

    19. AWD vehicles 

  19. Remove the 4 rear subframe bracket bolts.
    • To install, tighten to 63 N.m (46 lb-ft).
  20. Remove the trailing arm-to-knuckle bolt.
    • To install, tighten to 110 N.m (81 lb-ft).
  21. Loosen the trailing arm-to-subframe bolt and position the trailing arm aside.
    • To install, tighten to 110 N.m (81 lb-ft).

    22. All vehicles 

  22. Remove the LH lower shock bolt.
    • To install, tighten to 142 N.m (105 lb-ft) for AWD.
    • To install, tighten to 110 N.m (81 lb-ft) for FWD.
  23. Position a lifting table to support the rear subframe.
  24. With a wax pencil, mark the relational alignment of the rear subframe to the underbody at the mounting locations.

    25. FWD vehicles 

  25. Disconnect the 2 rear wheel speed sensor electrical connectors.
  26. Loosen, but do not completely remove the 2 RH rear subframe bolts.
    • To install, tighten to 115 N.m (85 lb-ft).
    Fig 5: Loosening RH Rear Subframe Bolts
    G04658074Courtesy of FORD MOTOR CO.

    27. All vehicles 

  27. Remove the 2 LH rear subframe bolts.
    • To install, tighten to 115 N.m (85 lb-ft).
  28. Correctly support the fuel tank and remove the LH rear fuel tank strap bolt.
    • To install, tighten to 35 N.m (26 lb-ft).
  29. Remove the rear auxiliary heater outlet line clamp and disconnect the line.
  30. Remove the front auxiliary heater outlet line clamp and disconnect the line.
  31. Remove the 2 middle rear auxiliary line bracket bolts.
    • To install, tighten to 5 N.m (44 lb-in).
  32. Remove the 2 middle rear auxiliary line brackets.
  33. Remove the 2 middle front auxiliary line bracket nuts.
    • To install, tighten to 5 N.m (44 lb-in).
  34. Remove the 2 middle front auxiliary line brackets.
    35. CAUTION: To avoid loss of refrigerant, or unintended damage to an auxiliary line that is not being removed, clearly differentiate which line is to be removed before cutting.
  35. Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary heater line(s) in the same position as the middle fitting on the replacement line(s).
  36. Remove the front auxiliary line bracket nut.
    • To install, tighten to 5 N.m (44 lb-in).
  37. Remove the front auxiliary line bracket.
  38. Remove the front portion of the auxiliary heater outlet line and/or auxiliary heater inlet line.
  39. Remove the rear auxiliary line bracket nut.
    • To install, tighten to 5 N.m (44 lb-in).
  40. Remove the rear auxiliary line bracket.
    41. NOTE: The LH side of the rear subframe, and the LH side of the fuel tank will have to be lowered slightly to provide clearance to remove the lines. Be sure to lower the rear subframe and fuel tank only as needed without stressing the attached components.
  41. Remove the rear portion of the auxiliary heater outlet line and/or the auxiliary heater inlet line.
  42. To install, reverse the removal procedure.
  43. Fill the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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