Free PDF Manual Guide

Shopping list from FORD dealer, $15.00 for 2 sets of heater hose o-rings and snap clips, $40.00 heater core, (cheaper at the dealer but no warrantee, aftermarket parts store model preferred by many @ $55) insulated foam tape to wrap new core with (parts dept just gave me what I needed), and a gallon of anti freeze.
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MANUAL AIR CONDITIONER: Heater Control Name Sheet No. 2 Air Conditioner Amplifier Assy Integration Control & Panel Bulb x5 Heater Control Housing Sub−assy Heater Control Housing Heater Blower Switch Radio Bracket No. 1 Heater Control Name Sheet No. 1 Control Knob Sub−assy AUTO AIR CONDITIONER: Heater Control Housing Sub−assy Control Knob Sub−assy Integration Control & Panel Bulb x9 Glove Compartment Door [Read the rest of this entry...]

COMPRESSOR CLUTCH CONTROL
Evaporator Temperature Switch
Although compressor clutch does not normally cycle on and off, an evaporator temperature switch turns off the compressor clutch if evaporator temperature decreases to 32øF (0øC). This prevents evaporator icing.

A/C Pressure Switch
A/C pressure switch is a triple-pressure switch, which monitors high side pressure. See Fig. 1. If pressure decreases to less than 17.4 psi (1.2 kg/cmý), A/C pressure switch interrupts power to compressor clutch (low-pressure cutout). Switch closes when pressure increases to more than 34.8 psi (2.4 kg/cmý).
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1) Disconnect negative battery cable and ground strap at transaxle. Disconnect positive battery cable. Remove battery and battery base. Remove drain plug, and drain transaxle fluid (remove fill plug to speed draining). Install drain plug with NEW washer, and tighten plug to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.
2) Disconnect wiring for starter motor, transaxle lock-up control solenoid and shift control solenoid. Remove starter. Disconnect mainshaft and countershaft speed sensor connectors. Remove complete air cleaner case assembly. Disconnect and remove throttle control cable at transaxle bracket.
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Tools required: – Cross head screwdriver, Flat blade screwdriver, 6mm and 7mm hose
clip drivers, Sharp craft knife.
1/ Open bonnet/hood. Remove the plastic engine cover. Remove the hose running between the throttle body housing and the top intercooler connection (bottom left hand corner of the picture above)
2/ Fit the new hose with the 25mm spout as shown above. If the hose is too long it will probably become misshapen, if this happens then remove and simply trim the ends with a sharp craft knife, only remove 10-15mm at any time and refit to check the hose shape after each cut if required. Once happy with the fit then secure with the hose clips supplied.
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Evaporator Case Assembly The evaporator case assembly is attached to the engine side of the dash panel. The case is a two-piece molded construction, one piece of which forms a cover over the evaporator core. An integral vacuum reservoir is part of the cover housing. This reservoir and the vacuum motor, which operates the outside/recirc air door, are linked through a check valve to a hose that supplies engine vacuum. The blower housing is an integral part of the evaporator case. It houses the blower motor and wheel assembly which attaches to the case through a mounting flange on the blower motor. The blower motor resistor assembly is attached to the case with its thermal elements extending into the air stream inside the evaporator case. The suction accumulator/drier is attached to the evaporator core by a support bracket.
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Installation Environment
1) The distance between the unit and outside wall or other goods should be kept over 200mm.The unit should be put in well-ventilated area and its temperature is within -10℃~+40 .℃
2) Check air supply pipeline of the unit and use air source with 3~10 bar to supply for the unit. When connecting the air source, please check if there is leakage in connector for air source and ensure that a certain distance between the air hose and heat source should be kept.
3) To ensure safety. Before connecting the air source, please confirm that the air pressure adjusting valve is closed. Never point the air outlet to personnel.
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Removal
1. Relieve the fuel pressure in the system by loosening the banjo bolt on the top of the fuel filter. Disconnect the fuel line from the fuel rail. It is a good idea to replace the washers. Disconnect the fuel harness holder and unbolt. Disconnect the hoses from the fuel pressure regulator (FPR).
2. Disconnect intake hose/pipe from throttle body. Disconnect all hoses leading to the throttle body and intake manifold. Disconnect throttle cable bracket on manifold and throttle cable from throttle body. Disconnect the cables to the the throttle position sensor (TPS) and the map sensor on the throttle body.
3. Unbolt two lower intake manifold bolts that secure manifold to engine block. This bracket willl still be used to accommodate the heater bypass pipe. Unbolt manifold from engine block. Remove manifold, throttle body, and fuel rail as one unit.
4. Remove the intake air bypass (IAB) vacuum tank, check valve and control solenoid unit. Due to the different design of your new manifold, these parts will no longer be used. Do not remove the FPR hose. This hose will be used in the re-installation process.
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Remove the attached body, if applicable. Remember to disconnect all electrical connections to the body, and fuel filler tube, before removing the body. The installation can also be completed using a lift to raise the vehicle. If using a lift, chassis body removal may not be necessary but removal of rear wheels will aid in installation.
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Congratulations! You have just purchased the best engineered, dyno-prove intake system available. Please check the contents of this box immediately. Report any defective or missing parts to the Authorized Injen Technology dealer you purchased this product from. Before installing any parts of this system, please read the instructions thoroughly. If you have any questions regarding installation please contact the dealer you purchased this product from. Installation DOES require some mechanical skills. A qualified mechanic is always recommended. *Do not attempt to install the intake system while the engine is hot. The installation may require removal of radiator fluid line that may be hot. Injen Technology offers a limited lifetime warranty to the original purchaser against defects in materials and workmanship. Warranty claims must be handled through the dealer from which the item was purchased.
Note: Disconnect the negative battery teriminal before starting this installation.
1 Remove the air intake box cover and intake air intake duct leading to the throttle body.
2 Remove the PCV pipe as seen in figure 4 and replace the water bypass valve with the 15”- 6mm hose provided in the kit. The coolant line port is located on the intake manifold housing . See diagram’s A or B The location of the coolant line port hose may vary depending on the year of your car. ( Do not attempt to remove any lines until your engine is cool to the touch.)
3 All Ex-models 94-97- Remove all of the components as seen in diagram C- #8. Since the cold air intake is not being used in this application the air resonator box can remain in the stock location. Once the components have been removed from the metal pipe leading to the EGR valve, you may cap-off or plug as indicated in figure 6 and diagram C. Use the 5mm vacuum cap to seal the line.
4 Screw the vibra-mount into the fender wall as seen in figure 3 and use the m6 nut and washer to attach it.
5 Place the step hose onto the throttle body and use two clamps and tighten the clamp on the throttler body at this point. See fig. 2
6 Place the end of the intake with the 1/2” aluminum nipple into the 3” side of the step hose and align the bracket on the intake to the vibra-mount stud and semi-tighten the nut and clamp. See figs. 5 and 7

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