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Utilimaster Aeromaster 2019 Manual

Heater with air conditioning
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Heater with Air Conditioning
2019 and Later Aeromaster
Contents
Safety Considerations...............................................................................................................2
AC System Overview.................................................................................................................3
Procedures .................................................................................................................................4
Blower Motor ..........................................................................................................................4
Control Head ..........................................................................................................................5
Condenser..............................................................................................................................7
Dryer ......................................................................................................................................7
Binary Switch .........................................................................................................................9
Hose Replacement...............................................................................................................10
Pressure Transducer ............................................................................................................12
Plenum .................................................................................................................................13
Internal Servo Motors ...........................................................................................................17
Passenger Side Vent ...........................................................................................................20
Heater Valve and Servo Motor .............................................................................................20
Evaporator and Heater Core Assembly ...............................................................................22
Heater Core..........................................................................................................................27
Evaporator Coil ....................................................................................................................31
Test System .............................................................................................................................34
NOTICE
The information in this document is generic. Details in illustrations and procedures
may differ from those in your vehicle. Because Utilimaster manufactures many different
customized vehicle bodies, this document cannot list and illustrate every possible option for
every vehicle. Nevertheless, the most common body options are described here. Use this
information as a guideline where it applies. Refer also to the separate chassis operator's
guide supplied by the chassis manufacturer.
03103436-A10030 Rev. B
Service
Guide
1 of 34

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Summary of Contents for Utilimaster Aeromaster 2019

  • Page 1: Table Of Contents

    NOTICE The information in this document is generic. Details in illustrations and procedures may differ from those in your vehicle. Because Utilimaster manufactures many different customized vehicle bodies, this document cannot list and illustrate every possible option for every vehicle. Nevertheless, the most common body options are described here. Use this information as a guideline where it applies.

  • Page 2: Safety Considerations

    Safety Considerations WARNING Avoid breathing AC refrigerant and lubricant vapor or mist. Utilimaster recommends that a licensed automotive air-conditioning specialist work on the vehicle’s air-conditioning (HVAC) system. Operate the engine only in a well-ventilated area. Use safety stands and/or wheel blocks whenever you are underneath the vehicle.

  • Page 3: Ac System Overview

    AC System Overview THERMOSTAT RESISTOR EVAPORATOR EVAPORATOR HOSE LOW PRESSURE LOW PRESSURE SWITCH SWITCH BINARY BINARY SWITCH SWITCH CHARGING PORT RECEIVER/ RECEIVER/ DRYER DRYER TRANSDUCER TRANSDUCER COMPRESSOR COMPRESSOR PORT PORT HOSE HOSE CONDENSER CONDENSER BLOCK HOSE BLOCK HOSE DRYER HOSE COMPRESSOR CONDENSER AC system overview (plenum omitted for clarity)

  • Page 4: Procedures

    Procedures Blower Motor Removal 1. Disconnect the wire harness. 2. Remove the (6) screws to the blower motor. 3. Disconnect the vent hose. Blower motor Installation 1. Connect the vent hose. 2. Secure the blower motor with (5) screws. Secure the wire harness and fasten wire harness clamp with (1) screw and flat washer.

  • Page 5: Control Head

    Control Head Removal NOTICE Depending on the model, it may help to remove the dash cover to access the HVAC controls. 1. Remove the (4) screws and nuts or the HVAC controls. 2. Unplug the fan switch from the HVAC controls. Control head connections (A) fan switch, (B) temp connector, (C) mode connector, (D) recirculation connector, (E) max AC connector, (F) backlight socket...
  • Page 6 NOTICE Ensure that the wire colors match at the connectors. 2. Connect the (4) wire harness connectors to the control head. Ensure that the male and female wire colors match the adjoining harnesses 3. Plug in the fan switch connector. 4.

  • Page 7: Condenser

    Condenser NOTICE The condenser is a chassis component. Refer to the chassis service information or your local dealer. Dryer Removal NOTICE It is strongly recommended that the dryer and expansion valve be replaced whenever the system is opened for service. 1.
  • Page 8 Installation NOTICE It is strongly recommended that the dryer and expansion valve be replaced at the same time. 1. Install binary switch. 2. Lubricate (2) new O-rings with mineral oil and attach to dryer. 3. Secure dryer hoses. 4. Torque nuts. 5.

  • Page 9: Binary Switch

    Binary Switch The binary switch is located on the dryer. The switch has two functions: high pressure cut-out and low pressure cut-out. Binary switch on dryer Removal 1. Disconnect wire harness. 2. Remove switch by turning counterclockwise and set aside. Installation 1.

  • Page 10: Hose Replacement

    Hose Replacement Example of replacement of air-conditioning hose between the compressor and the evaporator. NOTICE The hose connection at the compressor may be easier to access with the wheels turned completely to the right. 1. Remove the keys from the ignition. 2.
  • Page 11 9. Torque evaporator fitting. 10. Install hose on compressor. 11. Torque compressor fitting. COMPRESSOR TO EVAPORATOR TO CONDENSER FRONT Hose fittings on compressor (hoses removed for clarity) 12. See dryer removal and installation. Drier mounted under the hood 13. Torque hose fittings. 14.

  • Page 12: Pressure Transducer

    Pressure Transducer The 2016 and later Ford 6.8L gasoline engine has a pressure transducer that replaces the AC high pressure switch. The transducer sensor port is located on the compressor/condenser hose and connects to the chassis harness with a jumper harness. NOTICE This transducer is not backward compatible with 2015 and prior model year vehicles or with the 5.4L engine.

  • Page 13: Plenum

    Plenum Removal NOTICE This process does not require opening the engine coolant system or evacuating the AC system. Removal of the evaporator assembly is not required. The foot dump can be reused on the replacement plenum. Make note or photograph hose and wire configurations before removing them to ensure proper installation.
  • Page 14 4. Remove the 2-1/2" vent hoses. Vent hoses are held in place with barbed catches 5. Disconnect the wire harness at the RH side of the plenum. Plenum harness connector located between the plenum and evaporator assembly 14 of 34 03103436-A10030 Rev.
  • Page 15 6. From under the hood, remove the (4) nuts and flat washers. Plenum nuts under the windshield cowl 7. Pull the plenum away from cowl and place on a bench to service any of the internal components. Plenum removed (evaporator not shown for clarity) 15 of 34 03103436-A10030 Rev.
  • Page 16 Plenum Installation 1. Insert the plenum studs through the holes in the cowl. Install (4) flat washers and nuts. Torque the nuts to 25–29 lb•ft. 2. Connect the plenum harness to the evaporator assembly. 3. Connect the 2-1/2" duct hoses. 16 of 34 03103436-A10030 Rev.

  • Page 17: Internal Servo Motors

    Internal Servo Motors NOTICE There are two actuators (servo motors) on the plenum. Both the dash vents and/or the defrost/ foot dump motors can be replaced. 1. After the plenum is removed from the vehicle, use a Phillips-head screw driver to remove the (14) screws around the front (metal) panel and (2) screws from the face of the panel.
  • Page 18 3. Remove (2) screws from the back (facing) panel and remove the blower adaptor. Face panel screws and blower adaptor 4. Pull the plenum divider assembly out of the case. Plenum divider assembly removed 18 of 34 03103436-A10030 Rev. B...
  • Page 19 Dash Vent Servo 5. Disconnect the wire harness and remove (3) screws holding the dash vent servo motor. (Passenger's side) servo Foot Dump Servo 6. Disconnect the wire harness and remove the (3) nuts, spacers, and screws holding the defrost/ foot dump servo.

  • Page 20: Passenger Side Vent

    Passenger Side Vent The passenger side vent is held in place with a screw and spring from the back side Heater Valve and Servo Motor NOTICE The heater valve servo motor is mounted either on the cowl or mounted on top of the radiator bracket.
  • Page 21 4. To minimize the loss of coolant when the system is opened, clamp both hoses to and from the valve. Be careful not to nick, cut, or otherwise damage the hoses when clamping. Position the clamp jaws on the hose so that leading edges of the clamp do NOT bite into the hose 5.

  • Page 22: Evaporator And Heater Core Assembly

    Evaporator and Heater Core Assembly Removal NOTICE Make note or photograph hose and wire configurations before removing them to ensure proper installation. Reversing wires or hoses can damage AC components. 1. Turn off the engine and remove the keys from the ignition. 2.
  • Page 23 8. To minimize the loss of coolant when the system is opened, clamp both hoses to and from the bulkhead fitting on the cowl. Be careful not to nick, cut, or otherwise damage the hoses when clamping. Position the clamp jaws on the hose so that leading edges of the clamp do NOT bite into the hose 9.
  • Page 24 11. Cut and scrape all adhesive away from the evaporator hoses and fasteners. 12. Remove the (4) nuts and washers that attach the evaporator to the cowl. Evaporator fasteners The capillary tube is filled with gas and very fragile. Use caution when removing. 13.
  • Page 25 14. Disconnect the (2) wires to the thermostat, the blower motor harness, the recirculation servo motor and plenum harnesses at the evaporator. Evaporator harnesses and thermostat wires 25 of 34 03103436-A10030 Rev. B...
  • Page 26 Installation 1. Connect the (3) wire harnesses and the thermostat wires. 2. Insert the evaporator studs through the holes in the cowl. 3. Secure the evaporator with (4) flat washers and nuts. 4. Torque 7–8 lb•ft. 5. From under the hood, seal all cracks and openings around the heater and AC hose connections. 6.

  • Page 27: Heater Core

    Heater Core Removal 1. Remove the evaporator assembly from the vehicle and set on a bench. 2. Remove the recirculation vent filter. Recirculation vent filter 3. Disconnect the blower motor wire harness. Do NOT remove the blower motor. 4. Remove the (22) screws around the perimeter of the casing. Casing screws 27 of 34 03103436-A10030 Rev.
  • Page 28 5. Remove (1) fine thread screw from the plenum adaptor. Fine thread plenum adaptor screw 6. Carefully pull the the thermostat probe out while pulling the casing apart. 7. Cut the top of the heater core gasket. Cut and peal back foam gasket. 28 of 34 03103436-A10030 Rev.
  • Page 29 8. Remove the (2) screws behind the gasket. Screws behind the foam gasket 9. From inside the casing, scrape/remove the sealant away from the pass-through holes. Sealant at pass-through 29 of 34 03103436-A10030 Rev. B...
  • Page 30 10. Remove the heater core. Heater core Installation 1. Install the heater core and secure the (2) screws on the front side of the casing. 2. Install the foam gasket on the front side. 3. Apply sealant around the pass-through on the inside of the casing. 4.

  • Page 31: Evaporator Coil

    7. Seal around the thermostat probe. 8. Secure the blower wire harness connector. 9. Clean the recirculation vent filter and install. 10. Install the evaporator assembly into the vehicle. Evaporator Coil Removal 1. Remove the heater core. 2. Remove the sealant at the pass-through and from the screw heads casing platform. (A) sealant, (B) screws, (C) casing platform 3.
  • Page 32 4. Remove (3) screws from the front of the casing. Front casing screws 5. Remove (2) screws at the base of the evaporator, (1) at the front and (1) at the rear. Casing screws at base of the evaporator 32 of 34 03103436-A10030 Rev.
  • Page 33 NOTICE Do NOT lift the casing platform straight up. The platform SLIDES out to the left toward the servo motor side. 6. Remove the platform from the base by lifting from the inboard side (where servo motor is) and sliding it out. Slide the casing platform out to the left Casing platform removed 7.

  • Page 34: Test System

    Utilimaster Customer Service 800-237-7806 FVSPartsOrder@Utilimaster.com Email: Heating with Air Conditioning 2019 and Later Aeromaster July 2021 Utilimaster., 603 Earthway Boulevard, Bristol, Indiana 46507 USA © 34 of 34 03103436-A10030 Rev. B...

This manual is also suitable for:

Aeromaster 2020Aeromaster 2021

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