With Automatic Temperature Control
REMOVAL1. Disconnect battery ground cable.
2. Discharge the refrigerant from the air conditioning system using an approved recovery unit. Observe all safety precautions.
NOTE: Whenever the evaporator case is removed, it will be necessary to replace the suction accumulator/drier.
Plenum/Evaporator Case And Air Inlet Duct Assembly:
3. Disconnect the suction hose from the suction accumulator/drier using Spring Lock Coupling Tool T81P-19623-G1 and G2 or equivalent. Plug the openings to the suction accumulator/drier and the suction hose and position the hose away from the evaporator assembly.
4. Unplug the two-wire connector from the clutch cycling pressure switch on the suction accumulator/drier.
5. Disconnect the liquid line from the evaporator inlet tube using Spring Lock Coupling Tool T81P-19623-G1 and G2 or equivalent. Plug the openings to the liquid line and the evaporator inlet tube. Position the liquid line away from the evaporator assembly.
6. Drain the radiator coolant into a clean container. Save the coolant for refilling the cooling system.
7. Loosen the heater hose clamps and disconnect the heater hoses from the inlet and outlet heater core tubes.
8. From the passenger compartment, turn the steering wheel to the left to position the RH front wheel so that the wheel well splash panel support bracket is accessible.
9. Remove the screw and splash panel support bracket from the back portion of the wheel well. This will allow the splash panel to be depressed slightly for extra clearance when removing and replacing the evaporator assembly.
10. Remove the six screws holding the RH side of the hood seal bracket assembly. Remove the copper hood ground clip from underneath the hood seal. Remove the hood seal bracket assembly to the RH side of the vehicle.
11. Loosen the retaining clamp and disconnect the emission hose that passes over the top of the evaporator case assembly. Position the emission hose, all vacuum hoses, and movable wires away from the evaporator case assembly.
12. Disconnect the blower motor ground wire from the body frame and position the wire away from the evaporator assembly.
13. Disconnect the blower motor wiring connector from the wiring harness hard shell connector.
14. Disconnect the two large wiring harnesses (which cross the evaporator assembly) at the various connecting points. Position them away from the evaporator assembly.
15. From the passenger side of dash panel, fold back the carpeting, if necessary, on the RH side of the floor. Remove the bottom LH screw of the two screws that support the inlet recirculation air duct assembly.
16. From the passenger compartment, disconnect the ambient sensor air tube from the evaporator sensor air tube port.
17. From the engine side of the dash panel, remove three nuts (one upper and two lower) from the three evaporator assembly mounting studs. Also remove the two screws (one drill-point and one sheet metal) from the blower motor and wheel portion of the case assembly.
18. Pull the bottom of the evaporator case assembly away from the dash panel to disengage the evaporator ambient sensor air tube port and the two bottom studs. Move the top of the evaporator assembly away from the dash panel, disengaging it from the top stud, and maneuver the case up and over the wheel well splash panel. The splash panel may be pushed downward slightly for additional clearance.
INSTALLATION
1. Position the evaporator assembly near the dash panel by maneuvering it down past the wheel splash panel. If necessary, push the splash panel downward slightly for extra clearance.
2. Engage the sensor air tube port into the dash panel port opening and the two bottom dash panel studs into the evaporator assembly stud holes. Move the top of the evaporator assembly toward the dash panel while engaging the top dash panel stud into the evaporator assembly stud hole.
3. Replace, but do not tighten, the three stud nuts.
4. Replace and tighten the two screws (one drill-point and one sheet metal). Be careful to return the drill-point screw to the correct hole which is located on top of the case to the right of the blower motor and wheel assembly. Tighten the three nuts previously installed in step 3.
5. Position the two large wiring harnesses across the evaporator case assembly and connect the various connectors.
6. Connect the blower motor wiring connector to the wiring harness hard shell connector.
7. Connect the blower motor ground wire and accompanying engine ground wire to the body frame.
8. Place the emission hose clamp on the hose, connect the hose, tighten the clamp, and position it over the evaporator case assembly along with the vacuum hoses and wires previously moved.
9. Replace the hood seal bracket assembly and insert the copper hood ground clip underneath the hood seal. Install the six screws which secure the RH side of the hood seal bracket assembly.
10. Place the heater core hose clamps onto the heater hoses and connect the inlet and outlet hoses to the inlet and outlet heater core tubes. Position the hose clamps and tighten them. Replace the coolant with Ford part number 8A-19549-A or equivalent in the cooling system.
11. Remove the plugs from the liquid line and the evaporator inlet tube and install new 0-rings dipped in clean specified refrigerant oil. Connect the liquid line to the evaporator inlet tube.
12. Remove the plugs from the suction accumulator/drier and the suction hose and install new 0-rings dipped in clean specified refrigerant oil. Connect the suction hose to the suction accumulator/drier.
13. Connect the two-wire electrical connector to the clutch cycling pressure switch.
14. Leak test, evacuate, and charge the refrigeration system following the recommended procedures and safety precautions.
15. Connect the battery ground cable.
NOTE: On vehicles equipped with Electronic Engine Control (EEC), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
16. Install the wheel well splash panel bracket.
17. From the passenger compartment, install the recirculation air duct assembly screw.
18. Connect the ambient air sensor tube to the evaporator air tube port.
19. Check the air conditioning system for proper operation.