With Manual A/C

CAUTION: If an evaporator core leak is suspected the core must be leak tested before it is removed from the vehicle.

REMOVAL
1. Remove the evaporator case from the vehicle. Service and Repair

NOTE: Whenever the evaporator core is replaced, it will be necessary to replace the suction accumulator/drier.

2. Remove the dash panel seal.

Fig. 16 Exploded View Evaporator Case. Town Car:

3. Remove the heat shield from the bottom of the evaporator case.
4. Remove the six screws attaching the two halves of the evaporator case together.
5. Separate the two halves of the evaporator case and remove the evaporator core and suction accumulator/drier assembly.
6. Disconnect the suction accumulator/drier inlet from the evaporator core outlet tube.
7. Remove the retaining screw from the suction accumulator/drier and evaporator core mounting brackets and remove the accumulator/drier from the evaporator core.

INSTALLATION

NOTE: When replacing an evaporator core in a refrigerant system that contains a six cylinder aluminum compressor, a measured quantity of 500 viscosity refrigerant oil should be added to the core to ensure that the total oil charge in the system is correct before the system is operated. Three fluid ounces of clean refrigerant oil should be poured directly into the inlet pipe of the replacement core with the pipe held vertically so the oil will drain into the core.

1. Attach the suction accumulator/drier to the evaporator core mounting bracket with a retaining screw.
2. Install a new 0-ring lubricated with clean refrigerant oil and connect the accumulator/drier inlet connection to the outlet tube of the evaporator core. Tighten the fittings using a backup wrench to prevent component damage.
3. Position the evaporator core assembly to the RH half of the evaporator case.
4. Apply caulking cord or similar sealer to the case flange and around the evaporator core tubes.
5. Position the evaporator case LH half and the dash panel gasket to the case RH half.
6. Install the support strap on the evaporator inlet tube.
7. Install the seven screws to attach the two halves of the case together. The center screw on the front of the case also attaches the support strap.
8. Install the dash panel seal.
9. Install a new heat shield on the bottom of the evaporator case assembly with staples. Install the evaporator case in the vehicle.
10. Leak-test, evacuate, and charge the refrigeration system following the recommended procedures and safety precautions.