Evaporator Core: Service and Repair

NOTE: If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak-tested before it is removed from the vehicle. for leak-test procedures.

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





REMOVAL
1. Remove the A/C evaporator core housing from the vehicle.
2. Remove six screws retaining the two halves of the A/C evaporator core housing together.
3. Separate the two halves of the A/C evaporator core housing and using a razor blade carefully cut the A/C evaporator case dash panel seal at the seams.
4. Disconnect the suction accumulator/drier inlet from the evaporator core outlet tube.
5. Remove the retaining screw from the suction accumulator/drier and evaporator core mounting bracket and remove the suction accumulator/drier from the A/C evaporator core.
6. Remove retaining screw from inlet tube bracket and remove A/C evaporator core.

INSTALLATION
1. Pour 90 ml (3 ounces) of clean Motorcraft YN-12b refrigerant oil meeting Ford specification WSH-M1C231-B directly into the inlet pipe of the replacement A/C evaporator core with the pipe held vertically so the oil will drain into the A/C evaporator core.

NOTE: When replacing an A/C evaporator core in a refrigerant system, Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B should be added to the A/C evaporator core to make sure the total oil charge in the system is correct before the system is operated.

2. Attach the suction accumulator/drier to the evaporator core mounting bracket with a retaining screw.
3. Install a new O-Ring seal lubricated with clean Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and connect the suction accumulation drier inlet connection to the outlet tube of the evaporator core. Tighten using a backup wrench to prevent component damage.
4. Position the A/C evaporator core assembly to the RH half of the A/C evaporator core housing.
5. Apply Caulking Cord D6AZ- 19560-A or equivalent meeting Ford specification ESB-M4G32-A to the A/C evaporator core housing flange and around the evaporator core tubes.
6. Position the A/C evaporator core housing LH half and dash panel gasket to the case RH half.
7. Install support strap on evaporator inlet tube.
8. Install six screws to attach the two halves of the housings together. The center screw on the front of the housing also retains the support strap.
9. Install the A/C evaporator core housing in the vehicle.
10. Install new A/C evaporator core orifice. Service and Repair
11. Leak-test, evacuate and charge the refrigeration system following the recommended procedures and safety precautions. Discharging and Recovery