Evaporator Core: Service and Repair

REMOVAL

CAUTION: To prevent refrigerant system contamination, if you are replacing the A/C evaporator housing you must also replace the suction accumulator/drier.

NOTE:
- If the A/C evaporator core leak is suspected, the A/C condenser core must be leak tested before it is removed from the vehicle.
- The A/C evaporator core is not serviced separately from the A/C evaporator housing. If the A/C evaporator core needs to be replaced, replace the A/C evaporator housing as an assembly.

1. Disconnect the battery ground cable.
2. Recover the refrigerant. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant Recovery, Refrigerant Recovery







3. Disconnect the A/C vacuum line.

CAUTION: Plug all ports to prevent contamination from dirt and moisture.







4. Disconnect the rear condenser to evaporator line spring lock coupling.

CAUTION: Plug all ports to prevent contamination from dirt or moisture.







5. Remove the suction line support clip retaining nuts.







6. Disconnect the suction line spring lock coupling.

CAUTION: Plug all ports to prevent contamination from dirt or moisture.

7. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel - Replacement, Service and Repair







8. Remove the RH windshield defroster nozzle connector.
- Remove the push pin.
- Remove the screw and the RH windshield defroster nozzle connector.







9. Loosen the A/C evaporator outlet duct clamp bolt.







10. Disconnect the A/C blower motor electrical connector.







11. Disconnect the vacuum control motor vacuum connector.







12. Detach the vacuum lines from the A/C evaporator housing retainer.







13. Remove the nuts and the A/C evaporator housing.







14. Disconnect the vacuum line.







15. Remove the screws and the A/C vacuum reservoir tank and bracket.







16. Remove the two inlet duct door vacuum control motor retaining nuts.







17. Remove the push nut and the vacuum control motor.







18. Remove the screws and the air inlet duct.







19. Remove the screws and the blower motor.







20. Remove the screws and the heater blower motor switch resistor.







21. Remove the evaporator tube dash panel seal and the drain tube dash panel seal


INSTALLATION
1. Service the replacement A/C evaporator core with the correct amount of PAG Compressor Oil Motorcraft YN-12b, F2AZ-19577-AC or equivalent meeting Ford specification WSH-M1C231-B.
2. Install the evaporator tube dash panel seal and the drain tube dash panel seal.







3. Install the heater blower motor switch resistor.







4. Install the blower motor.







5. Install the air inlet duct.







6. Install the inlet duct door vacuum control motor.







7. Install the push nut on the inlet duct door lever.







8. Install the A/C vacuum reservoir tank and bracket.







9. Install the A/C evaporator housing.







10. Tighten the bolt.







11. Attach the vacuum lines to the A/C evaporator housing retainer.







12. Connect the vacuum control motor vacuum connector.







13. Install the RH windshield defroster nozzle connector.
14. Install the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument Panel, Service and Repair, Instrument Panel - Replacement, Service and Repair






15. Connect the rear condenser to evaporator line and the suction line spring lock couplings.







16. Connect the A/C vacuum line.
17. Connect the battery ground cable.
18. Leak test the A/C system.