Evaporator Case: Service and Repair

REMOVAL
1. Disconnect the battery ground cable.
2. Recover the refrigerant.
3. Drain the radiator so that the coolant level is below the heater core.
4. Raise the vehicle.
5. Remove the RH front wheel and tire.







6. Remove the screws from the RH fender apron and remove the fender apron.







7. Remove the nuts.
8. Lower the vehicle.
9. Remove the blower motor switch resistor.







10. Disconnect the connector.







11. Disconnect the evaporator to compressor suction line from the suction accumulator drier.







12. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube.







13. Remove the nuts and position the purge valve and bracket away from the evaporator core housing.







14. Remove the heater hoses from the heater core.







15. Disengage the connectors from the bracket.







16. Disconnect the connector.







17. Remove the nut and reposition the wire harness away from the evaporator housing.







18. Disengage the harness from the bracket.







19. Remove the pin-type retainer and clip and remove the instrument panel lower insulator.







20. Fold back the carpet and remove the screw.







21. Inside the vehicle, remove the screw.







22. Remove the nuts (engine side).







23. Remove the in-car temperature sensor hose and elbow from the evaporator housing (if equipped).







24. Remove the evaporator housing.

INSTALLATION
1. Position the evaporator core housing on the dash panel.







2. Install the in car temperature sensor hose.







3. Install the nuts.







4. Install the screw.







5. Install the screw.







6. Install the RH lower instrument panel insulator.
7. Raise the vehicle.







8. Install the nuts.







9. Position fender apron and install the bolts.
10. Install the front wheel and tire.
11. Lower the vehicle.







12. Connect the connector.







13. Install the connectors.







14. Install the wire harness push connector.







15. Position harness and install the nut.







16. Install the nuts.







17. Install the heater hoses.
- Lubricate the coolant hoses with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A.







18. Connect the evaporator compressor suction line to the suction accumulator/drier.







19. Connect the condenser to evaporator tube.







20. Connect the connector.
21. Install the blower motor switch resistor.
22. Connect the battery ground cable.
23. Fill the cooling system.
24. Evacuate and recharge the refrigerant system.