Service Procedure

1. Drain the coolant from the cooling system following procedures outlined in Section 03-03 of the appropriate Explorer Service Manual.

2. Cut a 25 mm (1") section out of each heater hose approximately 127 mm (5") from the heater core inlet and outlet tubes.








3. Install the Water Shutoff Valve (F4TZ-18495-A) in the hoses. Refer to Figures 1 and 2. Secure the hoses using electrical tape or tie straps as shown.

4. Install hose clamps and tighten to 2 N.m (18 lb-in).

5. Remove right front wheel assembly.

6. Loosen right inner fender well to gain access to the -19D605- wiring harness.





7. Attach Vacuum Tee (F4TZ-19C828-A) to the fresh/recirc air door vacuum motor as shown in Figure 4.

8. 1993 model year Explorers perform this Step:





a. Replace the original -19D605- wiring harness with the new Harness (F4TZ-19D605-A) which has an additional vacuum line. Refer to Figure 3 (View A) and install Vacuum Line (F27Z-19C828-AA).

9. 1991-92 model year Explorers perform this Step:

a. Drill a 12 mm hole at the location shown in Figure 3 (View A) and install Vacuum Line (F27Z-19C828-AA).

10. Reattach the inner fender well.

11. Reinstall the right front wheel assembly.

12. Attach the existing vacuum line from the A/C control to the end of the tee and the additional line (white) from the new harness to the other side of the tee. Refer to Figure 4 for proper hose routing.

13. Recover refrigerant charge as outlined in Section 12-03 of the 1993 Explorer Service Manual.

14. Remove the radiator grille by removing the five (5) plastic retainers located across the top of the grille.

15. Remove the two (2) screws that attach the grille to the headlamp housing.

16. Use a flat blade screwdriver to depress the spring tabs which are accessible through the lower outboard grille openings. Detach the grille from the headlamp housings.

17. Remove the grille from the vehicle.

18. Remove the radiator. Refer to Section 12-03 of the appropriate Service Manual.

19. Remove the radiator top and bottom seals and discard.

20. Remove the condenser. Refer to Section 12-03 of the appropriate Service Manual.

21. Remove the old condenser seals and discard.





22. Install the Radiator Air Side Deflector (F2TZ-8310-A), Radiator Air Lower Deflector (F4TZ-8327-B) and Radiator Side Deflector Seal (F4TZ-8348-A) as shown in Figure 5.








23. Install the lower A/C Condenser Seal (F4TZ-19E572-A), the A/C Condenser Top/Corner Seal (F4TZ-19E572-C) and the Radiator Bottom Seal (F4TZ-19E572-F) as shown in Figures 6 and 7.





24. Install the A/C condenser, the A/C Condenser LH Seal (F4TZ-19E572-B) and the A/C Condenser RH Seal (F4TZ-19E572-D) as shown in Figures 6 and 8.

25. Install the radiator and the Radiator Top Seal (F4TZ-19E572-E).





26. Install the radiator grille and the two (2) Upper Radiator Air Deflectors (F4TZ-8327-A and F4TZ-8327-C) as shown in Figure 9.

27. Fill the cooling system and evacuate/recharge the A/C system.

28. Verify proper cooling and A/C system functions.

29. Verify that the water shutoff valve functions in Max A/C and Off modes.

NOTE:
ADVISE CUSTOMER THAT THE WATER SHUTOFF VALVE HAS BEEN INSTALLED AND THAT THE TEMPERATURE CONTROL LEVER DOES NOT FUNCTION IN MAX A/C. TEMPERATURE IN MAX A/C CAN BE CONTROLLED BY ADJUSTING THE FAN SPEED.