Main Climate Control

REMOVAL

NOTE:
^ Installation of a new suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from failed A/C compressor or damage to the suction accumulator/drier.
^ 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.

1. Recover the refrigerant.
2. Remove the battery.







3. Remove the battery tray.
1 Remove the screws.
2 Remove the battery tray.







4. Move the oil fill pipe out of the way.
1 Remove the screw.
2 Move the oil fill pipe.







5. Move the windshield washer reservoir cover out of the way.
1 Remove the screws.
2 Move the windshield washer reservoir cover.







6. Disconnect the evaporator discharge line.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.







7. Disconnect the compressor suction line.
1 Remove the screw.
2 Disconnect the compressor suction line.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.

NOTE: If the vehicle is equipped with a standard A/C system, carry out this step. If the vehicle is equipped with an auxiliary A/C-heater system, proceed to Step 8.







8. Disconnect the suction accumulator/drier line spring lock coupling.

NOTE: If the vehicle is equipped with an auxiliary A/C-heater system, then carry out Steps 8 and 9. If the vehicle is equipped with a standard A/C system proceed to Step 10.







9. Remove the screw.







10. Disconnect the condenser to evaporator tube.
1 Remove the screw.
2 Disconnect the condenser to evaporator tube.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.







11. Move the compressor discharge line isolator.
1 Remove the screw.
2 Move the compressor discharge line.

NOTE: On vehicles equipped with a 4.2L engine, carry out this step; all others proceed to Step 12.







12. Disconnect condenser core refrigerant lines.
1 Disconnect the compressor discharge line.
2 Disconnect the condenser to evaporator tube.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.







13. Remove the screws and the evaporator core housing support bracket.







14. Remove the evaporator cover.
1 Remove the six screws.
2 Remove the five screws.
3 Remove the evaporator cover.







15. Remove the A/C evaporator core.
1 Remove the seal.
2 Remove the A/C evaporator core.

CAUTION: Do not damage the cooling fins while handling the A/C evaporator core.

INSTALLATION
1. Service the new A/C evaporator core with the correct amount of PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent meeting Ford specification WSH-M1C231-B.







2. Install the A/C evaporator core.
1 Install the A/C evaporator core.
2 Install the seal.

CAUTION: Use care not to damage the cooling fins while handling the A/C evaporator core.







3. Install the evaporator cover.
1 Install the evaporator cover.
2 Install the five screws.
3 Install the six screws.







4. Install the evaporator core housing support bracket and screws.







5. Connect the condenser core refrigerant lines.
1 Lubricate the new O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent meeting Ford specification WSH-M1C231-B and install the O-ring seals.
2 Connect the condenser to evaporator tube.
3 Connect the compressor discharge line.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.







6. Install the compressor discharge line isolator.
1 Install the compressor discharge line isolator.
2 Install the screw.

NOTE: On vehicles equipped with a 4.2L engine, carry out this step, all others proceed to Step 7.







7. Connect the condenser to evaporator tube.
1 Connect the condenser to evaporator tube.

NOTE: Lubricate the new O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent meeting Ford specification WSH-M1C231-B.

2 Install the O-ring seals.
3 Install the screw.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.







8. Connect the auxiliary evaporator to compressor tube spring lock coupling.

NOTE: If the vehicle is equipped with an auxiliary A/C-heater system, carry out Steps 8 and 9. If the vehicle is equipped with a standard A/C system, proceed to Step 10.







9. Install the screw.







10. Connect the compressor suction line.
1 Lubricate the new O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent meeting Ford specification WSH-M1C231-B and install the O-ring seals.
2 Connect the compressor suction line.
3 Install the screw.

NOTE: If the vehicle is equipped with a standard A/C system, carry out this step. If the vehicle is equipped with an auxiliary A/C heater system, proceed to Step 11.







11. Connect the evaporator discharge line.
1 Lubricate the new O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C), or equivalent meeting Ford specification WSH-M1C231-B and install the O-ring seals.
2 Connect the evaporator discharge line.

CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.







12. Install the windshield washer reservoir cover.
1 Install the windshield washer reservoir cover.
2 Install the screws.







13. Install the oil fill pipe.
1 Install the oil fill pipe.
2 Install the screw.







14. Install the battery tray.
15. Install the battery.
16. Evacuate and charge the A/C system.