A/C Evaporator - Removal/Installation Procedure
84ford1Article No. 84-25-1
AIR CONDITIONING EVAPORATOR REMOVAL AND INSTALLATION PROCEDURE
LINCOLN-MERCURY 1984 LINCOLN CONTINENTAL/MARK VII
The following procedure supersedes the procedure published in the 1984 Shop Manual.
Evaporator Assembly Removal
Mark VII
1. Discharge the refrigerant from the A/C system following the recommended procedures (Shop Manual Section 36-32). Observe all safety precautions.
2. Disconnect the ground cable from the battery negative (-) terminal.
3. Remove the carburetor air cleaner.
4. Disconnect and plug the heater hoses at the heater core. Then blow coolant from the heater core.
5. Disconnect the wire harness connector from the clutch cycling pressure switch located on top of the suction accumulator/drier.
6. Disconnect the liquid line and the accumulator/ drier inlet tube from the evaporator core tubes. Use a back-up wrench to prevent component damage. Cap all fittings to prevent the entrance of dirt and excessive moisture.
FIGURE 1:
FIGURE 2:
7. Remove two (2) nuts retaining the accumulator/ drier bracket to the dash panel (Figure 1).
8. Position the accumulator/drier and the liquid line aside and remove the two evaporator retaining nuts (Figures 1 and 2).
Figure 3:
9. Working in the passenger compartment, remove the steering column opening cover from the instrument panel (Figure 3).
10. Remove the instrument panel left and right sound insulators (Figure 3).
11. Remove the right and left side cowl trim panels.
Figure 4:
12. Remove the right side finish panel from the instrument panel (Figure 4).
13. Disconnect and position the console assembly out of the way (Shop Manual Section 45-31).
Figure 5:
14. Carefully pry the defroster opening grille from the instrument panel (Figure 5).
Figure 3:
15. Remove one (1) screw attaching the lower center of the instrument panel to the floor brace (Figure 3).
16. Remove the shroud fron the steering column.
17. Remove the steering column opening reinforcement.
18. Disconnect the transmission indicator cable from the steering column.
19. Remove the steering column to brake pedal support retaining nuts and lay the steering column down against the front seat.
Figure 5:
20. Remove the nut attaching the instrument panel to the brake pedal and steering column support (Figure 5).
21. Remove the instrument panel attaching screws (Figure 5) and lay the instrument panel back on the front seat. Disconnect wiring harness connectors as necessary.
FIGURE 6:
22. Disconnect the harness connectors from the blower motor wires and the blower motor speed controller (Figure 6).
23. Disconnect the EATC sensor hose and elbow from the evaporator case (Figure 6).
24. Disconnect the EATC harness at the control assy.
25. Disconnect the antenna cable from the radio and from the strap retaining the cable to the evaporator case.
FIGURE 7:
26. Disconnect the rear seat duct adaptor from the floor duct (Figure 7).
FIGURE 2:
27. Remove the three (3) evaporator attaching screws (Figure 2) and remove the evaporator assembly from the vehicle.
Evaporator Assembly Installation
FIGURE 2:
Mark VII
1. Position the evaporator assembly to the dash panel and install the three (3) attaching screws in the passenger compartment (Figure 2). Do not tighten the screws at this time. Check the evaporator drain tube to be certain it is through the opening and is not pinched or kinked.
2. Working in the engine compartment install the two (2) nuts to retain the evaporator assembly to the dash panel. Then, tighten the retaining nuts and attaching screws.
FIGURE 6:
3. Position the instrument panel near the dash panel and connect the radio antenna, EATC harness to the control assembly, harness to the blower motor speed controller (Figure 6), blower motor wires and the EATC sensor hose and elbow assembly and any additional wire harness connectors disconnected in step 21 of the removal procedure.
Figure 5:
4. Move the instrument panel into position and install the attaching screws (Figure 5). BE CERTAIN THAT THE A/C PLENUM (ATTACHED TO THE INSTRUMENT PANEL) IS CORRECTLY ALIGNED AND SEALED AT THE EVAPORATOR OUTLET OPENING. Air leakage to the floor area will result if the plenum is not sealed at the evaporator case outlet.
5. Install the nut retaining the instrument panel to the brake pedal and steering column support (Figure 5).
6. Position the steering column to the brake pedal and steering column support and install the retaining nuts.
7. Connect the transmission selector indicator to the steering column and adjust as necessary.
8. Install the steering column opening reinforcement.
9. Install the steering column shroud.
Figure 3:
10. Install the screw to attach the lower center of the instrument panel to the floor brace (Figure 3).
Figure 5:
11. Install the defroster opening grille (Figure 5).
12. Install the right and left side cowl trim panels.
13. Install the right and left instrument panel sound insulators.
FIGURE 7:
14. Install the rear seat duct adaptor (Figure 7) and the console assembly (Shop Manual Section 45-31).
Figure 4:
15. Install the instrument panel right finish panel (Figure 4).
Figure 3:
16. Install the steering column opening cover (Figure 3).
FIGURE 1:
17. Position the accumulator/drier mounting bracket over the studs on the dash panel (Figure 1) and
loosely install the two (2) nuts.
18. Connect the accumulator/drier inlet tube to the evaporator core outlet tube using a new O-ring lubricated with clean refrigerant oil. Do not tighten the connection.
19. Connect the liquid line to the evaporator core inlet tube using a new O-ring lubricated with clean refrigerant oil. Do not tighten the connection.
20. Tighten the two (2) nuts retaining the accumulator/drier to the dash panel (Figure 1).
21. Tighten the two refrigerant line connections at the evaporator core to specification. Use a backup wrench to prevent component damage.
22. Connect the harness connector to the clutch cycling pressure switch.
23. Connect the heater hoses to the heater core.
24. Fill the radiator to the specified level with a 50/50 mixture of coolant and water.
25. Connect the ground cable to the battery negative (-) terminal.
26. Install the carburetor air cleaner.
27. Leak test, evacuate and charge the A/C system following the recommended procedures and safety precautions in Section 36-32 of the Shop Manual.
28. Check the EATC system and all instrument panel functions for proper operations.
Evaporator Assembly Removal
Continental
1. Discharge the refrigerant from the A/C system following the recommended procedures (Shop Manual Section 36-32). Observe all safety precautions.
2. Disconnect the ground cable from the battery negative (-) terminal.
3. Remove the carburetor air cleaner.
4. Disconnect and plug the heater hoses at the heater core. Then, blow coolant from heater core.
5. Disconnect the wire harness connector from the clutch cycling pressure switch located on top of the suction accumulator/drier.
6. Disconnect the liquid line and the accumulator/ drier inlet tube from the evaporator core tubes. Use a back-up wrench to prevent component damage. Cap all fittings to prevent the entrance of dirt and excessive moisture.
FIGURE 1:
FIGURE 2:
7. Remove two (2) nuts retaining the accumulator/ drier bracket to the dash panel (Figure 1).
8. Position the accumulator/drier and the liquid line aside and remove the two evaporator retaining nuts (Figures 1 and 2).
FIGURE 8:
9. Working in the passenger compartment, remove the steering column opening cover from the instrument panel (Figure 8).
10. Remove the instrument panel left and right sound insulators (Figure 8).
11. Remove the right and left side cowl trim panels.
12. Remove the ash tray recepticle from the instrument panel.
FIGURE 9:
13. Remove two (2) screws attaching the lower center of the instrument panel to the floor brace (Figure 9).
14. Remove the shroud from the steering column and disconnect the transmission and indicator cable from the steering column.
FIGURE 10:
15. Remove the instrument panel pad (Shop Manual Section 45 and Figure 10.)
16. Remove the steering column to brake pedal support retaining nuts and lay the steering column down against the front seat.
FIGURE 9:
17. Remove the nut attaching the instrument panel to the brake pedal and steering column support (Figure 9).
18. Remove the instrument panel attaching screws (Figure 9) and lay the instrument panel back on the front seat. Disconnect wiring harness connectors as necessary.
FIGURE 6:
19. Disconnect the harness connectors from the blower motor wires and the blower motor speed controller (Figure 6).
20. Disconect the EATC sensor hose and elbow from the evaporator case (Figure 6).
21. Disconnect the EATC harness at the control assembly
22. Disconnect the antenna cable from the radio and from the strap retaining the cable to the evaporator case.
FIGURE 11:
23. Using a sharp knife, carefully slit the carpet on the top of the transmission tunnel as shown in Figure 11. Then, fold the carpet back to expose the rear seat heater duct.
Figure 12:
24. Using a saw or hot knife, cut the top and side from the rear seat heat duct as shown in Figure 12 and remove the top from the floor duct.
FIGURE 2:
25. Remove the three (3) evaporator attaching screws (Figure 2) and remove the evaporator assembly from the vehicle.
Evaporator Assembly Installation
Continental
1. Position the evaporator assembly to the dash panel and install the three (3) attaching screws in the passenger compartment (Figure 2). Do not tighten the screws at this time. Check the evaporator drain tube to be certain it is through the opening in the dash panel and is not pinched or kinked.
2. Working in the engine compartment install the two (2) nuts to retain the evaporator assembly to the dash panel. Then, tighten the retaining nuts and attaching screws.
3. Place the top cut from the rear seat heat duct on the duct and tape in place with duct tape. Be sure to cover all seams to prevent air leakage. Then, reposition the carpet over the rear seat heat duct.
FIGURE 6:
4. Position the instrument panel near the dash panel and connect the radio antenna, EATC harness to the control assembly, harness to the blower motor speed controller (Figure 6), blower motor wires and the EATC sensor hose and elbow assembly and any additional wire harness connectors disconnected in step 22 of the removal procedure.
FIGURE 9:
5. Move the instrument panel into position and install the attaching screws (Figure 9). BE CERTAIN THAT THE A/C PLENUM (ATTACHED TO THE INSTRUMENT PANEL) IS CORRECTLY ALIGNED AND SEALED AT THE EVAPORATOR OUTLET OPENING. Air leakage to the floor area will result if the plenum is not sealed at the evaporator case outlet.
6. Install the nut retaining the instrument panel to the brake pedal and steering column support (Figure 9).
7. Position the steering column to the brake pedal and steering column support and install the retaining nuts.
8. Connect the transmission selector indicator to the steering column and adjust as necessary.
9. Install the steering column opening reinforcement.
10. Install the steering column shroud.
11. Install the two (2) screws to attach the lower center of the instrument panel to the floor brace (Figure 9).
12. Install the right and left side cowl trim panels.
13. Install the right and left instrument panel sound insulators.
FIGURE 10:
14. Install the instrument panel pad (Section 45 Shop Manual and Figure 10.)
FIGURE 8:
15. Install the steering column opening cover (Figure 8).
FIGURE 1:
16. Position the accumulator/drier mounting bracket over the studs on the dash panel (Figure 1) and loosely install the two (2) nuts.
17. Connect the accumulator/drier inlet tube to the evaporator core outlet tube using a new O-ring lubricated with clean refrigerant oil. Do not tighten the connection.
18. Connect the liquid line to the evaporator core inlet tube using a new O-ring lubricated with clean refrigerant oil. Do not tighten the connection.
19. Tighten the two (2) nuts retaining the accumulator/drier to the dash panel (Figure 1).
20. Tighten the two refrigerant line connections at the evaporator core to specification. Use a backup wrench to prevent component damage.
21. Connect the harness connector to the clutch cycling pressure switch.
22. Connect the heater hoses to the heater core.
23. Fill the radiator to the specified level with a 50/50 mixture of coolant and water.
24. Connect the ground cable to the battery negative (-) terminal.
25. Install the carburetor air cleaner.
26. Leak test, evacuate and charge the A/C system following the recommended procedures and safety precautions in Section 36-32 of the Shop Manual.
27. Check the EATC system and all instrument panel functions for proper operations.
OTHER APPLICABLE ARTICLES: None WARRANTY STATUS "INFORMATION ONLY"