Evaporator Core: Service and Repair

A/C Evaporator Core Housing Removal

1. Disconnect battery ground cable.

2. Discharge the refrigerant from the A/C system.

3. NOTE: Whenever the A/C evaporator core housing is removed, it will be necessary to replace the suction accumulator / drier. Disconnect the evaporator to compressor suction line from the suction accumulator/drier using Spring Lock Coupling Disconnect Tool T81P-19623-G1 or G2 and plug the openings to prevent dirt and excessive moisture from entering. Position the hose away from suction accumulator / drier assembly.





4. Disconnect the condenser to evaporator tube from the A/C evaporator core inlet tube using Spring Lock Coupling Disconnect Tool T81P-19623-G1 and G2 and plug the openings. Position the condenser to evaporator tube away from the A/C evaporator core housing assembly.

5. Drain coolant from radiator. Save coolant for reuse.

6. Loosen the hose clamps and disconnect the heater water hoses (18472) from the heater core tubes.

7. Remove the two nuts retaining purge valve mounting bracket to the cowl top extension. Position purge valve and bracket away from A/C evaporator core housing.

8. Remove radiator coolant recovery reservoir. Position radiator coolant recovery reservoir forward, away from A / C evaporator core housing.

9. Disconnect A / C blower motor lead assembly from the main wiring harness and remove the hard-shell connector from the heater blower motor switch resistor.





10. Disconnect the large wire harness (which crosses the A / C evaporator core housing) at the hard shell connecting point and position it away from the A/C evaporator core housing.





11. From passenger side of dash panel, fold carpeting back on the RH side of the floor. Remove the bottom LH screw of the two screws that support the A/C recirculating air duct.

12. From the engine side of the dash panel, remove the three nuts (one upper and two lower) from the three evaporator assembly mounting studs. Also remove the two screws (one drill point and one sheet metal) from the blower motor and blower motor wheel assembly portion of the case A/C evaporator core housing.

13. Pull the bottom of the A/C evaporator core housing assembly away from the dash panel to disengage the two bottom studs. Move the top of the A / C evaporator core housing assembly away from the dash panel disengaging it from the top stud and maneuver the case up and over the wheel well splash panel.

A/C Evaporator Core

NOTE: 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.

NOTE: Whenever the A/C evaporator core is replaced, it will be necessary to replace the suction accumulator / drier.





Removal

1. Remove the A / C evaporator core housing (19A559) from the vehicle as outlined.

2. Remove A/C evaporator case dash panel seal.

3. Remove the A/C evaporator case cover insulator from the bottom of the A / C evaporator core housing.

4. Remove six screws retaining the two halves of the A/C evaporator core housing together.

5. Separate the two halves of the A / C evaporator core housing and remove the A/C evaporator core and suction accumulator/drier assembly.

6. Disconnect the suction accumulator/drier inlet from the evaporator core outlet tube.

7. Remove the retaining screw from the suction accumulator/drier and evaporator core mounting brackets and remove the suction accumulator / drier from the A / C evaporator core.

Installation

1. NOTE: When replacing an A/C evaporator core in a refrigerant system, Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M 1 C23 1-B should be added to the A/C evaporator core to ensure that the total oil charge in the system is correct before the system is operated. Pour 90 ml (3 ounces) of clean Motorcraft YN- 1 2b refrigerant oil meeting Ford specification WSH-M1C231-B directly into the inlet pipe of the replacement A/C evaporator corewith the pipe held vertically so the oil will drain into the A/C evaporator core.

2. Attach the suction accumulator/drier to the evaporator core mounting bracket with a retaining screw.

3. Install a new 0-ring seal lubricated with clean Motorcraft YN- 1 2b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B and connect the suction accumulation drier inlet connection to the outlet tube of the evaporator core. Tighten using a backup wrench to prevent component damage.

4. Position the A/C evaporator core assembly to the RH half of the A/C evaporator core housing.

5. Apply Caulking Cord D6AZ-1 9560-A or equivalent meeting Ford specification ESB-M4G 32-A to the A / C evaporator core housing flange and around the evaporator core tubes.

6. Position the A/C evaporator core housing LH half and dash panel gasket to the case RH half.

7. Install support strap on evaporator inlet tube.

8. Install seven screws to attach the two halves of the housings together. The center screw on the front of the housing also retains the support strap.

9. Install A/C evaporator case dash panel seal.

10. Install a new heat shield on the bottom of the A/C evaporator core housing with staples.

11. Install the A / C evaporator core housing in the vehicle as outlined.

12. Leak test, evacuate and charge the refrigeration system following the recommended procedures and safety precautions.

Installation

1. Position the A/C evaporator core housing assembly next to the dash panel by maneuvering it down past the wheel well splash panel.

2. Engage the two bottom dash panel studs into the A/C evaporator core housing assembly stud holes. Move the top of the A/C evaporator core housing assembly toward the dash panel while engaging the top dash panel stud into the A/C evaporator core housing assembly stud hole.

3. Replace, but do not tighten, the three stud nuts.

4. Replace the two screws (one drill point and one sheet metal) and tighten to 2.5-3.2 N-m (22-28 lb-in). Be careful to return the drill point screw to the correct hole which is located on top of the A / C evaporator core housing and to the right of the A/C blower motor and blower motor wheel assembly. Tighten the three stud nuts previously installed to 2.5-3.2 N-m (22-28 lb-in).

5. Position the wire harness connector across the A/C evaporator core housing assembly and connect the various connectors.

6. Connect lead assembly to the blower motor and heater blower motor switch resistor.

7. Install radiator coolant recovery reservoir to wheel well splash panel with two retaining nuts.

8. Install purge valve mounting bracket to the cowl top extension with two retaining nuts.

9. Place the hose clamps onto the heater water hoses and carefully connect the hoses to the inlet and outlet heater core tubes. Position the hose clamps and tighten to specification. Refill coolant system.

10. CAUTION: Make sure correct 0-ring seals are installed whenever an A/C fitting is serviced. Leaks and refrigerant loss may result. Remove the plugs from the evaporator inlet tube and the condenser to evaporator tube and install new 0-ring seals dipped in clean refrigerant oil. Connect the condenser to evaporator tube to the evaporator inlet tube.

11. Remove the plugs from the suction accumulator/drier outlet and the evaporator to compressor suction line and install new 0-ring seals dipped in clean refrigerant oil. Connect the evaporator to compressor suction line to the suction accumulator / drier.

12. Leak-test, evacuate and charge the refrigeration system following the recommended procedures and safety precautions.

13. From the passenger compartment, install the A/C recirculating air duct screw.

14. Check the A/C system for proper operation.