Evaporator Core: Service and Repair

REMOVAL

NOTE: The evaporator core is serviced as a core and housing assembly. The evaporator core, internal doors, seals and door linkage are included with the housing. Transfer the blower motor and wheel assembly, heater core and cover, dash panel seals and vacuum actuators to the new housing.

1. Remove the rear seat airflow duct.
2. Remove the instrument panel.
3. Drain the coolant from the radiator so that the coolant level is below the heater core.
4. Recover the refrigerant.







5. Loosen the screw and disconnect the electrical connector from the Powertrain Control Module (PCM).







6. Disconnect the heater water hoses from the heater core.







7. Disconnect the vacuum supply hose.







8. Disconnect the condenser to evaporator tube and the evaporator to accumulator tube spring lock couplings from the A/C evaporator core.







9. Disconnect the evaporator housing electrical connectors.







10. Remove the nuts and the washers at the cowl panel.







11. Remove the screws and the A/C evaporator housing.







12. Remove the screws and the metal cover.







13. Remove the screws and the A/C electronic blend door actuator.







14. Remove the A/C air intake flue damper assist spring.







15. Depress the locking ramp and remove the A/C damper door shaft from the air temperature control door shaft.

CAUTION: Do not attempt to bend any part of the A/C damper door shaft. It is brittle and will break.







16. Remove the A/C evaporator case outlet door shaft.

CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.







17. Remove the A/C tube dash panel seal and the A/C evaporator drain tube seal.

INSTALLATION

NOTE: Transfer the blower motor and wheel assembly, heater core and cover, dash panel seals and actuators to the new housing.

1. Lubricate the new A/C evaporator core with the correct amount of PAG compressor oil, YN-12c, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B.







2. Install the A/C tube dash panel seal and the A/C evaporator drain tube seal.







3. Install the A/C electronic blend door actuator and the metal cover.







4. Install the A/C evaporator housing and the screws







5. Install the nuts and washers at the cowl panel.







6. Connect the evaporator housing electrical Connectors.







7. Connect the condenser to evaporator tube and the evaporator to accumulator tube spring lock couplings to the A/C evaporator core.







8. Connect the vacuum supply hose.







9. Connect the heater water hoses.
- Lubricate the heater water hoses with Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A.







10. Connect the electrical connector to the powertrain control module.
11. Install the instrument panel.
12. Install the rear seat airflow duct.
13. Fill the engine cooling system.
14. Evacuate and charge the A/C system.