Evaporator Case: Service and Repair

SPECIAL SERVICE TOOL(S) REQUIRED


















Removal

1. Disconnect the battery ground cable.
2. Discharge the A/C system. Please refer to Heating ad Air Conditioning/Service and Repair/ Service and Repair
3. Disconnect the electrical connectors from the blower motor, the heater blower motor switch resistor and the A/C cycling switch.
4. Disconnect the vacuum line (part of A/C blower motor feed extension) from the A/C vacuum check valve.
5. Disconnect vacuum connector from rear of A/C evaporator housing.
6. Disconnect hose from radiator coolant recovery and windshield washer reservoirs to vacuum connector.
7. Remove evaporator core housing heat shield screw and two push clips.
8. Remove the nuts and two bolts from the radiator coolant recovery and windshield washer reservoirs.
9. Use Spring Lock Coupling Disconnect Tool T85L-19623-A to disconnect the A/C manifold and tube from the suction accumulator/drier, please refer to Heating and Air Conditioning/Coupler HVAC/Service and Repair/ Service and Repair
10. Disconnect the condenser to evaporator tube from the evaporator inlet tube and cap the openings to prevent the entry of dirt and moisture.
11. Remove speed control servo from inner fender and place securely out of the way.
12. Disconnect the electrical connectors from the engine air cleaner tube and the top part of the engine air cleaner.
13. Disconnect and remove the engine air cleaner tube and the top part of the engine air cleaner.
14. Remove the three nuts from the engine compartment side of the A/C evaporator housing and one nut from the passenger compartment side of the A/C evaporator housing.
15. Remove the A/C evaporator housing.

Installation

1. Position the A/C evaporator housing on three studs from dash panel.
2. Install three nuts on the engine compartment side and one nut on the passenger compartment side. Tighten nuts to 3-5 Nm (27-44 lb-in).
3. Install the evaporator core housing heat shield screw and two push clips. Tighten screw to 2-3 Nm (21-25 lb-in).
4. Install the engine air cleaner tube and the top part of the engine air cleaner.
5. Install the speed control servo. Tighten speed control servo bolt to 9-12 Nm (7-9 lb-ft).
6. Remove all caps from openings and connect the condenser to evaporator tube to the evaporator inlet tube.

NOTE: Use a new 0-ring lubricated with clean Motorcraft YN-12b refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B.

7. Connect the A/C manifold and tube to the suction accumulator/drier.
8. Install the radiator coolant recovery and windshield washer reservoir. Tighten the two radiator coolant recovery and windshield washer reservoir bolts and nuts to 6-8 Nm (52-71 lb-in).
9. Connect hose to radiator coolant recovery and windshield washer reservoir to vacuum connector.
10. Connect vacuum connector to rear of A/C evaporator housing.
11. Connect the vacuum line (part of A/C blower motor feed extension) from the A/C vacuum check valve.
12. Connect the electrical connectors to the blower motor, the A/C blower motor resistor and the A/C cycling switch.
13. Charge, leak test and check for proper A/C system operation. Please refer to Heating ad Air Conditioning/Service and Repair/ Service and Repair
14. Connect the battery ground cable.

NOTE: When battery voltage is removed from the powertrain control module (PCM), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance.