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HVAC Housing (Evaporator Core Housing)

Removal & Installation

To Remove:

CAUTION
Only refrigerant compressor oil (mineral oil) (F73Z-19577-AA/Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals and it should not be added to the R-134a refrigerant system as an A/C compressor lubricant. Only PAG refrigerant compressor oil F7AZ-19589-DA/Motorcraft YN-12-C) or an equivalent meeting the manufacturer’s specifications should be used as an A/C compressor lubricant.

NOTE: The evaporator core cannot be serviced separately. It can only be serviced with the evaporator core housing assembly.

NOTE: If you suspect an evaporator core leak, you must leak test the evaporator core before it is removed from the vehicle.

NOTE: When repairing the refrigerant system, it is not necessary to install a new suction accumulator unless there is evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

  1. Drain the cooling system.
  2. Recover the refrigerant.
  3. Remove the air cleaner outlet pipe and the suction accumulator.
  4. Remove the screws and nuts on the coolant reservoir and windshield washer reservoir, and then move them to the side.
  5. On vehicles with speed control ONLY: Detach the speed control servo by disconnecting the electrical connector, removing the bolt, then detaching the cable from the evaporator core housing. Move the speed control servo to the side.
  6. Disconnect the electrical connectors for the blower motor and blower motor resistor.
  7. Disconnect the heater hoses.
  8. Detach the pin-type retainer and move the windshield washer hose to the side.
  9. Disconnect and detach the heater control valve vacuum hose.
  10. Disconnect the vacuum supply hose near the evaporator core housing.
  11. Disconnect the condenser to evaporator line spring lock coupling from the evaporator core inlet and throw away the O-ring seals.
  12. In the lower passenger side dash panel, inside the passenger compartment, disconnect the vacuum hose connector and remove the nut.

    NOTE: Remove the splash shield electrical connector locators before removal.

    NOTE: Disconnect the vacuum lines from the vacuum storage reservoir on the right-hand splash shield.

  13. Remove the nuts and the evaporator core housing.

To Install:

CAUTION
Make sure to lubricate the refrigerant system with clean PAG oil.

NOTE: If necessary, lubricate the coolant hoses with plain water only.

  1. Install the evaporator core housing and nuts.
  2. In the lower passenger side dash panel, inside the passenger compartment, connect the vacuum hose connector and install the nut.
  3. Connect the condenser to evaporator line spring lock coupling to the evaporator core inlet with new O-ring seals lubricated with clean mineral oil.
  4. Connect the vacuum supply hose near the evaporator core housing.
  5. Connect and attach the heater control valve vacuum hose.
  6. Correctly position the windshield washer hose then attach the pin-type retainer.
  7. Connect the heater hoses.
  8. Connect the electrical connectors for the blower motor and blower motor resistor.
  9. On vehicles with speed control ONLY: Correctly position the speed control servo to the side then attach the speed control servo by attaching the cable to the evaporator core housing, installing the bolt, then connecting the electrical connector.
  10. Install the screws and nuts on the coolant reservoir and windshield washer reservoir.
  11. Install the air cleaner outlet pipe and the suction accumulator.
  12. Refill the system with refrigerant.
  13. Evacuate, leak test, and charge the refrigerant system.

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