Auxiliary Evaporator Core Assembly

Removal

NOTE: Whenever a refrigerant line, expansion valve or evaporator core in the auxiliary system is replaced, it will be necessary to replace the suction accumulator drier in the main system.

1. Remove first bench seat, if so equipped.






2. Remove auxiliary heater and/or air conditioner cover assembly retaining screws an(l remove cover assembly (Fig. 6).
3. Discharge the refrigerant system following recommended service procedures. Observe all safety precautions.
4. Using backup wrenches to prevent component damage, disconnect suction line from evaporator core and liquid line from expansion valve. Cap all open refrigerant line connections to prevent entrance of dirt and moisture.
5. Disconnect heater hoses (if equipped with an auxiliary heater) from auxiliary heater core and plug hoses with suitable 15.875mm (5/8-inch) plugs.






6. Remove four screws retaining evaporator core and mounting bracket to auxiliary case assembly (Fig. 17).
7. Remove evaporator core, expansion valve and core mounting plate from case assembly (Fig. 17).
8. If evap9rator core is to be replaced, remove expansion valve and mounting plate from evaporator core.

Installation

1. Connect expansion valve to evaporator core in let tube using a new 0-ring lubricated with clean refrigerant oil. Tighten connection to 21-27 N.m (15-20 ft-lb) using a backup wrench to prevent component damage.
2. Clamp the expansion valve capillary bulb to evaporator core outlet tube making sure bulb makes good contact with outlet tube. Clean both surfaces. Wrap capillary bulb and outlet tube with insulating tape, Motorcraft YZ-1 or equivalent.
3. Wrap ends of evaporator core with insulating tape.
4. Attach mounting plate to expansion valve end of evaporator core with two screws.
5. Carefully position evaporator core to case and refrigerant lines Use new O-rings lubricated with clean refrigerant oil at refrigerant line connections.
6. Tighten refrigerant line connections; suction line to evaporator core 41-47 N.m (30-35 ft-lb), liquid line to expansion valve 14-20 N.m (10-15 ft-lb). Use a backup wrench to prevent component damage.
7. Install four screws that retain evaporator core mounting brackets to evaporator case.
8. Remove plugs from heater hoses.
9. Connect heater hoses to heater core. Tighten hose clamps to 14-20 N.m (12-18 in-lb). DO NOT overtighten hose clamps.
10. Fill radiator to specified level with coolant.
11. Leak-test, evacuate and charge the refrigerant system following recommended service procedures. Observe all safety precautions.






12. Install auxiliary heate and/or air conditioner cover assembly (Fig. 6).
13. Install bench seat, if so equipped. Tighten retaining bolts 34-61 N.m (25-45 ft-lb).