Evaporator Core: Service and Repair

Fig. 13 Evaporator Case Tab Drilling Continental And Mark VII:

Fig. 6 Cutting Between Raised Outlines Of Evaporator Case:

Whenever an evaporator core is replaced, it will be necessary to replace the suction/accumulator dryer.
1. On models equipped with airbag, disarm airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING.
2. On all models, remove instrument panel and lay it on front seat as outlined in BODY ELECTRICAL SAFETY AND ENTERTAINMENT/INSTRUMENT PANELS AND CLUSTER. Service and Repair
3. Discharge refrigerant from air conditioning system.
4. On models equipped with 2.3L/4-140 engine, remove speed control servo. Service and Repair
5. On all models, working from inside engine compartment, disconnect air conditioning lines from evaporator core at dash panel.
6. Remove low pressure line from accumulator/dryer, then cap all open lines to prevent contamination of system.
7. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8 inch and 3/4 inch plugs.
8. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core.
9. Working from inside passenger compartment, remove screw attaching air inlet duct and blower housing assembly support brace to cowl top panel.
10. Disconnect vacuum supply hose (black) from in-line vacuum check valve in engine compartment.
11. Disconnect blower motor wires from wire harness, then wire harness from blower motor resistor.
12. Working from inside engine compartment, remove two nuts retaining evaporator case to dash panel.
13. Working from inside passenger compartment, remove two screws attaching evaporator case support brackets to cowl top panel.
14. Remove one screw retaining bracket below evaporator case to dash panel.
15. Carefully pull evaporator case from dash panel, then remove case from vehicle.
16. Remove four screws retaining air inlet duct to evaporator case, then duct.
17. Remove foam seal from evaporator core tubes.
18. Drill 3/16 inch hole in both upright tabs as shown in Fig. 5.
19. Using a small saw blade, cut top of evaporator case between raised outlines as shown in Fig. 6.
20. Remove two screws retaining blower motor resistor to evaporator case, then resistor.
21. Fold cutout flap from opening and lift evaporator core from case.
22. Reverse procedure to install, reactivate airbag system, if equipped.