Evaporator Core: Service and Repair

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

Fig. 14 Cutting Evaporator Case. Continental And Mark VII:

Fig. 15 Removing Evaporator Case From Core. Continental And Mark VII:

1. Remove evaporator case.
2. Disconnect and remove vacuum harness.
3. Remove six screws attaching recirculation duct, then remove duct.
4. Remove two screws from air inlet duct and remove duct from evaporator case.
5. Remove support bracket, then screws holding electronic connector bracket to recirculation duct.
6. Remove blend door actuator and cold engine lockout switch.
7. Remove molded seal from evaporator core tubes.
8. Drill a (3/16 inch) hole in both upright tabs on top of evaporator case, Fig. 13.
9. Using a hot knife or small saw blade, cut top of evaporator case between raised outline, Fig. 14.
10. Fold cutout cover back from opening and lift evaporator core from case, Fig. 15.
11. Reverse procedure to install noting the following:
a. Transfer four foam core seals to new evaporator core.
b. Install caulking cord No. D9AZ-19560-A or equivalent to seal evaporator case against leakage along cut line.
c. Rearm airbag.