Aerostar 2WD V6-182 3.0L (1995)
Evaporator Core: Service and Repair
Front
A/C Evaporator Core
Removal
1.
Disconneot the cable from the battery negative (ground) terminal.
2.
Discharge the refrigerant from the air conditioning system. Observe all safety precautions.
3.
Remove the air cleaner and air inlet duct.
4.
Disconnect the electrical hard shell connectors from the blower motor, the heater blower motor switch resistor, the A/C cycling switch.
5.
Disconnect the condenser to evaporator tube from the inlet tube and the evaporator to compressor suction lines from the suction
accumulator/drier, using the spring lock coupling tools. Cap all open refrigerant lines to prevent the entry of dirt and moisture.
6.
Disconnect the A / C vacuum check valve from the engine source line and disconnect the vacuum line from the vacuum control motor.
7.
Remove the two A/C accumulator bracket holding the suction accumulator/drier to the A/C evaporator core and the clamp from around the
inlet tube. Disconnect the suction accumulator/drier from the outlet tube and remove the suction accumulator/drier. Cap all open refrigerant
connections to prevent the entry of dirt and moisture.
8.
Remove the eleven screws holding the A/C blower housing to the A/C evaporator case. Remove the A/C blower housing from the vehicle.
9.
Remove the A/C evaporator core from the vehicle.
Installation
1.
Position the A/C evaporator core into the installed A/C evaporator case.
2.
Position the A/C blower housing to the A/C evaporator case and install with eleven screws.
3.
After checking the male fitting on the suction accumulator/drier for a missing or damaged garter spring and, replacing or repairing as
necessary, install two new specified 0-rings lubricated with clean refrigerant oil into the male fitting. Insert the male fitting into the outlet tube
until the A/C tube lock coupling clip is fully engaged.
4.
Install the A/C accumulator bracket around the suction accumulator/drier and install the clamp around the inlet line. Tighten the screws to 2
N.m (18 lb-in) minimum.
5.
After checking the condenser to evaporator tube for a missing or damaged garter spring and replacing or repairing as necessary, install two
new specified 0-rings lubricated with clean refrigerant oil into the male fitting. Insert the male fitting into the inlet tube until the A/C tube lock
coupling clip is fully engaged.
6.
Install the evaporator to compressor suction lines to the suction accumulator/drier, using the same procedure as for the condenser to evaporator
tube above.
7.
Connect the electrical hard shell connectors to the blower motor, A/C cycling switch, heater blower motor switch resistor.
8.
Connect the vacuum line to the vacuum control motor. Connect the vacuum source line from the engine to the A/C vacuum check valve.
9.
Charge the A/C system. Observe all safety precautions.
10.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control
module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Connect the cable to the battery negative (ground) terminal.
11.
Check the air conditioning system for refrigerant leaks and proper operation.
