Grand Marquis V8-302 5.0L VIN F FI (1985)
Evaporator Case: Service and Repair
With Manual A/C
REMOVAL
1. Discharge the refrigerant from the A/C system into an approved recovery unit while observing all safety precautions.
2. Disconnect the suction hose from the suction accumulator/drier and plug the openings to prevent dirt and excessive moisture from entering.
Position the hose away from evaporator assembly.
3. Disconnect the liquid line from the evaporator inlet tube and plug the openings. Position the liquid line away from the evaporator assembly.
4. Disconnect the two-wire connector plug from the pressure control de-ice switch on the suction accumulator/drier.
5. Drain coolant from radiator. Save coolant for reuse.
6. Loosen the heater hose clamps and disconnect the heater hoses from the heater core tubes.
7. Remove the six screws holding the right side of the hood seal bracket assembly. Remove the copper hood ground clip from underneath the hood
seal and fold the hood seal assembly to the left side of the vehicle.
8. Loosen the retaining clamp and disconnect the emission hose that passes over the top of the evaporator case assembly. Position the emission hose
and all vacuum hoses and movable wires away from the evaporator case assembly.
9. Disconnect the blower motor lead assembly from the main wiring harness.
10. Disconnect the two large wire harnesses (which cross the evaporator assembly) at the various hard shell connecting points and position them away
from the evaporator assembly.
11. From the passenger side of dash panel, fold carpeting back on the right side of the floor. Remove the bottom left screw of the two screws that
support the inlet recirculation air duct assembly.
12. From the engine side of the dash panel, remove the three nuts (one upper and two lower) from the three evaporator assembly mounting studs. Also
remove the two screws (one drill point and one sheet metal) from the blower motor and wheel assembly portion of the case assembly.
13. Pull the bottom of the evaporator case assembly away from the dash panel to disengage the two bottom studs. Move the top of the case assembly
away from the dash panel disengaging it from the top stud and maneuver the case up and over the wheel well splash panel.
INSTALLATION
1. Position the evaporator assembly next to the dash panel by maneuvering it down past the wheel well splash panel.
Evaporator Case/Plenum Removal
2. Engage the two bottom dash panel studs into the evaporator assembly stud holes. Move the top of the case assembly towards the dash panel while
engaging the top dash panel stud into the evaporator assembly stud hole.
3. Replace, but do not tighten, the three stud nuts.
4. Replace and tighten the two screws (one drill point and one sheet metal). Be careful to return the drill point screw to the correct hole which is
located on top of the case and to the right of the blower motor and wheel assembly. Tighten the three stud nuts previously installed.
5. Position the two large wire harnesses across the evaporator case assembly and connect the various connectors.
6. Connect the blower motor lead assembly to the main wiring harness.
7. Place the emission hose clamp on the hose, tighten the clamp and position it over the evaporator case assembly along with the vacuum hoses and
wires previously moved.
8. Unfold the hood seal bracket assembly and insert the copper hood ground clip underneath the hood seal. Install the four screws that secure the
