| Removal and Installation Special Tool(s) | | Remover/Installer, coolant hose clamp 303-397 | | | Disconnect Tool, spring lock coupling 3/4" (white) 412-040 | General Equipment Hose clamp - coolant hose | | -
Evacuate the air conditioning (A/C) system.
For additional information, refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
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Remove the right-hand headlamp unit.
For additional information, refer to: Headlamp Assembly (417-01 Exterior Lighting, Removal and Installation).
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Remove the engine cover (1.8L shown). - Remove the oil filler cap.
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CAUTION:If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water. Detach the brake fluid reservoir from the water trap and secure it to one side. | | | -
Remove the windshield wiper arm cover (if installed). | | | -
CAUTION:Make sure that the windshield wiper motor is in the park position. Remove the windshield wiper arms. | | | -
Remove the cowl grille. - Detach the cowl grille clips.
- Detach the cowl grille from the windshield glass lower weatherstrip and remove.
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Remove the windshield wiper linkage bolt. | | | -
Remove the bulkhead extension. - Pull the bulkhead extension out of the clips.
| 10. Remove the components in the order indicated in the following illustration(s) and table(s). CAUTION:Close off the A/C dehydrator and evaporator to stop dirt from entering. 3 - Low pressure switch connector 4 - Bolt, evaporator outlet pipe to A/C evaporator 6 - Bracket - evaporator outlet pipe (unclip) 11. To install, reverse the removal procedure. CAUTION:Move the windshield wiper motor to the parked position before installing the wiper arms. NOTE:Install new O-rings for the evaporator outlet pipe. NOTE:Coat the evaporator outlet pipe O-rings with clean refrigerant oil before installation. | | -
Check the angle of the windshield wiper arms in relation to the windshield.
For additional information, refer to: Windshield Wiper Blade and Pivot Arm Adjustment (501-16 Wipers and Washers, General Procedures).
| Removal Details Item 1 : Coolant hose, coolant expansion tank (only 1.6L diesel engine) | | -
Empty the coolant expansion tank. | | | -
CAUTION:Clamp shut the coolant hose of the expansion tank using the hose clamp, to prevent coolant escaping from the hose. Clamp the coolant hose shut. | Item 2 : Coolant expansion tank | | -
Unclip the coolant expansion tank and place to one side. | Item 5 : Nut, evaporator outlet pipe to A/C dehydrator | | -
NOTE:Only vehicles with 1.6L Duratec-16V (Sigma) Remove the retaining clip of the evaporator outlet pipe. | | | -
NOTE:Only vehicles with 1.6L Duratec-16V (Sigma) Detach the evaporator outlet pipe from the dehydrator using the special tool. | |
