Ford Workshop Service and Repair Manuals

Remover, fluid pipe 1/2" (blue)

412-027 (34-001)

Remover, fluid pipe 5/8" (black)

412-038 (34-003)

Remover/installer, coolant hose clip

303-397 (24-003)

1. Drain the air conditioning system. For additional information, refer to Section  412-00 Climate Control System - General Information.

2. Drain the cooling system. For additional information, refer to Section  303-03 Engine Cooling.

3. Remove the crash padding. For additional information, refer to Section  501-12 Instrument Panel and Console.

4. Pull the vacuum line from the hose.

5. 

   NOTE:Blow out the heat exchanger with compressed-air.
   Detach the heating hoses from the heat exchanger using the special tool.

6. Disconnect the connector from the air recirculation / intake solenoid (if equipped).

7. Pull out the plugs.
   1. Blower motor plug.
   2. Blower motor resistor connector (if equipped).

8. Remove the A/C refrigerant line brackets.

9. 

   CAUTION:Immediately close off the A/C refrigerant lines and evaporator using plugs.
   Detach the left-hand refrigerant line from the A/C evaporator using the special tool.

10. 

    CAUTION:Immediately close off the A/C refrigerant lines and evaporator using plugs.
    Detach the right-hand refrigerant line from the A/C evaporator using the special tool.

11. Remove the retaining nuts from the heat exchanger housing and the evaporator.

12. Detach the heat exchanger housing and evaporator from the cross member.
    1. Remove the retaining nut.
    2. Remove the retaining bolt.

13. Remove the windshield air duct.
    1. Remove the retaining bolt.
    2. Release the retaining tabs.

14. Pull the right-hand and left-hand air hoses from the heat exchanger housing and evaporator (left-hand side shown).

15. Remove the vacuum reservoir.
    1. Disconnect the connector from the temperature flap servo motor (if equipped).
    2. Disconnect the vacuum hoses.
    3. Remove the retaining bolt.

16. Remove the retaining bolts from the heater air duct (heat exchanger housing shown removed for clarity).

17. Remove the heater air duct.
    1. Remove the retaining bolt.
    2. Slide the air ducting upwards.
    3. Undo the left- and right-hand retaining straps.

18. Disconnect the temperature sensor connector.

19. Remove the heat exchanger.
    • Unclip the heat exchanger cover.

20. Detach the heat exchanger housing and evaporator from the bulkhead.

21. Remove the heat exchanger housing and evaporator.

1. 

   NOTE:Install new refrigerant line O-rings.
   

   NOTE:Lubricate the refrigerant line O-rings with clean refrigerant oil before installing.
   Refit the components in reverse order.