A/C Evaporator - Cold Air Leaks/Cold Air Radiation
86ford22 Article No. 86-4-6HEATER/AIR CONDITIONING SYSTEM - COLD AIR LEAKS AND/OR COLD AIR RADIATION FROM EVAPORATOR ASSEMBLY
FORD 1982 FAIRMONT, GRANADA; 1982-85 MUSTANG, THUNDERBIRD; 1983-85 LTD
LINCOLN-MERCURY 1982 ZEPHYR; 1982-86 CAPRI, COUGAR; 1983-85 MARQUIS
Some passengers may experience discomfort while in the vehicle during cold weather because of cold air leaks and/or radiation to the cold evaporator assembly. The probable cause of the air leaks is an inadequate seal at one or more of the following locations: (1) the recirc door, (2) the outside air inlet gasket, and (3) the connection between the blower housing and evaporator case. Heat radiation, as a source of discomfort, is directly related to the proximity of the cold evaporator assembly to the passenger's legs.
Service Procedure for Cold Air Leaks
1. From the outside/recirc air door:
^ Remove the air inlet duct and blower housing assembly (19486) from the vehicle.
^ Separate the air inlet duct assembly (19A618) from the blower housing assembly (19930).
^ Remove the screw (42127) which attaches the outside-recirc door to its operating shaft (19A819); then remove and replace the door (19A813).
2. From the outside air inlet gasket:
^ Check the air inlet gasket (5401807) for any interference with cowl sound absorber or wiring harness which might deform the gasket and allow cold air to be bypassed into the passenger compartment instead of through the duct.
^ Check for gasket damage.
^ Eliminate any parts interference which may exist.
^ Replace the gasket if damage to its sealing surface is found.
3. From the mating surfaces between the blower housing assembly and evaporator case:
^ Check to determine whether cold air is escaping between the surfaces of the blower housing and evaporator case.
^ If a leak does exist, apply a silicone-based sealer between the adjacent surfaces on an as-required basis until the leak is corrected.
Service Procedure for Cold Air Radiation
A new air conditioner evaporator cover assembly (E5DZ-19C967-A) has been released for service to insulate that portion of the bottom surface of the evaporator case which is causing the radiation of passenger warmth to the cold evaporator surface. The procedure for installing the cover is as follows:
^ Some vehicles are equipped with a modesty panel which is to be removed to provide access to the evaporator case.
^ Remove the lower attaching screw (42127) from the thermal limiter resistor assembly.
^ Remove the two screws (42134) which attach the air inlet duct assembly (19A618) to the A/C blower housing assembly (19930).
Figure 19:
^ Refer to Figure 19. Install the service replacement cover assembly (E5DZ-19C967-A) using the two screws removed during the preceding step. Substitute screw 42134 (No. 10-12x.62) for the resistor attaching screw (42127) and secure the cover at its third attaching point through the resistor attaching hole and into the evaporator case.
Figure 20:
Service Procedure for Cold Air Escaping on the Right Side of the Floor Duct
Addition of a locally fabricated baffle to the opening in the right end of the floor duct (18C433) will redirect the flow of air into the passenger compartment. The procedure is as follows:
1. Using a template provided in Figure 20, make a sheet metal baffle from stock on hand or obtained locally. Cut the baffle and bend it along the breaklines shown on the template.
2. Refer again to Figure 20. Position the baffle, as shown in the illustration, so that a half-inch area along the right side of the right side outlet in the duct is blocked.
3. Attach the baffle with pop rivets or screws.
4. Apply black tape over the baffle, as shown in Figure 20.
PART NUMBER PART NAME CLASS
E5DZ-19C967-A Evaporator Case Cover C
OTHER APPLICABLE ARTICLES: 85-20-3
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual.
OPERATION: SP19930A85
TIME: 1.0 Hr. - Mustang/Capri 1.1 Hrs. - Fairmont/Granada/Zephyr 1.3 Hrs. - LTD/Marquis 1.5 Hrs. - Thunderbird/Cougar DLR. CODING: Basic Part No. 19930 - Code: 48