A/C Evaporator Case - Water Leaks To Interior
87ford5
AIR CONDITIONING - LEAKS CONDENSATION Article No.
(WATER) INTO PASSENGER COMPARTMENT 87-9-2
FORD: 1986-87 TAURUS
LINCOLN-MERCURY: 1986-87 SABLE
ISSUE: Condensation (water) leaking and entering into the passenger compartment may be caused by the air flow inside the A/C evaporator case creating a whirlpool of air that pulls water from the sump area and discharges it into the air stream.
ACTION: To correct this, install a baffle assembly (E7DZ-19A999-A) in the A/C evaporator case downstream from the evaporator core. Refer to the following service procedure for stepby-step instructions.
1. Disconnect the ground cable from the battery.
2. Remove the left side cowl trim panel.
3. Set the system temperature control to Maximum cooling.
4. Remove the steering column opening cover from below the column (4 screws).
5. Remove two (2) bolts attaching steering column to steering column support.
6. Remove ashtray and disconnect wire from lighter.
7. Remove the radio trim and radio.
8. Remove radio speaker grilles and defroster trim cover.
9. Remove instrument panel upper three (3) attaching bolts.
10. Remove instrument panel brace bolt.
11. Remove lower left instrument panel attaching bolt.
12. Remove the right side "A" pillar moulding and the right cowl side trim panel.
13. Disconnect the wire connectors at the right side cowl and door sill area.
14. Remove the lower bolt attaching the instrument panel to the right side cowl.
15. Disconnect the blower motor and resistor wires on Manual A/C-Heater vehicles.
16. On ATC vehicles, disconnect the blower motor and two (2) additional harness connectors and the aspirator hose from the evaporator case.
Figure 1:
17. Pull the right side of the instrument panel rearward away from the cowl and disconnect the instrument panel plenum from the instrument panel. Two (2) bolts attach the plenum to lower edge of instrument panel (Figure 1) and one (1) screw to defroster duct. Then, position the plenum to the side.
Figure 2:
Figure 3:
18. Install the baffle (E7DZ-19A999-A) in the evaporator case as shown in Figures 2 and 3.
Figure 1:
19. Position plenum to instrument panel and install the two (2) attaching bolts and one (1) screw, Figure 1.
20. Position plenum to instrument panel to the cowl and install the top center attaching bolt.
21. Install the right and left bolts to attach the instrument panel to the cowl sides.
22. Install the bolt to attach the instrument panel lower center brace to the lower edge of the instrument panel.
23. On ATC vehicles, connect the blower motor wires and the other two (2) harness connectors to the evaporator case and reconnect the aspirator hose.
a. On non-ATC vehicles, connect the blower motor and resistor wires.
24. Install the remaining instrument panel to cowl top upper attaching screws.
25. Install the speaker grilles and defroster opening trim cover.
26. Reconnect the wire harness connectors located in the right side cowl and door sill area.
27. Install the right side cowl trim panel and the right side "A" pillar moulding.
28. Install two (2) steering column to support retaining bolts.
29. Install the steering column opening cover.
30. Install the left side cowl trim panel.
31. Install the radio and the radio trim.
32. Install the ashtray and connect the wire to the lighter.
33. Connect the ground cable to the battery and check the A/C system and all instrument panel components for proper operation.
PART NUMBER PART NAME CLASS
E7DZ-19A999-A Baffle Assembly B
OTHER APPLICABLE ARTICLES: Supersedes 86-24-3
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual
OPERATION: SP870902A
TIME: 1.3 Hrs.
DLR. CODING: Basic Part No. 19860 - Code: 47