Tauras/Sable
TAURUS/SABLE EVAPORATOR CORE REPLACEMENT1. Disconnect battery ground cable.
2. Remove radio cluster as outlined in the Service Manual, Section 15-01.
3. Remove two (2) bolts and remove the steering column opening cover from under steering column.
4. Remove sound insulators from under steering column.
5. Remove three (3) screws retaining lower steering column shroud and remove shroud.
6. Remove two (2) bolts and steering column reinforcement from under steering column.
7. Disconnect all electrical connections from steering column switches.
8. Remove four (4) nuts retaining steering column support brace, disconnect PRNDL cable (column shift) and lower steering column.
9. Disconnect park brake release cable from park brake and disconnect ignition switch wiring connector.
10. Remove instrument cluster finish panel and disconnect all instrument cluster finish panel electrical connections.
11. Remove four (4) retaining screws from instrument cluster and...
a. disconnect speedometer cable (if equipped),
b. disconnect wiring and remove instrument cluster.
12. Remove one (1) bolt at steering column opening attaching instrument panel to brace.
13. Remove one (1) instrument panel brace retaining bolt (under the radio area).
14. Remove sound insulator under glove compartment by removing two (2) push nuts that secure insulator to studs on the evaporator case.
15. Remove three (3) screws attaching glove compartment assembly to instrument panel and remove door assembly.
16. Remove LH and RH cowl side trim panels.
17. Disconnect electrical connections at RH cowl side.
18. Remove three (3) screws retaining instrument panel to cowl top panel.
19. Remove one (1) screw at instrument panel RH side.
20. Remove two (2) instrument panel-to-center console nuts.
21. Remove cup holder and shift lever opening retaining screw.
22. Remove shift lever rearward.
23. Remove shift lever opening cover (snaps out).
24. Remove eight (8) console-to-floor bracket retaining screws (the two (2) rear screws are under the mat in the rear storage bin).
25. Disconnect all necessary electrical connections and remove console.
26. Remove two (2) nuts and two (2) screws retaining instrument panel to cowl panel behind center console.
27. Remove one (1) screw at instrument panel LH side.
28. Gently pull instrument panel away from RH side of cowl panel.
29. Place a drain pan or suitable container under heater hose connections at the cowl panel.
30. Discharge refrigerant from the A/C system at service access gauge port valve located in suction line, following the recovery procedure.
CAUTION:
OBSERVE ALL SAFETY PRECAUTIONS
31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture.
32. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core.
33. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment.
34. Remove screw holding instrument panel shake brace to evaporator case and remove instrument panel shake brace.
35. Remove two (2) screws retaining floor register and rear seat duct to bottom of evaporator case.
36. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment.
37. Remove two (2) screws retaining support brackets to cowl top panel.
38. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench.
39. Remove the evaporator core from the case following the procedure in the appropriate service manual.
40. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual.
41. Install the evaporator case in the vehicle by reversing the removal procedure.
NOTE:
CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED.