Operation CHARM: Car repair manuals for everyone.

Mustang

MUSTANG EVAPORATOR CORE REPLACEMENT

1. Disconnect battery ground cable.

2. Remove two (2) access covers at rear of console (snaps out) to gain access to arm rest retaining bolts.

3. Remove armrest-to-floor bracket retaining bolts and remove armrest assembly (snaps out of console).

4. Remove gearshift opening finish panel (snaps out). On vehicles equipped with manual transmissions, shift boot is attached to bottom of finish panel. Remove shift knob and slide boot and finish panel up to shift lever to remove.

5. To remove top finish panel, position emergency brake lever in the UP position. Remove four (4) retaining screws and lift panel up. Disconnect necessary wire connectors.

6. Remove two (2) console-to-rear floor bracket retaining screws.

7. Insert a small screwdriver into two (2) notches at bottom of front upper panel and snap out.

8. There are three (3) combinations of radio cover finish panels:

a. Radio opening cover plate with storage bin (radio delete option).

b. Radio with storage bin.

c. Radio with graphic equalizer (one unit).

^ Combination a: Use a small screwdriver and pry radio cover finish panel out of console.

^ Combinations b and c: The radio must be removed first. Refer to Service Manual, Section 15.01, for procedure.

9. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor.

10. Remove four (4) console bracket retaining screws. Remove console from vehicle.

11. Remove three (3) bolts retaining steering column opening cover and reinforcement panel. Remove cover.

12. Remove steering column opening reinforcement by removing two (2) bolts.

13. Remove two (2) bolts retaining steering column opening reinforcement and remove reinforcement.

14. Remove six (6) steering column retaining nuts, two (2) retaining the hood release mechanism and four (4) retaining column to lower brake pedal support. Lower steering column to floor.

15. Remove steering column upper and lower shrouds and disconnect wiring from multi-function switch.

16. Remove steering column through-bolt and nut on engine side of cowl panel. Remove steering column from vehicle.

17. Remove brake pedal support nut.

18. Snap out defroster grille.

19. Remove screws from speaker grilles. Snap out speaker covers.

20. Remove front screws retaining RH and LH scuff plates at cowl side trim panels.

21. Remove LH and RH cowl side trim panels.

22. Disconnect electrical connections at RH cowl side panel.

23. Remove cowl side retaining bolts, (one at each end).

24. Remove five (5) cowl top attaching screws.

25. Gently pull instrument panel away from RH side of cowl panel. Disconnect speedometer cable, air conditioning controls and wire connectors.

26. Place a drain pan or suitable container under heater hose connections at the cowl panel.

27. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure.

NOTE:
OBSERVE ALL SAFETY PRECAUTIONS.

28. 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.

29. 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.

30. Remove screw holding air inlet duct and blower housing assembly support brace to cowl top panel.

31. Disconnect the vacuum line (black), from in-line vacuum check valve in engine compartment.

32. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment.

33. Inside the passenger compartment, remove two (2) screws retaining evaporator case support brackets to cowl top panel.

34. Remove one screw retaining bracket below evaporator case to cowl panel.

35. 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.

36. Remove the evaporator core from the case following the procedure in the appropriate service manual.

37. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual.

38. Install the evaporator case in the vehicle by reversing the removal procedure.

NOTE:
CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED