Ford Ranger, Explorer & Mountaineer Repair & Service Manual 1991-1999

AIR CONDITIONING EVAPORATOR: REMOVAL AND INSTALLATION

EXPLORER, MOUNTAINEER MODELS

Refer to illustrations 19.5, 19.6 and 19.7

1. The evaporator core is located in a housing on the engine compartment side of the firewall.
   
   NOTE: Before replacing an evaporator core, determine for certain that the core is leaking by having a leak test performed with special equipment at dealer service department or automotive air conditioning repair facility.
   
   
2. Have the refrigerant discharged and recovered at a dealer or air conditioning service shop.
   
   Note: Whenever the evaporator core is replaced with a new one, the accumulator/ drier will also have to be replaced (see Section 18).
   
   
3. Disconnect the refrigerant lines at the firewall (See illustration 18.4).
   
   
4. Refer to Sections 6 and 13 and remove the coolant recovery tank and disconnect the wiring to the blower motor.
   
   
5. Inside the vehicle, remove the one nut and disconnect the vacuum connector from the evaporator housing (see illustration).
   
   
6. On the engine-compartment side of the firewall, remove the three nuts from the housing studs (see illustration 14.16 and the accompanying illustration). Pull the blower motor / evaporator housing assembly out of the vehicle.
   
   
7. Out of the vehicle, remove the 11 screws holding the two halves of the case together (see illustration). On 5.0L V8 models, remove the heat shield first.
   
   
8. Remove the evaporator core from the case.
   
   BODY: RANGER (1992 and earlier models)
   
   Note: The bumper is heavy and somewhat awkward to remove and install - at least two people should perform this procedure.
   
   
9. Raise the front of the vehicle, support it securely on jackstands, block the rear wheels and set the parking brake.
   
   
10. Have an assistant hold onto the bumper assembly and remove the two bolts and nuts on each side securing the bumper to the frame.
    
    
11. If equipped with bumper guards, first remove the bumper guards from the bumper, then remove the bumper from the frame.
    
    
12. Don't lose the plastic insulators between the bumper and the frame. They must be reinstalled when the bumper is installed.
    
    
13. Installation is the reverse of the removal steps with the following additions:

a) If installing a new bumper, transfer the bumper guards, license plate holder and any additional items to the new bumper.

b) Tighten the bolts to the torque listed in this Chapter's Specifications.

• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams