Mercury Villager 2000-2002

Heater Core


Removal & Installation

The rear heater/air conditioning assembly must be removed as a complete unit in order to remove the heater core and/or evaporator core.

  1. Disconnect the negative battery cable.
  3. Drain the cooling system into a clean container for reuse.
  5. Discharge and recover the air conditioning system refrigerant.
  7. Remove or disconnect the following:

    Heater hoses at the bulkhead and plug
    Center seats
    2 left half seat belt lower anchor bolts
    Left rear cargo net retainers, if equipped
    Lift gate scuff plate and the 3 screws from the left rear quarter trim panel. Gently pry the rear seat remote control (if equipped) from the trim panel. Disconnect the remote control wiring connector and remove the rear radio control panel. Pull the top of the trim panel away from the body.
    Rear climate control panel wiring, if equipped
    Left front lap belt guide from the left quarter trim panel and pass the belt through the trim panel
    Trim panel from the vehicle
    Upper duct from the assembly (6 screws)
    Blower motor and resistor wiring
    Temperature blend and vent door actuator connectors

  9. Raise and safely support the vehicle. Use the spring lock coupling tool to disconnect and plug the refrigerant line connections from beneath the vehicle.
  11. Lower the vehicle.
  13. Remove or disconnect the following:

    4 heater/air conditioning assembly bolts and the assembly from the vehicle
    Heater core and/or evaporator core from the assembly


To install:

  1. Install or connect the following:

    Heater core and/or evaporator core into the assembly and the 4 retaining bolts

  3. Raise and safely support the vehicle.
  5. Using new O-rings, reconnect the refrigerant lines to the evaporator.
  7. Lower the vehicle.
  9. Install or connect the following:

    All wiring connectors
    Upper air duct with the 6 screws
    Trim panel and pass the lap seat belt through the panel slot
    Rear climate control panel
    Rear radio and rear remote control
    Remaining trim panel and components

  11. Refill the cooling system.
  13. Connect the negative battery cable.
  15. Evacuate and charge the air conditioning system.
  17. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.