The following is a general removal procedure of A/C evaporator core. The evaporator is removed differently from different vehicles.
For example, a 1994 Ford Taurus/Mercury Sable instructs you to, "Using a hot knife, cut the top of the air conditioning evaporator housing between the raised outline."
Use a hacksaw or a hot knife to cut the case. Reprinted with the permission of Ford Motor Company.
But a 1993 Ford Probe manual says to simply remove the blower motor and assembly screws before separating the case halves and removing the evaporator.
Split case halves to remove evaporator. Reprinted with the permission of Ford Motor Company.
The following procedure assumes that access to the evaporator has been determined.
- Recover the refrigerant.
- Drain the radiator if the heater hose(s) has to be removed to gain access.
- Remove the heater hose(s), if necessary.
- Remove any wiring harness, heat shields, brackets, covers, and braces that may restrict access to the evaporator core.
- Remove the liquid line at the thermostatic expansion valve (TXV) or fixed orifice tube (FOT).
- Remove the suction line at the evaporator or accumulator outlet.
- Gain access to the evaporator core as outlined in the service manual.
- Lift the evaporator from the vehicle.
- Drain the oil from the evaporator into a calibrated cup.
- For replacement, reverse the preceding procedure. First, replace the oil with the same amount and type you previously drained.