Section 12-03A: Air Conditioning System
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Evaporator Core

NOTE: Whenever an evaporator core is replaced, it will be necessary to replace the suction/accumulator drier.

 

Removal

  1. Remove evaporator case as outlined.
  1. Remove four screws retaining air inlet duct to evaporator case. Remove duct.
  1. Remove foam seal from evaporator core tubes.
  1. Drill a 3/16-inch hole in both upright tabs on top of evaporator case as shown.


Drilling Holes in Evaporator Case Tabs




  1. Using a small saw blade, cut top of evaporator case between raised outlines as shown.


Cutting Evaporator Case




  1. Remove two screws retaining blower motor resistor to evaporator case. Remove resistor.
  1. Fold cutout flap from opening and lift evaporator core from case.


Removing Evaporator Core from Case




 

Installation

  1. Transfer two foam core seals to new evaporator core.
  1. Position evaporator core in case and close cutout cover.
  1. Install a spring nut (Part No. 381863-S2) on each of two upright tabs.


Securing Cutout Cover in Closed Position




NOTE: Ensure hole in spring nut is aligned with 3/16-inch hole drilled in tab. Then, install and tighten a screw (Part No. 381944-S9) in each spring nut (through hole in tab to secure cutout cover in closed position).

  1. Install Caulking Cord D6AZ-19560-A (ESB-M4G32-A) or equivalent to seal evaporator case against leakage along cut line.


Caulking Cord Installation




  1. Using new caulking cord (rope sealer), assemble air inlet duct to evaporator case (four screws).
  1. Install blower motor resistor (two screws).
  1. Install foam seal over evaporator core and heater core tubes.
  1. Install evaporator case assembly.