Model: Mark VII
Engine Size: 5.0
Refrigerant Type: R-12
Country of Origin: United States
I have my evaporator/heater box out of the car and am trying to remove and reinstall the new evap. The shop manual says to cut the box on 3 sides allowing the top to swing open. However, the box the manual shows has 2 tabs that are to be cut and then used to hold the top in place, once the new evap. is in place, with the use of a spring nut and bolt. My box does not have these tabs so I'm not sure how to hold the swung open part to the box. The box itself appears to be glued together, although I'm not sure of this, and for this reason don't want to try and force it open. Has anyone been thru this with a '91 Mark VII that could provide a little guidance?
Remove instrument panel and evaporator case. Remove seal from evaporator core tubes. Drill 3/16" diameter holes in both upright tabs on top of evaporator case (1/4" down from notch in tabs).
Using small saw, cut through center of tabs (and drilled holes) following top seam of evaporator case. Cut along tab side and short sides of seam only. Fold cut-out flap back and remove evaporator core from case.
Install new seal on evaporator core. Install core and close cut-out cover. Use Caulking Cord (D9AZ-19560-A) to seal cut-out cover. Install lock-nuts and bolts through drilled holes in upright tabs. To complete installation, reverse removal procedure. Evacuate, recharge and leak test A/C system.
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