This procedure covers the removal and replacement of the AC evaporator core, which requires complete dashboard removal and AC system recovery and recharge.

Warnings

Tools required

Parts

• AC evaporator core × 1 — Motorcraft YD-1219 or equivalent
• Evaporator case foam seals × 1 — Use OEM specification
• AC line O-rings (assorted sizes) × 1 — Use OEM specification
• Expansion valve (TXV) × 1 — Replace if contaminated
• PAG oil for AC system × 1 — PAG-46 for EcoBoost
• Cabin air filter × 1 — Motorcraft FP-67 or equivalent
• R-134a refrigerant × 1 — Use certified automotive refrigerant
• Receiver drier/accumulator × 1 — Replace when system is opened

Fluids

• PAG-46 AC compressor oil — 0.25 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated
3. Recover all AC refrigerant using approved recovery machine and record amount removed
4. Disconnect negative battery cable and wait minimum 2 minutes for airbag system to discharge
5. Remove both front seats to access dashboard mounting bolts and improve workspace
6. Remove center console completely, including shift lever trim and all storage compartments
7. Remove all lower dashboard trim panels on both driver and passenger sides
8. Remove steering column covers and lower steering column to access points
9. Document refrigerant oil amount from recovery machine to calculate replacement oil quantity

Procedure

1. 1

   Disconnect AC lines at firewall
   Locate the AC line connections at the firewall on passenger side. Using proper size wrench, disconnect the liquid line and suction line from the evaporator. Immediately cap all open fittings to prevent moisture contamination. Remove and discard all O-rings from the fittings.
2. 2

   Remove instrument panel top cover
   Remove the defrost grille panels. Remove screws securing the instrument panel top cover. Carefully lift the top cover away, disconnecting any electrical connectors for ambient light sensors or other components. Store in safe location to prevent scratching.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
3. 3

   Disconnect instrument cluster and HVAC controls
   Remove instrument cluster bezel and disconnect cluster electrical connectors. Remove HVAC control panel and disconnect all electrical and vacuum connections. On models with digital climate control, carefully disconnect the control module harness. Label all connectors with tape for reassembly.
4. 4

   Remove center stack and radio assembly
   Remove all center stack trim panels working from bottom to top. Disconnect antenna, USB ports, and all electrical connectors. Remove radio/infotainment unit mounting bolts and carefully withdraw unit. Disconnect remaining harnesses from back of unit and set aside.
5. 5

   Disconnect and remove dashboard wiring harnesses
   Locate the main instrument panel wiring harness connectors on driver side near the fuse panel and passenger side near the glove box. Disconnect all main harness connectors, BCM connectors, and ground points. Remove harness retaining clips and carefully route harnesses away from dashboard structure.
6. 6

   Remove dashboard mounting bolts
   Locate and remove all dashboard mounting bolts. There are typically 4 bolts along the top of the dash at windshield, 2 bolts at each A-pillar, 2-3 bolts at center tunnel, and multiple bolts along the bottom edge. Verify all fasteners are removed before attempting to pull dashboard.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Remove instrument panel assembly
   With an assistant supporting the dashboard, carefully pull the entire instrument panel rearward. Watch for any remaining electrical connections or harness routing. Lift and maneuver the dashboard out through the passenger door opening. This assembly is heavy and awkward - use care to avoid damage to door seals or seats.
8. 8

   Remove HVAC housing mounting hardware
   With dashboard removed, the HVAC housing is now accessible. Remove the blower motor assembly by disconnecting electrical connector and removing mounting screws. Remove all bolts and nuts securing the HVAC case to the firewall. There are typically 4-6 mounting points.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
9. 9

   Separate HVAC case and access evaporator
   Remove the evaporator case cover screws around the perimeter of the HVAC housing. Carefully separate the case halves. The evaporator core will be visible inside the case. Note the position of all foam seals and air direction doors before removal.
   Torque spec

   Evaporator Case Screws5 Nm (4 lb-ft)
10. 10

    Remove expansion valve and evaporator core
    Disconnect the expansion valve (TXV) from the evaporator inlet. Remove the expansion valve mounting and set aside for inspection. Carefully lift the evaporator core from the case, noting the orientation of inlet and outlet tubes. Inspect case for debris, leaves, or signs of water damage.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)
11. 11

    Clean and prepare evaporator case
    Thoroughly clean the evaporator case interior with approved AC system cleaner. Remove all old foam seals and gasket material. Inspect the case for cracks, especially around screw bosses. Check condensate drain tube for blockage and clear if necessary. Allow case to dry completely.
12. 12

    Install new evaporator core
    Add the specified amount of fresh PAG-46 oil to the new evaporator core (typically 2-3 oz). Install new foam seals on the evaporator mounting surfaces. Carefully position the new evaporator core into the case, ensuring proper orientation of tubes and that all seals are properly seated.
13. 13

    Install expansion valve and reassemble case
    Install new or cleaned expansion valve to the evaporator inlet with new O-ring. Apply small amount of PAG oil to O-ring before installation. Carefully align and join the case halves, ensuring no pinched seals or misaligned components. Install all evaporator case screws in star pattern to ensure even clamping.
    Torque spec

    Expansion Valve10 Nm (7 lb-ft)

    Evaporator Case Screws5 Nm (4 lb-ft)
14. 14

    Reinstall HVAC assembly to firewall
    Position the HVAC case assembly against the firewall, aligning all mounting points and ensuring the evaporator tubes protrude through firewall openings correctly. Install all mounting bolts and verify case is firmly seated against firewall seal. Reinstall blower motor assembly.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Connect AC lines with new O-rings
    Install new O-rings on all AC line fittings. Coat O-rings lightly with PAG oil. Connect the liquid line and suction line to the evaporator tubes at firewall. Hand-tighten first, then torque to specification using appropriate wrench.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)

Reassembly

1. Reinstall dashboard assembly in reverse order of removal, ensuring all wiring harnesses are properly routed and connected
2. Verify all electrical connectors are fully seated and locked before applying power
3. Torque all dashboard mounting bolts to specification in sequence from center outward
4. Reinstall steering column to proper position and verify operation before final assembly
5. Install new cabin air filter during reassembly
6. Reconnect negative battery cable after all dashboard components are secured
7. Replace receiver drier/accumulator as system was opened to atmosphere

Verification

• Perform AC system vacuum test - pull vacuum to 29+ inches Hg and hold for minimum 30 minutes to verify no leaks
• Recharge AC system with exact amount of R-134a recorded during recovery, adding replacement refrigerant oil as needed
• Start engine and verify blower motor operation at all speeds
• Test AC system performance - center vent temperature should reach 38-42°F within 5 minutes at idle
• Check all dashboard functions including gauges, climate controls, radio, and all switches
• Verify no refrigerant leaks at evaporator connections using electronic leak detector
• Confirm proper airflow from all vents in all mode positions (defrost, floor, panel)
• Test for unusual odors from vents that might indicate improper installation or contamination
• Verify no air leaks around dashboard edges or unusual noises from HVAC case

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