How do you remove the A/C evaporator core cover?

Bad heater core you will need to replace it. About a 2 hour job, very easy to do:


Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement.
Remove the HVAC filter cover.
Remove the heater core/evaporator tube seals from the module.
Remove the heater core cover screws (1).
Remove the heater core retaining screws (1).
Remove the heater core retaining straps.
Remove the heater core.
Remove the rubber seals from the inlet/outlet pipes of the heater core.

Installation Procedure

Install rubber seals to the outlet/inlet pipes of the heater core.
Install the heater core to the module.
Install the heater core retaining straps.



Install the heater core retaining screws (1).
Install the heater core cover.



Install the heater core cover screws (1).



Install the heater core/evaporator tube seal from the module.
Install the HVAC filter cover.
Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement.

Heater core is removed from inside the cabin. About a two hour job. The hardest part is removing the hoses in the engine bay.
In the cabin, remove the beauty panel under the glovebox; remove the glovebox, and move the HVAC controller. The heater housing, or cover is held with two screws, and the core is held with one screw (clamp).
Remove the HVAC module assembly. Refer to HVAC Module Assembly Replacement.
Remove the HVAC filter cover.
Remove the heater core/evaporator tube seals from the module.
Remove the heater core cover screws (1).
Remove the heater core retaining screws (1).
Remove the heater core retaining straps.
Remove the heater core.
Remove the rubber seals from the inlet/outlet pipes of the heater core.

Installation Procedure

Install rubber seals to the outlet/inlet pipes of the heater core.
Install the heater core to the module.
Install the heater core retaining straps.



Install the heater core retaining screws (1).
Install the heater core cover.



Install the heater core cover screws (1).



Install the heater core/evaporator tube seal from the module.
Install the HVAC filter cover.
Install the HVAC module assembly. Refer to HVAC Module Assembly Replacement.

This is the best that I can do for you, hope this works

Hi there,

Remove heater/evaporator case. Remove vacuum source line from heater core tube seal. Remove seal from heater core tubes.
Remove heater core access cover screws. Remove access cover and seal from heater/evaporator case. Lift heater core and case seals out of heater/evaporator case.
Installation
If installing new heater core, transfer case seals to new core. Install heater core and seals into heater/evaporator case. Install heater core access cover on case. Install seal on heater core tubes. To complete installation, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.

HEATER/EVAPORATOR CASE
Removal

• Disconnect negative battery cable. Drain coolant from radiator. Gently pull instrument panel away from right side of dash panel.
• Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect heater hoses from heater core. Plug heater core tubes or drain coolant by blowing coolant from heater core using low pressure compressed air. Disconnect vacuum supply hose from inside engine compartment.
• Disconnect A/C lines from evaporator core. Plug A/C lines and evaporator core tubes. Remove instrument panel assembly brace to evaporator case bracket screw. Remove assembly brace.
• Remove floor register and rear floor duct from bottom of heater/evaporator case. Remove nuts securing heater/evaporator case to firewall. Remove 2 screws securing support brackets to cowl top panel. Carefully pull heater/evaporator case away from firewall. Remove heater/evaporator case.
• To install, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.

INSTRUMENT PANEL
Removal & Installation

• Position front wheels in straight-ahead position. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section. Disconnect negative battery cable. Remove steering column trim shrouds.
• Disconnect all electrical connections from steering column switches. Remove cover from under steering column. Remove 4 bolts and reinforcement from under steering column. Disconnect parking brake release control motor from parking brake and ignition switch connector.
• Disengage insulator retainer. Remove insulator. Remove 4 nuts and reinforcement below steering column. Remove 4 nuts securing steering column to instrument panel and lower column to front seat. Disconnect PRNDL cable (A/T models).
• Ensure ignition switch is locked to prevent steering column from turning. Remove 4 instrument cluster retaining screws. Disconnect speed control cable and vehicle speed sensor (if equipped). Disconnect electrical connectors and remove instrument cluster. At steering column opening, remove one bolt securing instrument panel to brace. Remove one instrument panel brace bolt (below radio area).
• Remove sound insulator under glove box by removing 2 push nuts securing insulator to studs on climate control case. Remove glove box door and compartment. Remove air cleaner housing, battery and battery tray. Disconnect wires of main wire loom in engine compartment. Disengage rubber grommet from firewall. Feed wiring into passenger compartment through hole in firewall.
• Remove right and left kick panels. Disconnect wires from instrument panel at right and left kick panel sides. Remove screws on left and right sides of instrument panel.
• Pull up to unsnap right and left speaker opening covers. Remove speaker covers. Working through steering column and glove box openings, reach under instrument panel and disconnect electrical connectors, vacuum hoses, A/C-heater control panel cables, and radio antenna cable.
• Support instrument panel. Remove 3 screws attaching top of instrument panel to cowl top. Disconnect remaining wires. Remove instrument panel. To install instrument panel, reverse removal procedure.

Hope this helps...

Removal & Installation To Remove:

1. Disconnect the negative battery cable.
2. Drain the coolant from the engine.
3. Recover the refrigerant.
4. Remove the glove compartment.
5. Remove the floor air outlet.
6. If equipped with a diesel engine, remove the powertrain control module.
7. Remove the kick panel trim.
8. Remove the blower motor.
9. Remove the steering column.
10. Tilt back the instrument panel assembly.
11. Remove the coolant recovery reservoir from the engine compartment.
12. Disconnect the heater hoses and the evaporator tube.
13. Remove the accumulator.
14. Remove the fasteners and the HVAC module assembly.
15. Remove the cover plate on the bottom of the HVAC module.
16. Remove the heater core and seal from the HVAC module.
17. Remove the case cover from the HVAC module.
18. Remove the evaporator core.

HVAC module mounting fastener locations

HVAC module components

To Install:
NOTE: If a new evaporator is being installed, add 3 fl oz (90 ml) of refrigerant oil to the new evaporator.

1. Install the evaporator core.
2. Install the case cover.
3. Install the heater core and the seal.
4. Install the cover plate on the bottom of the evaporator case to the HVAC module.
5. Install the HVAC module in the vehicle.
6. Install the accumulator.
7. Connect the evaporator tube and heater hoses.
8. Install the coolant recovery reservoir.
9. Install the instrument panel.
10. Install the steering column.
11. Install the blower motor and cover.
12. Install the kick panel trim.
13. Install the powertrain control module and tray.
14. Install the floor air outlet.
15. Add coolant to the cooling system.
16. Connect the negative battery cable.
17. Evacuate and charge the A/C system.
18. Check the system for leaks.

Heater Core Removal

1. Partially drain the cooling system.
   

1. Remove the tube gasket from the heater core tubes.
   

1. Remove four heater core access cover retaining screws and remove the access cover from the A/C evaporator housing (19850).
   

1. Remove A/C electronic blend door actuator.
   

1. Slide heater core (18476) and seals from the A/C evaporator housing.
   

Installation

1. Install the heater core in the A/C evaporator housing with the tube gasket on the outside of the case.
   

1. Install A/C electronic blend door actuator as described.
   

1. Position the heater core cover on the A/C evaporator housing. Install the four retaining screws.
   

1. Refill the cooling system.
   
   
   
   
   
   
   
   Item Part Number Description 1 18596 Heater Core Tube Gasket 2 18476 Heater Core 3 18B300 Heater Core Cover 4 390747-S2 Screw (4 Req'd) 5 18N267 Heater Core Cover Seal
   
   
   Hope this helps... Cobra
   

Section 12-03A: Air Conditioning System—Manual A/C-Heater 1996 Thunderbird, Cougar Workshop Manual REMOVAL AND INSTALLATION Heater Core Removal

1. Partially drain the cooling system.
   

1. Remove the tube gasket from the heater core tubes.
   

1. Remove four heater core access cover retaining screws, and remove the access cover from the A/C evaporator housing (19850).
   

1. Remove A/C electronic door actuator.
   

1. Slide heater core (18476) and seals from the A/C evaporator housing (19850).
   

Installation

1. Install the heater core (18476) in the A/C evaporator housing (19850) with the tube gasket on the outside of the case.
   

1. Install the A/C electronic door actuator as described.
   

1. Position the heater core cover on the A/C evaporator housing (19850). Install the four retaining screws.
   

1. Refill the cooling system.
   
   
   Heater Core
   
   
   
   
   
   Item Part Number Description 1 18596 Heater Core Tube Gasket 2 18476 Heater Core 3 18B300 Heater Core Cover 4 390747-S2 Screw (4 Req'd) 5 18N267 Heater Core Cover Seal

1. Disconnect the negative battery cable.
   
   CAUTION After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.
   
   
2. Drain the cooling system into a clean container for reuse.
   
3. Disconnect the heater hoses from the heater core.
   
4. Remove the steering column by performing the following procedure:
   
   • Position the front wheels in the straight-ahead direction.
     
   • At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.
     
     CAUTION Safely store the air bag module with the front side facing upward.
     
     
   • Remove the steering wheel-to-steering column nut.
     
   • Using a steering wheel puller, press the steering wheel from the steering column.
     
   • Remove the parking brake release handle screws and move the release handle aside.
     
   • Remove the hood release screws and move the hood release aside.
     
   • Remove the 2 instrument panel-to-steering column cover screws and the cover.
     
   • Remove the instrument panel steering column opening reinforcement bolts and the reinforcement.
     
   • Remove the ignition switch bolt and disconnect the ignition switch electrical connector.
     
   • At the base of the steering column, disconnect the electrical connectors.
     
   • If equipped with an automatic transmission, remove the transmission range indicator bolt and the cable.
     
   • If equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket.
     
   • Disconnect the brake shift interlock solenoid electrical connector.
     
   • Remove the air bag sliding contact.
     
   • Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt.
     
   • Remove the lower steering column-to-instrument panel nuts and the steering column.
     
5. Remove the instrument panel by performing the following procedure:
   
   • Disconnect the Brake Pedal Position (BPP) switch electrical connector.
     
   • Remove the push pins and remove both cowl side trim panels.
     
   • At the right side cowl panel, disconnect the electrical connectors and ground wires.
     
   • Remove both sides windshield garnish moldings.
     
   • Disconnect the power distribution box from its bracket and move it aside.
     
   • In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors.
     
   • Pull the bulkhead electrical connector handle and disconnect the wiring harness.
     
   • Remove the passenger’s side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.
     

Store the air bag module in a safe location with the front facing upward.

• Disconnect the blend door actuator’s electrical connector.
  
• Disconnect the climate control vacuum harness connector.
  
• Disconnect the radio’s antenna connector.
  
• Remove the glove compartment.
  
• Remove the instrument panel defroster grille.
  
• Remove the upper instrument panel bolts.
  
• If equipped, remove the upper series floor console.
  
• Under the steering column, remove the instrument panel brace bolt.
  
• At both sides, remove the windshield side garnish moldings.
  
• Remove both the right and left instrument panel-to-cowl bolts.
  
• Remove the fuse panel door.
  
• Pull the instrument panel away from the dash.
  
• Loosen the instrument panel-to-body harness bolt and disconnect the harness.
  
• Using an assistant, remove the instrument panel.
  

1. At the PCM, disconnect the electrical connector; then, remove the 2 PCM cover nuts, the cover and the PCM.
   
   NOTE The PCM is located at the right side of the instrument panel.
   
   
2. Remove the evaporator core by perform the following procedure:
   
   • Discharge and recover the air conditioning system refrigerant.
     
   • Remove the refrigerant lines from the evaporator core. Discard the O-rings.
     
   • Disconnect the air conditioning cycling switch.
     
   • Disconnect the blower motor electrical connectors.
     
   • Disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo.
     
   • Remove the windshield washer reservoir/coolant recovery reservoir, and move it aside.
     
   • Disconnect the air conditioning manifold and tube from the accumulator/drier.
     
   • Disconnect the condenser-to-evaporator tube.
     
   • Inside the vehicle, disconnect the air conditioning system vacuum harness and the evaporator housing mounting nut.
     
   • In the passenger’s compartment, remove the evaporator housing-to-chassis nut.
     
   • In the engine compartment, remove the 3 evaporator housing-to-chassis nuts.
     
   • Remove the air conditioning accumulator from the evaporator core.
     
   • If equipped with a 5.0L engine, remove the evaporator housing heat shield screw, clips and the shield.
     
   • Remove the evaporator housing cover screws and the cover.
     
   • Remove the evaporator core from the housing.
     
3. Remove the PCM ground strap screw and the heat sink.
   
4. In the engine compartment, remove the heater housing air plenum nuts.
   
5. Remove the heater core-to-air plenum cover screws and the cover.
   
6. Remove the heater core.
   

you have to remove the instrument panel first.

SECTION 412-03: Air Conditioning 2001 Continental Workshop Manual
REMOVAL AND INSTALLATION Evaporator Core Removal
NOTE: The evaporator core is serviced as a core and housing assembly. The evaporator core, internal doors, seals and door linkage are included with the housing. Transfer the blower motor and wheel assembly, heater core and cover, dash panel seals and vacuum actuators to the new housing.

1. Remove the rear seat airflow duct (18C420). For additional information, refer to Section 412-01 .

1. Remove the instrument panel (04320). For additional information, refer to Section 501-12 .

1. Drain the coolant from the radiator so that the coolant level is below the heater core (18476). For additional information, refer to Section 303-03 .

1. Recover the refrigerant. For additional information, refer to Section 412-00 .

1. Loosen the screw and disconnect the electrical connector from the powertrain control module (PCM) (12A650).

1. Disconnect the heater water hoses (18472) from the heater core.

1. Disconnect the vacuum supply hose.

1. Disconnect the condenser to evaporator tube and the evaporator to accumulator tube spring lock couplings from the A/C evaporator core (19860). For additional information, refer to Section 412-00 .

1. Disconnect the evaporator housing electrical connectors.

1. Remove the nuts and the washers at the cowl panel.

1. Remove the screws and the A/C evaporator housing.

1. Remove the screws and the metal cover.

1. Remove the screws and the A/C electronic blend door actuator.

1. Remove the A/C air intake flue damper assist spring (19917).

1. CAUTION: Do not attempt to bend any part of the A/C damper door shaft (19A580). It is brittle and will break.
   Depress the locking ramp and remove the A/C damper door shaft from the air temperature control door shaft.

1. CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
   Remove the A/C evaporator case outlet door shaft (19B752).

1. Remove the A/C tube dash panel seal (19B588) and the A/C evaporator drain tube seal (19B739).

I assume he used a leak tester and found a leak in the evap which is inside the plenum housing. Need to remove the plenum to get access to the evap. big job. If you are technical, you could remove the plenum assembly and let him replace the evap & then let you out the plenum back in. Then take back to have him evacuate and recharge system.
-------------------------------
SECTION 412-03: Air Conditioning 1999 Town Car Workshop Manual
REMOVAL AND INSTALLATION Evaporator Core Removal and Installation
NOTE: The evaporator core is not separately serviceable. It is serviced only with the evaporator core housing assembly.
NOTE: Installing a new suction accumulator is not required when repairing the refrigerant system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.
NOTE: If an evaporator core leak is suspected, the evaporator core must be leak tested before it is removed from the vehicle. For additional information, refer to Section 412-00 .

1. Remove the evaporator core housing. For additional information, refer to Section 412-02 .

1. Transfer the components from the old evaporator core housing to the new evaporator core housing

1. Install the evaporator core housing. For additional
2. information, refer to Section 412-02

---------------------------------------------------------------------------
Evaporator Core Housing Removal

1. Disconnect the battery ground cable (14301).

1. Recover the refrigerant. For additional information, refer to Section 412-00 .

1. Drain the radiator. For additional information, refer to Section 303-03 .

1. Remove the screws and the RH cowl vent screen.

1. Disconnect the vacuum hoses and the wire harness connector from the evaporative emission canister purge valve (EVAP canister purge valve) (9C915).

1. Remove the nuts and remove the evaporative emission canister purge valve.

1. Remove the heater hoses from the heater core.

1. Remove the screw and reposition the windshield washer fluid reservoir.

1. Disengage the four wire harness retainers from the top of the RH fender apron.

1. Remove the RH front wheel and tire.

1. Remove the screws from the RH fender apron and remove the fender apron.

1. Disconnect the wire harness connector from the A/C cycling switch (19E561).

1. Disconnect the wire harness connector from the blower motor (18527).

1. Disengage the wire harness connector from the retainer.

1. Disconnect the evaporator to compressor suction line from the suction accumulator/drier (19C836). For spring lock couplings disconnect and connect general procedure, refer to Section 412-00 .

1. CAUTION: To prevent damage to the fitting and the tube, use a backup wrench when removing the suction accumulator/drier.
   Disconnect the suction accumulator/drier from the A/C evaporator core.

1. Remove the clamp screw retaining the A/C accumulator mounting bracket to the A/C evaporator core housing and remove the suction accumulator/drier.

1. Disconnect the condenser to evaporator tube from the A/C evaporator core (19860). For spring lock couplings disconnect and connect general procedure, refer to Section 412-00 .

1. Remove the RH instrument panel insulator.
   • Remove the pushpins.
   • Disengage the courtesy lamp holder.
   • Disconnect the power point wire harness connector and remove the RH instrument panel insulator.

1. Remove the in-car temperature sensor hose and elbow from the evaporator housing.

1. Remove the nuts at the top of the evaporator housing.

1. Remove the nuts at the bottom of the evaporator housing.

1. Remove the screw and nut near the blower motor.

1. Remove the screws.

1. Separate the housing and remove the blower motor and A/C evaporator core.

1. Disconnect the wire harness connector.

1. Remove the evaporator core cover.

This is a big job which involves discharging and removing parts of the A/C system as well as removing parts of the dash. I had the core done on a 94 Sable years ago and it was a very labor intensive and expensive job. Here are some instructions I found for a 94 Taurus which should be the same thing or similiar, but I don't guarantee that. Please note that these instructions were not tested by me and may contain errors or be incomplete in some way. For example "remove instrument panel" sounds simple but in reality is a process in itself requiring the removal of many screws. Naturally you would have to recharge the A/C and refill the coolant when done.
__________________________________________
Removal

1. Remove instrument panel and lay it on front seat.
2. Remove A/C evaporator housing as outlined.
3. Remove vacuum source line from heater dash panel seal (18529).
4. Remove heater dash panel seal from heater core tubes (refer to Heater Case Assembly).
5. Remove four heater core access cover retaining screws and remove heater core cover (18B300) from A/C evaporator housing.
6. Lift heater core and seals from A/C evaporator housing.
________________________________________________
Installation

1. Transfer three foam core seals to new heater core.
2. Install heater core and seals into A/C evaporator housing.
3. Position heater core cover on A/C evaporator housing. Install four retaining screws.
4. Install heater dash panel seal on heater core tubes.
5. Install vacuum source line through heater dash panel seal.
6. Install A/C evaporator housing into vehicle as outlined.
7. Reinstall dashboard components.

Best of Luck!

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