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Drain the cooling system and disconnect the heater hoses from the heater core tubes. Plug the hoses and the heater core tubes to prevent coolant leakage.
Remove the 3 nuts located below the windshield wiper motor attaching the left end of the plenum to the dash panel. Remove the 1 nut retaining the upper left corner of the evaporator case to the dash panel.
Disconnect the vacuum supply hose(s) from the vacuum source. Push the grommet and vacuum supply hose(s) into the passenger compartment.
Remove the right and left lower instrument panel insulators.
On 1990-00 vehicles:
Remove the cross body brace and disconnect the wiring harness from the temperature blend door actuator.
Disconnect the ATC sensor tube from the evaporator case connector.
Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
Remove the 2 hush panels.
Remove 1 plastic push fastener retaining the floor air distribution duct to the left end of the plenum. Remove the left screw and loosen the right screw on the rear face of the plenum and remove the floor air distribution duct.
Remove the 2 nuts from the 2 studs along the lower flange of the plenum.
Carefully move the plenum rearward to allow the heater core tubes and the stud at the top of the plenum to clear the holes in the dash panel. Remove the plenum from the vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull the lower edge of the instrument panel rearward, as necessary, while rolling the plenum from behind the instrument panel.
Remove the 4 retaining screws from the heater core cover and remove the cover from the plenum assembly. Pull the heater core and seal assembly from the plenum assembly.
Carefully install the heater core and seal assembly into the plenum assembly. Visually check to ensure that the core seal is properly positioned. Position the heater core cover and install the 4 retaining screws.
Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
Position the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the evaporator case.
Install the 3 nuts on the studs along the lower flange and one on the upper flange of the plenum. Install the 3 nuts below the windshield wiper motor to attach the left end of the plenum to the dash panel and the one nut to retain the upper left corner of the evaporator case to the dash panel.
Position the floor air distribution duct on the plenum. Install the 2 screws and plastic push fastener. If removed, position the panel door vacuum motor to the mounting bracket and install the 2 attaching screws.
Connect the white vacuum hose to the outside-recirculating door vacuum motor. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install the floor duct.
If equipped with manual air conditioning, connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable.
If equipped with ATC, proceed as follows:
Connect the temperature control cable to the ATC sensor and adjust the cable. Route and connect the vacuum harness connector to the ATC sensor and connect the electrical connector to the ATC servo connector. Do not block the sensor aspirator exhaust port with the excess vacuum harness. Install the ATC sensor tube between the sensor and the evaporator connector.
Connect the ATC sensor tube to the evaporator case connector.
Install the cross body brace and connect the wiring harness to the blend door actuator.
Install the bolt to attach the lower right end of the instrument panel to the side cowl. Install the right side cowl trim panel and tighten the right door sill plate attaching screws.
Connect the vacuum supply hose(s) to the vacuum source.
Install the right and left lower instrument panel insulators and install the 2 hush panels.
Unplug the heater core tubes and the heater hoses and connect the heater hoses to the heater core tubes. Fill the cooling system.
Connect the negative battery cable and check the system for proper operation. I hope this helps. Don,t forget to rate my answer.
It is located on the left frame rail in front of left rear tire.It has a plastic clip in each fuel line that will be white in color.Remove the clip then disconnect fuel line.Make sure to replace the clips,DO NOT reuse the old ones. Install the new clips into the connector then snap the connectors on to the filter.
Check your gas cap. If someplace can test it you might luck out. This website advertises manuals and info online. The evaporator cannister is suppose to purify excess fuel vapors. But a system which is not sealed will code an error lamp.
Unfortunately, this type of information is not provided by the manufacturer's as a download. However, there still remain's a solution. You can go to most automotive supply stores, and purchase manuals for your vehicle that contain step by step proceedure's to repairing almost everything on your car, these manuals usually also detail the electrical wiring in diagrams in the back of the manuals.
You can find these manuals at most automotive stores such as Autozone, Petboys and such. They usually rin from $8 - $20+ depending on how detailed the manuals are.
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If the one under the hood is missing, you can try using the free online manuals from autozone.com by registering and adding your car to your online garage. You get access to manuals for the cars in your garage that have diagrams and repair how-to information for free!
Vehicles involved in the recall include the following:
1998-2002 Ford Ranger 1992-1997 Lincoln Town Car 1992-1997 Ford Expedition 1992-1997 Mercury Grand Marquis 1993-1998 Lincoln Mark VIII 1993-1995 Taurus SHO 1999-2001 Ford Explorer 1999-2001 Mercury Mountaineer 2001-2002 Ford Explorer Sport 2001-2002 Ford Explorer Sport Trac 1992-1993 E150-350 Vans 1997-2002 E150-350 vans 1993 Ford F-Series pickups 1993 Ford Bronco 1994 Mercury Capri 2003-2004 Ford F0150 Lightning 1995-2002 Ford F53 motor homes.