Evaporator Case: Service and Repair
REMOVAL1. Remove the suction accumulator/drier.
2. Drain the radiator.
3. Remove the RH battery.
4. Disconnect the electrical connector from the vacuum pump (7.3L diesel engine).
5. Remove the bolts (7.3L diesel engine).
6. Disconnect the vacuum hose and remove the vacuum pump and mounting bracket (7.3L diesel engine).
7. Disconnect the speed control servo connector (5.4L and 6.8L gasoline engines).
8. Remove the bolts and remove the speed control servo (5.4L and 6.8L gasoline engines).
9. Remove the nuts from the vacuum reservoir tank.
10. Disconnect the vacuum hoses and remove the vacuum reservoir tank.
11. Remove the nuts and reposition the manifold absolute pressure sensor and bracket (7.3L diesel engine), or the vapor management valve and bracket (5.4L and 6.8L gasoline engines).
12. Loosen the A/C manifold tube retaining bolt and reposition the A/C manifold and tube assembly (7.3L diesel engine).
13. Disconnect the condenser to evaporator tube from the A/C evaporator core.
14. Loosen the clamps and remove the intercooler outlet tube (7.3L diesel engine).
15. Disconnect the heater hoses from the heater core.
16. Disconnect the electrical connectors.
17. Remove the screws and remove the evaporator core housing support bracket.
18. Remove the screw and reposition the radio interference suppression cable.
19. From inside the vehicle, disconnect the vacuum harness connector.
20. Through the glove compartment opening, remove the upper retaining nuts.
21. Inside the vehicle, remove the right hand trim panel and remove the lower retaining nuts.
22. Remove the evaporator core housing.
INSTALLATION
1. Position the evaporator core housing against the cowl panel.
2. Install the upper retaining nuts but do not tighten them.
3. Install the lower retaining nuts but do not tighten them.
4. Connect the vacuum harness connector.
5. Install the radio interference suppression cable.
6. Install the evaporator core housing support bracket, but do not tighten the screws.
7. Inside the vehicle tighten the upper retaining nuts.
8. Tighten the lower retaining nuts.
9. Tighten the evaporator core housing support bracket screws.
10. Connect the electrical connectors.
11. Connect the heater hoses to the heater core.
^ Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water only, if needed.
12. Install the intercooler outlet tube (7.3L diesel engine).
13. Connect the condenser to evaporator tube to the A/C evaporator core.
14. Install the A/C manifold and tube assembly (7.3L diesel engine).
^ Lubricate the O-ring seal with PAG Refrigerant Compressor Oil (R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B.
15. Install the manifold absolute pressure sensor and bracket (7.3L diesel engine) or the vapor management valve and bracket (5.4L and 6.8L gasoline engines).
16. Install the vacuum reservoir tank.
17. Install the vacuum pump and connect the vacuum hoses (7.3L diesel engine).
18. Connect the vacuum pump connector (7.3L diesel engine).
19. Install the speed control servo (5.4L and 6.8L gasoline engines).
20. Install the speed control servo connector (5.4L and 6.8L gasoline engines).
21. Install the suction accumulator/drier.
22. Install the RH battery.
23. Fill the cooling system.