Main Climate Control

EVAPORATOR CORE

Removal and Installation

CAUTION: Refrigerant Compressor Oil (Mineral Oil) F73Z-19577-AA (Motorcraft YN-9-A) should be used to lubricate R-134a refrigerant system O-ring seals only and should not be added to R-134a refrigerant systems as an A/C compressor lubricant. PAG Refrigerant Compressor Oil F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSH-M1C231-B only should be used as an A/C compressor lubricant.

NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator.

All vehicles
1. Recover the refrigerant.
2. Disconnect the battery.

Vehicles with 4.6L, 5.4L or 6.8L engine
3. Remove the air cleaner assembly.
4. Remove the battery.







5. Remove the battery tray.
1 Remove the bolts.
2 Remove the battery tray.







6. Remove the bolt and clamp and the oil filler tube.







7. Disconnect the condenser fittings.
1 Disconnect the condenser outlet fitting.
2 Disconnect the condenser inlet fitting.
- Discard the O-ring seals.

Vehicles with 6.0L diesel engine







8. Remove junction box bracket bolts.







9. Remove the junction box bracket bolt and position the junction box aside.
10. Remove the engine cover.







11. NOTE: Charge air cooler (CAC) side shown, turbocharger side similar.

Loosen the CAC tube clamps.







12. Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.







13. Remove the conduit and position the wiring aside.
- Disconnect the locking tab.
- Remove the bolts.
- Disconnect the push pin and remove the wiring harness.







14. Remove the bolts for the CAC tube and oil fill tube.







15. Disconnect the oil fill tube at the valve cover.







16. Remove the retaining nuts, CAC tube, oil fill tube and bracket.







17. Remove the bolt and position the MAP sensor aside.







18. Disconnect the condenser fittings.
- Discard the O-ring seals.

All vehicles







19. Remove the washer reservoir filler tube.
1 Remove the screws.
2 Remove the washer reservoir filler tube.







20. Disconnect the evaporator outlet fitting.
- Discard the O-ring seal.







21. Disconnect the high-pressure cutoff switch electrical connector.







22. NOTE: Vehicle without auxiliary A/C shown, vehicles with auxiliary A/C similar.

Disconnect the compressor manifold and tube suction fitting.
1 Remove the screw.
2 Disconnect the fitting.
- Discard the O-ring seal.

Vehicles with auxiliary A/C







23. Disconnect the suction accumulator fitting.
- Discard the O-ring seals.

All vehicles







24. Disconnect the evaporator inlet fitting.
1 Remove the screw.
2 Disconnect the evaporator inlet fitting.
- Discard the O-ring seal.







25. Remove the screws and the evaporator housing support bracket.







26. Remove the evaporator core cover.
1 Remove the five screws.
2 Remove the four screws.
3 Remove the evaporator core cover.

27. Remove the evaporator core.
28. To install, reverse the removal procedure.
- Install new O-rings lubricated in clean mineral oil.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.

29. Evacuate, leak-test and charge the refrigerant system.