Evaporator Core Housing
EVAPORATOR CORE HOUSINGRemoval
All vehicles
1. Remove the suction accumulator.
2. Remove the RH battery.
3. Remove the RH fender splash shield.
4. Disconnect the heater control valve vacuum hose (if equipped).
Vehicles with 6.0L Diesel
5. Disconnect the vacuum pump electrical connector.
6. Remove the bolts.
7. Disconnect the vacuum connector and remove the vacuum pump and mounting bracket.
8. Disconnect the glow plug controller electrical connector and detach the wire harness.
9. Remove the nuts and the glow plug controller.
Vehicles with automatic transmission
10. Remove the nut and position the transmission fluid indicator tube aside.
Vehicles with 5.4L or 6.8L
11. Remove the oil filler neck.
12. Disconnect the speed control servo electrical connector.
13. Remove the bolts and position the speed control servo aside.
All vehicles
14. Disconnect the vacuum connectors and remove the vacuum reservoir.
15. Remove the nuts and position the sensor bracket aside.
All vehicles
16. Disconnect the A/C fittings.
1 Disconnect the auxiliary evaporator outlet line fitting (if equipped).
2 Disconnect the auxiliary evaporator inlet line fitting (if equipped).
3 Disconnect the evaporator inlet fitting.
- Discard the O-ring seals.
17. NOTE: Vehicle with manual climate control shown, vehicles with EATC similar.
Disconnect the electrical connectors.
18. Remove the bolts and the evaporator core housing support bracket.
- Detach the wire harness and vacuum line retainers.
19. Remove the bolt and position the cable aside.
20. Remove the RH lower instrument panel insulator.
21. Lower the glove compartment.
22. From inside the vehicle, disconnect the vacuum harness connector.
- Detach the vacuum harness connector from the heater core housing.
23. Working through the glove compartment opening, remove the upper retaining nuts.
24. Remove the lower retaining nuts.
25. Remove the evaporator core housing.
Installation
All Vehicles
1. NOTE: Be sure the vacuum harness is correctly routed through the dash panel opening.
Position the evaporator core housing on the dash panel.
2. NOTE: Have an assistant hold the evaporator core housing in place while installing the upper nuts.
Install, but do not tighten the upper retaining nuts.
3. Install, but do not tighten the lower retaining nuts.
4. Connect the vacuum harness connector.
- Attach the vacuum harness connector to the heater core housing.
5. Reposition the cable and install the bolt.
6. Position the evaporator core housing support bracket and install, but do not tighten, the bolts.
7. Tighten the upper retaining nuts.
8. Tighten the lower retaining nuts.
9. Tighten the evaporator core housing support bracket bolts.
10. NOTE: Vehicle with manual climate control shown, vehicles with EATC similar.
Connect the electrical connectors.
11. NOTE: Install new O-ring seals.
Connect the A/C fittings.
1 Connect the auxiliary evaporator outlet line fitting (if equipped).
2 Connect the auxiliary evaporator inlet line fitting (if equipped).
3 Connect the evaporator inlet line fitting.
12. Position the sensor bracket and install the nuts.
Vehicles with 5.4L or 6.8L
13. Position the speed control servo and install the bolts.
14. Connect the speed control servo electrical connector.
15. Install the oil filler neck.
Vehicles with automatic transmission
16. Position the transmission fluid level indicator and install the nut.
Vehicles with 6.0L Diesel
17. Position the glow plug controller and install the nuts.
18. Connect the glow plug controller and attach the wire harness.
19. Position the vacuum pump and install the bolts.
- Connect the vacuum connectors.
20. Connect the vacuum pump electrical connector.
All vehicles
21. Connect the heater control valve vacuum connector (if equipped).
22. Connect the vacuum reservoir vacuum connectors.
23. Install the RH fender splash shield.
24. Install the RH battery.
25. Install the suction accumulator.