Auxiliary Evaporator Outlet and Inlet Line
Auxiliary Evaporator Outlet and Inlet Line
Removal
NOTE: The auxiliary evaporator inlet and outlet lines are not supplied together as an assembly for Expedition or Navigator vehicles. The auxiliary evaporator inlet line and outlet line are each installed from the factory as one-piece assemblies. The replacement parts are supplied as separate kits containing multiple-piece lines for ease of installation.
NOTE: The auxiliary evaporator inlet and outlet lines for Expedition EL or Navigator L vehicles are installed from the factory as a single one-piece assembly including both lines. The replacement part is supplied as a multiple-piece kit for ease of installation.
NOTE: For Expedition or Navigator vehicles, the following procedure can be used to remove and install one or both the auxiliary evaporator inlet and auxiliary evaporator outlet lines. If only one auxiliary evaporator line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure. For Expedition EL or Navigator L vehicles, both lines must be removed.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.
2. Recover the refrigerant. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.
3. NOTE: If only one auxiliary evaporator line is to be removed, disconnect only the desired line.
Remove the auxiliary evaporator outlet and inlet line front fitting nut(s) and disconnect the fitting(s).
- Discard the O-ring seals and gasket seals.
4. Remove the spare tire.
5. Remove the RH front wheel and tire. For additional information, refer to Wheels and Tires Removal and Replacement.
6. Remove the RH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.
7. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket.
8. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt.
Expedition or Navigator only
9. NOTE: Both A/C fittings must be disconnected even if only one line is to be removed.
Disconnect the auxiliary evaporator outlet and inlet line rear fittings.
- Discard the O-ring seals.
Expedition EL or Navigator L only
10. Remove the RH rear wheel and tire assembly. For additional information, refer to Wheels and Tires Removal and Replacement.
11. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting.
- Discard the gasket seals.
All vehicles
12. Remove the muffler. For additional information, refer to Exhaust System Muffler and Tailpipe.
13. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield.
14. Remove the 3 muffler heat shield bolts and the heat shield.
15. Remove the 2 exhaust hanger bolts and the exhaust hanger.
16. Remove the RH Catalyst Monitor Sensor (CMS). For additional information, refer to Electronic Engine Controls Catalyst Monitor Sensor.
17. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield.
18. Remove the 3 remaining auxiliary line bracket nuts and the auxiliary line brackets.
19. NOTE: If installing only one auxiliary evaporator line, cut only the desired line.
Assemble and lay out the replacement line(s) in the same position as the existing line(s) and, using a suitable tool, cut the auxiliary evaporator line(s) in the same position as the fittings on the new line(s).
Expedition EL or Navigator L only
20. Remove the center section(s) of the auxiliary evaporator line(s) through the RH rear wheel well opening between the body and the frame.
Expedition or Navigator only
21. Remove the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the front of the vehicle between the RH catalytic converter and frame.
All vehicles
22. Remove the remaining auxiliary evaporator inlet and outlet line pieces.
Installation
Expedition or Navigator only
1. Install the rear portion of the auxiliary evaporator line(s) and connect the auxiliary evaporator outlet and inlet line rear fittings.
- Install new O-ring seals.
Expedition EL or Navigator L only
2. Install the rear portion of the auxiliary evaporator outlet and inlet line.
3. Connect the auxiliary evaporator outlet and inlet line rear fitting and install the nut.
- Install new gasket seals.
- Tighten to 12 Nm (106 lb-in).
All vehicles
4. Install the front portion of the auxiliary evaporator outlet and inlet line(s).
5. Connect the evaporator outlet and inlet line front fitting(s) and install the nut(s).
- Install new O-ring seals and gasket seals.
- Tighten to 15 Nm (133 lb-in).
Expedition EL or Navigator L only
6. NOTE: Loosely connect, but do not tighten, the fittings.
Install the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the front of the vehicle through RH rear wheel well opening between the body and the frame.
Expedition or Navigator only
7. NOTE: Loosely connect, but do not tighten, the fittings.
Install the center section(s) of the auxiliary evaporator line(s) by manipulating the line(s) toward the rear of the vehicle through the opening between the RH catalytic converter and frame.
All vehicles
8. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts.
- Tighten to 5 Nm (44 lb-in).
9. NOTE: Expedition/Navigator shown, Expedition EL or Navigator L similar.
Tighten the middle auxiliary evaporator line fittings.
10. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed.
11. Install the RH catalytic converter heat shield and the 3 rear catalytic converter heat shield bolts.
12. Install the exhaust hanger and the 2 exhaust hanger bolts.
13. Install the muffler heat shield and the 3 muffler heat shield bolts.
14. Install the RH CMS. For additional information, refer to Electronic Engine Controls Catalyst Monitor Sensor.
15. Install the muffler. For additional information, refer to Exhaust System Muffler and Tailpipe.
16. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt.
17. Install the front auxiliary line bracket and the front auxiliary line bracket nut.
- Tighten to 5 Nm (44 lb-in).
18. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts.
19. Install the RH front fender splash shield.
20. Install the RH front wheel. For additional information, refer to Wheels and Tires Removal and Replacement.
Expedition EL or Navigator L only
21. Install the RH rear wheel and tire assembly. For additional information, refer to Wheels and Tires Removal and Replacement.
All vehicles
22. Install the spare tire.
23. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Climate Control System - General Information and Diagnostics Climate Control System.
24. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Climate Control System - General Information and Diagnostics Electronic Leak Detection Fluorescent Dye Leak Detection Air Conditioning (A/C) System Recovery, Evacuation and Charging.