Evaporator Core: Service and Repair

Evaporator Outlet Line - 3.5L, 3.7L













Removal and Installation

NOTE: The O-ring seals used on this vehicle are not interchangeable with all similarly sized O-ring seals used on other Ford products. Use only the O-ring seals specified for this vehicle.

1. Recover the refrigerant.

2. Remove the upper intake manifold.

3. Remove the ground strap nut at the RH shock tower.

4. Detach the pin-type retainer from the evaporator outlet line bracket.

5. Remove the evaporator outlet line bracket stud bolt.
- To install, tighten to 11 Nm (97 lb-in).


6. Disconnect the evaporator outlet line spring lock coupling.
- Discard the O-ring seals.


7. Remove the insulation from the Thermostatic Expansion Valve (TXV) fitting opening at the dash panel.

8. Remove the TXV (Thermostatic Expansion Valve) fitting nut and disconnect the fitting.
- Discard the O-ring seals.

- To install, tighten to 8 Nm (71 lb-in).


9. Remove the evaporator outlet line.

10. To install, reverse the removal procedure.
- Install new O-ring seals.

- Add the correct amount of clean PAG oil to the refrigerant system.


11. Evacuate, leak test and charge the refrigerant system.