Evaporator Core: Service and Repair

EVAPORATOR CORE

Removal and Installation

NOTE:
- If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle.
- Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the suction accumulator.


Vehicles with 6.0L Diesel







1. Remove the retainers and the insulator.
2. Remove the evaporator core housing.

Vehicles with 5.4L and 6.8L







3. Remove the oil filler neck.
4. Remove the suction accumulator.







5. Disconnect the A/C fittings.
1 Disconnect the auxiliary evaporator inlet line fitting (if equipped).
2 Disconnect the auxiliary evaporator outlet line fitting (if equipped).
3 Disconnect the condenser to evaporator line.
- Discard the O-ring seals.







6. Remove the nuts and reposition the bracket.







7. Remove the screws and remove the evaporator core housing support bracket.

All vehicles







8. Remove the retainers and the evaporator core cover heat shield.







9. Remove the 10 screws and the evaporator core cover.







10. Remove the evaporator core.
11. To install, reverse the removal procedure.
- Install new O-ring seals.
- Lubricate the refrigerant system with the correct amount of clean PAG oil.

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