Auxiliary Evaporator Outlet and Inlet Line
AUXILIARY EVAPORATOR OUTLET AND INLET LINEPart 1:
Part 2:
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.
- 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.
- 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.
- Installation of a new receiver/drier cartridge 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 receiver/drier cartridge.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Recover the refrigerant.
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 fender splash shield.
6. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket.
7. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt.
Expedition or Navigator only
8. 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
9. Remove the RH rear wheel and tire assembly.
10. Remove the auxiliary evaporator outlet and inlet line rear fitting nut and disconnect the fitting.
- Discard the gasket seals.
All vehicles
11. Remove the muffler.
12. Remove the 3 spare tire carrier splash shield bolts and the spare tire carrier splash shield.
13. Remove the 3 muffler heat shield bolts and the heat shield.
14. Remove the 2 exhaust hanger bolts and the exhaust hanger.
15. Remove the RH catalyst monitoring sensor.
16. Remove the 3 remaining RH catalytic converter heat shield bolts and the heat shield.
17. Remove the 3 remaining auxiliary line bracket nuts and the auxiliary line brackets.
18. 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).
19. NOTE:
- Expedition EL shown.
- For Expedition EL or Navigator L vehicles, the middle portion of the auxiliary evaporator outlet and inlet lines can be removed through the RH rear wheel well opening between the body and the frame.
Remove the auxiliary evaporator line(s) in 3 separate 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 (9 lb-ft).
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 (11 lb-ft).
6. NOTE: Loosely connect, but do not tighten, the fittings.
Install the middle auxiliary evaporator line(s).
7. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts.
- Tighten to 5 Nm (44 lb-in).
8. NOTE: Expedition/Navigator shown, Expedition EL or Navigator L similar.
Tighten the middle auxiliary evaporator line fittings.
9. Inspect the auxiliary evaporator lines for correct installation. Loosen, reposition and tighten as needed.
10. Install the RH catalytic converter heat shield and the 3 rear catalytic converter heat shield bolts.
11. Install the exhaust hanger and the 2 exhaust hanger bolts.
12. Install the muffler heat shield and the 3 muffler heat shield bolts.
13. Install the RH catalyst monitoring sensor.
14. Install the muffler.
15. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt.
16. Install the front auxiliary line bracket and the front auxiliary line bracket nut.
- Tighten to 5 Nm (44 lb-in).
17. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts.
18. Install the RH front fender splash shield.
19. Install the RH front wheel.
Expedition EL or Navigator L only
20. Install the RH rear wheel and tire assembly.
All vehicles
21. Install the spare tire.
22. Lubricate the refrigerant system with the correct amount of clean PAG oil.
23. Evacuate, leak test and charge the refrigerant system.