Evaporator Core: Service and Repair

Evaporator Outlet Line





Removal and Installation

All vehicles

1. Recover the refrigerant.

2. If equipped, remove the 4 nuts and the strut tower cross brace.





5.4L (4V) vehicles

3. Drain the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.

4. Disconnect the 2 heater hose connections at the rear of the RH cylinder head and position the heater hoses aside.





5. Remove the Exhaust Gas Recirculation (EGR) system module tube.

3.7L vehicles

6. Remove the battery tray.

5.0L (4V) vehicles

7. Disconnect the positive and negative battery cables at the battery.

8. Remove the engine appearance cover.

All vehicles

9. Remove the evaporator outlet line fitting nut and disconnect the fitting.
- Discard the O-ring seal and gasket seal.

- To install, tighten to 15 Nm (133 lb-in).


10. Remove the evaporator outlet line bracket bolt.
- To install, tighten to 7 Nm (62 lb-in).


11. Remove the Thermostatic Expansion Valve (TXV) fitting nut and disconnect the fitting.
- Discard the gasket seals.

- To install, tighten to 15 Nm (133 lb-in).


12. Remove the evaporator outlet line.

13. To install, reverse the removal procedure.
- Install new gasket seals and O-ring seals.

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


5.4L (4V) vehicles

14. Fill the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.

All vehicles

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