Ford Explorer: Rear Climate Control / Removal and Installation - Rear Evaporator Rear Outlet and Inlet Line

Removal

All vehicles

NOTICE: During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

NOTE: Removal steps in this procedure may contain installation details.

NOTE: The rear evaporator inlet and outlet lines are installed from the factory as a single one-piece assembly. The replacement part is supplied as an assembly, containing the rear heater core inlet and outlet lines and the rear evaporator inlet and outlet lines.

1. Recover the refrigerant. Refer to the appropriate Recovery procedure in Group 412.
   

1. Drain the cooling system. Refer to the appropriate procedure in Group 303.
   

1. Remove the RHR wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the retainers and position aside RHR wheel splashshield.
   

1. • Release the clamps, disconnect the rear heater inlet and outlet lines.
     
   • Remove the rear evaporator inlet and outlet line nuts and disconnect the fitting.
     
   • Make sure to cover any open ports to prevent debris from entering the system.
     Torque: 133 lb.in (15 Nm)

1. Remove the rear subframe.
   Refer to: Rear Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Remove the cowl panel.
   Refer to: Cowl Panel (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the catalytic converter.
   Refer to: Catalytic Converter (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Catalytic Converter RH (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Catalytic Converter RH (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Catalytic Converter RH (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. NOTE: 2.3L shown, other engines similar.

   
   
   1. Remove the rear evaporator outlet line nut.
      Torque: 159 lb.in (18 Nm)
   2. Remove the rear evaporator inlet line nut.
      Torque: 71 lb.in (8 Nm)
   3. Disconnect the rear coolant lines.
      
   • Make sure to cover any open ports to prevent debris from entering the system.
     

Hybrid vehicles

1. Remove the high voltage battery.
   Refer to: High Voltage Battery - Hybrid Electric Vehicle (HEV) (414-03 High Voltage Battery, Mounting and Cables, Removal and Installation).
   

1. Remove the cabin heater coolant diverter valve.
   Refer to: Cabin Heater Coolant Diverter Valve (412-03 Supplemental Climate Control, Removal and Installation).
   

All vehicles

1. NOTE: Powertrain removed for clarity.

   
   
   • Remove the push pin type retainer.
     
   • Remove the retainers and the under floor heat shields.
     Torque: 71 lb.in (8 Nm)

1. NOTE: Powertrain removed for clarity.

   
   
   • Remove the push pin type retainers.
     
   • Remove the retainer and the under floor heat shield.
     Torque: 71 lb.in (8 Nm)

Hybrid vehicles

1. Remove the routing bracket retainers and position aside the high voltage battery cables.
   Torque: Nm

All vehicles

1. Remove the rear climate control lines support bracket retainers.
   Torque: 44 lb.in (5 Nm)

1. Remove the retainers and remove the heat shield.
   Torque: 71 lb.in (8 Nm)

1. NOTE: Non hybrid shown, hybrid vehicles similar.

   Remove the mounting bracket retainers and remove the rear climate control lines.
   Torque: 44 lb.in (5 Nm)

Installation

1. To install, reverse the removal procedure.
   

1. NOTICE: Only use the specified material to lubricate the seals.

   Install and lubricate new O-ring seals. Refer to the appropriate Specifications in Group 412.
   

1. Fill and bleed the cooling system. Refer to the appropriate procedure in Group 303.
   

1. Lubricate the refrigerant system with the correct amount of clean refrigerant oil. Refer to the appropriate Refrigerant Oil Adding procedure in Group 412.