Ford Fusion: Climate Control System - General Information / Evaporator Inlet and Outlet Manifold. Removal and Installation

Removal

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.

All vehicles

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

1.6L/2.0L

1. Remove the RHF fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

All vehicles

1. NOTICE: Make sure that all openings are sealed.

   1. Remove the condenser outlet line nut, the A/C compressor inlet line nut and disconnect the fittings. Discard the O-ring seals and gasket seals.
      Torque:
         1:   89 lb.in (10 Nm)
         2:   133 lb.in (15 Nm)
   • Make sure to cover any open ports to prevent debris from entering the system.
     

1. NOTICE: Make sure that all openings are sealed.

   1. Remove the evaporator inlet and outlet manifold bracket nut, bolt and release the retainer.
      Torque:
         1:   18 lb.in (2 Nm)
         2:   106 lb.in (12 Nm)
   • Make sure to cover any open ports to prevent debris from entering the system.
     

1. NOTE: If equipped

   Release the retainer and position the evaporator inlet and outlet line aside.
   Torque: 133 lb.in (15 Nm)

1. NOTICE: Make sure that all openings are sealed.

   
   Remove the evaporator inlet and outlet manifold nut, disconnect the fitting and remove the evaporator inlet and outlet manifold. Discard the gasket seals.
   
   • Make sure to cover any open ports to prevent debris from entering the system.
     Torque: 133 lb.in (15 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. Lubricate the refrigerant system with the correct amount of clean PAG oil. Refer to the appropriate Refrigerant Oil Adding procedure in Group 412.