Auxiliary Heater Outlet and Inlet Line

Auxiliary Heater Outlet and Inlet Line









Removal

NOTE: The auxiliary heater inlet and outlet lines are not supplied together as an assembly. The auxiliary heater 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.

NOTE: The following procedure can be used to remove and install one or both the auxiliary heater inlet and auxiliary heater outlet lines. If only one auxiliary heater line is to be removed and installed, cut or disconnect only the desired line at the specified points within the procedure.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Drain the engine coolant. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.

3. Remove the spare tire.

4. Remove the RH front wheel and tire. For additional information, refer to Wheels and Tires Removal and Replacement.

5. Remove the RH fender splash shield. For additional information, refer to Front End Body Panels Fender Splash Shield.

6. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line.

Disconnect the auxiliary heater outlet and/or inlet line front quick disconnect fitting(s).

7. Working through the RH fender well opening, remove the front auxiliary line bracket nut and the front auxiliary line bracket.

8. Working through the RH fender well opening, remove the RH catalytic converter heat shield front bolt.





Expedition EL or Navigator L only

9. Remove the RH rear wheel and tire assembly.

All vehicles

10. NOTE: If only one auxiliary heater line is to be removed, disconnect only the desired line.

Disconnect the auxiliary heater outlet and inlet line rear quick disconnect fitting(s) from the heater core at the floor pan connection.

11. Remove the muffler. For additional information, refer to Exhaust System Muffler and Tailpipe.

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 muffler heat shield.

14. Remove the 2 exhaust hanger bolts and the exhaust hanger.

15. Remove the RH Catalyst Monitor Sensor (CMS). For additional information, refer to Electronic Engine Controls Catalyst Monitor 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 line brackets.





18. NOTE: If installing only one auxiliary heater 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 heater line(s) in the same position as the fittings on the new line(s).

Expedition EL or Navigator L only

19. Remove the center section(s) of the auxiliary heater line(s) through the RH rear wheel well opening between the body and the frame.





Expedition or Navigator only

20. Remove the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the front of the vehicle between the RH catalytic converter and frame.





All vehicles

21. Remove the remaining auxiliary heater inlet and outlet line pieces.

Installation

All vehicles

1. Install the rear portion of the auxiliary heater outlet and inlet line(s) and connect the quick disconnect fittings.

2. Install the front auxiliary heater line(s) and connect the quick disconnect fittings.

Expedition EL or Navigator L only

3. NOTE: Loosely connect, but do not tighten, the fittings.

Install the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the front of the vehicle through RH rear wheel well opening between the body and the frame.





Expedition or Navigator only

4. NOTE: Loosely connect, but do not tighten, the fittings.

Install the center section(s) of the auxiliary heater line(s) by manipulating the line(s) toward the rear of the vehicle through the opening between the RH catalytic converter and frame.





All vehicles

5. Starting from the rear of the vehicle, install the first 3 auxiliary line brackets and nuts.
- Tighten to 5 Nm (44 lb-in).

6. Tighten the middle auxiliary heater line fittings.

7. Inspect the auxiliary heater lines for correct installation. Loosen, reposition and tighten as needed.

8. Install the RH catalytic converter heat shield and the 3 catalytic converter heat shield rear bolts.

9. Install the RH CMS. For additional information, refer to Electronic Engine Controls Catalyst Monitor Sensor.

10. Install the exhaust hanger and the 2 exhaust hanger bolts.

11. Install the muffler heat shield and the 3 muffler heat shield bolts.

12. Install the muffler. For additional information, refer to Exhaust System Muffler and Tailpipe.

13. Install the spare tire carrier splash shield and the 3 spare tire carrier splash shield bolts.

14. Working through the RH fender well opening, Install the RH catalytic converter heat shield front bolt.

15. Install the front auxiliary line bracket and the front auxiliary line bracket and nut.
- Tighten to 5 Nm (44 lb-in).

16. Install the RH front fender splash shield.

17. Install the RH front wheel and tire. For additional information, refer to Wheels and Tires Removal and Replacement.

Expedition EL or Navigator L only

18. Install the RH rear wheel and tire. For additional information, refer to Wheels and Tires Removal and Replacement.

All vehicles

19. Install the spare tire.

20. Fill the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.