In automotive assembly facilities worldwide, many critical vehicle systems such as brakes, power steering, radiator, and air conditioning require the appropriate fluid to function. In order to insure that these critical vehicle systems receive the correct amount of properly treated fluid, automotive manufacturers employ a method called Evacuation and Fill.Due to their closed-loop design, many critical vehicle systems must be first exposed to vacuum prior to being flooded with fluid. Only after the evacuation and fill process is complete will the critical vehicle system be able to perform as specified.It has long been thought, but never proven, that humidity and entrenched fluid were major hindrances to the Evacuation and Fill process. Consequently, Ford Motor Company Advanced Manufacturing Technology Development, Sandalwood Enterprises, Kettering University, and Dominion Tool & Die conducted a detailed project on this subject. The focus of the project was as follows:Determine the effect of humidity and entrenched fluid on the evacuation process. Propose new technologies and methods to compensate for the presence of humidity and entrenched fluid.This paper will address the technical approach taken, as well as the laboratory and field research conducted, and concludes with basic research findings and field application results.