Removal & Installation
Drain coolant from radiator. Disconnect heater hoses from heater core tubes. Cap hoses. Disconnect vacuum hose from water control valve. Remove evaporator housing. See EVAPORATOR HOUSING & CORE.
Remove instrument panel. See INSTRUMENT PANEL. Remove Powertrain Control Module (PCM) and its heat sink. Remove 4 heater air plenum nuts from firewall. Remove heater core access cover-to-plenum assembly screws. Remove heater core. To install, reverse removal procedure.
EVAPORATOR HOUSING & CORE
Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect A/C cycling switch harness connector. Disconnect blower motor and resistor harness connectors.
Disconnect hoses from heater core tubes, at firewall. Disconnect heater water control valve vacuum hose. Remove mounting bolt and position speed control servo aside. Remove nuts and screws and move washer/coolant reservoir assembly aside.
Disconnect manifold and tube assembly from accumulator-drier. Disconnect condenser-to-evaporator tube at evaporator inlet. Cap openings. Disconnect vacuum harness and evaporator case mounting nut from inside vehicle. Remove one nut under dash, 3 nuts under hood, and evaporator housing.
Disconnect accumulator-drier from evaporator. On vehicles with 5.0L engines, remove evaporator housing heat shield. On all vehicles, remove remove evaporator housing screws. Remove evaporator core and accumulator-drier.
Removal & Installation
Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove steering column. See appropriate STEERING COLUMNS article in STEERING. Disconnect brake pedal position switch harness connector. Disconnect clutch pedal position switch harness connector (if equipped). Remove left and right cowl side trim panels.
Disconnect harness connectors and ground wires on right cowl panel. Disconnect power distribution box from its bracket and position aside.
Disconnect 3 bulkhead wiring harness connectors from inside engine compartment. Pull bulkhead harness connector handle to disconnect main harness. Remove passenger's side air bag.
Disconnect electronic blend door actuator harness connector. Disconnect A/C-heater control panel vacuum harness connector. Disconnect radio antenna cable in-line connector. Press glove box release tabs inward while raising glove box to remove it.
Remove instrument panel defrost grille. Remove 5 instrument panel cowl top bolts. Remove floor console (if equipped). See FLOOR CONSOLE.
Remove instrument panel brace bolt. Remove both windshield side garnish moldings. Remove right instrument panel cowl side bolt. Remove instrument panel fuse panel door. Remove left instrument panel cowl side bolt.
Carefully position instrument panel away from dash panel. Remove bolt and disconnect instrument panel-to-body electrical harness. With an assistant, remove instrument panel from vehicle. To install, reverse removal procedure.