PLENUM & HEATER CORE
Removal & Installation
Disconnect battery ground cable. Disconnect heater hoses from heater core tubes. Plug heater hoses and heater core tubes. See Fig. 7.
Remove 3 nuts (below windshield wiper motor) attaching left side of plenum to dash panel. Remove nut retaining upper left corner of evaporator case to dash panel. Remove left and right lower instrument panel insulators.
Disconnect control system vacuum supply hose from vacuum source. Push grommet and vacuum supply hose into passenger compartment. Remove instrument panel screws, and pull instrument panel out as far as possible without removing harness connectors.
Loosen right door sill plate. Remove right side cowl trim panel. Remove cross body brace. Disconnect harness from temperature blend door actuator. Disconnect sensor tube from evaporator case connector.
Disconnect vacuum jumper harness at multiple vacuum connector, near floor air-distribution duct. Disconnect White vacuum hose from outside/recirculating door vacuum motor. Remove both hush panels.
Remove plastic push fastener retaining floor air-distribution duct to left of plenum and 2 screws on rear face of plenum. Remove floor air-distribution duct.
Remove nuts from 2 studs along lower flange of plenum. Carefully move plenum rearward to allow heater core tubes and stud at top of plenum to clear holes in dash panel. Remove plenum from vehicle by rotating top of plenum forward, and then down and out from under instrument panel. Complete removal by carefully pulling rearward as necessary while rolling plenum from behind instrument panel.
Remove 4 retaining screws from heater core cover, and remove cover from plenum assembly. Pull heater core and seal from plenum assembly. To install, reverse removal procedure.
Saturday, December 20th, 2008 AT 10:27 AM