PLENUM & HEATER CORE
Removal & Installation
Disconnect battery ground cable. Remove heater outlet floor duct. Remove instrument panel. See INSTRUMENT PANEL . Disconnect heater hoses from core tubes. Plug ends of hoses and tubes to prevent coolant loss.
Remove nut retaining upper left corner of evaporator core housing to dash panel. Disconnect vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment. Disconnect White vacuum hose from air inlet duct door vacuum actuator.
Remove nuts from studs along lower flange of heater air plenum chamber. Remove heater air plenum by pulling assembly rearward.
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.
Removal & Installation
Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove driver's air bag module retaining nuts. Disconnect air bag module and horn switch electrical connectors. Remove driver's air bag module.
Open glove box and disconnect glove box isolator. Push in on door tabs and place glove box door in full down position. Release trim panel retaining clips. Disconnect clock connector and remove trim panel. Disconnect passenger's air bag module electrical connector. Remove passenger's air bag module retaining bolts and screws, and remove air bag module.
Disconnect speed control servo connector. Remove mounting nuts and place speed control servo aside. Disconnect brake fluid sensor, wiper motor, and left side engine compartment in-line electrical connectors. Unseat left side wiring harness grommet. Disconnect blower motor, A/C pressure cut-off switch and right side engine compartment in-line electrical connectors. Disconnect vacuum line.
Raise and support vehicle. Remove right side wheel and tire. Remove front fender splash shield bolts and position splash shield away from instrument panel. Unseat right side wiring harness grommet. Reinstall right wheel and tire. Lower vehicle. Remove left and right side scuff plates and cowl side trim panels. Disconnect crash sensor electrical connector. Separate antenna cable lead in connector. Remove right side ground bolts.
Remove bulkhead electrical connectors. Disconnect hose from evaporator housing. Position right and left side weatherstrips aside. Feed right side wiring harness through dash panel. Remove center carpet insert. Disconnect A/C-heater control panel vacuum harness. Remove instrument panel tunnel brace. Remove left side instrument panel insulator. Disconnect courtesy light connector.
Remove instrument panel lower steering column opening cover. Remove steering column opening cover reinforcement. Disconnect vacuum connectors under instrument panel. Remove nut and position steering column brace aside. Remove pinch bolt and separate intermediate shaft from steering column. Disconnect shift cable from steering column. Remove left side ground bolt. Disconnect left side wiring connectors.
Remove defroster grille. Remove instrument panel cowl top screws. Remove left and right cowl side attaching nuts. With aid of an assistant, feed left side wiring harness through dash panel, while removing instrument panel from vehicle. To install, reverse removal procedure.
Saturday, March 21st, 2009 AT 5:03 PM