1. Drain coolant from radiator. Disconnect heater hoses from heater core, and plug openings. In passenger compartment, remove instrument panel. See INSTRUMENT PANEL . 2. Remove plenum assembly. See PLENUM ASSEMBLY . Remove heater core from plenum assembly. To install, reverse removal procedure. INSTRUMENT PANEL Removal & Installation 1. Disconnect negative battery cable. Disconnect wiring connectors in engine compartment. Remove 2 bolts retaining hood latch control handle and cable. Remove 2 bolts attaching parking brake release. 2. Remove console (if equipped). Move transfer case control to far forward position (if equipped). Remove instrument panel steering column cover by removing 2 screws and pulling on cover to release grasshopper clips. 3. Remove bracket bolt at right of accelerator pedal. Remove instrument panel steering column reinforcement (6 screws). Remove 2 TK yoke nuts from vehicle cross beam, and remove TK yoke. 4. Open fuse panel door, and remove 2 bolts holding instrument panel to cowl. Remove bolt from right side of instrument panel. Remove one threadless fastener and 2 push-pins attaching insulator to lower right hand instrument panel. 5. Carefully lift edge of defroster grille, and pull up on grille to release clips and tension tabs. Remove defroster grille. Remove 4 bolts at top of instrument panel. Pull panel back from cowl. To install, reverse removal procedure. PLENUM ASSEMBLY Removal & Installation 1. Disconnect negative battery cable. In passenger compartment, remove instrument panel. See INSTRUMENT PANEL . Remove heater hoses from heater core, and plug hoses. 2. Remove blower motor assembly. See BLOWER MOTOR ASSEMBLY . Remove nuts from plenum studs at firewall in engine compartment. Pull plenum away from firewall, and remove plenum assembly. To install, reverse removal procedure. WARNING: To avoid injury from accidental air bag deployment, read and follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section. Page 1 of 1 5/2/2010 ...
Sometimes you can loosen the left side stuff, and remove right side bolts and pull right side out enough to remove the cover to the heater core when the plunum has had all holding nuts removed. This tip is from Mitchell on Demand tip section.
Posted By: #40Fan Flag Post For Monitor Review
Shop: CHUBBUCK MOTORS
Date: 10/10/2008 6:41:02 PM
I am offering this tip because of the notation in the "Estimator" when looking up heater core removal. The notation being "Does not include System Recharge" which might lead you to believe that you need to evacuate the A/C.
When you proceed with the removal of the Plenum Assy to gain access to the heater core there are four studs that stick through the firewall. Two of them help hold the Evaporator housing to the firewall, two are on their own. The Evap housing has three nuts that hold it to the firewall, while again, two are shared with the Plenum. From the looks of it you might have to completely remove the Evap housing to get the inner nuts off of the Plenum, because the nuts are stacked with the Evap housing between. But, you don't.
Refer to picture below.
The Red squares show where an exterior nut is located. The far right square points to two of the nuts. One is located directly behind the engine (use a long extension and 7/16" wobble) and the other is on the lower inside part of the Evap housing.
Green squares point to the nuts that are located behind the Evap housing.
Once you have the outer (red) nuts removed, you can pull the Evap housing forward about 1 1/2" and have room to loosen the inner (green) nuts. With a helper pulling the Plenum a little, you can get all three off without the A/C being opened.