Heater-A/C Housing Removal and Installation

WARNING: IF EQUIPPED WITH ATC, THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE PROCEEDING WITH THIS OPERATION.

1. Disconnect the battery negative cable.
2. Drain the coolant from cooling system.
3. Remove the air conditioner expansion valve (if equipped).
4. Disconnect the heater hoses from heater core. Then plug or cap the tubes on heater core. This will prevent spilling coolant into the interior of vehicle during unit removal.
5. Remove the condensate drain tube.
6. Disconnect the A/C-heater vacuum supply line from vacuum supply nipple (in the engine compartment).
7. Remove the four A/C-heater assembly-to-dash panel attaching nuts.
8. Remove the passenger side front seat.
9. Remove the kick panel/sill cover at right door opening.

Cut Line For EVAP Case Removal:

10. Remove the body computer located at the lower right section of the right front door pillar.
11. Remove the glove box assembly.
12. Remove the carpeted panels from both sides of the console.
13. Un-clip the radio antenna cable from the metal support located behind and below the glove box opening.
14. Instrument panel removal is not necessary to remove the A/C-heater assembly from the vehicle. Although, part of the lower instrument panel must be cut. The cut line is marked: CUT HERE FOR A/C HTR REMOVAL. This cut line is stamped (indented) into the right-outer side of the instrument panel padding (outboard of the glove box opening). Using a hacksaw blade, cut the instrument panel padding along the indented line from point A to point B. CUT THE PLASTIC ONLY. Do not cut the metal support behind the instrument panel padding.
15. Remove the metal support behind and below the glove box opening, and the cut piece of the instrument panel.
16. Remove the radio choke, security alarm module and the lamp outage module from above the glove box opening (if equipped).
17. Remove the plastic cover under the steering column.
18. Remove the metal support under the steering column.
19. Remove the under-panel silencer pad from under the glove box opening.
20. Remove the lower heat distribution duct (3 screws).
21. Remove the air distribution duct through the opening at the left side of instrument panel.
22. Reach through glove box opening and disconnect the demister hoses from the top of the A/C-heater assembly.
23. Disconnect the temperature control cable from the bottom of the A/C-heater assembly and position out of the way.
24. Disconnect wiring at the blower motor and fin-sensing cycling clutch switch electrical connectors.
25. Un-plug the antenna cable from the radio.
26. Remove the metal (A/C-heater-to-instrument panel) hanger strap from the upper part of the A/C heater assembly.
27. Roll back the floor carpeting from under the A/C-heater assembly far enough to avoid restricting unit removal.
28. Remove the A/C-heater assembly through the opening on the right side of the console, and remove unit from vehicle.

NOTE: The instrument panel (to the left side of the glove box opening) must be slightly folded back to remove the unit from the vehicle. If wrinkles appear in the instrument panel after the unit has been installed, they may be removed using a heat gun.

To install, reverse steps (28) through (13). If wrinkles have appeared in the instrument panel, apply low heat from a heat gun over the wrinkled area. Do not overheat the instrument panel padding or the surrounding area.

Reverse steps (12) through (1). If equipped with A/C, evacuate and charge the refrigerant system.