Evaporator Case: Service and Repair

NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor.

REMOVAL AND INSTALLATION

WARNING: If equipped with air conditioning, the refrigeration system must be completely empty before proceeding.

CAUTION: Disconnect battery negative cable, in engine compartment, before servicing instrument panel.

1. Set parking brake.
2. Disconnect battery negative cable.
3. Using a refrigerant recovery machine, remove refrigerant from the A/C system.
4. Disconnect all engine compartment lines and vacuum hoses.
5. Drain engine coolant. Plug coolant lines.

INSTRUMENT PANEL CLUSTER BEZEL
1. To remove top cover use a flat blade tool. Pry up on either end and continue across the full length of the top cover.
2. To remove cluster bezel grille use the removal tool. Using tool at either end pull up and remove grille.
3. Remove six mounting screws from the hood and message center assembly. Using a flat blade tool pry up on either end and remove module and disconnect wire connector.
4. Reach behind lower right corner of center bezel and pull to disconnect attaching clip. Repeat in all of the corners and remove bezel. Disconnect ash receiver wire and lamp assembly if equipped.
5. Remove three instrument cluster bezel screws on the bottom of bezel and three at the upper left. Pulling up and rearward on the top edge of bezel remove bezel.
6. Disconnect POD switches wiring connectors.

LOWER RIGHT INSTRUMENT PANEL

Steering Column Cover:

1. Remove steering column cover.
2. Remove premium console.
3. Remove center trim bezel. Remove ash receiver lamp and socket if equipped.
4. Remove A/C heater control.
5. Disconnect cigar lighter.
6. Remove screw in air duct.

Glove Box:

7. Remove attaching screws and right lower panel. Screw location:
- One screw outboard right of lower panel
- Two screws in ash receiver/cupholder opening
- Two screws bottom on the lower right
- One screw in heater duct above heater control.
- Remove glove box attaching screws and disconnect check straps.
- Disconnect glove box lamp.

INSTRUMENT PANEL REMOVAL

WARNING: Chock wheels when instrument panel is to be rolled down. The steering column is removed and transmission may be out of park. Release the park brake before the release cable is disconnected. Disconnecting park brake cable while park brake is engaged may cause personal injury.

Silencer Panel:

1. Remove lower left instrument panel silencer.
2. Set parking brake and shift gear selector into low.
3. Remove lower left reinforcement.
4. Disconnect transmission range indicator at column.
5. Unhook transmission range indicator cable eyelet from column actuating arm:
- Release column insert lock tab.
- Squeeze legs together and lift insert from steering column, leave insert free.
- Place cable on instrument panel to avoid transmission range indicator cable damage during removal.
6. Remove steering column. Service and Repair
7. Remove lower right instrument panel silencer.
8. Remove floor braces.
9. Remove A-pillar intermediate and sill scuff garnish moldings.
10. Unfasten the hood release mechanism from the side cowl.
11. Disconnect the brake light switch, parking brake switch and bulk head wiring connectors.
12. Under the hood disconnect the ABS connector and resistor block. Unseat the grommet at the dash panel and feed wiring back into passenger compartment.
13. Remove the two nuts, securing the instrument panel, at the steering column support brace.
14. Loosen the instrument panel roll up bolts.
15. Remove the six screws securing the instrument panel at the fence line.
16. Roll the instrument panel back and hang it from the short position of the roll up hook.
17. With instrument panel hanging in the short position disconnect the left side body wiring connections.
18. Roll the instrument panel to the long position on the roll up hook and perform the following operations:
- Disconnect the antenna cable.
- Disconnect the blower motor lead connection.
- Disconnect the temperature control cable from the A/C or heater unit.
- Disconnect the vacuum lines from the climate control assembly
- Disconnect the right side body wiring connectors.
19. Remove instrument panel from vehicle.
20. Disconnect the A/C unit hanger strap from the unit and temporarily reposition.
21. Remove the rubber condensate drain tube (in engine compartment).
22. Remove the four nuts (in the engine compartment) securing the unit to the dash panel.
23. Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down. Pull it rearward to remove it from vehicle.

To install the assembly, reverse the preceding operation.

NOTE: When installing cluster, do not kink or bind transmission range indicator guide tube and position guide tube in original location.
Move shift lever to Neutral (N) and note pointer location. Move shift lever to D, L and P note pointer location. Adjust, if necessary to center pointer on N.