Removal

1. Disconnect battery. This must be done to prevent accidental airbag deployment.

2. Using on A/C recovery unit, remove all R-134a refrigerant from the A/C system. Refer to Service Manual Procedures for A/C system evacuation and charge.

3. Unfasten air cleaner hose and air intake plenum from the engine for later removal.

4. Unfasten harness hold-down and plastic pushpins from right strut tower securing engine/transmission wiring connectors. Move harness aside for clearance of air distribution duct removal and access to expansion valve. (3.5L)

5. Guide air cleaner hose and air intake plenum towards right strut tower and remove.

6. Clamp heater hoses between engine and heater core inlet and outlet tubes to prevent loss of anti-freeze.

7. Remove hose clamps and disconnect heater hoses from the engine side of the dash panel. Keep the heater tubes elevated to prevent loss of coolant. Plug the heater core inlet and outlet tubes to prevent anti-freeze from spilling on the vehicle interior during removal. If appropriate plugs cannot be found, pull back carpet and use caution when removing unit.

NOTE:
LUBRICANT MAY BE APPLIED TO HELP SLIDE HOSE CLAMPS DOWN FROM SEATED POSITION.

8. Undo fasteners and remove oval heater hose retainer and gasket from the engine side of the dash panel.

9. Disconnect expansion valve from evaporator. Refer to expansion valve removal in service manual for complete procedure. Cap the expansion valve and evaporator openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing.

CAUTION:
The lubricant used in this air conditioning system absorbs moisture readily (similar to brake fluid). Do not leave any portion of the system open for extended periods of time.

10. Remove push-on wiring harness clamp from stud on harness running along engine compartment dash panel.

11. Remove the three heater housing retaining nuts from the studs. These studs project through the dash panel into the engine compartment.

12. Remove right and left interior door post kick panels.

13. Remove right and left side bezel end caps from either end of the instrument panel. These caps are held in place by a series of clips.





14. Remove ash receiver. Remove the radio and A/C control lower center bezel which is held in place by six clips. This can be done by carefully prying the bezel from the instrument panel (Figure 1).

15. Remove the radio and unplug the radio connections, and set aside.

16. Remove the heater A/C control head, unplug connectors, and set aside.





17. Remove the center instrument panel bezel (Figure 2). This bezel is held in place by four clips. It can be removed by carefully prying it from the instrument panel. Disconnect wiring at bezel.

18. If the vehicle is equipped with a center console, remove shift knob and surrounding console bezel. Remove fasteners and place console out of the way.

19. Unbolt rear console mounting bracket.

20. Remove air duct for rear heater vents.

21. Release the glove box to allow access to mounting screws. There are four screws located behind the glove box. Remove these screws and then close the glove box.

22. Remove left and right kick panels.

23. Remove lower bolster retaining screws.





24. Carefully lower the bolster and disconnect the trunk release and glove box light wiring. Unplug cigar lighter and ash receiver light wiring. Then remove the lower bolster from the vehicle. (Figure 3).

25. Remove the center duct mounting bolt located directly above the Airbag Control Module (ACM).

26. Free the radio antenna connector from the hamess.

27. Remove the instrument panel top cover. It is held in place by retainer clips at both ends of the cover. To remove, carefully pry upward at one end of the cover until the clip is disengaged. Proceed to the opposite side and gradually pry the rear edge of the top cover along the entire width of the panel.

28. Remove left and right windshield pillar trim covers.





29. Disconnect the scan tool (DRB) connector from (diagonal) steering column support bracket (Figure 4).

30. Remove instrument panel ground strap. This strap is located on the lower left side of the Airbag Control Module (ACM) mounting bracket.

31. Disconnect wiring to Airbag Control Module (ACM).

32. Remove under column and right floor air distribution ducts.

33. Remove (Diagonal) Steering column support bracket.

34. Disconnect blower module connector, blower motor connector, and all related HVAC unit wiring connectors. Unplug the brake lamp switch wiring connector at the bracket.

35. Remove Airbag Control Module (ACM) mounting bolts.

36. Remove fuse panel mounting bracket on driver-side of I/P from cowl.

37. Unbolt the Body Control Module (BCM) mounting bracket from cowl and let hang loose from I/P.

38. Disconnect wiring running to passenger door in kick panel area.

39. Unclip the wiring hamess running along the driver side A-pillar. This will allow the I/P to move out and away from the cowl.

40. Remove seven bolts that hold instrument panel to the cowl. Five bolts are located at the base of the windshield, with one at each side of the upper I/P.

41. Remove steering column retaining bolts and allow the steering column to lower to the left side of the seat. Do not completely remove the column from the vehicle.

NOTE:
COVER THE STEERING WHEEL, COLUMN, AND SEATS TO ENSURE NO DAMAGE OR TEARS BEFORE MOVING INSTRUMENT PANEL.

42. Pull the upper instrument panel away from the base of the windshield. The instrument panel will be moved with all harnesses and gauges still in the panel. Maneuver the I/P out and pivot the passenger side onto passenger seat.

43. Remove the airbag module and brace from the vehicle.

44. Remove the upper 2 bolts and 1 center nut which hold the heater housing to the dash panel.

45. Carefully roll the heater housing out of the vehicle.

46. Refer to Evaporator Removal and Installation in the service manual for repair procedures.