Heater Core: Service and Repair
Less Air Conditioning
Fig. 6 Typical instrument panel. 1983-88 Cougar & Thunderbird:
Fig. 7 Heater core less A/C. 1982 Cougar XR-7, 1982-88 Thunderbird, 1983-88 Cougar & 1983-86 LTD & Marquis:
REMOVE THE INSTRUMENT PANEL ASSEMBLY:
1. Disconnect battery ground cable.
2. Remove steering column cover, then the instrument panel reinforcement under steering column opening.
3. Remove 2 nuts securing hood latch release handle mounting bracket to brake pedal support under steering column.
4. Remove sound insulator from lower left side of instrument panel, Fig. 6.
5. Remove 2 steering column clamp attaching nuts and lower steering column to rest on front seat.
6. Remove instrument panel pad attaching screws and the pad.
7. Disconnect speedometer cable from speedometer.
8. Remove console cover or tray.
9. Remove 4 console switch panel cover attaching screws, then disconnect electrical connectors and remove switch panel.
10. Remove console attaching screws, then disengage console from instrument panel and position aside.
11. Remove 2 pins attaching glove compartment door straps to glove compartment and allow door to hang down on hinge.
12. Remove instrument panel brace attaching bolt from glove compartment opening.
13. Remove brake pedal support attaching nut from lower edge of instrument panel.
14. Remove instrument panel brace attaching bolt from lower edge of instrument panel on left side of console extension.
15. Remove instrument panel-to-cowl side panel attaching bolt from both sides of instrument panel.
16. Support instrument panel and remove 3 instrument panel-to-cowl top panel attaching screws.
17. Move instrument panel rearward, disconnect necessary electrical connectors and vacuum hoses, and rest panel on front seat.
REMOVE THE HEATER CASE:
18. Drain cooling system, then disconnect hoses from heater core. Cover hoses and heater core tubes to prevent leakage.
19. Remove 2 nuts securing heater case to dash panel from engine compartment.
20. Working in passenger compartment, remove screws attaching heater case support bracket and air inlet duct support bracket to cowl top panel.
21. Remove nut retaining bracket at left end of heater case to dash panel and nut securing bracket below case to dash panel.
22. Pull heater case away from dash panel to gain access to heater core access cover attaching screws.
DISASSEMBLE THE HEATER CASE:
23. Remove heater core access cover attaching screws and the cover.
24. Remove heater core and seals from heater case, Fig. 7.
25. Remove the 2 seals from heater core tubes.
26. Reverse procedure to install.
With Air Conditioning
Fig. 9 Instrument panel trim panel (Typical). 1982 Cougar XR-7, Thunderbird & 1983-86 LTD & Marquis:
REMOVE THE INSTRUMENT PANEL ASSEMBLY:
1. Disconnect battery ground cable.
2. Remove steering column cover assembly, then remove left and right finish panels, Fig. 9.
3. Remove two screws from sides of instrument panel pad and retainer assembly.
4. Remove pad and retainer assembly and upper finish panel.
5. Remove steering column attaching bolts, then carefully lower steering column just enough to allow access to transmission gear selector lever cable assembly. Reach between steering column and instrument panel, then carefully lift selector lever cable from lever and remove cable clamp from steering column tube.
6. Lower steering column and allow to rest on front seat.
7. Remove screw attaching instrument panel to brake pedal support through steering column opening.
8. Disconnect temperature door cable from door and heater/evaporator cable bracket.
9. Disconnect vacuum hose connectors at evaporator housing.
10. Disconnect blower motor resistor wire from resistor on heater/evaporator case and blower motor feed wire at in-line connector.
11. Support instrument panel, then remove three screws attaching top of instrument panel to cowl.
12. Remove one screw attaching each end of instrument panel to cowl side panels, then remove two screws attaching instrument panel to floor.
13. Move instrument panel rearward and disconnect speedometer cable and any wires that will prevent instrument panel from being placed on front seat. Use care when removing instrument panel to prevent damage to panel or steering column surfaces.
14.
REMOVE THE HEATER CASE:
18. Drain cooling system, then disconnect hoses from heater core. Cover hoses and heater core tubes to prevent leakage.
19. Discharge refrigerant from A/C system at the service valve on the suction line. When system is fully discharged, disconnect and cap high and low pressure lines.
20. Remove 2 nuts securing heater case to dash panel from engine compartment.
21. Working in passenger compartment, remove screws attaching heater case support bracket and air inlet duct support bracket to cowl top panel.
22. Remove nut retaining bracket at left end of heater case to dash panel and nut securing bracket below case to dash panel.
23. Pull heater case away from dash panel to gain access to heater core access cover attaching screws.
DISASSEMBLE THE HEATER CASE:
Fig. 8 Heater core with A/C. 1982 Cougar XR-7, 1982 Granada, 1982-83 Fairmont & Zephyr, 1982-88 Thunderbird, 1983-88 Cougar & 1983-86 LTD & Marquis:
24. Remove heater core access cover attaching screws and the cover.
25. Remove heater core and seals from heater case, Fig. 8.
26. Remove the 2 seals from heater core tubes.
27. Reverse procedure to install.