With Air Conditioning
Evaporator Case/Plenum Removal/Installation:
REMOVAL
1. Disconnect the negative (ground) cable from the battery negative (-) terminal.
2. Disconnect the heater hoses from the heater core tubes. Plug the ends of the heater hoses to prevent coolant loss.
3. Plug the heater core tubes securely to prevent coolant leakage from the heater core during plenum removal.
4. Disconnect control system vacuum supply hose from vacuum source and push grommet and vacuum supply hose into passenger compartment.
5. Remove the three glove compartment hinge screws, disconnect the check strap, and remove the glove compartment.
6. Loosen the RH door sill plate and remove the RH side cowl trim panel.
7. Remove the bolt attaching the lower RH end of the instrument panel to the side cowl.
8. Remove the instrument panel pad as outlined.
Removal
1. Remove two screws attaching the instrument panel pad to the instrument panel at each defroster opening. Use extreme care not to drop the screws into the defroster openings (Fig. 16).
2. Remove one screw attaching each outboard end of the pad to the instrument panel.
3. On Ford Crown Victoria, remove one pad attaching screw near the upper RH corner of the glove compartment door.
4. Remove five screws attaching the lower edge of the pad to the instrument panel. Pull the instrument panel pad rearward and remove it from vehicle.
Evaporator Case/Plenum Removal/Installation:
5. Remove one bolt located below the windshield wiper motor attaching the LH end of the plenum to the dash panel (Fig. 19).
6. Disengage the temperature control cable housing from the bracket on top of the plenum. Disconnect the cable from the temperature blend door crank arm.
7. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
8. Disconnect the white vacuum hose from the outside air door vacuum motor.
9. Remove one plastic push fastener retaining the floor air distribution duct to the LH end of the plenum and remove the floor air distribution duct
10. Remove two nuts from the two studs along the lower flange of the plenum.
11. Carefully move plenum rearward to allow heater core tubes and stud at the top of the plenum to clear the holes in the dash panel. Remove plenum from vehicle by rotating top of plenum forward, down and out from under the instrument panel. Carefully pull lower edge of instrument panel rearward as necessary while rolling plenum from behind the instrument panel.
Installation
1. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
2. Position plenum under instrument panel with the register duct opening up and the heater core tubes down. Rotate plenum up behind the instrument panel and position plenum to the dash panel. Insert heater core tubes and mounting studs through their respective holes in the dash panel and the plenum.
Evaporator Case/Plenum Removal/Installation:
3. Install two nuts on the studs along the lower flange of the plenum (Fig. 19).
4. Install one bolt below the windshield wiper motor to attach the LH end of the plenum to the dash panel.
Panel Door Vacuum Motor:
5. Position panel door vacuum motor to mounting bracket and install two attaching screws.
6. Connect the white vacuum hose to the outside air door vacuum motor.
7. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct.
8. Connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable as outlined under Adjustments.
9. Install the bolt to attach the lower RH end of the instrument panel to the side cowl.
10. Install the RH side cowl trim panel and tighten the RH door sill plate attaching screws.
11. Install instrument panel pad as outlined.
Installation
Instrument Panel Pad Removal And Installation:
1. Position the instrument panel pad to the instrument panel and install five screws along the lower edge of the pad (Fig. 16).
2. Install one screw to each outboard end of the pad to the instrument panel.
3. On Ford Crown Victoria, install one pad attaching screw near the upper RH corner of the glove compartment door.
4. Install two pad attaching screws at each defroster opening. Use care not to drop the screws into the defroster opening.
5. Install the glove compartment door.
6. Connect the vacuum supply hose to the vacuum supply.
7. Unplug the heater core tubes and connect the heater hoses to the heater core tubes.
8. Add coolant to the proper cooling system level. Ensure that the correct coolant mixture is maintained.
9. Connect battery ground cable. Check the system for proper operation.
NOTE: On vehicles equipped with Electronic Engine Control (EEC), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.