With Air Conditioning

REMOVAL
1. Disconnect the battery ground cable.
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.

Plenum/Evaporator Case And Evaporator Assembly:

4. Remove the three nuts located below the windshield wiper motor attaching the LH end of the plenum to the dash panel.
5. Remove one nut retaining the upper LH corner of the evaporator case to the dash panel.
6. Remove the LH and the RH lower instrument panel insulators.
7. Disconnect the control system vacuum supply hose from the vacuum source. Push the grommet and the vacuum supply hose into the passenger compartment.
8. Remove the three glove compartment hinge screws, disconnect the check arms, and remove the glove compartment.
9. Loosen the RH door sill plate and remove the RH side cowl trim panel.
10. Remove the bolt attaching the lower RH end of the instrument panel to the side cowl.

Instrument Panel Pad Removal And Installation:

11. Remove the instrument panel pad.
12. Disengage the temperature control cable housing from the bracket on top of the plenum. Disconnect the cable from the temperature blend door crank arm.
13. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
14. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
15. Remove the two screws attaching the passenger (rear) side of the floor air distribution duct to the plenum. It may be necessary to remove the two screws attaching the partial (lower) panel door vacuum motor to the mounting bracket to gain access to the right screw.

Floor Air Distribution Duct:

16. Remove one plastic push fastener retaining the floor air distribution duct to the LH end of the plenum and two screws on the rear face of the plenum, and remove the floor air distribution duct.
17. Remove the two nuts from the two studs along the lower flange of the plenum.
18. Carefully move the plenum rearward to allow the heater core tubes and the stud at the top of the plenum to clear the holes in the dash panel. Remove the plenum from the vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull the lower edge of the instrument panel rearward as necessary while rolling the 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 the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and the mounting studs through their respective holes in the dash panel and the evaporator case.
3. Install the three nuts on the studs along the lower flange and one on the upper flange of the plenum.
4. Install three nuts below the windshield wiper motor to attach the LH end of the plenum to the dash panel.
5. Install one nut to retain the upper LH corner of the evaporator case to the dash panel.
6. Position the floor air distribution duct to the plenum. Install the two screws and the plastic push fastener.
7. If removed, position the panel door vacuum motor to the mounting bracket. Install the two attaching screws.
8. Connect the white vacuum hose to the outside-recirculating door vacuum motor.
9. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install the floor duct.
10. 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.
11. Install the bolt to attach the lower RH end of the instrument panel to the side cowl.
12. Install the RH side cowl trim panel and tighten the RH door sill plate attaching screws.
13. Install the instrument panel pad.
14. Install the glove compartment door and check arms.
15. Connect the vacuum supply hose to the vacuum supply.
16. Install the RH and the LH lower instrument panel insulators.
17. Unplug the heater core tubes and connect the heater hoses to the heater core tubes.
18. Fill the cooling system with coolant to replace coolant lost during removal of the plenum.
19. Connect the battery ground cable.

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.

20. Check the system for proper operation.