Without 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 the plenum removal.
4. Disconnect the control system vacuum supply hose from the vacuum source and push the grommet and the vacuum supply hose into the passenger compartment.
5. Remove the RH and the LH lower instrument panel insulators.
6. Remove the three glove compartment hinge screws, disconnect the check strap, and remove the glove compartment.
7. Loosen the RH door sill plate and remove the RH side cowl trim panel.
8. Remove the bolt attaching the lower RH end of the instrument panel to the side cowl.

Instrument Panel Pad Removal And Installation:

9. Remove the instrument panel pad.

Plenum Assembly:

10. Remove one bolt located below the windshield wiper motor attaching the LH end of the plenum to the dash panel.
11. Disengage the temperature control cable housing from the bracket on top of the plenum. Disconnect the cable from the temperature blend door crank arm.
12. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
13. Disconnect the white vacuum hose from the outside air door vacuum motor.

Floor Air Distribution Duct:

14. 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.
15. Remove two nuts from the two studs along the lower flange of the plenum.
16. 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 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 own. 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 plenum.
3. Install three nuts on the studs along the lower flange and one nut on 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. Connect the white vacuum hose to the outside air door vacuum motor.
6. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Reinstall the floor duct.
7. 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.
8. Install the bolt to attach the lower RH end of the instrument panel to the side cowl.
9. Install the RH side cowl trim panel and tighten the RH door sill plate attaching screws.
10. Install the instrument panel pad.
11. Install the glove compartment door.
12. Connect the vacuum supply hose to the vacuum supply.
13. Install the RH and the LH lower instrument panel insulators.
14. Unplug the heater core tubes and connect the heater hoses to the heater core tubes.
15. Add coolant to the proper cooling system level. Ensure that the correct coolant mixture is maintained.
16. 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.