Without A/C
REMOVAL1. Disconnect battery ground cable.
2. Remove instrument panel.
3. Place a drain pan or suitable container under the heater water hose connections at the cowl panel.
4. Raise vehicle.
5. Disconnect heater water hoses from heater core inlet and outlet tubes. Plug heater water hoses and heater core tubes to prevent coolant loss during removal of A/C evaporator housing.
6. Disconnect vacuum supply hose (black) from vacuum source in engine compartment.
7. Lower vehicle.
8. Remove nut retaining A/C evaporator housing to cowl panel.
9. Working from inside vehicle, remove nut from upper crossmember brace.
10. Remove bolt from bottom mounting bracket and remove crossmember brace.
11. Pull off A/C plenum demister adapters from right and left sides of A/C evaporator housing.
12. Remove two screws retaining ram air intake duct to A/C evaporator housing. Release three retaining clips and remove ram air intake duct from A/C evaporator housing.
13. Remove screw securing A/C vacuum reservoir tank and bracket to A/C evaporator housing.
14. Disconnect two vacuum hoses from A/C vacuum reservoir tank and bracket and remove A/C vacuum reservoir tank and bracket from A/C evaporator housing.
15. Remove two screws and airbag diagnostic monitor bracket from heater outlet floor duct.
16. Remove screw securing air transfer duct to heater outlet floor duct. Push transfer duct up inside of heater outlet floor duct. Remove three screws securing heater outlet floor duct to heater core cover using #20 Torx socket. Release a retaining tab on each side of heater outlet floor duct and remove heater outlet floor duct from heater core cover.
17. Release four retaining tabs, remove two clips and remove heater core cover containing heater core, and vacuum hose from vehicle.
18. Remove three screws, amplifier and radio power booster equalizer amplifier bracket from vehicle, if equipped.
19. Remove five screws retaining A/C evaporator housing to instrument panel reinforcement. Rotate A/C evaporator housing away from instrument panel reinforcement and remove A/C evaporator housing from vehicle.
INSTALLATION
1. Rotate A/C evaporator housing into position on instrument panel reinforcement. Secure with five retaining screws.
2. Align locating pins and install heater core cover with heater core and vacuum hose to A/C evaporator housing. Install two attaching clips and use additional metal service clips, W703056-5300, if required.
3. Install heater outlet floor duct to heater core cover. Secure with three screws and additional metal service clips. Slide air transfer duct down to engage with rear seat airflow duct. Secure air transfer duct in the position with screw.
4. Attach air-bag control monitor bracket to heater outlet floor duct with four retaining screws.
5. Install ram air intake duct to A/C evaporator housing and secure with two screws.
6. Install right and left A/C plenum demister adapters to A/C evaporator housing.
7. Install A/C vacuum reservoir tank and bracket to A/C evaporator housing and secure with screw. Connect two vacuum hoses and A/C vacuum check valve to A/C vacuum reservoir tank and bracket
8. Install radio power booster equalizer amplifier bracket with three retaining screws, it equipped.
9. Secure upper crossmember brace with nut.
10. Secure bottom mounting bracket with bolt.
11. Install instrument panel.
12. Working from inside engine compartment, install nut retaining A/C evaporator housing to cowl panel.
13. Raise vehicle.
14. Connect heater water hoses to heater core tubes.
15. Connect vacuum source line.
16. Service coolant system.
17. Connect battery ground cable.
18. After repairs have been completed, check the coolant level in the radiator and in the radiator coolant recovery reservoir. Fill as required with the recommended coolant mixture.