Removal and Installation

REMOVAL
1. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. Service and Repair

2. Drain the coolant from the radiator so the coolant level is below the heater core.







3. Remove the windshield wiper arms.
1 Remove the nuts (one each side).
2 Remove the windshield wiper arms.

4. Remove the cowl top cover.







5. Remove the fasteners and the fresh air inlet duct.







6. Remove the screws and the windshield wiper mounting arm and pivot shaft with the cowl extension as an assembly.







7. Disconnect the heater hoses.







8. Remove the nut at the cowl side.







9. Remove the screw and nut from the evaporator core housing.







10. Disconnect the vacuum hoses.







11. Disconnect the electrical connectors.







12. Position back the carpet from the plenum chamber. Cut each side of the rear footwell duct and bend back the duct.

CAUTION: Do not excessively cut the rear footwell duct. Make sure to only cut the rear footwell duct to the point that allows the heater floor duct to be removed with the plenum chamber as an assembly.







13. Remove the nuts from the lower flange of the plenum chamber.







14. Remove the nut from the upper flange of the plenum chamber and remove the plenum chamber.

INSTALLATION
1. Install the plenum chamber and the upper flange nut.
2. Install the plenum chamber lower flange nuts.
3. Install the screw and nut at the evaporator core housing.
4. Connect the heater hoses.
- Lubricate the coolant hoses with MERPOL(R) meeting Ford specification ESE-M99B144-B or plain water only, if needed.

5. Install the nut at the cowl side.
6. Install the windshield wiper mounting arm and pivot shaft with the cowl extension as an assembly.
7. Install the fresh air inlet duct.
8. Install the cowl top cover.
9. Install the windshield wiper arms.
10. Connect the plenum chamber electrical connectors.
11. Connect the plenum chamber vacuum hoses.







12. Close the rear footwell duct around the heater outlet floor duct, install a tie strap, and position back the carpet.

NOTE: Make sure to sufficiently seal the rear footwell duct to the heater outlet floor duct.

13. Install the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. Service and Repair
14. Top-off the engine cooling system.