AutoZone 1981 Mercedes Benz 240D 2.4L Diesel 4cyl | Repair Guides | Heating, Ventilation, & Air Conditioning | Heater Core | Removal & Installation 2 | AutoZone.com

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    1981 Mercedes Benz 240D 2.4L Diesel 4cyl

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    405 N COLLEGE ST
    (479) 443-4043

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    Expedition, Navigator 2006-2007

    Removal & Installation 2

    Print

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait 1 minute for the SRS module to deplete its energy.

    4.  
    5. Drain the cooling system into a clean container for reuse.
    6.  
    7. Remove the instrument panel by performing the following procedure:

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel components-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Exploded view of the floor console components-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the bulkhead electrical connectors from inside the engine compartment-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the audio unit ground and the GEM/CTM ground bolts-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the instrument panel bolts through the steering column opening-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the passenger side ground bolt-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Detach the passenger side instrument panel main harness connectors-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the instrument panel bolt on the relay bracket-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the instrument panel bolts through the passenger side air bag module opening-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the instrument panel reinforcement bolt below the driver-s side corner of the glove compartment-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Position the carpet aside and loosen the instrument panel floor brace-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the passenger side instrument panel cowl side nut-Lincoln Navigator



      Click image to see an enlarged view

      Fig. On Navigator, remove the defroster grille assembly-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the cowl panel mounting bolts-Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the instrument panel-Lincoln Navigator

      1. If equipped, remove the floor console assembly.
      2.  
      3. Remove the lower steering column cover bolts and the cover.
      4.  
      5. Remove both front door scuff plates.
      6.  
      7. Remove both side cowl trim panels.
      8.  
      9. Disconnect the electrical connector from the Brake Pedal Position (BPP) switch.
      10.  
      11. Remove the radio ground and the GEM/CTM ground bolts.
      12.  
      13. Disconnect the left side instrument panel main wiring harness connector.
      14.  
      15. In the engine compartment, remove the bulkhead wiring harness connector bolts and disconnect the wiring connectors.
      16.  
      17. In the driver-s compartment, release the 6 locking tabs and remove the bulkhead electrical connector from the instrument panel.
      18.  
      19. Disconnect the air bag diagnostic monitor electrical connector.
      20.  
      21. Disconnect the inertia fuel shutoff switch electrical connector.
      22.  
      23. Remove the right side ground bolts.
      24.  
      25. Disconnect the right side instrument panel wiring harness connectors.
      26.  
      27. Disconnect the electronic blend door actuator electrical connector.
      28.  
      29. Disconnect the climate control head vacuum harness connector.
      30.  
      31. Remove the steering column opening cover reinforcement nuts and the cover reinforcement.
      32.  
      33. At the base of the steering column, disconnect the air bag sliding contact and the anti-theft sensor electrical connectors.
      34.  
      35. At the steering column, disconnect the remaining electrical connectors.
      36.  
      37. If equipped with a transmission range indicator, remove the bolt and disconnect the cable.
      38.  
      39. Remove the steering column-to-instrument panel nuts and lower the steering column.
      40.  
      41. Remove the right side front fender splash shield screws and move the shield away from the panel.
      42.  
      43. Disconnect the antenna cable from the antenna base.
      44.  
      45. Remove the instrument panel relay cover and disconnect the auto lamp sensor electrical connector and/or the sunload sensor connector.
      46.  
      47. Remove the glove box.
      48.  
      49. At the passenger-s air bag module, remove the screws, disconnect the electrical connector and remove the air bag module.
      50.  

    8.  

    Place the air bag module in a safe place with the front facing upward.

    1. Remove the right side assist handle screw covers, the screws and the handle.
    2.  
    3. At both doors, pull back the weather-strip seals and remove the windshield garnish moldings.
    4.  
    5. Remove the instrument panel reinforcement bolt below the left side corner of the glove box.
    6.  
    7. Through the air bag module opening, remove the instrument panel bolts.
    8.  
    9. Remove the instrument panel defroster grille assembly and the instrument panel cowl top bolts.
    10.  
    11. At the relay bracket, remove the instrument panel bolt.
    12.  
    13. At the lower left side of the cigar lighter, remove the instrument panel bolt.
    14.  
    15. At the both sides, remove the instrument panel-to-cowl side nuts.
    16.  
    17. At the steering column opening, remove the instrument panel bolts.
    18.  
    19. Remove the upper instrument panel floor brace bolt.
    20.  
    21. Using an assistant, remove the instrument panel.
    22.  

    1. If equipped with the 5.4L 4V engine, remove the junction block splash shield.
    2.  
    3. If equipped with the 5.4L 4V engine, remove the bolts and disconnect the cable ends from the starter relay.
    4.  
    5. If equipped with the 5.4L 4V engine, remove the junction block bracket.
    6.  
    7. Compress the holding tabs and disconnect the heater hoses from the heater core.
    8.  
    9. Remove the air conditioning plenum screw and the air conditioning plenum demister adapter.
    10.  
    11. Disconnect the vacuum line.
    12.  
    13. Remove the heater core bracket screws and the bracket.
    14.  
    15. Remove the 13 heater housing plenum camber cover screws and the heater housing plenum chamber cover.
    16.  
    17. Remove the blend door assembly from the heater housing.
    18.  
    19. Remove the heater core.

      Click image to see an enlarged view

      Fig. View of the heater core-Lincoln Navigator

    20.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the blend door assembly to the heater housing.
    4.  
    5. Install the 13 heater housing plenum camber cover and the heater housing plenum chamber cover screws.
    6.  
    7. Install the heater core bracket and the bracket screws.
    8.  
    9. Connect the vacuum line.
    10.  
    11. Install the air conditioning plenum demister adapter and the air conditioning plenum screw.
    12.  
    13. Connect the heater hoses to the heater core.
    14.  
    15. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Install the upper instrument panel floor brace bolt.
      4.  
      5. At the steering column opening, install the instrument panel bolts.
      6.  
      7. At the both sides, install the instrument panel-to-cowl side nuts.
      8.  
      9. At the lower left side of the cigar lighter, install the instrument panel bolt.
      10.  
      11. At the relay bracket, install the instrument panel bolt.
      12.  
      13. Install the instrument panel cowl top bolts and the instrument panel defroster grille assembly.
      14.  
      15. Through the air bag module opening, install the instrument panel bolts.
      16.  
      17. Install the instrument panel reinforcement bolt below the left side corner of the glove box.
      18.  
      19. At both doors, install the windshield garnish moldings and the weather-strip seals.
      20.  
      21. Install the right side assist handle, the screws and the handle screw covers.
      22.  
      23. At the passenger-s air bag module, install the air bag module, connect the electrical connector and install the air bag module screws.
      24.  
      25. Install the glove box.
      26.  
      27. Connect the auto lamp sensor electrical connector and/or the sunload sensor connector; then, install the instrument panel relay cover.
      28.  
      29. Connect the antenna cable to the antenna base.
      30.  
      31. Install the right side front fender splash shield and screws.
      32.  
      33. Install the steering column and the steering column-to-instrument panel nuts.
      34.  
      35. If equipped with a transmission range indicator, connect the cable and install the bolt.
      36.  
      37. At the steering column, connect the remaining electrical connectors.
      38.  
      39. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors.
      40.  
      41. Install the steering column opening cover reinforcement and the cover reinforcement nuts.
      42.  
      43. Connect the climate control head vacuum harness connector.
      44.  
      45. Connect the electronic blend door actuator electrical connector.
      46.  
      47. Connect the right side instrument panel wiring harness connectors.
      48.  
      49. Install the right side ground bolts.
      50.  
      51. Connect the inertia fuel shutoff switch electrical connector.
      52.  
      53. Connect the air bag diagnostic monitor electrical connector.
      54.  
      55. In the driver-s compartment, install the bulkhead electrical connector to the instrument panel.
      56.  
      57. In the engine compartment, connect the bulkhead wiring harness connectors and the install wiring connector bolts.
      58.  
      59. Connect the left side instrument panel main wiring harness connector.
      60.  
      61. Install the radio ground and the GEM/CTM ground bolts.
      62.  
      63. Connect the electrical connector to the Brake Pedal Position (BPP) switch.
      64.  
      65. Install both side cowl trim panels.
      66.  
      67. Install both front door scuff plates.
      68.  
      69. Install the lower steering column cover and the cover bolts.
      70.  
      71. If equipped, install the floor console assembly.
      72.  

    16.  
    17. Refill the cooling system.
    18.  
    19. Connect the negative battery cable.
    20.  
    21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    22.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Depower the supplemental restraint system (SRS).
    4.  
    5. Disconnect the negative battery cable.
    6.  
    7. Recover the refrigerant.
    8.  
    9. Drain the engine coolant.

      Click image to see an enlarged view

      Fig. Expedition Instrument panel Exploded view

    10.  
    11. If equipped with adjustable pedals, move the pedals to the full forward position.
    12.  
    13. Place the gear shift lever in NEUTRAL and apply the parking brake.
    14.  
    15. Position the front seat forward.
    16.  
    17. Remove the 2 front floor console rear bolts.
    18.  
    19. Position the front seats rearward.
    20.  
    21. Remove the 2 front floor console front bolts.
    22.  
    23. Remove the 2 bolt covers.
    24.  
    25. Remove the shifter trim ring.
    26.  
    27. Position the gear shift lever indicator bezel aside.
    28.  
    29. Release the 4 retainers and position aside.
    30.  
    31. Remove the front floor console tray mat.
    32.  
    33. Remove the front floor console screw.
    34.  
    35. Disconnect the shifter cable.
    36.  
    37. Remove the floor console front screws.
    38.  
    39. Loosen the bulkhead electrical connector bolt.
    40.  
    41. Disconnect the bulkhead electrical connector
    42.  
    43. Disconnect the electrical connector.
    44.  
    45. Remove the front floor console.
    46.  
    47. Remove the instrument panel steering column cover.
    48.  
    49. Remove the screws.
    50.  
    51. Release the cover from the instrument panel.
    52.  
    53. Remove the hood release handle bolt and position aside.
    54.  
    55. Remove the instrument panel lower cover.
    56.  
    57. Remove the bolt from the parking brake handle and position aside
    58.  
    59. Remove the bolts and the steering column reinforcement panel.
    60.  
    61. Loosen the bolt and disconnect the LH instrument panel bulkhead connector.
    62.  
    63. Disconnect the LH electrical connectors
    64.  
    65. Disconnect the park brake indicator connector.
    66.  
    67. Disconnect the cruise control deactivator and the brake on/off switch electrical connector
    68.  
    69. Disconnect the electrical connector located above the data link.
    70.  
    71. Disconnect the steering wheel position sensor electrical connector
    72.  
    73. Disconnect the steering column shift cable from the shift lever.
    74.  
    75. Remove the steering column shift cable and position aside.
    76.  
    77. Remove the shift cable from the bracket.
    78.  
    79. Remove the shift cable and retainer from the steering column.
      WARNING
      Secure the steering wheel to prevent any rotation or damage to the clockspring.

    80.  
    81. Remove the pinch bolt and separate the intermediate shaft from the steering column.
    82.  
    83. If equipped, remove the 3 pin-type retainers and the valance panel.
    84.  
    85. If equipped, disconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
    86.  
    87. Disconnect the stability control sensor cluster electrical connector.
    88.  
    89. Disconnect the wiring harness from the console bracket
    90.  
    91. Remove the satellite radio antenna from the wiring harness, if equipped
    92.  
    93. Remove the RH instrument panel side finish panel.
    94.  
    95. Disconnect the RH instrument panel electrical connectors.
    96.  
    97. Remove the RH ground bolt.
    98.  
    99. Disconnect the in-line antenna connector.
    100.  
    101. Lower the glove compartment.
    102.  
    103. Disconnect the electrical connectors.
      NOTE
      There are 6 electrical connectors.

    104.  
    105. Position the carpet aside, remove the bolts and the instrument panel floor brace.
    106.  
    107. Remove the instrument panel defroster grille.
    108.  
    109. Remove the instrument panel cowl bolts.
    110.  
    111. Remove the LH instrument panel bolts.
    112.  
    113. Remove the RH instrument panel bolts.
      NOTE
      This step requires an assistant.

    114.  
    115. Remove the instrument panel.
      NOTE
      Two bullet connectors align the instrument panel to the bulkhead.

    116.  
    117. Disconnect the 2 heater hose quick disconnect fittings at the heater core.
    118.  
    119. Remove the auxiliary evaporator outlet and inlet line fitting nuts and disconnect the fittings.
    120.  
    121. Disconnect the evaporator outlet and inlet fittings.
    122.  
    123. Detach the thermostatic expansion valve (TXV) manifold and tube assembly from the line 2 brackets.
    124.  
    125. Detach the TXV manifold and tube assembly bracket from the heater core and evaporator core housing stud at the dash panel.
    126.  
    127. Remove the 3 heater core and evaporator core housing nuts.
    128.  
    129. Detach the 4 satellite radio antenna cable pin-type retainers from the heater core and evaporator core housing (if equipped).
    130.  
    131. Detach the 3 body harness electrical connectors from the bracket below the air inlet duct.
    132.  
    133. Remove the air inlet duct bracket nut.
    134.  
    135. Remove the 4 tunnel instrument panel bracket bolts and the tunnel instrument panel bracket.
    136.  
    137. Detach the rear foot well duct from the heater core and evaporator core housing.
    138.  
    139. Remove the plenum chamber nut.
    140.  
    141. Remove the heater core and evaporator core housing.
    142.  
    143. Remove the 8 plenum chamber screws.
    144.  
    145. Release the plenum chamber clip and position the plenum chamber aside
    146.  
    147. Remove 2 heater core fitting clips and the dash panel seal.
    148.  
    149. Remove the heater core tube bracket screw and the heater core tube bracket.
    150.  
    151. Remove the heater core bracket screw and the heater core bracket.
    152.  
    153. Remove the heater core.

      Click image to see an enlarged view

      Fig. Heater core and Evaporator core housing heater core removal shown

    154.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the heater core bracket screws and bracket.
    4.  
    5. Install the heater core tube bracket and screws.
    6.  
    7. Install the heater core fitting clips and dash panel seal.
    8.  
    9. Install the plenum chamber clip and reposition the plenum chamber.
    10.  
    11. Install the plenum chamber screws.
    12.  
    13. Install the heater core and evaporator core housing.
    14.  
    15. Install the plenum chamber nut.
    16.  
    17. Install the rear foot well duct from the heater core and evaporator core housing.
    18.  
    19. Install the four tunnel instrument panel bracket bolts and the tunnel instrument panel bracket
    20.  
    21. Install the air inlet duct bracket nut.
    22.  
    23. Reattach the three body harness electrical connectors to the bracket below the air inlet duct.
    24.  
    25. Install the four satellite radio antenna cable pin-type retainers to the heater core and evaporator core housing (if equipped).
    26.  
    27. Install the three heater core and evaporator core housing nuts.
    28.  
    29. Install the TXV manifold and tube assembly bracket to the heater core and evaporator core housing stud at the dash panel.
    30.  
    31. Install the thermostatic expansion valve (TXV) manifold and tube assembly to the line brackets.
    32.  
    33. Reconnect the evaporator outlet and inlet fittings.
    34.  
    35. Install the auxiliary evaporator outlet and inlet line fitting nuts and connect the fittings.
    36.  
    37. Reconnect the two heater hose quick disconnect fittings at the heater core.
      NOTE
      Two bullet connectors align the instrument panel to the bulkhead.

    38.  
    39. With the help of an assistant install the instrument panel.
    40.  
    41. Install the right and left panel bolts.
    42.  
    43. Install cowl bolts.
    44.  
    45. Install instrument panel defroster grill.
    46.  
    47. Reposition carpet install floor brace and bolts.
    48.  
    49. Reconnect the six electrical connectors.
    50.  
    51. Install lower glove compartment.
    52.  
    53. Reconnect antenna connector.
    54.  
    55. Install right ground bolt.
    56.  
    57. Install right finish panel and electrical connector.
    58.  
    59. If removed. Install satellite radio antenna.
    60.  
    61. Reconnect the wiring harness from the console bracket.
    62.  
    63. Reconnect the stability control sensor cluster electrical connector.
    64.  
    65. If removed, Reconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
    66.  
    67. If removed, install the three pin-type retainers and the valance panel.
    68.  
    69. Install the steering intermediate shaft pinch bolt.
      WARNING
      Secure the steering wheel to prevent any rotation or damage to the clockspring.

    70.  
    71. Install the shift cable and retainer from the steering column.
    72.  
    73. Install the shift cable in the bracket.
    74.  
    75. Install the steering column shift cable into the shift lever.
    76.  
    77. Reconnect the steering wheel position sensor electrical connector.
    78.  
    79. Reconnect the electrical connector located above the data link.
    80.  
    81. Reconnect the cruise control deactivator and the brake on/off switch electrical connector.
    82.  
    83. Reconnect the park brake indicator connector.
    84.  
    85. Reconnect the left side electrical connectors.
    86.  
    87. Reconnect the left side instrument panel bulkhead connector and tighten bolt.
    88.  
    89. Install the bolts and the steering column reinforcement panel.
    90.  
    91. Install hood release and parking brake handles. Tighten mounting screws, if equipped install electrical connector.
    92.  
    93. Install the instrument panel lower cover.
    94.  
    95. Install the instrument panel steering column cover
    96.  
    97. Install the front floor console.
    98.  
    99. Reconnect the bulk head electrical connector and bolt.
    100.  
    101. Tighten the floor console front screws.
    102.  
    103. Reconnect the shifter cable.
    104.  
    105. Install the front floor console screw.
    106.  
    107. Install the front floor console tray mat.
    108.  
    109. Reconnect the four retainers.
    110.  
    111. Install the shifter trim ring.
    112.  
    113. Install the two front floor console front bolts and covers.
    114.  
    115. Reposition the front seats forward.
    116.  
    117. Install the two front floor console rear bolts.
    118.  
    119. Replace antifreeze and bleed cooling system.
    120.  
    121. Vacuum and recharge A/C system, check for leaks.
    122.  
    123. Power up (SRS) System.
    124.  
    125. Connect the negative battery cable.
    126.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Depower the supplemental restraint system (SRS).
    4.  
    5. Disconnect the negative battery cable.
    6.  
    7. Recover the refrigerant.
    8.  
    9. Drain the engine coolant.

      Click image to see an enlarged view

      Fig. Navigator Instrument panel Exploded view

    10.  
    11. If equipped with adjustable pedals, move the pedals to the full forward position.
    12.  
    13. Place the shift lever in NEUTRAL and apply the parking brake.
    14.  
    15. Position the front seat forward
    16.  
    17. Remove the two front floor console rear bolts.
    18.  
    19. Position the front seats rearward.
    20.  
    21. Remove the shifter trim ring.
    22.  
    23. Remove the front floor console finish panel.
    24.  
    25. Pull upward on the rear of the finish panel to release the retainers.
    26.  
    27. Position the shifter lever indicator bezel aside.
    28.  
    29. Disconnect the shift cable.
    30.  
    31. Remove the front floor console front screws.
    32.  
    33. Loosen the bulkhead electrical connector bolt.
    34.  
    35. Disconnect the bulkhead electrical connector.
    36.  
    37. Disconnect the electrical connector.
    38.  
    39. Remove the left and right front floor console side finish panels.
    40.  
    41. If equipped, disconnect the electrical connector.
    42.  
    43. Remove the left and right front floor console front bolts and the floor console.
    44.  
    45. If equipped, remove the right instrument panel insulator.
    46.  
    47. Disconnect the instrument panel insulator lamp.
    48.  
    49. Remove the left and right cowl trim panels.
    50.  
    51. Remove the scuff plate.
    52.  
    53. Remove the cowl trim panel
    54.  
    55. Position the left and right door weather-strip seals aside.
    56.  
    57. Remove the left and right assist handles.
    58.  
    59. Remove the covers.
    60.  
    61. Remove the bolts.
      NOTE
      Release the top attachments by pulling inboard first and then upward to release the lower hook.

    62.  
    63. Remove the instrument panel steering column cover.
    64.  
    65. Remove the screws.
    66.  
    67. Release the cover from the instrument panel.
    68.  
    69. Disconnect the electrical connector, if equipped
    70.  
    71. Position the hood release and parking brake release handles aside.
    72.  
    73. Remove the screws.
    74.  
    75. Position the release handles aside.
    76.  
    77. Remove the bolts and the steering column reinforcement panel.
    78.  
    79. Loosen the bolt and disconnect the left instrument panel bulkhead connector.
    80.  
    81. Disconnect the left electrical connectors.
    82.  
    83. Disconnect the park brake indicator connector.
    84.  
    85. Disconnect the cruise control deactivator and the brake on/off switch electrical connector.
    86.  
    87. Disconnect the electrical connector located above the data link.
    88.  
    89. Disconnect the steering wheel position sensor electrical connector
    90.  
    91. Disconnect the steering column shift cable from the shift lever.
    92.  
    93. Remove the steering column shift cable and position aside.
    94.  
    95. Remove the shift cable from the bracket.
    96.  
    97. Remove the shift cable and retainer from the steering column.
      WARNING
      Secure the steering wheel to prevent any rotation or damage to the clockspring.

    98.  
    99. Remove the pinch bolt and separate the intermediate shaft from the steering column.
    100.  
    101. If equipped, remove the three pin-type retainers and the valance panel.
    102.  
    103. If equipped, disconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
    104.  
    105. Disconnect the stability control sensor cluster electrical connector.
    106.  
    107. Disconnect the wiring harness from the console bracket.
    108.  
    109. Remove the satellite radio antenna from the wiring harness, if equipped.
    110.  
    111. Remove the right instrument panel side finish panel.
    112.  
    113. Disconnect the right instrument panel electrical connectors.
    114.  
    115. Remove the right ground bolt.
    116.  
    117. Disconnect the in-line antenna connector.
    118.  
    119. Lower the glove compartment.
    120.  
    121. Disconnect the electrical connectors.
      NOTE
      There are six electrical connectors.

    122.  
    123. Position the carpet aside, remove the bolts and the instrument panel floor brace.
    124.  
    125. Remove the instrument panel defroster grille.
    126.  
    127. Remove the instrument panel cowl bolts.
    128.  
    129. Remove the left instrument panel bolts.
    130.  
    131. Remove the right instrument panel bolts.
      NOTE
      This step requires an assistant.

    132.  
    133. Remove the instrument panel.
      NOTE
      Two bullet connectors align the instrument panel to the bulkhead.

    134.  
    135. Disconnect the two heater hose quick disconnect fittings at the heater core.
    136.  
    137. Remove the auxiliary evaporator outlet and inlet line fitting nuts and disconnect the fittings
    138.  
    139. Disconnect the evaporator outlet and inlet fittings.
    140.  
    141. Detach the thermostatic expansion valve (TXV) manifold and tube assembly from the line two brackets.
    142.  
    143. Detach the TXV manifold and tube assembly bracket from the heater core and evaporator core housing stud at the dash panel.
    144.  
    145. Remove the three heater core and evaporator core housing nuts.
    146.  
    147. Detach the four satellite radio antenna cable pin-type retainers from the heater core and evaporator core housing (if equipped).
    148.  
    149. Detach the three body harness electrical connectors from the bracket below the air inlet duct.
    150.  
    151. Remove the air inlet duct bracket nut.
    152.  
    153. Remove the plenum chamber nut.
    154.  
    155. Remove the four tunnel instrument panel bracket bolts and the tunnel instrument panel bracket.
    156.  
    157. Detach the rear foot well duct from the heater core and evaporator core housing.
    158.  
    159. Remove the plenum chamber nut.
    160.  
    161. Remove the heater core and evaporator core housing.
    162.  
    163. Remove the plenum chamber screws.
    164.  
    165. Release the plenum chamber clip and position the plenum chamber aside
    166.  
    167. Remove the heater core fitting clips and the dash panel seal.
    168.  
    169. Remove the heater core tube bracket screw and the heater core tube bracket.
    170.  
    171. Remove the heater core bracket screw and the heater core bracket.
    172.  
    173. Remove the heater core.

      Click image to see an enlarged view

      Fig. Heater core and Evaporator core housing heater core removal shown

    174.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the heater core bracket screws and bracket.
    4.  
    5. Install the heater core tube bracket and screws.
    6.  
    7. Install the heater core fitting clips and dash panel seal.
    8.  
    9. Install the plenum chamber clip and reposition the plenum chamber.
    10.  
    11. Install the plenum chamber screws.
    12.  
    13. Install the heater core and evaporator core housing.
    14.  
    15. Install the plenum chamber nut.
    16.  
    17. Install the rear foot well duct from the heater core and evaporator core housing.
    18.  
    19. Install the four tunnel instrument panel bracket bolts and the tunnel instrument panel bracket
    20.  
    21. Install the air inlet duct bracket nut.
    22.  
    23. Reattach the three body harness electrical connectors to the bracket below the air inlet duct.
    24.  
    25. Install the four satellite radio antenna cable pin-type retainers to the heater core and evaporator core housing (if equipped).
    26.  
    27. Install the three heater core and evaporator core housing nuts.
    28.  
    29. Install the TXV manifold and tube assembly bracket to the heater core and evaporator core housing stud at the dash panel.
    30.  
    31. Install the thermostatic expansion valve (TXV) manifold and tube assembly to the line brackets.
    32.  
    33. Reconnect the evaporator outlet and inlet fittings.
    34.  
    35. Install the auxiliary evaporator outlet and inlet line fitting nuts and connect the fittings.
    36.  
    37. Reconnect the two heater hose quick disconnect fittings at the heater core.
      NOTE
      Two bullet connectors align the instrument panel to the bulkhead.

    38.  
    39. with the help of an assistant install the instrument panel.
    40.  
    41. Install the right and left panel bolts.
    42.  
    43. Install cowl bolts.
    44.  
    45. Install instrument panel defroster grill.
    46.  
    47. Reposition carpet install floor brace and bolts.
    48.  
    49. Reconnect the six electrical connectors.
    50.  
    51. Install lower glove compartment.
    52.  
    53. Reconnect antenna connector.
    54.  
    55. Install right ground bolt.
    56.  
    57. Install right finish panel and electrical connector.
    58.  
    59. If removed. Install satellite radio antenna.
    60.  
    61. Reconnect the wiring harness from the console bracket.
    62.  
    63. Reconnect the stability control sensor cluster electrical connector.
    64.  
    65. If removed, Reconnect the electronic automatic temperature control (EATC) hose from the evaporator case.
    66.  
    67. If removed, install the three pin-type retainers and the valance panel.
    68.  
    69. Install the steering intermediate shaft pinch bolt.
      WARNING
      Secure the steering wheel to prevent any rotation or damage to the clockspring.

    70.  
    71. Install the shift cable and retainer from the steering column.
    72.  
    73. Install the shift cable in the bracket.
    74.  
    75. Install the steering column shift cable into the shift lever.
    76.  
    77. Reconnect the steering wheel position sensor electrical connector.
    78.  
    79. Reconnect the electrical connector located above the data link.
    80.  
    81. Reconnect the cruise control deactivator and the brake on/off switch electrical connector.
    82.  
    83. Reconnect the park brake indicator connector.
    84.  
    85. Reconnect the left side electrical connectors.
    86.  
    87. Reconnect the left side instrument panel bulkhead connector and tighten bolt.
    88.  
    89. Install the bolts and the steering column reinforcement panel.
    90.  
    91. Install hood release and parking brake handles. Tighten mounting screws, if equipped install electrical connector.
    92.  
    93. Install instrument panel cover and screws.
    94.  
    95. Install left and right assist handles, tighten bolts and replace covers.
    96.  
    97. Reposition the left and right door weather-strip seals.
    98.  
    99. Install the cowl trim panel.
    100.  
    101. Install the scuff plate.
    102.  
    103. Install the left and right cowl trim panels.
    104.  
    105. Reconnect the instrument panel insulator lamp.
    106.  
    107. If removed, install the right instrument panel insulator.
    108.  
    109. Install the left and right front floor console front bolts and the floor console.
    110.  
    111. Install the left and right front floor console side finish panels, if equipped reconnect electrical connector.
    112.  
    113. Reconnect the bulkhead electrical connector and bolt.
    114.  
    115. Install the front floor console front screws.
    116.  
    117. Reposition the shifter lever indicator bezel and reconnect the shift cable.
    118.  
    119. Install the front floor console finish panel.
    120.  
    121. Install the shifter trim ring.
    122.  
    123. Reposition the front seats.
    124.  
    125. Install the two front floor console rear bolts.
    126.  
    127. Replace antifreeze and bleed cooling system.
    128.  
    129. Vacuum and recharge A/C system, check for leaks.
    130.  
    131. Power up (SRS) System.
    132.  
    133. Connect the negative battery cable.
    134.  

     
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