Continental 2000-2002

Removal & Installation

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  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 for at least 1 minute for the SRS or air bag module to deplete its energy.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the driver-s side air bag module by removing or disconnecting the following:
    CAUTION
    Place the SRS module in a safe place with the front facing upward.



    SRS module-to-steering wheel bolts, (located at both sides of the steering wheel)
     
    SRS module (carefully) and disconnect the electrical connector
     
    Horn switch electrical connector
     

  8.  
  9. Remove the passenger-s side SRS module by removing or disconnecting the following:
    CAUTION
    Place the SRS module in a safe place with the front facing upward



    Push inward on the 2 glove box door tabs and lower it
     
    SRS module-s electrical connector
     
    SRS module-to-instrument panel bolts and the module
     

  10.  
  11. Remove the instrument panel by removing or disconnecting the following:
    NOTE
    Check the upper cowl clips for damage; if necessary, replace them.



    Floor or mini console (if equipped)
     
    Rear seat climate control air duct sleeve (if equipped)
     
    Left side instrument panel insulator pushpins and the insulator; then, disconnect the courtesy lamp
     
    Instrument panel steering column cover screws and the cover
     
    Pull the hood release handle, remove the screws and move it aside
     
    Pull the parking brake handle, remove the bolts, the parking brake release handle and the cable
     
    Steering column opening cover reinforcement-to-instrument panel bolts and the cover reinforcement
     
    Release the cable and the conduit from the parking brake actuator
     
    Steering column
     
    Loosen the bolt and disconnect the left side outboard bulkhead electrical connector
     
    Loosen the bolt and disconnect the left side inboard bulkhead electrical connector
     
    Heated seat switch electrical connectors (if equipped)
     
    2 steering column mounting support-to-instrument cowl brace bolts
     
    Instrument panel dash brace-to-instrument panel bolt
     
    Instrument panel dash brace nut and move the brace aside
     
    Right side instrument panel insulator pushpins and the insulator; then, disconnect the courtesy lamp
     
    Vacuum harness connector
     
    In-line electrical harness connector
     
    Scuff plate and the cowl trim panel (located on the right side)
     
    Antenna connector
     
    Brake shift interlock actuator cable
     
    Pry out the instrument panel defroster opening grille assembly, disconnect the 2 electrical connectors and remove the assembly
     
    Upper instrument panel-to-cowl screws
     
    Instrument panel support-to-cowl side nut (located on the right side)
     
    Instrument panel support-to-cowl side bolts (located on the left side); then, loosen the instrument panel support-to-cowl side captive bolt
     
    Pull the instrument panel rearward; then, disconnect the Electronic Air Temperature Control (EATC) hose from the heater plenum and make sure all electrical connectors are disconnected
     
    Instrument panel with the help of an assistant
     

  12.  
  13. Loosen the screw and disconnect the PCM electrical connector.
  14.  
  15. Disconnect the heater hoses from the heater core.
  16.  
  17. Remove or disconnect the following:
    WARNING
    Do not bend any part of the air conditioning damper door shaft for it is brittle and will break.



    2 metal cover-to-heater/air conditioning housing screws and the metal cover (located below the heater core cover)
     
    Electrical harness connector (at the heater core cover); then, remove the air conditioning electronic blend door actuator-to-heater/air conditioning housing screws and the actuator
     
    Air conditioning air intake flue damper assist spring
     

  18.  
  19. Depress the air conditioning damper door shaft locking ramp, disconnect it from the air temperature control door shaft, swing the locking ramp counterclockwise and remove it from the air conditioning damper door shaft.
  20.  
  21. Move the air conditioning damper door shaft counterclockwise and remove it.
  22.  
  23. Remove or disconnect the following:

    Heater core cover-to-heater/air conditioning housing screws and the cover
     
    Heater core cover seal
     
    Heater core from the heater/air conditioning housing

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel and related components-Continental



    Click image to see an enlarged view

    Fig. Exploded view of the floor console and related components-Continental



    Click image to see an enlarged view

    Fig. View of the air temperature control door shaft and heater core cover-Continental



    Click image to see an enlarged view

    Fig. View of the heater core-Continental

     

  24.  

To install:

  1. Install or connect the following:
    WARNING
    Do not bend any part of the air conditioning damper door shaft for it is brittle and will break.



    Heater core to the heater/air conditioning housing
     
    Heater core cover seal
     
    Heater core cover and the cover-to-heater/air conditioning housing screws
     
    Air conditioning damper door shaft and move it clockwise and install it
     
    Air conditioning damper door shaft locking ramp, swing the locking ramp clockwise and connect it to the air temperature control door shaft
     
    Air conditioning air intake flue damper assist spring
     

  2.  
  3. At the heater core cover, install the air conditioning electronic blend door actuator and the actuator-to-heater/air conditioning housing screws; then, connect the electrical harness connector.
  4.  
  5. Install or connect the following:

    Metal cover and the 2 metal cover-to-heater/air conditioning housing screws (located below the heater core cover)
     
    Heater hoses to the heater core
     
    PCM electrical connector and tighten the screw
     

  6.  
  7. Install the instrument panel by installing or connecting the following:

    Instrument panel with the help of an assistant
     
    Pull the instrument panel rearward; then, connect the Electronic Air Temperature Control (EATC) hose to the heater plenum and make sure all electrical connectors are connected
     
    Instrument panel support-to-cowl side bolts and the instrument panel support-to-cowl side captive bolt (located on the left side)
     
    Instrument panel support-to-cowl side nut (located on the right side)
     
    Upper instrument panel-to-cowl screws
     
    2 electrical connectors and the instrument panel defroster opening grille assembly
     
    Brake shift interlock actuator cable
     
    Antenna connector
     
    Scuff plate and the cowl trim panel (located on the right side)
     
    In-line electrical harness connector
     
    Vacuum harness connector
     
    Right side instrument panel insulator and secure the insulator with the pushpins; then, connect the courtesy lamp
     
    Instrument panel dash brace and the brace nut
     
    Instrument panel dash brace-to-instrument panel bolt
     
    2 steering column mounting support-to-instrument cowl brace bolts
     
    Heated seat switch electrical connectors (if equipped)
     
    Left side inboard bulkhead electrical connector and tighten the bolt
     
    Left side outboard bulkhead electrical connector and tighten the bolt
     
    Steering column
     
    Cable and the conduit to the parking brake actuator
     
    Steering column opening cover reinforcement and the cover reinforcement-to-instrument panel bolts
     
    Parking brake handle, the bolts and the cable
     
    Hood release handle and the screws
     
    Instrument panel steering column cover and the cover screws
     
    Left side instrument panel insulator and secure the insulator with the pushpins; then, connect the courtesy lamp
     
    Rear seat climate control air duct sleeve, if equipped
     
    Floor or mini console, if equipped
     

  8.  
  9. Install the passenger-s side SRS module by installing or connecting the following:

    SRS module and torque the module-to-instrument panel bolts to 62-97 inch lbs. (7-11 Nm)
     
    SRS module-s electrical connector
     
    Glove box door
     

  10.  
  11. Install the driver-s side air bag module by installing or connecting the following:

    Horn switch electrical connector
     
    Electrical connector and install the SRS module
     
    SRS module-to-steering wheel bolts (located at both sides of the steering wheel), and torque the bolts to 90-122 inch lbs. (10-14 Nm)
     

  12.  
  13. Refill the cooling system.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  18.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is several years old

Continental 1995-00



  1. Disconnect the battery ground cable
  2.  
  3. Remove the console glove compartment. Disconnect the power point electrical connector. If equipped, disconnect the cellular phone antenna cable and coaxial cable from the console glove compartment. If equipped, disconnect the cellular phone antenna cable and coaxial cable.
  4.  
  5. If equipped, remove the compact disc changer. Remove the screws. Disconnect the electrical connector. Remove the digital audio compact disc player.
  6.  
  7. Place the gearshift lever in the 1 position.
  8.  
  9. Remove the console top panel. Disconnect the cigar lighter electrical connector.
  10.  
  11. Remove the floor console to floor bracket screws.
  12.  
  13. Remove the floor console to gearshift bracket screws.
  14.  
  15. Remove the floor console. Slide the floor console rearward. Remove the floor console. Disconnect the three electrical connectors.
  16.  


CAUTION
Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

  1. Remove the passenger side air bag module.
  2.  


WARNING
Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.


WARNING
Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.


WARNING
Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment.

  1. Disconnect the battery ground cable and wait at least one minute.
  2.  
  3. Push in on the two glove compartment door tabs and position downward.
  4.  
  5. Disconnect the passenger air bag module electrical connector. Remove the passenger air bag module retaining bolts.
  6.  
  7. Remove the passenger air bag module.
  8.  


NOTE
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.

  1. If equipped, remove the rear seat climate control air duct sleeve.
  2.  
  3. Remove the steering column.
  4.  


CAUTION
Do not remove the steering column, steering wheel and air bag module as an assembly from the vehicle. Unless the steering column is locked to prevent rotation; or the lower end of the steering shaft is wired to prevent the steering wheel from being rotated, damage to the air bag sliding contact will occur.


NOTE
All steering column components are assembled with specific fasteners. They are designed with a thread locking system to prevent loosening due to vibrations associated with normal vehicle operation. Make sure vehicle front wheels are in the straight-ahead position

  1. Remove the ignition switch lock
  2.  
  3. Remove the steering wheel.
  4.  
  5. Remove the air bag sliding contact.
  6.  
  7. Remove the tilt wheel handle and shank by unscrewing it from the steering column.
  8.  
  9. Remove the four upper and lower steering column shroud retaining screws. Remove the upper steering column shroud and lower steering column shroud.
  10.  
  11. Remove the lower instrument panel trim cover.
  12.  
  13. Unsnap the steering column lower trim panel.
  14.  
  15. Remove the release lever hood retaining screws.
  16.  
  17. Remove the brake release retaining screws.
  18.  
  19. Remove the instrument panel steering column opening cover reinforcement
  20.  
  21. Remove the instrument panel reinforcement brace.
  22.  
  23. Disconnect the shift cable and bracket from the steering column by removing two screws.
  24.  
  25. Disconnect the transmission shift cable loop from the shift tube hook (column shift).
  26.  
  27. Remove the two multi-function switch retaining screws and set the multi-function switch aside.
  28.  
  29. Remove the retaining screw and remove the wiring connector from the ignition switch.
  30.  
  31. Remove two front steering column nuts and the steering column impact absorber
  32.  
  33. Remove the pinch bolt from the steering column lower yoke.
  34.  
  35. While supporting the column assembly, remove two rear column assembly retaining nuts.
  36.  
  37. Disconnect the shift cable and bracket from the selector lever pivot. Disconnect the shift cable from the steering column shift tube lever. Disconnect the shift cable from the steering column bracket.
  38.  
  39. Remove the shift cable and bracket from the lower column mounting.
  40.  
  41. Remove two shift lock actuator-retaining screws and remove the shift lock actuator (console shift only).
  42.  
  43. Remove the steering column from the vehicle.
  44.  
  45. Release the cable from the parking brake actuator.
  46.  
  47. Release the cable conduit from the parking brake actuator.
  48.  
  49. To disconnect the driver's side outboard bulkhead electrical connector. Loosen the bolt. Disconnect the driver's side bulkhead electrical connector.
  50.  
  51. To disconnect the driver's side inboard bulkhead electrical connector. Loosen the bolt. Disconnect the driver's side bulkhead electrical connector.
  52.  
  53. If equipped, disconnect the heated seat switch electrical connectors.
  54.  
  55. Remove the steering column mounting support to instrument cowl brace bolts.
  56.  
  57. Remove the instrument panel dash brace to instrument panel bolt.
  58.  
  59. Loosen the nut that secures the instrument panel dash brace. Position the instrument panel dash brace aside.
  60.  
  61. Remove the pin-type retainers. Remove the passenger side instrument panel insulator. Remove the courtesy lamp.
  62.  
  63. Disconnect the vacuum harness connector.
  64.  
  65. Disconnect the in-line electrical harness connector.
  66.  
  67. Position the passenger side scuff plate aside.
  68.  
  69. Remove the passenger side cowl trim panel.
  70.  
  71. Disconnect the antenna in-line connector.
  72.  
  73. Remove the ignition/shifter interlock cable from the bracket and the shifter interlock cam.
  74.  
  75. Remove the instrument panel defroster opening grille assembly.
  76.  
  77. Lift upward to release the instrument panel defroster opening grille assembly from the instrument panel.
  78.  
  79. Disconnect the two electrical connectors (one each side).
  80.  
  81. Remove the instrument panel defroster opening grille assembly.
  82.  
  83. Remove the instrument panel cowl top screws.
  84.  
  85. Remove the passenger side instrument panel support to cowl side nut.
  86.  
  87. Remove the driver's side instrument panel support to cowl side bolts.
  88.  
  89. Loosen the driver's side instrument panel support to cowl side captive bolt.
  90.  
  91. Position the instrument panel away from the cowl.
  92.  
  93. Disconnect the electronic air temperature control (EATC) hose from the heater plenum.
  94.  


NOTE
Two technicians are required to carry out this step.

  1. Remove the instrument panel.
  2.  


NOTE
Check the cowl top clips for damage, looseness, or stripped fasteners.

  1. Drain the coolant from the radiator so that the coolant level is below the heater core
  2.  
  3. Loosen the screw and disconnect the electrical connector from the powertrain control module (PCM).
  4.  
  5. Disconnect the heater water hoses from the heater core.
  6.  
  7. Remove the screws and the metal cover.
  8.  
  9. Remove the A/C electronic blend door actuator.
  10.  
  11. Disconnect the wire harness connector.
  12.  
  13. Remove the screws and remove the A/C electronic blend door actuator.
  14.  
  15. Remove the A/C air intake flue damper assist spring.
  16.  


CAUTION
Do not attempt to bend any part of the A/C damper door shaft. It is brittle and will break.

  1. Depress the locking ramp and remove the A/C damper door shaft from the air temperature control door shaft.
  2.  


CAUTION
Do not attempt to bend any part of the lever. It is brittle and will break.

  1. Remove the A/C evaporator case outlet door shaft.
  2.  
  3. Remove the screws and the heater core cover.
  4.  
  5. Remove the heater core cover seal.
  6.  
  7. Remove the heater core.
  8.  
  9. Installation is the reversal of the removal process.
  10.  
  11. To exchange a loose or damaged cowl top clip with a new clip, remove the metal insert and then carefully release the clip from the cowl. Do not pry on the clip or damage to the cowl sheet metal may occur.
  12.  


NOTE
To install a new fastener, remove the metal insert from the cowl top clip and exchange it with the new fastener. If any portion of the cowl top clip falls into the cowl, use Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to prevent the broken portion from rattling within the cowl.


NOTE
Two technicians are required to carry out this step.

  1. Position the instrument panel. Connect the EATC hose to the heater plenum.
  2.  
  3. Install the instrument panel cowl top screws.
  4.  
  5. Install the instrument panel defroster opening grille assembly.
  6.  
  7. Connect the electrical connectors (one each side).
  8.  
  9. Install the instrument panel defroster opening grille assembly.
  10.  
  11. Install the driver's side instrument panel support to cowl side bolts.
  12.  
  13. Tighten the driver's side instrument panel support to cowl side captive bolt.
  14.  
  15. Install the passenger side instrument panel support to cowl side nut.
  16.  
  17. Install the ignition/shifter interlock cable into the bracket and the shifter interlock cam.
  18.  
  19. Connect the antenna in-line connector.
  20.  
  21. Install the passenger side cowl trim panel.
  22.  
  23. Install the passenger side scuff plate.
  24.  
  25. Connect the in-line electrical harness connector.
  26.  
  27. Connect the vacuum harness connector.
  28.  
  29. Position the passenger side instrument panel insulator. Install the pin-type retainers. Install the courtesy lamp.
  30.  
  31. Position the instrument panel dash brace.
  32.  
  33. Install the instrument panel dash brace to instrument panel bolt.
  34.  
  35. Install the steering column mounting support to instrument panel cowl brace bolts.
  36.  
  37. Tighten the instrument panel dash brace nut.
  38.  
  39. Installation from this point is the reversal of the removal process.
  40.  

 
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