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    2007 Pontiac Grand Prix 3.8L SFI OHV 6cyl

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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Removal & Installation 6

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    Ford Expedition And Excursion; Lincoln Navigator



    Removal & Installation
    Expedition And Navigator
    1. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait 1 minute for the SRS module to deplete its energy.

    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Remove the instrument panel by performing the following procedure:

      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

      Fig. Remove the passenger side ground bolt-Ford Expedition and Lincoln Navigator



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

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



      Click image to see an enlarged view

      Fig. Remove the cowl panel mounting bolts-Ford Expedition and Lincoln Navigator



      Click image to see an enlarged view

      Fig. Remove the instrument panel -Ford Expedition and 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 autolamp 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.  

    6.  

    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 weatherstrip 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. On Expedition, remove the upper instrument panel cowl covers and bolts.
    10.  
    11. On Navigator, remove the instrument panel defroster grille assembly and the instrument panel cowl top bolts.
    12.  
    13. At the relay bracket, remove the instrument panel bolt.
    14.  
    15. At the lower left side of the cigar lighter, remove the instrument panel bolt.
    16.  
    17. At the both sides, remove the instrument panel-to-cowl side nuts.
    18.  
    19. At the steering column opening, remove the instrument panel bolts.
    20.  
    21. Remove the upper instrument panel floor brace bolt.
    22.  
    23. Using an assistant, remove the instrument panel.
    24.  

    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-Ford Expedition and 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. On Navigator, install the instrument panel cowl top bolts and the instrument panel defroster grille assembly.
      14.  
      15. On Expedition, install the upper instrument panel cowl bolts and covers.
      16.  
      17. Through the air bag module opening, install the instrument panel bolts.
      18.  
      19. Install the instrument panel reinforcement bolt below the left side corner of the glove box.
      20.  
      21. At both doors, install the windshield garnish moldings and the weatherstrip seals.
      22.  
      23. Install the right side assist handle, the screws and the handle screw covers.
      24.  
      25. At the passenger-s air bag module, install the air bag module, connect the electrical connector and install the air bag module screws.
      26.  
      27. Install the glove box.
      28.  
      29. Connect the autolamp sensor electrical connector and/or the sunload sensor connector; then, install the instrument panel relay cover.
      30.  
      31. Connect the antenna cable to the antenna base.
      32.  
      33. Install the right side front fender splash shield and screws.
      34.  
      35. Install the steering column and the steering column-to-instrument panel nuts.
      36.  
      37. If equipped with a transmission range indicator, connect the cable and install the bolt.
      38.  
      39. At the steering column, connect the remaining electrical connectors.
      40.  
      41. At the base of the steering column, connect the air bag sliding contact and the anti-theft sensor electrical connectors.
      42.  
      43. Install the steering column opening cover reinforcement and the cover reinforcement nuts.
      44.  
      45. Connect the climate control head vacuum harness connector.
      46.  
      47. Connect the electronic blend door actuator electrical connector.
      48.  
      49. Connect the right side instrument panel wiring harness connectors.
      50.  
      51. Install the right side ground bolts.
      52.  
      53. Connect the inertia fuel shutoff switch electrical connector.
      54.  
      55. Connect the air bag diagnostic monitor electrical connector.
      56.  
      57. In the driver-s compartment, install the bulkhead electrical connector to the instrument panel.
      58.  
      59. In the engine compartment, connect the bulkhead wiring harness connectors and the install wiring connector bolts.
      60.  
      61. Connect the left side instrument panel main wiring harness connector.
      62.  
      63. Install the radio ground and the GEM/CTM ground bolts.
      64.  
      65. Connect the electrical connector to the Brake Pedal Position (BPP) switch.
      66.  
      67. Install both side cowl trim panels.
      68.  
      69. Install both front door scuff plates.
      70.  
      71. Install the lower steering column cover and the cover bolts.
      72.  
      73. If equipped, install the floor console assembly.
      74.  

    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.  

    Ford Explorer And Mercury Mountaineer



    Removal & Installation
    1998-00
    1. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Disconnect the heater hoses from the heater core.
    6.  
    7. Remove the steering column by performing the following procedure:
      1. Position the front wheels in the straight-ahead direction.
      2.  
      3. At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.
        CAUTION
        Safely store the air bag module with the front side facing upward.

      4.  
      5. Remove the steering wheel-to-steering column nut.
      6.  
      7. Using a steering wheel puller, press the steering wheel from the steering column.
      8.  
      9. Remove the parking brake release handle screws and move the release handle aside.
      10.  
      11. Remove the hood release screws and move the hood release aside.
      12.  
      13. Remove the 2 instrument panel-to-steering column cover screws and the cover.
      14.  
      15. Remove the instrument panel steering column opening reinforcement bolts and the reinforcement.
      16.  
      17. Remove the ignition switch bolt and disconnect the ignition switch electrical connector.
      18.  
      19. At the base of the steering column, disconnect the electrical connectors.
      20.  
      21. If equipped with an automatic transmission, remove the transmission range indicator bolt and the cable.
      22.  
      23. If equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket.
      24.  
      25. Disconnect the brake shift interlock solenoid electrical connector.
      26.  
      27. Remove the air bag sliding contact.
      28.  
      29. Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt.
      30.  
      31. Remove the lower steering column-to-instrument panel nuts and the steering column.
      32.  

    8.  
    9. Remove the instrument panel by performing the following procedure:
      1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
      2.  
      3. Remove the push pins and remove both cowl side trim panels.
      4.  
      5. At the right side cowl panel, disconnect the electrical connectors and ground wires.
      6.  
      7. Remove both sides windshield garnish moldings.
      8.  
      9. Disconnect the power distribution box from its bracket and move it aside.
      10.  
      11. In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors.
      12.  
      13. Pull the bulkhead electrical connector handle and disconnect the wiring harness.
      14.  
      15. Remove the passenger-s side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.
      16.  

    10.  

    Store the air bag module in a safe location with the front facing upward.

    1. Disconnect the blend door actuator-s electrical connector.
    2.  
    3. Disconnect the climate control vacuum harness connector.
    4.  
    5. Disconnect the radio-s antenna connector.
    6.  
    7. Remove the glove compartment.
    8.  
    9. Remove the instrument panel defroster grille.
    10.  
    11. Remove the upper instrument panel bolts.
    12.  
    13. If equipped, remove the upper series floor console.
    14.  
    15. Under the steering column, remove the instrument panel brace bolt.
    16.  
    17. At both sides, remove the windshield side garnish moldings.
    18.  
    19. Remove both the right and left instrument panel-to-cowl bolts.
    20.  
    21. Remove the fuse panel door.
    22.  
    23. Pull the instrument panel away from the dash.
    24.  
    25. Loosen the instrument panel-to-body harness bolt and disconnect the harness.
    26.  
    27. Using an assistant, remove the instrument panel.
    28.  

    1. At the PCM, disconnect the electrical connector; then, remove the 2 PCM cover nuts, the cover and the PCM.
      NOTE
      The PCM is located at the right side of the instrument panel.

    2.  
    3. Remove the evaporator core by perform the following procedure:
      1. Discharge and recover the air conditioning system refrigerant.
      2.  
      3. Remove the refrigerant lines from the evaporator core. Discard the O-rings.
      4.  
      5. Disconnect the air conditioning cycling switch.
      6.  
      7. Disconnect the blower motor electrical connectors.
      8.  
      9. Disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo.
      10.  
      11. Remove the windshield washer reservoir/coolant recovery reservoir, and move it aside.
      12.  
      13. Disconnect the air conditioning manifold and tube from the accumulator/drier.
      14.  
      15. Disconnect the condenser-to-evaporator tube.
      16.  
      17. Inside the vehicle, disconnect the air conditioning system vacuum harness and the evaporator housing mounting nut.
      18.  
      19. In the passenger-s compartment, remove the evaporator housing-to-chassis nut.
      20.  
      21. In the engine compartment, remove the 3 evaporator housing-to-chassis nuts.
      22.  
      23. Remove the air conditioning accumulator from the evaporator core.
      24.  
      25. If equipped with a 5.0L engine, remove the evaporator housing heat shield screw, clips and the shield.
      26.  
      27. Remove the evaporator housing cover screws and the cover.
      28.  
      29. Remove the evaporator core from the housing.
      30.  

    4.  
    5. Remove the PCM ground strap screw and the heat sink.
    6.  
    7. In the engine compartment, remove the heater housing air plenum nuts.
    8.  
    9. Remove the heater core-to-air plenum cover screws and the cover.
    10.  
    11. Remove the heater core.

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel assembly-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the upper series floor console-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the evaporator housing-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the evaporator core-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the heater core-Ford Explorer and Mercury Mountaineer

    12.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the heater core-to-air plenum cover and the cover screws.
    4.  
    5. In the engine compartment, install the heater housing air plenum nuts.
    6.  
    7. Install the PCM ground strap screw and the heat sink.
    8.  
    9. Install the evaporator core by perform the following procedure:
      1. Install the evaporator core to the housing.
      2.  
      3. Install the evaporator housing cover and the cover screws.
      4.  
      5. If equipped with a 5.0L engine, install the evaporator housing heat shield, clips and the shield screw.
      6.  
      7. Install the air conditioning accumulator to the evaporator core.
      8.  
      9. In the engine compartment, install the 3 evaporator housing-to-chassis nuts.
      10.  
      11. In the passenger-s compartment, install the evaporator housing-to-chassis nut.
      12.  
      13. Inside the vehicle, connect the air conditioning system vacuum harness and the evaporator housing mounting nut.
      14.  
      15. Connect the condenser-to-evaporator tube.
      16.  
      17. Connect the air conditioning manifold and tube to the accumulator/drier.
      18.  
      19. Install the windshield washer reservoir/coolant recovery reservoir.
      20.  
      21. Install the speed control servo, the bolt and connect the speed control servo connector.
      22.  
      23. Connect the blower motor electrical connectors.
      24.  
      25. Connect the air conditioning cycling switch.
      26.  
      27. Using new O-rings, install the refrigerant lines to the evaporator core.
      28.  

    10.  
    11. Install the PCM, the cover and the PCM cover nuts; then, disconnect the electrical connector.
    12.  
    13. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Connect the harness and tighten the instrument panel-to-body harness bolt.
      4.  
      5. Push the instrument panel away toward the dash.
      6.  
      7. Install the fuse panel door.
      8.  
      9. Install both the right and left instrument panel-to-cowl bolts.
      10.  
      11. At both sides, install the windshield side garnish moldings.
      12.  
      13. Under the steering column, install the instrument panel brace bolt.
      14.  
      15. If equipped, install the upper series floor console.
      16.  
      17. Install the upper instrument panel bolts.
      18.  
      19. Install the instrument panel defroster grille.
      20.  
      21. Install the glove compartment.
      22.  
      23. Connect the radio-s antenna connector.
      24.  
      25. Connect the climate control vacuum harness connector.
      26.  
      27. Connect the blend door actuator-s electrical connector.
      28.  
      29. Install the passenger-s side air bag module, connect the electrical connector and install the air bag module-to-instrument panel screws.
      30.  
      31. Connect the bulkhead electrical connector wiring harness.
      32.  
      33. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts.
      34.  
      35. Connect the power distribution box to its bracket.
      36.  
      37. Install both sides windshield garnish moldings.
      38.  
      39. At the right side cowl panel, connect the electrical connectors and ground wires.
      40.  
      41. Install both cowl side trim panels and the push pins.
      42.  
      43. Connect the Brake Pedal Position (BPP) switch electrical connector.
      44.  

    14.  
    15. Install the steering column by performing the following procedure:
      1. Install the lower steering column and the steering column-to-instrument panel nuts; then, torque the nuts to 10-13 ft. lbs. (13-17 Nm).
      2.  
      3. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt and torque to 19-25 ft. lbs. (26-34 Nm).
      4.  
      5. Install the air bag sliding contact.
      6.  
      7. Connect the brake shift interlock solenoid electrical connector.
      8.  
      9. If equipped with an automatic transmission, connect the shift cable from the steering column shift tube lever and the steering column bracket.
      10.  
      11. If equipped with an automatic transmission, install the transmission range indicator cable and bolt.
      12.  
      13. At the base of the steering column, connect the electrical connectors.
      14.  
      15. Connect the ignition switch electrical connector and install the ignition switch bolt.
      16.  
      17. Install the instrument panel steering column opening reinforcement and the reinforcement bolts.
      18.  
      19. Install the instrument panel-to-steering column cover and the 2 cover screws.
      20.  
      21. Install the hood release and the hood release screws.
      22.  
      23. Install the parking brake release handle and the release handle screws.
      24.  
      25. Install the steering wheel to the steering column.
      26.  
      27. Install the steering wheel-to-steering column nut and torque the nut to 25-34 ft. lbs. (34-46 Nm).
      28.  
      29. At the both sides of the steering wheel, install the air bag module, connect the air bag electrical connector, install the steering wheel-to-air bag module screws and the cover plugs.
      30.  

    16.  
    17. Connect the heater hoses to the heater core.
    18.  
    19. Refill the cooling system.
    20.  
    21. Connect the negative battery cable.
    22.  
    23. Evacuate and charge the air conditioning system.
    24.  
    25. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    26.  

    1. Disconnect the negative battery cable.
      CAUTION
      After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

    2.  
    3. Drain the cooling system into a clean container for reuse.
    4.  
    5. Disconnect the heater hoses from the heater core.
    6.  
    7. Remove the steering column by performing the following procedure:
      1. Position the front wheels in the straight-ahead direction.
      2.  
      3. At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.
        CAUTION
        Safely store the air bag module with the front side facing upward.

      4.  
      5. Remove the steering wheel-to-steering column nut.
      6.  
      7. Using a steering wheel puller, press the steering wheel from the steering column.
      8.  
      9. Remove the parking brake release handle screws and move the release handle aside.
      10.  
      11. Remove the hood release screws and move the hood release aside.
      12.  
      13. Remove the 2 instrument panel-to-steering column cover screws and the cover.
      14.  
      15. Remove the instrument panel steering column opening reinforcement bolts and the reinforcement.
      16.  
      17. Remove the ignition switch bolt and disconnect the ignition switch electrical connector.
      18.  
      19. At the base of the steering column, disconnect the electrical connectors.
      20.  
      21. If equipped with an automatic transmission, remove the transmission range indicator bolt and the cable.
      22.  
      23. If equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket.
      24.  
      25. Disconnect the brake shift interlock solenoid electrical connector.
      26.  
      27. Remove the air bag sliding contact.
      28.  
      29. Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt.
      30.  
      31. Remove the lower steering column-to-instrument panel nuts and the steering column.
      32.  

    8.  
    9. Remove the instrument panel by performing the following procedure:
      1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
      2.  
      3. Remove the push pins and remove both cowl side trim panels.
      4.  
      5. At the right side cowl panel, disconnect the electrical connectors and ground wires.
      6.  
      7. Remove both sides windshield garnish moldings.
      8.  
      9. Disconnect the power distribution box from its bracket and move it aside.
      10.  
      11. In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors.
      12.  
      13. Pull the bulkhead electrical connector handle and disconnect the wiring harness.
      14.  
      15. Remove the passenger-s side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.
      16.  

    10.  

    Store the air bag module in a safe location with the front facing upward.

    1. Disconnect the blend door actuator-s electrical connector.
    2.  
    3. Disconnect the climate control vacuum harness connector.
    4.  
    5. Disconnect the radio-s antenna connector.
    6.  
    7. Remove the glove compartment.
    8.  
    9. Remove the instrument panel defroster grille.
    10.  
    11. Remove the upper instrument panel bolts.
    12.  
    13. If equipped, remove the upper series floor console.
    14.  
    15. Under the steering column, remove the instrument panel brace bolt.
    16.  
    17. At both sides, remove the windshield side garnish moldings.
    18.  
    19. Remove both the right and left instrument panel-to-cowl bolts.
    20.  
    21. Remove the fuse panel door.
    22.  
    23. Pull the instrument panel away from the dash.
    24.  
    25. Loosen the instrument panel-to-body harness bolt and disconnect the harness.
    26.  
    27. Using an assistant, remove the instrument panel.
    28.  

    1. At the PCM, disconnect the electrical connector; then, remove the 2 PCM cover nuts, the cover and the PCM.
      NOTE
      The PCM is located at the right side of the instrument panel.

    2.  
    3. Remove the evaporator core by perform the following procedure:
      1. Discharge and recover the air conditioning system refrigerant.
      2.  
      3. Remove the refrigerant lines from the evaporator core. Discard the O-rings.
      4.  
      5. Disconnect the air conditioning cycling switch.
      6.  
      7. Disconnect the blower motor electrical connectors.
      8.  
      9. Disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo.
      10.  
      11. Remove the windshield washer reservoir/coolant recovery reservoir, and move it aside.
      12.  
      13. Disconnect the air conditioning manifold and tube from the accumulator/drier.
      14.  
      15. Disconnect the condenser-to-evaporator tube.
      16.  
      17. Inside the vehicle, disconnect the air conditioning system vacuum harness and the evaporator housing mounting nut.
      18.  
      19. In the passenger-s compartment, remove the evaporator housing-to-chassis nut.
      20.  
      21. In the engine compartment, remove the 3 evaporator housing-to-chassis nuts.
      22.  
      23. Remove the air conditioning accumulator from the evaporator core.
      24.  
      25. If equipped with a 5.0L engine, remove the evaporator housing heat shield screw, clips and the shield.
      26.  
      27. Remove the evaporator housing cover screws and the cover.
      28.  
      29. Remove the evaporator core from the housing.
      30.  

    4.  
    5. Remove the PCM ground strap screw and the heat sink.
    6.  
    7. In the engine compartment, remove the heater housing air plenum nuts.
    8.  
    9. Remove the heater core-to-air plenum cover screws and the cover.
    10.  
    11. Remove the heater core.

      Click image to see an enlarged view

      Fig. Exploded view of the instrument panel assembly-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the upper series floor console-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the evaporator housing-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the evaporator core-Ford Explorer and Mercury Mountaineer



      Click image to see an enlarged view

      Fig. View of the heater core-Ford Explorer and Mercury Mountaineer

    12.  

    To install:

    1. Install the heater core.
    2.  
    3. Install the heater core-to-air plenum cover and the cover screws.
    4.  
    5. In the engine compartment, install the heater housing air plenum nuts.
    6.  
    7. Install the PCM ground strap screw and the heat sink.
    8.  
    9. Install the evaporator core by perform the following procedure:
      1. Install the evaporator core to the housing.
      2.  
      3. Install the evaporator housing cover and the cover screws.
      4.  
      5. If equipped with a 5.0L engine, install the evaporator housing heat shield, clips and the shield screw.
      6.  
      7. Install the air conditioning accumulator to the evaporator core.
      8.  
      9. In the engine compartment, install the 3 evaporator housing-to-chassis nuts.
      10.  
      11. In the passenger-s compartment, install the evaporator housing-to-chassis nut.
      12.  
      13. Inside the vehicle, connect the air conditioning system vacuum harness and the evaporator housing mounting nut.
      14.  
      15. Connect the condenser-to-evaporator tube.
      16.  
      17. Connect the air conditioning manifold and tube to the accumulator/drier.
      18.  
      19. Install the windshield washer reservoir/coolant recovery reservoir.
      20.  
      21. Install the speed control servo, the bolt and connect the speed control servo connector.
      22.  
      23. Connect the blower motor electrical connectors.
      24.  
      25. Connect the air conditioning cycling switch.
      26.  
      27. Using new O-rings, install the refrigerant lines to the evaporator core.
      28.  

    10.  
    11. Install the PCM, the cover and the PCM cover nuts; then, disconnect the electrical connector.
    12.  
    13. Install the instrument panel by performing the following procedure:
      1. Using an assistant, install the instrument panel.
      2.  
      3. Connect the harness and tighten the instrument panel-to-body harness bolt.
      4.  
      5. Push the instrument panel away toward the dash.
      6.  
      7. Install the fuse panel door.
      8.  
      9. Install both the right and left instrument panel-to-cowl bolts.
      10.  
      11. At both sides, install the windshield side garnish moldings.
      12.  
      13. Under the steering column, install the instrument panel brace bolt.
      14.  
      15. If equipped, install the upper series floor console.
      16.  
      17. Install the upper instrument panel bolts.
      18.  
      19. Install the instrument panel defroster grille.
      20.  
      21. Install the glove compartment.
      22.  
      23. Connect the radio-s antenna connector.
      24.  
      25. Connect the climate control vacuum harness connector.
      26.  
      27. Connect the blend door actuator-s electrical connector.
      28.  
      29. Install the passenger-s side air bag module, connect the electrical connector and install the air bag module-to-instrument panel screws.
      30.  
      31. Connect the bulkhead electrical connector wiring harness.
      32.  
      33. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts.
      34.  
      35. Connect the power distribution box to its bracket.
      36.  
      37. Install both sides windshield garnish moldings.
      38.  
      39. At the right side cowl panel, connect the electrical connectors and ground wires.
      40.  
      41. Install both cowl side trim panels and the push pins.
      42.  
      43. Connect the Brake Pedal Position (BPP) switch electrical connector.
      44.  

    14.  
    15. Install the steering column by performing the following procedure:
      1. Install the lower steering column and the steering column-to-instrument panel nuts; then, torque the nuts to 10-13 ft. lbs. (13-17 Nm).
      2.  
      3. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt and torque to 19-25 ft. lbs. (26-34 Nm).
      4.  
      5. Install the air bag sliding contact.
      6.  
      7. Connect the brake shift interlock solenoid electrical connector.
      8.  
      9. If equipped with an automatic transmission, connect the shift cable from the steering column shift tube lever and the steering column bracket.
      10.  
      11. If equipped with an automatic transmission, install the transmission range indicator cable and bolt.
      12.  
      13. At the base of the steering column, connect the electrical connectors.
      14.  
      15. Connect the ignition switch electrical connector and install the ignition switch bolt.
      16.  
      17. Install the instrument panel steering column opening reinforcement and the reinforcement bolts.
      18.  
      19. Install the instrument panel-to-steering column cover and the 2 cover screws.
      20.  
      21. Install the hood release and the hood release screws.
      22.  
      23. Install the parking brake release handle and the release handle screws.
      24.  
      25. Install the steering wheel to the steering column.
      26.  
      27. Install the steering wheel-to-steering column nut and torque the nut to 25-34 ft. lbs. (34-46 Nm).
      28.  
      29. At the both sides of the steering wheel, install the air bag module, connect the air bag electrical connector, install the steering wheel-to-air bag module screws and the cover plugs.
      30.  

    16.  
    17. Connect the heater hoses to the heater core.
    18.  
    19. Refill the cooling system.
    20.  
    21. Connect the negative battery cable.
    22.  
    23. Evacuate and charge the air conditioning system.
    24.  
    25. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    26.  

    2001
    1. Drain the radiator.
    2.  
    3. Remove the heater water hoses.
      WARNING
      Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

    4.  
    5. Remove the steering column.
    6.  
    7. Disconnect the brake pedal position (BPP) switch electrical connector.
    8.  
    9. If equipped, disconnect the clutch pedal position (CPP) switch electrical connector.
    10.  
    11. Remove the LH and RH cowl side trim panels.
    12.  
    13. Disconnect the electrical connectors and the ground wires on the RH cowl panel.
    14.  
    15. Disconnect the power distribution box from the bracket and position aside.
    16.  
    17. Disconnect the bulkhead wiring harness connectors from inside the engine compartment.
    18.  
    19. Remove the bulkhead connector insulator.
    20.  
    21. Unclip the bulkhead electrical connectors from the dash panel.
    22.  
    23. Remove the passenger side air bag module.
    24.  
    25. Disconnect the blend door actuator electrical connector.
    26.  
    27. Disconnect the climate control vacuum harness connector.
    28.  
    29. Disconnect the radio antenna cable in-line connector.
    30.  
    31. Raise the glove compartment.
    32.  
    33. Remove the instrument panel defroster opening grille.
    34.  
    35. Remove the instrument panel cowl top bolts.
    36.  
    37. If equipped, remove the upper series floor console.
    38.  
    39. Remove the instrument panel brace bolt from under the steering column opening.
    40.  
    41. Remove the windshield side garnish mouldings.
    42.  
    43. Remove the RH instrument panel cowl side bolt.
    44.  
    45. Remove the instrument panel fuse panel door.
    46.  
    47. Remove the LH instrument panel cowl side bolts.
    48.  
    49. Position the instrument panel away from the dash panel.
    50.  
    51. Disconnect the instrument panel to body harness.
      NOTE
      Two technicians are required to carry out this step.

    52.  
    53. Remove the instrument panel.
    54.  
    55. Recover the refrigerant. For additional information, refer to «Section 412-00».
    56.  
    57. Disconnect the A/C cycling switch.
    58.  
    59. Disconnect the blower electrical connectors.
    60.  
    61. Position the speed control servo aside.
    62.  
    63. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside.
    64.  
    65. Disconnect the A/C manifold and tube from the suction accumulator/drier.
    66.  
    67. Disconnect the condenser to evaporator tube.
    68.  
    69. Disconnect the A/C system vacuum harness and the A/C evaporator housing mounting nut inside the vehicle.
    70.  
    71. Remove the A/C evaporator housing.
    72.  
    73. Remove the powertrain control module (PCM).
    74.  
    75. Remove the PCM heat sink.
    76.  
    77. Remove the heater air plenum nuts from the engine side of the dash panel.
    78.  
    79. Remove the heater core cover to air plenum screws.
    80.  
    81. Lift off the cover.
    82.  
    83. Remove the heater core.
    84.  
    85. To install, reverse the removal procedure. Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.
    86.  

    1. Drain the radiator.
    2.  
    3. Remove the heater water hoses.
      WARNING
      Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

    4.  
    5. Remove the steering column.
    6.  
    7. Disconnect the brake pedal position (BPP) switch electrical connector.
    8.  
    9. If equipped, disconnect the clutch pedal position (CPP) switch electrical connector.
    10.  
    11. Remove the LH and RH cowl side trim panels.
    12.  
    13. Disconnect the electrical connectors and the ground wires on the RH cowl panel.
    14.  
    15. Disconnect the power distribution box from the bracket and position aside.
    16.  
    17. Disconnect the bulkhead wiring harness connectors from inside the engine compartment.
    18.  
    19. Remove the bulkhead connector insulator.
    20.  
    21. Unclip the bulkhead electrical connectors from the dash panel.
    22.  
    23. Remove the passenger side air bag module.
    24.  
    25. Disconnect the blend door actuator electrical connector.
    26.  
    27. Disconnect the climate control vacuum harness connector.
    28.  
    29. Disconnect the radio antenna cable in-line connector.
    30.  
    31. Raise the glove compartment.
    32.  
    33. Remove the instrument panel defroster opening grille.
    34.  
    35. Remove the instrument panel cowl top bolts.
    36.  
    37. If equipped, remove the upper series floor console.
    38.  
    39. Remove the instrument panel brace bolt from under the steering column opening.
    40.  
    41. Remove the windshield side garnish mouldings.
    42.  
    43. Remove the RH instrument panel cowl side bolt.
    44.  
    45. Remove the instrument panel fuse panel door.
    46.  
    47. Remove the LH instrument panel cowl side bolts.
    48.  
    49. Position the instrument panel away from the dash panel.
    50.  
    51. Disconnect the instrument panel to body harness.
      NOTE
      Two technicians are required to carry out this step.

    52.  
    53. Remove the instrument panel.
    54.  
    55. Recover the refrigerant. For additional information, refer to «Section 412-00».
    56.  
    57. Disconnect the A/C cycling switch.
    58.  
    59. Disconnect the blower electrical connectors.
    60.  
    61. Position the speed control servo aside.
    62.  
    63. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside.
    64.  
    65. Disconnect the A/C manifold and tube from the suction accumulator/drier.
    66.  
    67. Disconnect the condenser to evaporator tube.
    68.  
    69. Disconnect the A/C system vacuum harness and the A/C evaporator housing mounting nut inside the vehicle.
    70.  
    71. Remove the A/C evaporator housing.
    72.  
    73. Remove the powertrain control module (PCM).
    74.  
    75. Remove the PCM heat sink.
    76.  
    77. Remove the heater air plenum nuts from the engine side of the dash panel.
    78.  
    79. Remove the heater core cover to air plenum screws.
    80.  
    81. Lift off the cover.
    82.  
    83. Remove the heater core.
    84.  
    85. To install, reverse the removal procedure. Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.
    86.  

    2002
    1. Deactivate the supplemental restraints system (SRS).
    2.  
    3. Release the two floor console front clips (one each side).
    4.  
    5. On vehicles with manual transmission, remove the gearshift lever handle.
    6.  
    7. Remove the console finish panel mat.
    8.  
    9. On vehicles with automatic transmission:
      1. If equipped, remove the ashtray assembly.
      2.  
      3. Disconnect the electrical connector.
      4.  
      5. Remove the console finish panel screw.
      6.  

    10.  
    11. Remove the console finish panel by lifting up at the rear and sliding it rearward. Disconnect the electrical connector(s).
    12.  
    13. Remove the floor console front screws.
    14.  
    15. If equipped, disconnect the electrical connector and release the wiring harness locators.
    16.  
    17. Remove the floor console center bolts.
    18.  
    19. Remove the two floor console access covers (one each side).
    20.  
    21. Remove the two floor console rear bolts (one each side).
    22.  
    23. Remove the floor console by lifting up at the rear of the console and sliding it rearward.
    24.  
    25. Remove the screws and remove the snow shield.
    26.  
    27. Crimp off the coolant hoses and disconnect from the heater core.
    28.  
    29. Remove the instrument panel center support brackets.
    30.  
    31. Remove the assist handle bolt covers.
    32.  
    33. Remove the bolts and the passenger assist handle.
    34.  
    35. Remove the windshield side garnish moldings.
    36.  
    37. Remove the defroster opening grill.
    38.  
    39. Remove the upper instrument panel support bolts.
    40.  
    41. Remove the exterior cowl grill.
    42.  
    43. Remove the instrument panel support bolt.
    44.  
    45. Remove the two instrument panel side finish panels.
    46.  
    47. Lower the glove compartment.
    48.  
    49. Loosen the LH instrument panel side support bolts until half the threads are exposed.
      WARNING
      Be sure the instrument panel is properly supported to avoid possible damage to the instrument panel wiring or components. To avoid damage to the instrument panel wiring or components, do not use excessive force when moving the instrument panel away from the dash panel. The instrument panel may be supported by installing threaded rods or equivalent, with the same diameter and thread pitch, in place of the instrument panel support bolts.

    50.  
    51. Properly support the instrument panel and remove the RH instrument panel support bolts to allow the instrument panel to be pulled away from the dash panel.
    52.  
    53. Remove the center console floor duct.
    54.  
    55. Remove the screws and remove the RH floor duct.
    56.  
    57. Remove the screws and remove the LH floor duct.
    58.  
    59. Disconnect the electrical connectors and detach the pin-type retainers.
    60.  
    61. Remove the screws and remove the heater core tube cover.
    62.  
    63. Remove the RH heater core cover screws.
    64.  
    65. Remove the LH heater core cover screws and remove the heater core cover.
      NOTE
      The instrument panel will need to be moved to facilitate removal of the heater core.

    66.  
    67. Remove the heater core.
    68.  
    69. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed. Top-off the engine coolant level. For additional information. Reactivate the supplemental restraints system (SRS).
    70.  

    1. Deactivate the supplemental restraints system (SRS).
    2.  
    3. Release the two floor console front clips (one each side).
    4.  
    5. On vehicles with manual transmission, remove the gearshift lever handle.
    6.  
    7. Remove the console finish panel mat.
    8.  
    9. On vehicles with automatic transmission:
      1. If equipped, remove the ashtray assembly.
      2.  
      3. Disconnect the electrical connector.
      4.  
      5. Remove the console finish panel screw.
      6.  

    10.  
    11. Remove the console finish panel by lifting up at the rear and sliding it rearward. Disconnect the electrical connector(s).
    12.  
    13. Remove the floor console front screws.
    14.  
    15. If equipped, disconnect the electrical connector and release the wiring harness locators.
    16.  
    17. Remove the floor console center bolts.
    18.  
    19. Remove the two floor console access covers (one each side).
    20.  
    21. Remove the two floor console rear bolts (one each side).
    22.  
    23. Remove the floor console by lifting up at the rear of the console and sliding it rearward.
    24.  
    25. Remove the screws and remove the snow shield.
    26.  
    27. Crimp off the coolant hoses and disconnect from the heater core.
    28.  
    29. Remove the instrument panel center support brackets.
    30.  
    31. Remove the assist handle bolt covers.
    32.  
    33. Remove the bolts and the passenger assist handle.
    34.  
    35. Remove the windshield side garnish moldings.
    36.  
    37. Remove the defroster opening grill.
    38.  
    39. Remove the upper instrument panel support bolts.
    40.  
    41. Remove the exterior cowl grill.
    42.  
    43. Remove the instrument panel support bolt.
    44.  
    45. Remove the two instrument panel side finish panels.
    46.  
    47. Lower the glove compartment.
    48.  
    49. Loosen the LH instrument panel side support bolts until half the threads are exposed.
      WARNING
      Be sure the instrument panel is properly supported to avoid possible damage to the instrument panel wiring or components. To avoid damage to the instrument panel wiring or components, do not use excessive force when moving the instrument panel away from the dash panel. The instrument panel may be supported by installing threaded rods or equivalent, with the same diameter and thread pitch, in place of the instrument panel support bolts.

    50.  
    51. Properly support the instrument panel and remove the RH instrument panel support bolts to allow the instrument panel to be pulled away from the dash panel.
    52.  
    53. Remove the center console floor duct.
    54.  
    55. Remove the screws and remove the RH floor duct.
    56.  
    57. Remove the screws and remove the LH floor duct.
    58.  
    59. Disconnect the electrical connectors and detach the pin-type retainers.
    60.  
    61. Remove the screws and remove the heater core tube cover.
    62.  
    63. Remove the RH heater core cover screws.
    64.  
    65. Remove the LH heater core cover screws and remove the heater core cover.
      NOTE
      The instrument panel will need to be moved to facilitate removal of the heater core.

    66.  
    67. Remove the heater core.
    68.  
    69. To install, reverse the removal procedure. Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed. Top-off the engine coolant level. For additional information. Reactivate the supplemental restraints system (SRS).
    70.  

     
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