Ford Sable, Taurus 2000-05

Removal & Installation 3

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Ford Crown Victoria, Mercury Grand Marquis And Lincoln Town Car



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. If equipped, turn the air suspension service switch to the OFF position before raising the vehicle.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Front seats
     
    Carpeting
     
    Rear airflow duct
     
    Heater hoses
     

  8.  
  9. Remove the driver-s side air bag module by removing or disconnect the following:

    SRS module-to-steering wheel bolts, from both sides of the steering wheel.
     
    SRS module and disconnect the electrical connector
     
    Horn switch electrical connector
     

  10.  
  11. Remove the passenger-s side SRS module by removing or disconnecting the following:

    Open the glove box and disconnect the glove compartment isolator
     
    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
     

  12.  
  13. Remove the instrument panel by removing or disconnecting the following:

    Speed control servo nuts and move the servo aside
     
    Bolt and disconnect the left side bulkhead connector
     
    Left side bulkhead connector from the dash panel
     
    Windshield washer fluid reservoir screw, and position the reservoir aside
     
    Blower motor electrical connector
     
    Air conditioning pressure cut-off switch electrical connector
     
    In-line electrical harness connector
     
    Electronic Automatic Temperature Control (EATC) variable blower motor controller electrical connector
     
    Right front wheel
     
    Right front fender splash shield bolts and move the shield away from the cowl
     
    Wiring harness from the evaporator case
     
    Wiring harness from the cowl
     
    Right side instrument panel lower insulator pushpins, disconnect the power point electrical connector, remove the courtesy lamp from the socket and remove the insulator
     
    Unseat the wiring grommet and feed the wiring harness through the cowl
     
    Cowl side trim panels and the windshield side garnish moldings from both sides
     
    Locking clip and the Electronic Crash Sensor (ECS) module electrical connector
     
    Antenna connector
     
    Ground wire bolts from the right side
     
    EATC hose at the evaporator housing
     
    Bolt and disconnect the bulkhead connector from the right side
     
    Pull the door weatherstrip seals away from the instrument panel on both sides
     
    Tunnel brace trim cover
     
    Climate control head vacuum harness connector
     
    Instrument panel tunnel brace nuts and the brace
     
    Ground wire bolts from the left side
     
    Wiring harness connectors from the left side
     
    Parking brake switch electrical connector
     

    1. Pry out the instrument panel defroster opening grille, disconnect the electrical connectors and the remove the grille.
    2.  

  14.  
  15. Remove or disconnect the following:

    3 upper instrument panel screws
     
    Instrument panel cowl side nut from both sides
     
    Instrument panel cowl side bolt. From the left side
     
    Instrument panel
     
    Windshield wiper mounting arm and the pivot shaft
     
    Electrical connector and remove the upper cowl extension screw and the extension
     
    Vacuum hoses and the wire harness connector from the evaporative emissions canister purge valve
     
    Evaporative emissions purge valve nuts and the valve
     
    Cowl side nut
     
    Right side rear fender apron screws and reposition the apron
     
    Evaporator housing nut and screw
     
    Vacuum hoses and the wiring harness connectors
     
    Plenum chamber-s lower flange nuts
     
    Plenum chamber-s upper flange nut and the plenum chamber
     
    Heater core cover-to-heater plenum chamber screws and the cover
     
    Seal and the heater core

    Click image to see an enlarged view

    Fig. View of the instrument panel finish panels-Crown Victoria, Grand Marquis and Town Car



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Crown Victoria, Grand Marquis and Town Car



    Click image to see an enlarged view

    Fig. Exploded view of the heater air plenum chamber, the evaporator housing and the air inlet duct-Crown Victoria, Grand Marquis



    Click image to see an enlarged view

    Fig. View of the heater core-Crown Victoria, Grand Marquis and Town Car



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Town Car

     

  16.  

To install:

  1. Install or connect the following:

    Seal and the heater core
     
    Heater core cover and the cover-to-heater plenum chamber screws
     
    Plenum chamber and the plenum chamber-s upper flange nut
     
    Plenum chamber-s lower flange nuts
     
    Vacuum hoses and the wiring harness connectors
     
    Evaporator housing nut and screw
     
    Right side rear fender apron and the apron screws
     
    Cowl side nut
     
    Evaporative emissions purge valve and the valve nuts
     
    Vacuum hoses and the wire harness connector to the evaporative emissions canister purge valve
     
    Electrical connector; then, install the upper cowl extension screw and the extension
     
    Windshield wiper mounting arm and the pivot shaft
     

  2.  
  3. Install the instrument panel by install or connect the following:

    Instrument panel
     
    At the left side, install the instrument panel cowl side bolt
     
    Instrument panel cowl side nut on both sides
     
    3 upper instrument panel screws
     
    Electrical connectors and the install the instrument panel defroster opening grille
     
    Parking brake switch electrical connector
     
    Wiring harness connectors on the left side
     
    Ground wire bolts on the left side
     
    Instrument panel tunnel brace and the brace nuts
     
    Climate control head vacuum harness connector
     
    Install the tunnel brace trim cover.
     
    Door weatherstrip seals to the instrument panel on both sides
     
    Bulkhead connector and tighten the bolt on both sides
     
    EATC hose at the evaporator housing
     
    Ground wire bolts on the right side
     
    Antenna connector
     
    ECS module electrical connector and the locking clip
     
    Cowl side trim panels and the windshield side garnish moldings on both sides
     
    Feed the wiring harness through the cowl and seat the wiring grommet
     
    Right side instrument panel lower insulator, connect the power point electrical connector, install the courtesy lamp to the socket and secure the insulator with pushpins
     
    Wiring harness from the cowl
     
    Wiring harness to the evaporator case
     
    Right front fender splash shield and the shield bolts
     
    Right front wheel
     
    EATC variable blower motor controller electrical connector
     
    In-line electrical harness connector
     
    Air conditioning pressure cut-off switch electrical connector
     
    Blower motor electrical connector
     
    Windshield washer fluid reservoir and the reservoir screw
     
    Left side bulkhead connector to the dash panel
     
    Left side bulkhead connector and tighten the bolt
     
    Speed control servo and the servo nuts
     
    Right SRS module and torque the module-to-instrument panel bolts to 62-97 inch lbs. (7-11 Nm)
     
    Right SRS module electrical connector
     
    Glove compartment isolator
     
    Glove box door
     
    Horn switch electrical connector
     
    Electrical connector and install the left SRS module
     
    Left SRS module-to-steering wheel bolts on both sides of the wheel, and torque the bolts to 90-122 inch lbs. (10-14 Nm)
     
    Rear airflow duct
     
    Carpeting
     
    Front seats
     
    Heater hoses
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Operate the engine to normal operating temperature. Check the climate control operation and check for leaks.
  10.  

Lincoln LS



Removal & Installation
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Heater hose assembly
     
    Cabin air filter plenum
     
    Thermostatic expansion valve manifold and tube assembly
     
    Driver-s side air bag module
     
    Floor console and A/C duct
     
    Shift lever assembly, if equipped with automatic transmission
     
    Left and right instrument panel insulators
     
    Left and right door sill scuff plates
     
    Left and right door weatherstrips
     
    Left and right A pillar lower trim panels
     
    Left and right windshield side garnish moldings
     
    Instrument panel defroster opening grille assembly
     
    Instrument panel cowl top screws
     
    Instrument panel upper reinforcement bolts
     
    Left and right instrument panel side finish panels
     
    Hood release handle and cable
     
    Upper right bulkhead electrical connector
     
    Right instrument panel electrical connectors
     
    Passenger side tunnel electrical connector
     
    Steering column intermediate shaft
     
    Left junction box electrical connectors
     
    Left instrument panel electrical connectors
     
    Ignition shift interlock connector, if equipped
     
    4 instrument panel tunnel brace bolts
     
    Left outer instrument panel cowl side cover and reinforcement bolt
     
    Left instrument panel cowl side bolt and nut
     
    Right instrument panel cowl side bolt and nut
     
    Instrument panel
     
    Evaporator housing electrical connector
     
    Cowl top attachment bolt
     
    Evaporator housing attachment bolt
     
    3 evaporator nuts and washers in the engine compartment
     
    Rear seat floor ducts
     
    Evaporator core housing
     
    Evaporator core housing air inlet
     
    Bypass door harness connector
     
    Heater core
     

  8.  

To install:

  1. Install or connect the following:

    Heater core
     
    Bypass door harness connector
     
    Evaporator core housing air inlet
     
    Evaporator core housing
     
    Rear seat floor ducts
     
    3 evaporator nuts and washers in the engine compartment
     
    Evaporator housing attachment bolt
     
    Cowl top attachment bolt
     
    Evaporator housing electrical connector
     
    Instrument panel
     
    Instrument panel cowl top screws. Tighten to 27 inch lbs. (3 Nm).
     
    Right instrument panel cowl side bolt and nut. Tighten the fasteners to 15 ft. lbs. (20 Nm).
     
    Left instrument panel cowl side bolt and nut. Tighten the fasteners to 15 ft. lbs. (20 Nm).
     
    Left outer instrument panel cowl side cover and reinforcement bolt. Tighten the bolt to 15 ft. lbs. (20 Nm).
     
    Instrument panel upper reinforcement bolts. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    4 instrument panel tunnel brace bolts. Tighten the bolts to 15 ft. lbs. (20 Nm).
     
    Ignition shift interlock connector, if equipped
     
    Left instrument panel electrical connectors
     
    Left junction box electrical connectors
     
    Steering column intermediate shaft. Tighten the pinch bolt to 26 ft. lbs. (35 Nm).
     
    Passenger side tunnel electrical connector
     
    Right instrument panel electrical connectors
     
    Upper right bulkhead electrical connector
     
    Hood release handle and cable
     
    Left and right instrument panel side finish panels
     
    Instrument panel defroster opening grille assembly
     
    Left and right windshield side garnish moldings
     
    Left and right A pillar lower trim panels
     
    Left and right door weatherstrips
     
    Left and right door sill scuff plates
     
    Left and right instrument panel insulators
     
    Shift lever assembly, if equipped with automatic transmission
     
    Floor console and A/C duct
     
    Driver-s side air bag module
     
    Thermostatic expansion valve manifold and tube assembly
     
    Cabin air filter plenum
     
    Heater hose assembly
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Recharge the A/C system.
  6.  
  7. Start the engine and check for leaks.
  8.  

Mark VIII



Removal And Installation
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Transmission wiring harness at the transmission crossmember
     
    Left and right bulkhead electrical connectors
     
    Left air bag module
     
    Steering wheel
     
    Left instrument panel close-out panels
     
    Left reinforcement brace
     
    Left lower A/C duct
     
    Steering column electrical connectors
     
    Steering column lower yoke pinch bolt
     
    Steering column
     
    Instrument panel center finish panel
     
    Floor console support bracket
     
    Mobile phone and bracket, if equipped
     
    Gear shift selector housing
     
    Center console wiring harness connectors
     
    Mobile phone coaxial cable, if equipped
     
    Center console
     
    Radio
     
    Electronic Automatic Temperature Control (EATC) module
     
    Heater outlet duct
     
    Left and right door weatherstrips
     
    Left and right cowl trim panels
     
    Left and right roof side inner front moldings
     
    Mobile phone speaker connector, if equipped
     
    Instrument panel defroster grille
     
    Windshield wiper control module and bracket
     
    Left wiring harness connectors
     
    Shift interlock cable
     
    Right instrument panel close-out panel
     
    Glove compartment
     
    Right air bag module
     
    EATC sensor hose
     
    Climate control vacuum harness
     
    Wiring harness in-line connector
     
    Right cowl insulator panel
     
    Right wiring harness connectors
     
    Antenna cable
     
    Transmission wiring harness grommet
     
    Left instrument panel cowl side nuts
     
    Instrument panel center support nuts
     
    Instrument panel floor bracket
     
    Right instrument panel cowl side nut
     
    Instrument panel cowl top bolts
     
    Instrument panel
     
    A/C liquid line
     
    A/C accumulator/drier and bracket
     
    Vacuum supply hose
     
    Heater hoses
     
    Heater outlet floor ducts
     
    Evaporator housing from the vehicle
     
    A/C blend door actuator
     
    13 evaporator case screws
     
    Heater core cover screws
     
    Heater core
     

  8.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core cover screws. Tighten the screws to 18-26 inch lbs. (2-3 Nm).
     
    13 evaporator case screws. Tighten the screws to 18-26 inch lbs. (2-3 Nm).
     
    A/C blend door actuator
     
    Evaporator housing to the vehicle. Tighten the fasteners to 41-54 inch lbs. (5-6 Nm).
     
    Heater outlet floor ducts
     
    Heater hoses
     
    Vacuum supply hose
     
    A/C accumulator/drier and bracket
     
    A/C liquid line
     
    Instrument panel
     
    Instrument panel cowl top bolts. Tighten the bolts to 54-70 inch lbs. (6-8 Nm).
     
    Right instrument panel cowl side nut. Tighten the nut to 40-52 ft. lbs. (54-72 Nm).
     
    Instrument panel floor bracket. Tighten the bolts to 20-24 ft. lbs. (26-34 Nm).
     
    Instrument panel center support nuts. Tighten the nuts to 96-120 inch lbs. (10-14 Nm).
     
    Left instrument panel cowl side nuts. Tighten the nuts to 40-52 ft. lbs. (54-72 Nm).
     
    Transmission wiring harness grommet
     
    Antenna cable
     
    Right wiring harness connectors
     
    Right cowl insulator panel
     
    Wiring harness in-line connector
     
    Climate control vacuum harness
     
    EATC sensor hose
     
    Right air bag module
     
    Glove compartment
     
    Right instrument panel close-out panel
     
    Shift interlock cable
     
    Left wiring harness connectors
     
    Windshield wiper control module and bracket
     
    Instrument panel defroster grille
     
    Mobile phone speaker connector, if equipped
     
    Left and right roof side inner front moldings
     
    Left and right cowl trim panels
     
    Left and right door weatherstrips
     
    Heater outlet duct
     
    Electronic Automatic Temperature Control (EATC) module
     
    Radio
     
    Center console
     
    Mobile phone coaxial cable, if equipped
     
    Center console wiring harness connectors
     
    Gear shift selector housing
     
    Mobile phone and bracket, if equipped
     
    Floor console support bracket. Tighten the bolts to 27 inch lbs. (3 Nm).
     
    Instrument panel center finish panel
     
    Steering column. Tighten the nuts to 24-34 ft. lbs. (34-46 Nm).
     
    Steering column lower yoke pinch bolt. Tighten the bolt to 22-30 ft. lbs. (30-40 Nm).
     
    Steering column electrical connectors
     
    Left lower A/C duct
     
    Left reinforcement brace
     
    Left instrument panel close-out panels
     
    Steering wheel. Tighten the bolt to 25-34 ft. lbs. (34-46 Nm).
     
    Left air bag module
     
    Left and right bulkhead electrical connectors
     
    Transmission wiring harness at the transmission crossmember
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Recharge the A/C system.
  6.  
  7. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. View of the heater core-Lincoln Mark VIII

  8.  

Mustang



Removal And Installation
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Recover the A/C refrigerant, if equipped.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Radio
     
    CD player, if equipped
     
    Center console
     
    Left front wheel
     
    Left front inner fender
     
    Left bulkhead harness connector
     
    Left and right air bag modules
     
    Antenna cable connector
     
    Climate control vacuum harness connector
     
    Upper right instrument panel support bolt
     
    Left and right scuff plates
     
    Left and right A-pillar lower trim panels
     
    Left and right windshield side garnish moldings
     
    Left and right door weatherstrips
     
    Right main wire harness connectors
     
    Climate control wire harness connector
     
    Instrument panel steering column cover
     
    Instrument panel reinforcement
     
    Steering column intermediate shaft
     
    Left main wiring harness connectors
     
    Generic Electronic Module (GEM) connectors
     
    Electronic Crash Sensor (ECS) module connector
     
    Shift interlock cable, if equipped
     
    Shifter assembly harness connector, if equipped
     
    Temperature control cable
     
    4 center instrument panel support bolts
     
    Left instrument panel support bolt and nut
     
    Right instrument panel support bolt
     
    Instrument panel upper finish panel
     
    Upper instrument panel support bolts
     
    Instrument panel
     
    Heater hoses
     
    Vacuum supply hose
     
    A/C accumulator/drier
     
    A/C liquid line
     
    Evaporator housing
     
    Foam weather seal
     
    Heater core cover
     
    Heater core

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel, cover and reinforcement-Mustang



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



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    Fig. Exploded view of the heater/air conditioning housing assembly-Mustang



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    Fig. Evaporator case interior fasteners-Mustang



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    Fig. Evaporator case screw-Mustang



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    Fig. Evaporator case under-hood nuts-Mustang

     

  8.  

To install:

  1. Install or connect the following:

    Heater core
     
    Heater core cover
     
    Foam weather seal
     
    Evaporator housing. Tighten the fasteners to 71 inch lbs. (8 Nm).
     
    A/C liquid line
     
    A/C accumulator/drier
     
    Vacuum supply hose
     
    Heater hoses
     
    Instrument panel
     
    Upper instrument panel support bolts. Tighten the bolts to 80 inch lbs. (9 Nm).
     
    Instrument panel upper finish panel
     
    Right instrument panel support bolt. Tighten the bolt to 80 inch lbs. (9 Nm).
     
    Left instrument panel support bolt and nut. Tighten the bolt to 80 inch lbs. (9 Nm) and the nut to 35 ft. lbs. (48 Nm).
     
    4 center instrument panel support bolts. Tighten the bolts to 80 inch lbs. (9 Nm).
     
    Temperature control cable
     
    Shifter assembly harness connector, if equipped
     
    Shift interlock cable, if equipped
     
    ECS module connector
     
    GEM connectors
     
    Left main wiring harness connectors
     
    Steering column intermediate shaft. Tighten the pinch bolt to 35 ft. lbs. (47 Nm).
     
    Instrument panel reinforcement. Tighten the screws to 80 inch lbs. (9 Nm).
     
    Instrument panel steering column cover. Tighten the screws to 80 inch lbs. (9 Nm).
     
    Climate control wire harness connector
     
    Right main wire harness connectors
     
    Left and right door weatherstrips
     
    Left and right windshield side garnish moldings
     
    Left and right A-pillar lower trim panels
     
    Left and right scuff plates
     
    Upper right instrument panel support bolt. Tighten the bolt to 80 inch lbs. (9 Nm).
     
    Climate control vacuum harness connector
     
    Antenna cable connector
     
    Left and right air bag modules
     
    Left bulkhead harness connector
     
    Left front inner fender
     
    Left front wheel
     
    Center console
     
    CD player, if equipped
     
    Radio
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Recharge the A/C system.
  6.  
  7. Start the engine and check for leaks.
  8.  

Taurus And Sable



Removal And Installation
  1. 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.

  2.  
  3. Place the front wheels in the straight-ahead position.
  4.  
  5. Lock the steering column.
  6.  
  7. Remove or disconnect the following:

    SRS bolt covers from both sides of the steering wheel
     
    SRS module-to-steering wheel bolts
     
    SRS module and disconnect the electrical connector
     
    Steering wheel bolt and discard it
     

  8.  
  9. Press the steering wheel from the steering column.

    Lower steering column shaft bolt
     
    2 lower instrument panel cover-to-instrument panel screws and unsnap the lower cover from the instrument panel
     

  10.  
  11. Turn ignition switch to the RUN position
  12.  
  13. Insert a 1 / 8 in. (3mm) wire or pin punch in the lower steering column shroud hole, under the ignition switch; then, press on the pin while pulling out on the ignition switch lock cylinder and remove it from the steering column lock cylinder housing.
  14.  
  15. Remove or disconnect the following:

    3 steering column shroud screws and the shrouds
     
    Shift control selector lever boot
     
    Gearshift lever pin from the manual control lever and remove the lever
     
    Wiring connector at the bottom of the steering column and remove the wiring from the column, (if equipped with an overdrive lockout switch on the manual control lever)
     
    Electrical connectors
     
    Multi-function switch screws and move it aside
     
    Shift indicator cable from the shifter tube
     
    Shifter indicator-to-column adjustment cable screw
     
    Interlock cable and actuator (if equipped with a column shift)
     
    4 steering column-to-instrument panel bracket nuts and steering column
     
    Push pins and the lower instrument cover from the instrument panel reinforcement (at the passenger-s side)
     
    Console finish panel
     

  16.  
  17. Under the steering column, 2 instrument panel brace screws, the courtesy lamp socket, the 2 Diagnostic Link Connector (DLC) screws and the instrument panel brace.
  18.  
  19. If not equipped with an Electronic Automatic Temperature Control (EATC), disconnect the electrical connectors and the vacuum harness from the evaporator housing and the blower motor.
  20.  
  21. If equipped with an Electronic Automatic Temperature Control (EATC), remove the sensor hose/elbow and disconnect the electrical harness connectors and the vacuum hose harness from the evaporator housing.
  22.  
  23. Insert the Radio Removing tools 415-001into the integrated control panel faceplate; then, push the tools in approximately 1 1 / 2 in. (38mm) to release the retaining clips. Spread the tools slightly and pull the integrated control panel from the instrument panel.
  24.  
  25. Remove or disconnect the following:

    Electrical connectors and the automatic temperature control sensor hose and elbow, if equipped
     
    6 console center finish panel screws and the panel, (if equipped with a floor shift)
     
    4 instrument panel finish panel screws and panel, located at the right side of the steering column, (if equipped with a column shift)
     
    Instrument cluster finish panel-to-instrument panel clips and pull the finish panel straight out
     
    4 instrument cluster-to-instrument panel screws, the electrical connectors and the instrument cluster
     
    Upper finish panel (located at the top of the instrument panel)
     
    Light sensor amplifier connector, (if equipped with an autolamp)
     
    Instrument panel finish end panels on both sides of the instrument panel
     
    Front scuff plates and pull the door weatherstrip away from the instrument panel (on both sides of the instrument panel)
     
    3 instrument panel-to-upper cowl top panel screws
     
    2 screws at each end of the instrument panel
     
    Instrument panel electrical connectors and the parking brake switch
     
    Instrument panel
     

  26.  
  27. Drain the cooling system into a clean container for reuse
  28.  
  29. Remove or disconnect the following:
    WARNING
    Do not attempt to bend any part of the lever, for it is brittle and will break.



    Heater hoses from the heater core and plug the openings
     
    4 air conditioning electronic blend door actuator-to-heater/air conditioning housing assembly screws and the actuator
     
    Metal cover, disengage the spring from the heater core cover and from the lever
     
    Gently, depress the locking ramp and remove the lever from the secondary air temperature control door end
     

  30.  
  31. Rotate the primary air conditioning air temperature control door shaft downward, swing the metal link counterclockwise and remove it from the pin.
  32.  
  33. Remove the 3 heater core cover-to-heater/air conditioning housing assembly screws, the cover and the seal.
  34.  
  35. Press on the heater core tubes and remove the heater core from the heater/air conditioning housing assembly.

    Click image to see an enlarged view

    Fig. Remove the instrument panel insulator from the instrument panel reinforcement-Taurus and Sable



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    Fig. Manual air conditioning/heater equipped vehicles disconnection points-Taurus and Sable



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    Fig. EATC equipped vehicles disconnection points-Taurus and Sable



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    Fig. On floor shift vehicles, remove the console center finish panel-Taurus and Sable



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    Fig. On floor shift vehicles, remove the finish panel from around the integrated control panel-Taurus and Sable



    Click image to see an enlarged view

    Fig. If equipped with autolamps, detach the light sensor amplifier-Taurus and Sable



    Click image to see an enlarged view

    Fig. Unsnap the upper finish panel from the instrument panel-Taurus and Sable



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    Fig. Remove the instrument panel finish end panel-Taurus and Sable



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    Fig. Detach the electrical connectors-Taurus and Sable



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    Fig. Instrument panel-to-cowl panel mounting-Taurus and Sable



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    Fig. Remove the 4 blend door actuator retaining screws-Taurus and Sable



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    Fig. Secondary air temperature door connections-Taurus and Sable



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    Fig. Exploded view of the SRS module and the steering wheel assembly-Taurus and Sable



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    Fig. View of the integrated control panel-Taurus and Sable



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    Fig. Exploded view of the instrument panel-Taurus and Sable



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    Fig. View of the temperature control mechanism-Taurus and Sable



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    Fig. Exploded view of the heater core-Taurus and Sable

  36.  

To install:

  1. Install or connect the following:
    WARNING
    Do not use excessive force when installing the radio, the retaining clips can become damaged.



    Heater core to the heater/air conditioning housing assembly
     
    Heater core cover, the seal and the 3 heater core cover-to-heater/air conditioning housing assembly screws
     
    Lever to the secondary air conditioning air temperature control door end
     
    Spring to the lever, engage the spring to the heater core cover and install the metal cover
     
    Air conditioning electronic blend door actuator and the 4 actuator-to-heater/air conditioning housing assembly screws
     
    Heater hoses to the heater core
     
    Instrument panel with the help of an assistant
     
    Instrument panel electrical connectors and the parking brake switch
     
    2 screws at each end of the instrument panel with the help of an assistant
     
    3 instrument panel-to-upper cowl top panel screws
     
    Front scuff plates and the door weatherstrip (on both sides of the instrument panel)
     
    Instrument panel finish end panels (on both sides of the instrument panel)
     
    Electrical connector to the light sensor amplifier (if equipped with an autolamp)
     
    Upper finish panel (at the top of the instrument panel)
     
    Instrument cluster, electrical connectors and the 4 instrument cluster-to-instrument panel screws
     
    Instrument cluster finish panel and engage the finish panel-to-instrument panel clips
     
    Instrument panel finish panel and 4 panel screws, located at the right side of the steering column (if equipped with a column shift)
     
    Console center finish panel and the 6 panel screws (if equipped with a floor shift)
     
    Electrical connectors and the automatic temperature control sensor hose and elbow, if equipped
     
    Integrated control panel faceplate
     



    Sensor hose/elbow, the electrical harness connectors and the vacuum hose harness to the evaporator housing (if equipped with an Electronic Automatic Temperature Control (EATC)
     
    Connect the electrical connectors and the vacuum harness to the evaporator housing and the blower motor (if not equipped with an EATC)
     
    Instrument panel brace and the 2 Diagnostic Link Connector (DLC) screws
     
    Courtesy lamp socket and install the 2 instrument panel brace screws
     
    Console finish panel (if equipped with a floor shift)
     
    Lower instrument cover to the instrument panel reinforcement (located on the passenger-s side)
     
    Steering column and torque the 4 steering column-to-instrument panel bracket nuts to 10-13 ft. lbs. (13-17 Nm)
     
    Interlock cable and actuator (if equipped with a column shift)
     
    Shifter indicator-to-column adjustment cable screw
     
    Shift indicator cable to the shifter tube
     
    Multi-function switch and the screws
     
    Electrical connectors
     
    Wiring connector at the bottom of the steering column and install the wiring to the column (if equipped with an overdrive lockout switch on the manual control lever)
     
    Gearshift lever and the lever pin to the manual control lever
     
    3 steering column shroud screws and the shrouds
     
    Ignition switch to the steering column lock cylinder housing
     
    Lower instrument panel cover and the 2 lower cover-to-instrument panel screws
     
    Lower steering column shaft bolt and torque it to 17-20 ft. lbs. (22-26 Nm)
     
    Steering wheel to the steering column
     
    New steering wheel bolt and torque it to 26-33 ft. lbs. (34-46 Nm)
     
    SRS module and connect the electrical connector
     
    SRS module-to-steering wheel bolts and torque the bolts to 89-123 inch lbs. (10-14 Nm)
     
    SRS bolt covers
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  6.  

 
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