Mazda B-Series 1998-06

Removal & Installation

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1995-98 B Series Pick-Up Models





Click image to see an enlarged view

Fig. Exploded view of the blower motor housing and the heater air plenum assemblies

  1. Disconnect the negative battery cable. Allow the engine to cool down. Drain the cooling system to a level below the heater core fittings on the firewall.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Disconnect the heater hoses from the heater core tubes and plug hoses.
  2.  
  3. Remove the five nuts that secure the blower motor housing to the firewall.
  4.  
  5. Pull the housing away from the firewall. Disconnect any wire harness plugs which inhibit the housing.
  6.  
  7. Remove the remaining nuts which secure the heater air plenum (inside the passenger compartment) to the firewall.
  8.  
  9. In the passenger compartment, remove the instrument panel. Refer to Section 10.
  10.  
  11. Pull the heater air plenum rearward from the firewall and remove it from the vehicle.
  12.  
  13. Remove the heater core from the heater air plenum.
  14.  
  15. Inspect all air seals on the components and firewall and replace any that are damaged.
  16.  

To install:

  1. Install the heater core into the air plenum chamber.
  2.  
  3. Position the heater air plenum against the firewall from the passenger compartment.
  4.  
  5. Under the hood, install the plenum retaining nuts.
  6.  
  7. Install the blower motor housing to the firewall and install the attaching nuts.
  8.  
  9. Connect the heater hoses to the heater core tubes at the dash panel in the engine compartment. Do not over-tighten the hose clamps.
  10.  
  11. Install the instrument panel.
  12.  
  13. Check the coolant level and add coolant as required. Connect the negative battery cable.
  14.  
  15. Start the engine and check the system for coolant leaks.
  16.  

1999-01 B-Series Pick-Ups



  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the battery, wait for more than 1 minute for the air bag system to deplete its stored 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. Discharge and recover the air conditioning system refrigerant.
  8.  
  9. At the driver-s side, remove the SAS module and the steering wheel by performing the following procedure:
    1. Place the wheel in the straight-ahead position and turn the ignition switch to LOCK.
    2.  
    3. At both sides of the steering wheel, remove the cover clips.
    4.  
    5. Remove the steering wheel-to-SAS module bolts.
    6.  
    7. Carefully, lift the SAS module from the steering wheel and disconnect the electrical connector.
      CAUTION
      Place the SAS in a safe place with the module facing upward.

    8.  
    9. Remove the steering wheel-to-column nut.
    10.  
    11. Using a steering wheel puller, press the steering wheel from the steering column.
    12.  

  10.  
  11. At the passenger-s side, remove the SAS module by performing the following procedure:
    1. Remove the glove compartment and the glove compartment cover.
    2.  
    3. Remove the SAS module-to-dash bolts.
    4.  
    5. Carefully, lift the SAS module and disconnect the electrical connector.
      CAUTION
      Place the SAS in a safe place with the module facing upward.

    6.  

  12.  
  13. Remove the steering column by performing the following procedure:
    1. Remove the parking brake release handle.
    2.  
    3. Remove the hood release lever.
    4.  
    5. Remove the instrument panel steering column cover and the cover reinforcement.
    6.  
    7. Remove and disconnect the ignition switch electrical connector.
    8.  
    9. Disconnect the electrical harness connectors.
    10.  
    11. If equipped with an automatic transmission, remove the shift indicator cable bolt and the cable.
    12.  
    13. Remove the air bag sliding contact.
    14.  
    15. Remove the upper intermediate steering shaft-to-column shaft bolt; then, discard the bolt.
    16.  
    17. Remove the lower steering column nuts.
    18.  
    19. Remove the steering column nuts, column support and the column.
    20.  

  14.  
  15. Remove the instrument panel by performing the following procedures:
    1. Disconnect the Brake Pedal Position (BPP) switch connector.
    2.  
    3. If equipped, disconnect the Clutch Pedal Position (CPP) switch connector.
    4.  
    5. Remove the right and left hand scuff plates.
    6.  
    7. Remove both A-pillar trim plates.
    8.  
    9. Remove both front side trim panels.
    10.  
    11. Remove the fuse panel opening door.
    12.  
    13. In the engine compartment, disconnect the fuse box and position it aside.
    14.  
    15. In the engine compartment, remove and disconnect the bulkhead wiring harness connector.
    16.  
    17. Remove the valance panel.
    18.  
    19. Disconnect the following items:

      Air bag diagnostic monitor locking tab and connector
       
      Blend door actuator connector
       
      Climate control vacuum harness connector
       
      Radio antenna cable in-line connector
       

    20.  
    21. At the right cowl panel, disconnect the electrical connectors and the ground.
    22.  
    23. Under the steering column, remove the instrument panel brace bolt.
    24.  
    25. Remove the right and left instrument panel cowl sides.
    26.  
    27. Pull the instrument panel away from the cowl.
    28.  
    29. Disconnect the instrument panel-to-main electrical harness connector.
    30.  
    31. Using an assistant, remove the instrument panel.
    32.  

  16.  
  17. Remove the evaporator core housing by performing the following procedure:
    1. Disconnect the refrigerant lines from the evaporator core. Discard the O-rings.
    2.  
    3. Remove the engine air cleaner.
    4.  
    5. Remove the windshield washer reservoir/coolant recovery reservoir and move them aside.
    6.  
    7. Remove the vacuum reservoir tank and bracket; then, move it aside.
    8.  
    9. Disconnect the cruise control servo electrical connector.
    10.  
    11. Disconnect the manifold/tube assembly from the receiver drier.
    12.  
    13. Disconnect the air conditioning cycling switch connector.
    14.  
    15. Disconnect the blower motor connector and the resistor.
    16.  
    17. If equipped with a 3.0L or 4.0L engine, remove the support bracket.
    18.  
    19. Disconnect the windshield washer hose retainer and move it aside.
    20.  
    21. Disconnect the vacuum hose.
    22.  
    23. If equipped with a 4.0L engine, remove the air conditioning hose support retaining bolts from the back of the engine.
    24.  
    25. In the passenger compartment, disconnect the vacuum harness connector and nut.
    26.  
    27. Remove the evaporator core housing nuts and remove the housing.
    28.  

  18.  
  19. Remove the plenum chamber.
  20.  
  21. Remove the heater housing-to-heater core cover screws and the heater core.

    Click image to see an enlarged view

    Fig. View of the SAS module and steering wheel-Mazda Pick-Ups



    Click image to see an enlarged view

    Fig. View of the passenger-s side SAS module-Mazda Pick-Ups



    Click image to see an enlarged view

    Fig. Exploded view of the steering column assembly-Mazda Pick-Ups



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel assembly-Mazda Pick-Ups



    Click image to see an enlarged view

    Fig. View of the heater housing and heater core-Mazda Pick-Ups

  22.  

To install:

  1. Install the heater core and the heater housing-to-heater core cover screws.
  2.  
  3. Install the plenum chamber.
  4.  
  5. Install the evaporator core housing by performing the following procedure:
    1. Install the evaporator core housing and the housing nuts.
    2.  
    3. In the passenger compartment, connect the vacuum harness connector and nut.
    4.  
    5. If equipped with a 4.0L engine, install the air conditioning hose support retaining bolts to the back of the engine.
    6.  
    7. Connect the vacuum hose.
    8.  
    9. Connect the windshield washer hose retainer.
    10.  
    11. If equipped with a 3.0L or 4.0L engine, install the support bracket.
    12.  
    13. Connect the blower motor connector and the resistor.
    14.  
    15. Connect the air conditioning cycling switch connector.
    16.  
    17. Connect the manifold/tube assembly to the receiver drier.
    18.  
    19. Connect the cruise control servo electrical connector.
    20.  
    21. Install the vacuum reservoir tank and bracket.
    22.  
    23. Install the windshield washer reservoir/coolant recovery reservoir.
    24.  
    25. Install the engine air cleaner.
    26.  
    27. Using new O-rings, connect the refrigerant lines to the evaporator core.
    28.  

  6.  
  7. Install the instrument panel by performing the following procedures:
    1. Using an assistant, install the instrument panel.
    2.  
    3. Connect the instrument panel-to-main electrical harness connector.
    4.  
    5. Push the instrument panel toward from the cowl.
    6.  
    7. Install the right and left instrument panel cowl sides.
    8.  
    9. Under the steering column, install the instrument panel brace bolt.
    10.  
    11. At the right cowl panel, connect the electrical connectors and the ground.
    12.  
    13. Connect the following items:

      Air bag diagnostic monitor locking tab and connector
       
      Blend door actuator connector
       
      Climate control vacuum harness connector
       
      Radio antenna cable in-line connector
       

    14.  
    15. Install the valance panel.
    16.  
    17. In the engine compartment, install and connect the bulkhead wiring harness connector.
    18.  
    19. In the engine compartment, connect the fuse box.
    20.  
    21. Install the fuse panel opening door.
    22.  
    23. Install both front side trim panels.
    24.  
    25. Install both A-pillar trim plates.
    26.  
    27. Install the right and left hand scuff plates.
    28.  
    29. If equipped, connect the Clutch Pedal Position (CPP) switch connector.
    30.  
    31. Connect the Brake Pedal Position (BPP) switch connector.
    32.  

  8.  
  9. Install the steering column by performing the following procedure:
    1. Install the steering column, column support and the column nuts.
    2.  
    3. Install the lower steering column nuts.
    4.  
    5. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt.
    6.  
    7. Install the air bag sliding contact.
    8.  
    9. If equipped with an automatic transmission, install the shift indicator cable bolt and the cable.
    10.  
    11. Connect the electrical harness connectors.
    12.  
    13. Install and connect the ignition switch electrical connector.
    14.  
    15. Install the instrument panel steering column cover reinforcement and the cover.
    16.  
    17. Install the hood release lever.
    18.  
    19. Install the parking brake release handle.
    20.  

  10.  
  11. At the passenger-s side, install the SAS module by performing the following procedure:
    1. Carefully, install the SAS module and connect the electrical connector.
    2.  
    3. Install the SAS module-to-dash bolts.
    4.  
    5. Install the glove compartment and the glove compartment cover.
    6.  

  12.  
  13. At the driver-s side, install the SAS module and the steering wheel by performing the following procedure:
    1. Install the steering wheel-to-column nut.
    2.  
    3. Carefully, install the SAS module to the steering wheel and connect the electrical connector.
    4.  
    5. Install the steering wheel-to-SAS module bolts.
    6.  
    7. At both sides of the steering wheel, install the cover clips.
    8.  

  14.  
  15. Connect the heater hoses to the heater core.
  16.  
  17. Refill the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Evacuate and charge the air conditioning system.
  22.  
  23. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  24.  

2002-2003



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.


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

  4.  
  5. Drain the cooling system.
  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. Remove the parking brake release handle screws and move the release handle aside.
    2.  
    3. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
    4.  
    5. Remove both front door scuff plates.
    6.  
    7. Remove the push pins and remove both cowl side trim panels.
    8.  
    9. At the right side cowl panel, disconnect the electrical connectors and ground wires.
    10.  
    11. Remove both sides windshield garnish moldings.
    12.  
    13. Remove the instrument panel fuse door.
    14.  
    15. Disconnect the power distribution box from its bracket and move it aside.
    16.  
    17. In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors.
    18.  
    19. Pull the bulkhead electrical connector handle and disconnect the wiring harness.
    20.  
    21. Remove the passenger-s side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.
      WARNING
      Store the air bag module in a safe location with the front facing upward.

    22.  
    23. Disconnect the blend door actuator-s electrical connector.
    24.  
    25. Disconnect the climate control vacuum harness connector.
    26.  
    27. Disconnect the radio-s antenna connector.
    28.  
    29. Remove the glove compartment.
    30.  
    31. Remove the instrument panel defroster grille.
    32.  
    33. Remove the upper instrument panel bolts.
    34.  
    35. Under the steering column, remove the instrument panel brace bolt.
    36.  
    37. Remove both the right and left instrument panel-to-cowl bolts.
    38.  
    39. Pull the instrument panel away from the dash.
    40.  
    41. Loosen the instrument panel-to-body harness bolt and disconnect the harness.
    42.  
    43. Using an assistant, remove the instrument panel.
    44.  

  10.  
  11. Remove the evaporator core by performing 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. If equipped, remove the air conditioning vacuum reservoir tank/bracket screws and reposition the tank.
    6.  
    7. If equipped, disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo.
    8.  
    9. If equipped with a 3.0L or 4.0L engine, remove the support bracket.
    10.  
    11. Disengage the windshield washer hose retainer and move it aside.
    12.  
    13. Disconnect the vacuum hose and the retainer; then, move the hose aside.
    14.  
    15. Remove the passenger-s compartment nut.
    16.  
    17. At the back of the engine, remove the hose support bolts.
    18.  
    19. Remove the evaporator housing-to-chassis nuts.
    20.  
    21. Remove the air conditioning accumulator bracket screws.
    22.  
    23. Remove the evaporator housing cover screws, clips and the cover.
    24.  
    25. Remove the evaporator core from the housing.
    26.  

  12.  
  13. Disconnect the heater hoses from the heater core.
  14.  
  15. Remove the heater housing plenum chamber nuts and the plenum chamber.
  16.  
  17. Remove the heater core-to-heater housing screws and the cover.
  18.  
  19. Remove the heater core.

    Click image to see an enlarged view

    Fig. Instrument panel and related components-2002-2005



    Click image to see an enlarged view

    Fig. Evaporator core-2002-2003



    Click image to see an enlarged view

    Fig. Heater core cover-2002-2003



    Click image to see an enlarged view

    Fig. Heater core-2002-2003

  20.  

To install:

  1. Install the heater core.
  2.  
  3. Install the heater core-to-heater housing cover and the cover screws.
  4.  
  5. Install the heater housing plenum chamber and the plenum chamber nuts.
  6.  
  7. Connect the heater hoses to the heater core.
  8.  
  9. Install the evaporator core by performing the following procedure:
    1. Install the evaporator core to the housing.
    2.  
    3. Install the evaporator housing cover, clips and the cover screws.
    4.  
    5. Install the air conditioning accumulator bracket screws.
    6.  
    7. Install the evaporator housing-to-chassis nuts.
    8.  
    9. At the back of the engine, install the hose support bolts.
    10.  
    11. Install the passenger-s compartment nut.
    12.  
    13. Connect the vacuum hose and the retainer.
    14.  
    15. Engage the windshield washer hose retainer.
    16.  
    17. If equipped with a 3.0L or 4.0L engine, install the support bracket.
    18.  
    19. If equipped, install the speed control servo bolt and connect the connector.
    20.  
    21. If equipped, install the air conditioning vacuum reservoir tank and the bracket screws.
    22.  
    23. Using new O-rings, install the refrigerant lines to the evaporator core.
    24.  

  10.  
  11. 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 toward the dash.
    6.  
    7. Install both the right and left instrument panel-to-cowl bolts.
    8.  
    9. Under the steering column, install the instrument panel brace bolt.
    10.  
    11. Install the upper instrument panel bolts.
    12.  
    13. Install the instrument panel defroster grille.
    14.  
    15. Install the glove compartment.
    16.  
    17. Connect the radio-s antenna connector.
    18.  
    19. Connect the climate control vacuum harness connector.
    20.  
    21. Connect the blend door actuator-s electrical connector.
    22.  
    23. Install the passenger-s side air bag module, connect the electrical connector and torque the air bag module-to-instrument panel screws to 67-92 inch lbs. (7.6-10.4 Nm).
    24.  
    25. Connect the bulkhead electrical connector handle wiring harness.
    26.  
    27. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts.
    28.  
    29. Connect the power distribution box to its bracket.
    30.  
    31. Install the instrument panel fuse door.
    32.  
    33. Install both sides windshield garnish moldings.
    34.  
    35. At the right side cowl panel, connect the electrical connectors and ground wires.
    36.  
    37. Install both cowl side trim panels and the push pins.
    38.  
    39. Install both front door scuff plates.
    40.  
    41. Connect the brake pedal position (BPP) switch electrical connector.
    42.  
    43. Install the parking brake release handle and the release handle aside screws.
    44.  

  12.  
  13. 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.  

  14.  
  15. Refill the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Evacuate and charge the air conditioning system.
  20.  
  21. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  22.  

2004-2006



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    On some vehicles, when the battery cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.


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

  4.  
  5. Depower the SRS system.
  6.  
  7. Discharge the air conditioning system.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the suction accumulator.
  12.  
  13. If equipped with the 2.3L engine, remove the A/C compressor and the engine oil indicator and tube.
  14.  
  15. If equipped with the 3.0L or 4.0L engine, position the coolant reservoir and windshield washer reservoir aside.
  16.  
  17. Detach the speed control servo, on vehicles equipped with cruise control.
  18.  
  19. Disconnect the blower motor and blower motor resistor electrical connectors.
  20.  
  21. Disconnect the heater hoses.
  22.  
  23. Detach the pin-type retainer and position aside the windshield washer hose.
  24.  
  25. Disconnect and detach the heater control valve vacuum hose.
  26.  
  27. Disconnect the vacuum supply hose near the evaporator core housing.
  28.  
  29. Disconnect the condenser to evaporator line spring lock coupling from the evaporator core inlet. Discard the O-ring seals.
    NOTE
    This step is performed at the lower passenger side dash panel, inside the passenger compartment.

  30.  
  31. Disconnect the vacuum hose connector and remove the nut.
  32.  
  33. If equipped with the 4.0L engine, remove the vehicle splash guard. Remove the splash shield. On the right splash shield, disconnect the vacuum lines from the vacuum storage reservoir.
    NOTE
    Remove the electrical connector locators from the splash shield prior to removal.



    Click image to see an enlarged view

    Fig. Splash shield removal points



    Click image to see an enlarged view

    Fig. Evaporator core housing bolts-2004-2006

  34.  
  35. Remove the nuts and the evaporator core housing.
  36.  
  37. Lock the steering column.
  38.  
  39. Remove the front seats.
  40.  
  41. Remove the screws and position the parking brake release handle aside.
  42.  
  43. Remove the left and right lower cowl kick panels.
  44.  
  45. Position the parking brake assembly aside.
  46.  
  47. Remove the screws and position the hood release handle aside.
  48.  
  49. Remove the instrument panel steering column cover.
  50.  
  51. Remove the instrument panel steering column opening cover reinforcement.
  52.  
  53. Disconnect the brake pedal position (BPP) switch electrical connector from the steering column shaft.
  54.  
  55. If equipped, disconnect the clutch pedal position (CPP) switch electrical connector.
  56.  
  57. If equipped, disconnect the shift cable from the steering column.
  58.  
  59. Remove the steering column pinch bolt and disconnect the steering column intermediate shaft.
    NOTE
    To avoid damage to the clockspring, do not allow the steering shaft to rotate while the intermediate shaft is disconnected.



    Click image to see an enlarged view

    Fig. Steering column pinch bolt

  60.  
  61. Remove the left and right side garnish moldings.
    1. Remove the bolt covers and remove the bolts.
    2.  
    3. Remove the assist handle.
    4.  
    5. Remove the windshield side garnish molding.
    6.  

  62.  
  63. Remove the door moldings.
  64.  
  65. On regular cab vehicles
    1. Remove the screws.
    2.  
    3. Remove the scuff plate.
    4.  

  66.  
  67. Disconnect the electrical connectors and the ground wire from the RH side lower kick panel.
    NOTE
    To avoid damaging the bulkhead electrical connectors, be sure the release tab is fully depressed before pulling release lever into the disconnect position.

  68.  
  69. Disconnect the LH side bulkhead electrical connector. Press the release tab and pull the release lever.
  70.  
  71. Remove the audio unit. Insert the removal tool. Remove and support the audio unit.
  72.  
  73. Disconnect the audio unit electrical connector and antenna cable.
  74.  
  75. Lower the glove compartment. Press the release tabs inward while lowering the compartment.
  76.  
  77. Through the glove compartment opening, disconnect the blend door actuator electrical connector.
  78.  
  79. Through the glove compartment opening, disconnect the climate control vacuum harness connector.
  80.  
  81. Raise and secure the glove compartment. Press the release tabs inward while raising the glove compartment.
  82.  
  83. Remove the instrument panel defroster opening grille.
  84.  
  85. Remove the instrument panel cowl top bolts.
  86.  
  87. If equipped, remove the floor console.
  88.  
  89. If not equipped with the high-series floor console, remove the cup holders.
  90.  
  91. Release the clips and remove the restraints control module (RCM) cover.
  92.  
  93. If not equipped with high-series floor console, remove the consolette mat.
  94.  
  95. Remove the screws and remove the restraints control module (RCM) cover.
  96.  
  97. Remove the consolette base.
  98.  
  99. Remove the gearshift lever.
  100.  
  101. Remove the screws and remove the manual transmission consolette.
  102.  
  103. Disconnect the RCM electrical connector.
  104.  
  105. Pull the floor carpeting back.
  106.  
  107. On 2WD vehicles disconnect the instrument panel main harness.
  108.  
  109. On 4WD vehicles disconnect the instrument panel main harness. From underneath the vehicle, release the instrument panel main harness at the transfer case.
  110.  
  111. Remove the instrument panel side finish panel.
  112.  
  113. Disconnect the door harness electrical connector.
  114.  
  115. Remove the RH side instrument panel bolt. If necessary, transfer the components to the new instrument panel.
  116.  
  117. Remove the LH instrument panel cowl side bolts.
  118.  
  119. Remove the instrument panel.
  120.  
  121. Remove the powertrain control module (PCM).
  122.  
  123. Remove the PCM heat sink.
  124.  
  125. Remove the four nuts from the engine side of the dash panel. Position the plenum chamber on the vehicle floor.
  126.  
  127. Remove the heater core cover.
  128.  
  129. Remove the heater core.

    Click image to see an enlarged view

    Fig. Instrument panel and related components-2006



    Click image to see an enlarged view

    Fig. Heater core cover bolts-2004-2006



    Click image to see an enlarged view

    Fig. Heater core removal-2004-2006

  130.  

To install:

  1. To install, reverse the removal procedure.
  2.  
  3. During installation, be sure to install a new oval foam seal around the heater core inlet and outlet tubes.
  4.  
  5. Torque the steering column pinch bolt to 21 ft. lbs.
    NOTE
    To avoid damage to the clockspring, do not allow the steering shaft to rotate while the intermediate shaft is disconnected.

  6.  
  7. Lubricate the refrigerant system with the correct amount of clean PAG oil or equivalent. Install new O-ring seals lubricated in clean mineral oil. Lubricate the coolant hoses with plain water only, if needed.
  8.  
  9. Evacuate, leak test, and charge the refrigerant system.
  10.  

 
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