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Drain the cooling system and disconnect the heater hoses from the heater core tubes. Plug the hoses and the heater core tubes to prevent coolant leakage.
Remove the 3 nuts located below the windshield wiper motor attaching the left end of the plenum to the dash panel. Remove the 1 nut retaining the upper left corner of the evaporator case to the dash panel.
Disconnect the vacuum supply hose(s) from the vacuum source. Push the grommet and vacuum supply hose(s) into the passenger compartment.
Remove the right and left lower instrument panel insulators.
On 1990-00 vehicles:
Remove the cross body brace and disconnect the wiring harness from the temperature blend door actuator.
Disconnect the ATC sensor tube from the evaporator case connector.
Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
Remove the 2 hush panels.
Remove 1 plastic push fastener retaining the floor air distribution duct to the left end of the plenum. Remove the left screw and loosen the right screw on the rear face of the plenum and remove the floor air distribution duct.
Remove the 2 nuts from the 2 studs along the lower flange of the plenum.
Carefully move the plenum rearward to allow the heater core tubes and the stud at the top of the plenum to clear the holes in the dash panel. Remove the plenum from the vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull the lower edge of the instrument panel rearward, as necessary, while rolling the plenum from behind the instrument panel.
Remove the 4 retaining screws from the heater core cover and remove the cover from the plenum assembly. Pull the heater core and seal assembly from the plenum assembly.
Carefully install the heater core and seal assembly into the plenum assembly. Visually check to ensure that the core seal is properly positioned. Position the heater core cover and install the 4 retaining screws.
Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
Position the plenum under the instrument panel with the register duct opening up and the heater core tubes down. Rotate the plenum up behind the instrument panel and position the plenum to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the evaporator case.
Install the 3 nuts on the studs along the lower flange and one on the upper flange of the plenum. Install the 3 nuts below the windshield wiper motor to attach the left end of the plenum to the dash panel and the one nut to retain the upper left corner of the evaporator case to the dash panel.
Position the floor air distribution duct on the plenum. Install the 2 screws and plastic push fastener. If removed, position the panel door vacuum motor to the mounting bracket and install the 2 attaching screws.
Connect the white vacuum hose to the outside-recirculating door vacuum motor. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct. Install the floor duct.
If equipped with manual air conditioning, connect the temperature control cable housing to the bracket on top of the plenum and connect the temperature control cable to the temperature blend door crank arm. Adjust the temperature cable.
If equipped with ATC, proceed as follows:
Connect the temperature control cable to the ATC sensor and adjust the cable. Route and connect the vacuum harness connector to the ATC sensor and connect the electrical connector to the ATC servo connector. Do not block the sensor aspirator exhaust port with the excess vacuum harness. Install the ATC sensor tube between the sensor and the evaporator connector.
Connect the ATC sensor tube to the evaporator case connector.
Install the cross body brace and connect the wiring harness to the blend door actuator.
Install the bolt to attach the lower right end of the instrument panel to the side cowl. Install the right side cowl trim panel and tighten the right door sill plate attaching screws.
Connect the vacuum supply hose(s) to the vacuum source.
Install the right and left lower instrument panel insulators and install the 2 hush panels.
Unplug the heater core tubes and the heater hoses and connect the heater hoses to the heater core tubes. Fill the cooling system.
Connect the negative battery cable and check the system for proper operation. I hope this helps. Don,t forget to rate my answer.
wow. just did this one today. all i can say is have patience. you just have to take the dash completly apart top to bottom. you have to lower your steering colume to. you dont have to take the dash out of the car when you get it off enough on the passanger side just tie it up to the handle at the roof and you got access to the black box on the passanger side. you have to go under the hood and remove two bolts and two hoses to release the black box so you can get the heater core out. you also dont want to forget to disconnect the battery and drain your radiator. I watched my husban do this and i dont know how else to explain this or give better detail i hope i helped.
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If it is necessary to remove the heater assembly, the cooling system must be drained before removing the heater core.
When a heater core leaks, a new heater core is installed or the old one repaired. Heater Housing
The heater housing is usually under the dash and must be removed to gain access to the heater core.
Procedures for replacing the heater core vary with the year, make, and model of car. It threfore necessary to consult the manufacturer's repair manuals for the proper procedure for replacement.
The heater housing is disassembled to get to the heater core.
Remove the access panels(s) or the split heater/air conditioning case to gain acess to the heater core.
Remove the heater coolant hoses.
Remove the cable and/or vacuum control lines (if equipped).
Remove the heater core securing brackets and/or clamps.
Lift the core from the case. Do not use force. Take care not to damage the fins of the heater core when removing.
To reinstall the heater core, reverse the removal steps.
When the heater core leaks and must be repaired or replaced, it is a
very difficult and time-consuming job primarily because of the core's
location deep within the firewall of the car. For this reason always
leak test a replacement heater core before installation. .
Remove the radio/HVAC control module bezel. CAUTION The vehicles covered by this manual are equipped with a Supplemental Restraint System (SRS), which uses air bags. Whenever working near any of the SRS components, such as the impact sensors, air bag modules, steering column and instrument panel, disable the SRS, as described earlier in this section.
Remove the right instrument panel side trim.
Remove the two retaining screws at the lower right side support beam.
Remove the instrument panel support bolt at the A-pillar.
Remove the left instrument panel side trim and upper instrument panel bezel.
Remove the lower knee bolster and console screws at the instrument panel.
Remove the gearshift knob and shifter bezel.
Remove the mounting screws at the front and rear of the floor console. Remove the front and rear console halves.
Remove the right side instrument panel support strut.
Drain the cooling system into a suitable container, then disconnect the heater hoses at the cowl panel. Plug the heater core outlets to prevent coolant from spilling during unit housing removal.
Remove the mounting screws and heater core cover.
Remove the heater core from the vehicle. To install:
Carefully position the heater core unit into the heater housing.
Install the heater core cover onto the heater housing and tighten the mounting screws.
Install the right side instrument panel support strut.
Install the front and rear console halves.
Install the shifter bezel and gearshift knob.
Install the lower knee bolster and console screws at the instrument panel.
Install the upper instrument panel bezel and left instrument panel side trim.
Install the instrument panel support bolt at the A-pillar.
Install the two retaining screws at the lower right side support beam.
1.Disconnect the cable from the nrgative battery terminal. Drain the cooling system
2.Remove the cowl vent panel, Then disconnect the heater hoses from the heater core inlet and outler tubes at the firewall.
3. on models so equipped, disconnect the engine ground strap attached to one of the heater core tubes.
4.Remove the center dash support trim and the radio cassette box ashtray.
5. Pull back the carpeting and pull the rear airflow duct away from the main floor duct.
6. Remove the two instrument panel support brackets and the heater main floor duct.
7. Remove the screws and the heater core cover, the remove the heater core. (Be careful not to tear the foam sealing material).
8. When reinstalling the heater core in the housing, make sure the original foam sealing the material is intact and in place.
9. The remainder of the installation is the reverse of removal.
10. Fill the cooling system.
Run the engine and check for coolant leaks.
Any questions please feel free to post it and I will answer it.
the entire dash, door to door top to bottem has to be removed to be able to take out hvac housing so you can take apart to get at the core [recomend do heater core at same time] the dash comes out as an entire unit guages and all. bolts on ends under plastic covers,on top near winshield under vent trim.,bolts on floor in center below radio and a/c controlls,steering column has to come out. multiple wire connectors etc. its an all day job for a pro so its going to take awhile but its pretty straight forward
FIRST OF ALL YOU NEED TO DISABLE AIR BAGS.TURN OFF RADIO FIRST SO YOU WONT LOSE RADIO PLAYING CODE.DISCONNECT NEGATIVE BATTERY CABLE. WAIT 15 TO 20 MINUTES UNTIL AIR BAGS DISCHARGE.TO REMOVE HEATER AND AC CONTROL SWITCH.YOU NEED A FLAT TRIM TOOL USE TO PRY UP TRIM AROUND CONTROL SWITCH.SO YOU CAN REMOVE CONTROL SWITCH SCREWS AND REMOVE CONTROL SWITCH.
That is about a 9 hour job. The heater core in in the Heater Air plenum chamber which is behind the dash. the dash has to be removed to replace the heater core. It is an involved job. Lots of bolts, screws wireing connectord and vacume connectors to remove and un plug. Some are behind the inner fender splash guard. The book wants you to remove the complete Heater Air Plenum, But it can be done with Patience and finess.
If you have a knock or clicking noise behind the radio, it is the blend motor. The blend door is spring loaded and the gears in the blend motor are "stripped". The door is spring loaded so that the door is closed to the heater core. About 2 hours to replace and a lot of bending and stretching. You don't have to remove the dash, but all of the trim, radio, and controls will need to come out.