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IPD's website has a great video on the site that shows you step by step how everything comes apart and goes back together to change Heater Cores. It would be easier for you to watch that than have me explain. You have probably missed a screw somewhere.
You will need a torx bit set, I am not sure of the size, but all the torx screws in the removal should be the same size. First, removed the panel under the glove box, then remove the glove box itself. The you will see the SRS passenger air bag plate, which is held on by 3 nuts, 13mm if I remember right. Then take that out. Now you will see the blower to the right when looking through the opening in the glove box. To the left you will a black flat plug which is plugged into the back of the rectangular shaped Resistor; it has an ear on it where there is a screw attaching the resistor to the ventilation duct. Simply unplug the resistor and remove screw. Installation is reverse of removal.
why can't you remove the glove box? You can get at the door from under the dash but it's a ***** to do. try lubing the vent cables unless it uses the vacuum motor, if it uses the vac. motor it will be hard to get to without the glove box being out.
you must remove glove box,remove lower cover below glove box, get under dash and use flashlight and you will see the fan resistor in the evap box, it maybe held in with a t 20 torx screw otherwise pull aside tab and pull out
(2) remove the old cabin air filter. This is located under the glove box near
the footwell light. You can get to the filter by removing the plastic
covering under the glove box. This is held in by 2 torx screws. Remove
this, and you've reached the CAF.
(3) slide out the old CAF.
(4) slide in the new one. Really, there's nothing more than that.