Need to replace heater core

Big job, dificulty 8 on a 10 scale Heater Air Plenum Chamber Removal

1. Remove heater outlet floor duct (18C433) as described.
   

1. Remove instrument panel (04320). Refer to Section 01-12 .
   

Instrument Panel SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Radio Removing Tool 415-001 (T87P-19061-A)
Removal and Installation

1. Disconnect battery ground cable (14301).
   

1. Remove RF wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove three nuts in radiator coolant recovery reservoir area.
   

1. Remove bolt retaining front fender apron (16054) to front fender (16005) .
   

1. Position front fender splash shield out of the way.
   

1. Lower vehicle.
   

1. Tag and remove main harness connector from jumper harness (located in front of blower motor).
   

1. Remove steering column. Refer to Section 11-04 .
   

1. Remove RH cowl side trim panel (02344) and LH cowl side trim panels (02345) .
   

1. Tag and disconnect wiring connectors in LH and RH cowls.
   

1. Remove ground wire located on LH cowl side.
   

1. Remove RH instrument panel upper moulding (04268) and LHinstrument panel moulding (04389) from instrument panel (04320) by pulling away from instrument panel and snapping out of retainers. Disconnect wiring connectors as required.
   

1. Remove glove compartment (06010).
   

1. Remove instrument panel upper finish panel (044A90) and disconnect the A/C sunload sensor (19E663) and anti-theft indicator, if equipped.
   

1. Disconnect the heater water hoses (18472) from the heater core tubes. Plug the ends of the heater water hoses to prevent coolant loss.
   

1. Plug heater core tubes securely to prevent coolant leakage from heater core (18476).
   

1. Remove one nut retaining the upper LH corner of the A/C evaporator core housing (19A559) to the dash panel (01610) .
   

1. Disconnect two vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment.
   

1. Disconnect wiring harness from A/C electronic blend door actuator.
   

1. Disconnect the white vacuum hose from the heater and A/C air inlet duct door vacuum control motor (18A318).
   

1. Remove nuts from the studs along the lower flange of the heater air plenum chamber (18471).
   

1. Disconnect connectors to A/C electronic blend door actuator and electronic module on side of heater air plenum chamber.
   

1. Remove heater air plenum chamber by pulling rearward.
   

Heater Air Plenum Chamber and Air Inlet Duct





Item Part Number Description 1 19C836 Suction Accumulator/Drier 2 56956-S2 Screw (2 Req'd) 3 386877-S36 Screw 4 45445-S36 Nut and Washer Assy 5 19C928 A/C Recirculating Air Duct Screen 6 386877-S36M Screw (2 Req'd) 7 45332-S12 Nut and Washer 8 19B762 A/C Air Inlet Door Inner Seal 9 19C590 A/C Recirculating Air Duct 10 18471 Heater Air Plenum Chamber 11 18C433 Heater Outlet Floor Duct 12 55734-S2 Nut 13 19A559 A/C Evaporator Core Housing 14 45332-S2 Nut and Washer A — Tighten to 2.5-3.2 Nm (23-28 Lb-In)
Installation

1. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
   

1. Position the heater air plenum chamber under the instrument panel with the A/C register duct opening up and the heater core tubes down. Connect wire harness connector to A/C electronic blend door actuator and electronic module on side of heater air plenum chamber .
   

1. Rotate the heater air plenum chamber up behind the instrument panel and position the heater air plenum chamber to the dash panel. Insert the heater core tubes and mounting studs through their respective holes in the dash panel and the A/C evaporator core housing.
   

1. Install three nuts on the studs along the lower flange and one on the upper flange of the heater air plenum chamber.
   

1. Install three nuts below the windshield wiper motor (17508) to retain the LH end of the heater air plenum chamber to the dash panel.
   

1. Install one nut to retain the upper LH corner of the A/C evaporator core housing to the dash panel .
   

1. Connect the white vacuum hose to the heater and A/C air inlet duct door vacuum control motor.
   

1. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the heater outlet floor duct. Install heater outlet floor duct.
   

1. Connect the sensor tube to the evaporator case connector on EATC-equipped vehicles.
   

1. Connect vacuum supply hose to vacuum supply.
   

1. Unplug the heater core tubes and connect the heater water hoses to the heater core tubes.
   

1. Fill the cooling system with coolant to replace coolant lost during removal of the heater air plenum chamber.
   

1. Install heater outlet floor duct as described.
   

1. Install instrument panel. Refer to Section 01-12 .
   

Section 12-03A: Air Conditioning System—Manual A/C-Heater 1998 Crown Victoria, Grand Marquis Workshop Manual
REMOVAL AND INSTALLATION Heater Core Removal
NOTE: If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. Refer to Section 12-00 .

1. Remove the heater air plenum chamber (18471) assembly as described.
   

1. Remove the heater dash gasket (18570) from the heater air plenum assembly.
   

1. Remove the four retaining screws from the heater core cover (18B300) and remove the heater core cover from the heater air plenum chamber assembly.