With Air Conditioning

REMOVAL
1. Disconnect the negative (ground) cable from the battery negative (-) terminal.
2. Disconnect the heater hoses from the heater core tubes. Plug the ends of the heater hoses to prevent coolant loss.
3. Plug the heater core tubes securely to prevent coolant leakage from the heater core during plenum removal.

Evaporator Case/Plenum Removal:

4. Remove one bolt located below the windshield wiper motor attaching the left end of the plenum to the dash panel.
5. Remove one nut retaining the upper left corner of the heater case to the dash panel.
6. Disconnect control system vacuum supply hose from vacuum source and push grommet and vacuum supply hose into passenger compartment.
7. Remove the three glove compartment hinge screws, disconnect the check strap, and remove the glove compartment.
8. Loosen the right door sill plate and remove the right side cowl trim panel.
9. Remove the bolt attaching the lower right end of the instrument panel to the side cowl.

Instrument Panel Pad Removal And Installation:

10. Remove the instrument panel pad.
11. Disengage the temperature control cable housing from the bracket on top of the plenum. Then, disconnect the cable from the temperature blend door crank arm.
12. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
13. Disconnect the white vacuum hose from the outside air door vacuum motor.
14. Remove two screws attaching the passenger (rear) side of the floor air distribution duct to the plenum. It may be necessary to remove the two screws attaching the panel door vacuum motor to the mounting bracket to gain access to the right screw.
15. Remove one plastic push fastener retaining the floor air distribution duct to the left end of the plenum and remove the floor air distribution duct.
16. Remove two nuts from the two studs along the lower flange of the plenum.
17. Carefully move plenum rearward to allow heater core tubes and stud at the top of the plenum to clear the holes in the dash panel. Then, remove plenum from vehicle by rotating top of plenum forward, down and out from under the instrument panel. Carefully pull lower edge of instrument panel rearward as necessary while rolling plenum from behind the instrument panel.

INSTALLATION
1. Position plenum under instrument panel with the register duct opening up and the heater core tubes down. Rotate plenum up behind the instrument panel and position plenum to the dash panel. Insert heater core tubes and mounting studs through their respective holes in the dash panel and the plenum.
2. Install two nuts on the studs along the lower flange of the plenum.
3. Install one bolt below the windshield wiper motor to attach the left end of the plenum to the dash panel.
4. Install one nut to retain the upper left corner of the heater case to the dash panel.

Floor Air Distribution Duct:

5. Position the floor air distribution duct to the plenum and install two screws and the plastic push fastener.

Panel Door Vacuum Motor:

6. Position panel door vacuum motor to mounting bracket and install two attaching screws.
7. Connect the white vacuum hose to the outside air door vacuum motor.
8. Connect the vacuum jumper harness to the plenum harness at the multiple vacuum connector near the floor air distribution duct.
9. 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.
10. Install the bolt to attach the lower right end of the instrument panel to the side cowl.
11. Install the right side cowl trim panel and tighten the right door sill plate attaching screws.
12. Install the instrument panel pad.
13. Install the glove compartment door.
14. Route the vacuum supply hose through the dash panel and seat the grommet in the opening.
15. Connect the vacuum supply hose to the vacuum supply.
16. Unplug the heater core tubes and connect the heater hoses to the heater core tubes.
17. Add coolant to the proper cooling system level assuring that the correct coolant mixture is maintained.
18. Connect the ground cable to the battery negative (-) terminal and check the system for proper operation.

NOTE: On vehicles equipped with Electronic Engine Control (EEC), when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.