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Removal & Installation

  1. Remove instrument panel. See INSTRUMENT PANEL . Drain coolant from radiator so that coolant level is below heater core. Disconnect heater water hose. See Figure.
  2. Inside vehicle, remove nut. See Fig 1. Mark location of vacuum hoses and disconnect vacuum hoses. See Fig 2 and Fig 3 .
  3. Remove pin-type retainers and remove vacuum harness. See Fig 4. Disconnect electronic blend door actuator connector. See Figure. Remove nuts and disconnect electrical connectors. See Fig 5 and Fig 6.
    4. CAUTION: Do not excessively cut rear footwell duct. Make sure to only cut rear footwell duct to point that allows heater floor duct to be removed with plenum chamber as an assembly.
  4. Position back carpet from plenum chamber. Cut each side of rear footwell duct and bend back duct. See Fig 7. Remove plenum chamber. See Fig 8.
  5. To install, reverse removal procedure. Clean and lubricate coolant hoses with MERPOL® or plain water if needed. Close rear footwell duct around heater outlet floor duct, install a tie strap, and position back carpet. Make sure to sufficiently seal rear footwell duct to heater outlet floor duct. See Fig 9.
Fig 1: Removing & Installing Nut Inside Vehicle
G00218722Courtesy of FORD MOTOR CO.
Fig 2: Disconnecting Vacuum Hoses (1 Of 2)
G00218723Courtesy of FORD MOTOR CO.
Fig 3: Disconnecting Vacuum Hoses (2 Of 2)
G00218724Courtesy of FORD MOTOR CO.
Fig 4: Removing & Installing Pin-Type Retainers & Vacuum Harness
G00218725Courtesy of FORD MOTOR CO.
Fig 5: Removing & Installing Plenum Chamber Nuts
G00223678Courtesy of FORD MOTOR CO.
Fig 6: Removing & Installing Electrical Connector From Plenum Chamber
G00223679Courtesy of FORD MOTOR CO.
Fig 7: Cutting Sides Of Rear Footwell
G00218727Courtesy of FORD MOTOR CO.
Fig 8: Removing & Installing Plenum Chamber
G00218728Courtesy of FORD MOTOR CO.
Fig 9: Installing Rear Footwell Duct
G00218729Courtesy of FORD MOTOR CO.
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