UNDER THE HOOD
1. Disconnect Batteries 2. Remove Air Cleaner Assembly 3. Unbolt Dryer from firewall, but do not disconnect any A/C lines 4. Remove Computer from firewall 5. Remove bolts from Computer Bracket (the 2 on the right side of the bracket are heater box studs that hold the heater box on the firewall 6. Disconnect Htr Hoses at engine block and use compressed air to drain Htr Core (hoses can be left attached to Htr Core, they will fit through firewall) 7. Remove two (2) 11mm nuts from Htr Box studs (one behind the engine valve cover and one behind the Computer bracket)
NOTE: so far you've removed 4 nuts holding the heater box on the firewall ( 1 above the dryer, 1 at the bottom of the dryer, 1 behind the computer, and 1 behind the valve cover)
DASH REMOVAL
1. Remove the Glove Box and Disconnect two (2) electrical connections on the Htr Box and the Radio Antenna 2. Remove the plastic cover below the center of the dash and bracket behind it holding some electrical thing (sorry don't know what this is) 4. Remove six (5) 5/16" (actually I think these were 8 or 10mm, I think I only used 8,10,11,13 and maybe a 15 / 17mm sockets and wrenches for this job) screws from across the top of the Dash 5. Remove the Panel under the Steering Column 6
if you have an AUTO trans and a gear posn indicator disconnect the small cable or it WILL get broken 7. I didn't disconnect the Vacuum Line for the Htr Box above the Throttle Pedal 8. Remove two (2) nuts on studs that holds the Steering Column and set the Steering Column in the drivers seat 9. Remove the driver and passenger side Kick Panels 10. Loosen the bolts behind the Kick Panels for the Dash (hold on to Dash, it is loose now) and roll it towards the seats 11. Lift the passenger side of the Dash off of the lower bolt and set it back against the seat (this will make room to work on the Htr Box)
HTR BOX REMOVAL
1. Remove the ground strap above the Htr Box from the FIREWALL 2. Remove the 10mm nut near the passenger A-Pillar from the stud holding the Htr Box (I had trouble finding this one - it's in the top right corner of the heater box) 3. Remove the 10mm nut above the Htr Box where the ground strap came off 4. On mine, there was a second nut behind the ground strap holding the box to the firewall. I didn't see it and wasted a lot of time. 4. Pull the heater box in away from the firewall It will only pull away a few inches because the A/C lines / dryer are still attached, but it's enough. 5. Use a Phillips screwdriver to remove the 2 remaining bracket holding the tubes in place 6. . At this point I used a hacksaw to cut off the 2 tubes to get them through the firewall. 7) Heater core just pulls up out of the box.
RE-ASSEMBLY
1) Install the new heater core by placing the bottom left corner into the box (core is cocked toward driver side and moveable tubes near the hole where they go through the firewall. 2) Gently and slowly rotate the core clockwise keeping the tubes near the hole in the firewall. The core should drop down into the box.
Perform everything else in reverse order. Ensure Htr Box functions properly prior to re-installation. Take care not to kink Vac line on Htr Box when it goes back through firewall. Also, on mine, the stud at the bottom of the dryer fell off of the box. It was a pain to get it back into place. I had another set of hands to help me get the box back in place. That would be have been pretty tough to do alone. Like Busboy said in the other thread, "TAKE YOUR TIME" and don't force anything. GOOD LUCK!
I got this off another forum hope this helps.
Floyd
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