Operation CHARM: Car repair manuals for everyone.

Removal

1. Disconnect battery ground cable.
2. Remove instrument panel lower trim cover retaining screws and the cover.
3. Remove instrument panel support rod retaining screws and the rod.
4. Remove steering column wiring harness bulkhead connector retaining screw.
5. Disconnect automatic transaxle shift cable from lever with a screwdriver.

Fig. 15 Removing Cable From Column Mounting Bracket:




6. Compress cable retainer tangs with pliers and slide cable out of column mounting bracket.
7. Loosen screw securing anchoring bracket in place, then move bracket to key hole position and remove it from its mounting bracket.
8. Lift indicator wire off of pulley.
9. Pull sleeve down to expose steering column universal joint.

Fig. 16 Steering Column Shaft & Intermediate Shaft:




10. Make a reference mark on steering column shaft and intermediate shaft and remove bolt from intermediate shaft.
11. Remove bolts and nuts that hold steering column to instrument panel/brake sled.
12. Carefully lower steering column assembly to vehicle floor, then separate steering column shaft from intermediate shaft and remove column assembly from vehicle.
13. Remove defroster grille and remove bolts under grille.
14. Loosen but do not remove nut located near the parking brake release handle and nut which is located on the side kick panel.
15. Remove lower parking brake release handle retaining screws and the handle.
16. Remove ashtray, then disconnect cigarette lighter connectors and remove screw from ashtray cavity.

Fig. 17 Electrical Connections For Dash Panel:




17. Remove bolt from brake sled and disconnect all electrical connections.
18. Remove instrument panel to floor bracket attaching bolts.
19. Disconnect interior temperature sensor by pressing tabs together and pushing air temperature sensor hose rearward.
20. Carefully lift up and rearward to disengage and remove instrument panel, then remove floor duct extension.
21. Drain cooling system and discharge A/C system.
22. Squeeze and slide heater core hose clamps off of heater core tubes towards engine and carefully pry heater hoses off of heater core tubes.

NOTE:Heater core tubes are made of plastic and may break if too much pressure is applied.

23. Disconnect coolant level switch connector, then remove coolant reservoir retaining strap and move reservoir aside.
24. Disconnect blower motor electrical connector and vacuum hose.
25. Disconnect refrigerant lines from dash panel using appropriate tools from tool kit No. MS-1979 or equivalent.
26. Remove nuts holding A/C-heater housing to firewall.

Fig. 18 A/C-heater Housing:




27. From inside vehicle, remove nuts holding A/C-heater housing.
28. Carefully pull A/C-heater housing rearward and remove from vehicle.
29. Release plastic tabs and remove heater core.