Heater Core: Service and Repair
Less Air Conditioning
Fig. 6 Typical instrument panel. 1983-88 Cougar & Thunderbird:
Fig. 7 Heater core less A/C. 1982 Cougar XR-7, 1982-88 Thunderbird, 1983-88 Cougar & 1983-86 LTD & Marquis:
1. Disconnect battery ground cable.
2. Remove steering column cover, then the instrument panel reinforcement under steering column opening.
3. Remove 2 nuts securing hood latch release handle mounting bracket to brake pedal support under steering column.
4. Remove sound insulator from lower left side of instrument panel, Fig. 6.
5. Remove 2 steering column clamp attaching nuts and lower steering column to rest on front seat.
6. Remove instrument panel pad attaching screws and the pad.
7. Disconnect speedometer cable from speedometer.
8. Remove console cover or tray.
9. Remove 4 console switch panel cover attaching screws, then disconnect electrical connectors and remove switch panel.
10. Remove console attaching screws, then disengage console from instrument panel and position aside.
11. Remove 2 pins attaching glove compartment door straps to glove compartment and allow door to hang down on hinge.
12. Remove instrument panel brace attaching bolt from glove compartment opening.
13. Remove brake pedal support attaching nut from lower edge of instrument panel.
14. Remove instrument panel brace attaching bolt from lower edge of instrument panel on left side of console extension.
15. Remove instrument panel-to-cowl side panel attaching bolt from both sides of instrument panel.
16. Support instrument panel and remove 3 instrument panel-to-cowl top panel attaching screws.
17. Move instrument panel rearward, disconnect necessary electrical connectors and vacuum hoses, and rest panel on front seat.
18. Drain cooling system, then disconnect hoses from heater core. Cover hoses and heater core tubes to prevent leakage.
19. Remove 2 nuts securing heater case to dash panel from engine compartment.
20. Working in passenger compartment, remove screws attaching heater case support bracket and air inlet duct support bracket to cowl top panel.
21. Remove nut retaining bracket at left end of heater case to dash panel and nut securing bracket below case to dash panel.
22. Pull heater case away from dash panel to gain access to heater core access cover attaching screws.
23. Remove heater core access cover attaching screws and the cover.
24. Remove heater core and seals from heater case, Fig. 7.
25. Remove the 2 seals from heater core tubes.
26. Reverse procedure to install.
Fig. 9 Instrument panel trim panel (Typical). 1982 Cougar XR-7, Thunderbird & 1983-86 LTD & Marquis:
1. Disconnect battery ground cable.
2. Remove steering column cover assembly, then remove left and right finish panels, Fig. 9.
3. Remove two screws from sides of instrument panel pad and retainer assembly.
4. Remove pad and retainer assembly and upper finish panel.
5. Remove steering column attaching bolts, then carefully lower steering column just enough to allow access to transmission gear selector lever cable assembly. Reach between steering column and instrument panel, then carefully lift selector lever cable from lever and remove cable clamp from steering column tube.
6. Lower steering column and allow to rest on front seat.
7. Remove screw attaching instrument panel to brake pedal support through steering column opening.
8. Disconnect temperature door cable from door and heater/evaporator cable bracket.
9. Disconnect vacuum hose connectors at evaporator housing.
10. Disconnect blower motor resistor wire from resistor on heater/evaporator case and blower motor feed wire at in-line connector.
11. Support instrument panel, then remove three screws attaching top of instrument panel to cowl.
12. Remove one screw attaching each end of instrument panel to cowl side panels, then remove two screws attaching instrument panel to floor.
13. Move instrument panel rearward and disconnect speedometer cable and any wires that will prevent instrument panel from being placed on front seat. Use care when removing instrument panel to prevent damage to panel or steering column surfaces.
14. On 1982-86 models less A/C, perform steps 18 through 26 under ``Heater Core, Replace,'' ``1983-88 Cougar & Thunderbird, Less Air Conditioning.''
15. On 1983-86 models with A/C, perform steps 2 through 14 under ``Heater Core, Replace,'' ``1983-88 Cougar & Thunderbird, With Air Conditioning.''
Less Air Conditioning
Fig. 10 Heater core assembly (Late Production Models). 1982 Cougar & Granada & 1982-83 Fairmont & Zephyr:
Fig. 11 Heater case assembly (Early Production Models). 1982 Fairmont, Zephyr, Cougar & Granada:
Models with heater cases built after 11-1-81 use a one piece case, Fig. 10. This type case cannot be separated and all interior case components must be removed and installed through openings in case.
1. Disconnect battery ground cable and drain cooling system.
2. Disconnect heater hoses from heater core and seal the core tubes.
3. Remove glove box liner.
4. Remove instrument panel to cowl brace retaining screws and brace.
5. Place temperature control lever in the warm position.
6. Remove heater core cover retaining screws and the cover, Figs. 10 and 11.
7. From engine compartment, remove heater case assembly mounting stud nuts.
8. Push heater core tubes and seal toward passenger compartment to loosen heater core from case assembly.
9. Remove heater core through glove box opening.
10. Reverse procedure to install.
With Air Conditioning
Fig. 8 Heater core with A/C. 1982 Cougar XR-7, 1982 Granada, 1982-83 Fairmont & Zephyr, 1982-88 Thunderbird, 1983-88 Cougar & 1983-86 LTD & Marquis:
Fig. 10 Heater core assembly (Late Production Models). 1982 Cougar & Granada & 1982-83 Fairmont & Zephyr:
Models with heater cases built after 11-1-81 use a one piece case, Fig. 10. This type case cannot be separated and all interior case components must be removed and installed through openings in case.
1. Disconnect battery ground cable.
2. Remove screws attaching instrument cluster trim panel to instrument panel pad.
3. Remove instrument panel pad to instrument panel screws at each defroster opening.
4. Remove instrument panel pad edge to instrument panel screws, and pad.
5. Remove steering column lower cover to instrument panel screws then the cover.
6. On 1982-83 models, proceed as follows:
a. Remove steering column trim shroud attaching screws and the trim shrouds.
b. Remove steering column attaching nuts, then carefully lower steering column just enough to allow access to transmission gear selector lever cable assembly. Reach between steering column and instrument panel and carefully lift selector lever cable from lever and remove cable clamp from steering column tube.
c. Lower steering column and allow to rest on front seat.
7. On all models, remove instrument panel to brake pedal support screw at steering column opening.
8. Remove screw attaching lower brace to lower edge of instrument panel below radio.
9. Remove screw attaching the brace to lower edge of instrument panel.
10. Disconnect temperature control cable from blend door and evaporator case bracket.
11. Disconnect vacuum hose connectors from evaporator case.
12. Disconnect blower resistor wire connector from resistor on evaporator housing, then the blower motor feed wire at in-line connector.
13. Support instrument panel and, with an angle Phillips screwdriver, remove three screws attaching top of instrument panel to the cowl.
14. Remove screws attaching instrument panel to cowl side panels.
15. Move instrument panel rearward and disconnect speedometer cable and any wiring that will not permit the instrument panel to be positioned on the front seat.
16. On 1982-83 models, proceed as follows:
a. Discharge refrigerant from A/C system at the service valve on suction line. When system is fully discharged, disconnect and cap high and lower pressure lines.
b. Drain cooling system, then disconnect hoses from heater core. Cover hoses and heater core tubes to prevent leakage.
c. Remove screw securing air inlet duct and blower housing assembly support brace to cowl top panel.
d. Disconnect black vacuum supply hose from in-line check valve in engine compartment.
e. Disconnect blower motor electrical connectors from harness.
f. Disconnect electrical connector from blower motor resistor.
g. Remove two evaporator case-to-dash panel attaching nuts from engine compartment.
h. Working in passenger compartment, remove evaporator case support bracket-to-cowl top panel attaching screws.
i. Remove screw retaining bracket below evaporator case to dash panel.
j. Carefully remove evaporator case assembly from vehicle.
17. On all models, remove five heater core access cover attaching screws and the access cover, Fig. 8.
18. Remove heater core and seals from evaporator case.
19. Remove the two seals from heater core tubes.
20. Reverse procedure to install.