Note: This procedure requires recovery of the
air conditioning refrigerant. See an appropriately certified air conditioning
technician to have this recovery performed before commencing any air conditioning system
repair.
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| Remove negative cable from battery. |
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| Remove three 1/4 turn screws along top edge of panel and one
below the steering column |
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Pull panel forward and out. Remove chime module from bracket in panel.
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Air bag equipped:
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| Remove the four 7 mm hex head screws from bottom edge of trim
panel. |
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Remove the three Phillips screws securing trim panel to dash.
Remove trim panel. |
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| Pull horizontal panel down and forward. Remove chime
module wiring connectors or entire module by spreading the plastic clips securing it to
the panel. |
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| Remove the knee bolster by removing two 10mm bolts on left and
three 10mm bolts on right side of bolster. |
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| Remove rear console ashtray by opening, then lifting straight
up, remove 10mm nut (arrow) below ashtray. |
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Remove Park brake boot.
Rigid boot: Pull up front of park brake cover and slide off handle.
Leather boot: Pull up front to release boot, feed boot through opening in
console. |
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| Pull rear section of console back to disengage it from front
section. Lift up at front and slide over parking brake lever. |
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| Squeeze edges of shift boot in and lift up. |
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| Pull boot up far enough to access wiring for lighted shift
knob (if fitted) and unplug connector. |
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| Pull shift knob straight up to remove. A sharp tug is
required. |
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Remove insulation pad from around shifter (if fitted).
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| Remove power window switches and power window circuit breaker
by pushing straight up from below. |
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| Remove 10mm nut from behind shifter, holding rear of console
section to floor. |
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| Remove front ashtray by opening, then pulling straight up. |
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| Remove the two screws forward of the ashtray (arrows) and lift
out the ashtray / lighter assembly. |
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| Unplug lighter and illumination bulb. |
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| Remove bolt from below heater slides. Position shown in
mirror. |
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| Turn screws on either side of console, by firewall, 90° and remove. |
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| Pull front section of console up and to the rear to remove. |
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| Open glove compartment, remove pins from retaining straps. |
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| Press tab on flashlight socket and push socket out of holder. |
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| Remove wiring clips and remove glove compartment. |
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| Loosen the three 10mm nuts from hinge behind glove
compartment. Slide glove compartment forward to remove, hinge is slotted to allow removal
without removing the 10mm nuts. |
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Remove the two Phillips screws (upper green arrows) and two
1/4 turn clips (lower green arrows). Remove upper cover.
Do not remove the two gold anodized Phillips screws (red arrows). These screws should not
be touched unless glove compartment latch adjustment is required. |
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| Disconnect wiring to glove compartment light |
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| Pull main wiring harness away from plastic trim on left side
of glove compartment opening. |
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| Remove plastic cover from left side of glove compartment by
removing left most screw in glove compartment opening (blue arrow), and 1/4 turn clip
(green arrow). (click on image for larger view) |
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If you haven't already done so, evacuate refrigerant from A/C
system.
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| Disconnect refrigerant lines from expansion valve, hold valve
with appropriate sized wrench while loosening nuts on lines. Requires 17mm and 24mm open
end or line wrenches. |
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| Locate evaporator temperature sensor above heater valve on
left side of heater housing. This is removed to prevent damage to it or the evaporator
when the evaporator is slid out and back in to the housing. (click on image
for larger version) |
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| If necessary, the vent tubing can be removed for better
access. Early cars, remove concertina tube going to rear floor vents
All, remove Phillips screw and remove vent. |
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| Remove the four Torx T20 or Phillips screws from evaporator
cover on right side of heater box. A ball head Torx driver or a socket with a
universal attachment will be required to access screw closest to firewall. |
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| Pull sound insulation away from firewall for clearance. |
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| Remove cover from expansion valve. |
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| Slide evaporator out, slightly, to the right. |
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| Disconnect both pipes from expansion valve and remove
valve. 19 and 22 mm wrench required. |
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Installation:
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| Replace all O rings exposed during removal. |
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Non air bag equipped:
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| Ensure rear edge of panel locates correctly in bracket on
steering column. |
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Air bag equipped:
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Mount bolster first.
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| Ensure rear edge of horizontal panel seats in clip on center
console. |
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| Loosely insert the four 7 mm hex head screws through
horizontal panel into bolster. |
| Trim panel is slotted on bottom edge to allow it to be
inserted past the screws. Line up trim panel and install screws along upper edge
first, tightening the hex screws along bottom edge last. |
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