:	Jun 14, 2004

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Remove the intake manifold.

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Evacuate the A/C system.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Drain the cooling system.

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Remove the driver side front seat.

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Remove the instrument panel upper section.

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Release the 3 ground cables from the driver side lower A-pillar.   Remove the 2 nuts.

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Disconnect the 5 electrical connectors from the driver side lower A-pillar.

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Release the 3 ground cables from the passenger side lower A-pillar.   Remove the 2 nuts.

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Disconnect the heater motor electrical connector.

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Disconnect the 5 electrical connectors from the passenger side lower A-pillar.

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Disconnect 2 central junction box (CJB) electrical connectors.

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Disconnect 2 electrical connectors from the instrument panel center reinforcement.

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: Cover fibre optic cable connectors to minimise dust ingress and avoid bending the cables in a radius of less than 30 mm. If installed, disconnect the instrument panel center reinforcement fibre optic cables.   Disconnect the electrical connector.

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Remove the heater housing center ducts.

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Disconnect the steering column intermediate shaft from the steering column.   Note the fitted position.   Remove the special bolt and discard the nut.

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Release the heater housing from the instrument panel carrier.   Remove the 7 Torx screws.

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Remove the plenum chamber panel.

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Remove the instrument panel carrier to bulkhead Torx bolt.

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With assistance, remove the instrument panel.   Remove the 6 Torx bolts.

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: Before disconnecting or removing the components, ensure the area around the joint faces and connections are clean. Plug open connections to prevent contamination. Disconnect 2 heater hoses from the bulkhead.   Release the 2 clips.

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Release 2 A/C lines from the body.   Remove the nut.

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: Immediately cap all refrigerant lines to prevent ingress of dirt and moisture. Release 2 A/C lines from the bulkhead.   Remove the bolt.   Remove and discard the O-ring seals.

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Remove the 2 adaptor panels.   Remove the 4 nuts.

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Disconnect 2 drain tubes from the heater housing.

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Remove the driver side footwell duct.   Remove the 2 Torx screws.

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Remove the passenger side footwell duct.   Remove the 2 Torx screws.

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Driver side: Remove the heater housing to bulkhead Torx bolt.

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Passenger side: Remove the heater housing to bulkhead Torx bolt.

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Remove the heater housing.

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Disconnect the evaporator core temperature sensor electrical connector.

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Release the heater core housing.   Remove the 2 screws.   Remove the 8 clips.

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Remove the evaporator core.   Release the temperature sensor.

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Install the evaporator core.   Secure the temperature sensor.

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Secure the heater core housing.   Install the clips.   Tighten the screws.

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Connect the temperature sensor electrical connector.

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Install the heater housing.

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Passenger side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).

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Driver side: Install the heater housing to bulkhead Torx bolt and tighten to 6 Nm (4 lb.ft).

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Install the footwell ducts.   Tighten the Torx screws.

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Connect the drain tubes to the heater housing.

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Install the adaptor panels.   Tighten the nuts to 6 Nm (4 lb.ft).

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Secure the A/C lines to the bulkhead.   Clean the components.   Install new O-ring seals.   Tighten the bolt to 6 Nm (4 lb.ft).

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Secure the A/C lines to the body.   Tighten the nut to 6 Nm (4 lb.ft).

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Connect the bulkhead heater hoses.

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With assistance, install the instrument panel.   Tighten the Torx bolts to 25 Nm (18 lb.ft).

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Install the instrument panel carrier to bulkhead Torx bolt and tighten to 25 Nm (18 lb.ft).

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Install the plenum chamber panel.

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Secure the heater housing.   Tighten the screws.

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Connect the steering column intermediate shaft.   Install the special bolt and tighten the new nut to 22 Nm (16 lb.ft).

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Install the heater housing center ducts.

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Connect the instrument panel center reinforcement fibre optic cables.

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Connect the instrument panel center reinforcement electrical connectors.

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Connect the CJB electrical connectors.

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Connect the heater motor electrical connector.

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Connect the electrical connectors to the passenger side lower A-pillar.

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Connect the ground cables to the passenger side lower A-pillar.   Tighten the nuts to 10 Nm (7 lb.ft).

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Connect the electrical connectors to the driver side lower A-pillar.

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Connect the ground cables to the driver side lower A-pillar.   Tighten the nuts to 10 Nm (7 lb.ft).

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Install the instrument panel upper section.

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Install the front seat.

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Recharge the A/C system.

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Refill the cooling system.

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Install the intake manifold.