Crown Victoria V8-4.6L SOHC VIN 6 (1996)
Heater Core Case: Service and Repair
Removal
1. Disconnect battery ground cable.
2. Disconnect the heater hoses from the heater core tubes. Plug the ends of the heater hoses to prevent coolant loss.
3. Plug heater core tubes securely to prevent coolant leakage from heater core during plenum removal.
4. Remove three nuts located below the windshield wiper motor retaining the LH end of the plenum to the dash panel.
5. Remove one nut retaining the upper LH corner of the evaporator case to the dash panel.
6. Remove LH and RH lower instrument panel insulators.
7. Disconnect two vacuum supply hoses from vacuum source. Push grommet and vacuum supply hose into passenger compartment.
8. Remove all instrument panel retaining screws and pull the instrument panel back as far as possible without disconnecting any wire harnesses.
9. Loosen the RH door sill plate and remove the RH side cowl trim panel.
10. Remove cross body brace and disconnect wiring harness from temperature blend door actuator and disconnect the EATC sensor tube from the
evaporator case connector.
11. Disconnect the vacuum jumper harness at the multiple vacuum connector near the floor air distribution duct.
12. Disconnect the white vacuum hose from the outside-recirculating door vacuum motor.
13. Remove two hush panels.
14. Remove one plastic push fastener retaining the floor air distribution duct to the LH end of the plenum. Remove LH screw and loosen RH screw on
the rear face of the plenum and remove the floor air distribution duct.
15. Remove two nuts from the two studs along the lower flange of the plenum.
16. Carefully move plenum rearward to allow heater core tubes and the stud at the top of the plenum to clear holes in the dash panel. Remove plenum
from vehicle by rotating the top of the plenum forward, down and out from under the instrument panel. Carefully pull lower edge of instrument
panel rearward as necessary while rolling the plenum from behind the instrument panel.
