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Monday, July 11, 2011

Heater Core removal procedure on 2005 Ford Explorer?

Removal & Installation


NOTE
If a heater core leak is suspected, the heater core (18476) must be leak tested before it is removed from the vehicle.

  1. Before beginning service, read the -Precautions- at the beginning of this section.
  2. Prepare the vehicle for heater core removal:
    1. Remove the instrument panel. See -Instrument Panel- under the -Body- section.
    2. Remove the A/C evaporator housing. See -HVAC Evaporator Housing- section.
    3. Remove the Powertrain Control Module (PCM).

  3. Remove the PCM heat sink:
    1. Remove the ground strap screw.
    2. Remove the heat sink.

      Click image to see an enlarged view

      Fig. Remove the ground strap screw (1) and remove the heat sink (2)-2005 Explorer Sport-Trac


  4. Remove the four heater housing nuts from the engine side of the dash panel. Position the plenum chamber on the vehicle floor.
  5. Remove the heater core cover by removing the screws (1) and the heater core cover (2).

    Click image to see an enlarged view

    Fig. Remove the heater core cover by removing the screws (1) and the heater core cover (2)-2005 Explorer Sport-Trac

  6. Remove the heater core.

To install:

  1. Installation is the reverse of the removal procedure.
  2. During installation, be sure to install a new oval foam seal around the heater core inlet and outlet tubes.

Explorer And Explorer Sport-Trac



2000 Models
  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

  2. Drain the cooling system into a clean container for reuse.
  3. Disconnect the heater hoses from the heater core.
  4. Remove the steering column by performing the following procedure:
    1. Position the front wheels in the straight-ahead direction.
    2. At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.
      CAUTION
      Safely store the air bag module with the front side facing upward.

    3. Remove the steering wheel-to-steering column nut.
    4. Using a steering wheel puller, press the steering wheel from the steering column.
    5. Remove the parking brake release handle screws and move the release handle aside.
    6. Remove the hood release screws and move the hood release aside.
    7. Remove the 2 instrument panel-to-steering column cover screws and the cover.
    8. Remove the instrument panel steering column opening reinforcement bolts and the reinforcement.
    9. Remove the ignition switch bolt and disconnect the ignition switch electrical connector.
    10. At the base of the steering column, disconnect the electrical connectors.
    11. If equipped with an automatic transmission, remove the transmission range indicator bolt and the cable.
    12. If equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket.
    13. Disconnect the brake shift interlock solenoid electrical connector.
    14. Remove the air bag sliding contact.
    15. Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt.
    16. Remove the lower steering column-to-instrument panel nuts and the steering column.

  5. Remove the instrument panel by performing the following procedure:
    1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
    2. Remove the push pins and remove both cowl side trim panels.
    3. At the right side cowl panel, disconnect the electrical connectors and ground wires.
    4. Remove both sides windshield garnish moldings.
    5. Disconnect the power distribution box from its bracket and move it aside.
    6. In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors.
    7. Pull the bulkhead electrical connector handle and disconnect the wiring harness.
    8. Remove the passenger-s side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.


Store the air bag module in a safe location with the front facing upward.

  1. Disconnect the blend door actuator-s electrical connector.
  2. Disconnect the climate control vacuum harness connector.
  3. Disconnect the radio-s antenna connector.
  4. Remove the glove compartment.
  5. Remove the instrument panel defroster grille.
  6. Remove the upper instrument panel bolts.
  7. If equipped, remove the upper series floor console.
  8. Under the steering column, remove the instrument panel brace bolt.
  9. At both sides, remove the windshield side garnish moldings.
  10. Remove both the right and left instrument panel-to-cowl bolts.
  11. Remove the fuse panel door.
  12. Pull the instrument panel away from the dash.
  13. Loosen the instrument panel-to-body harness bolt and disconnect the harness.
  14. Using an assistant, remove the instrument panel.

  1. At the PCM, disconnect the electrical connector; then, remove the 2 PCM cover nuts, the cover and the PCM.
    NOTE
    The PCM is located at the right side of the instrument panel.

  2. Remove the evaporator core by perform the following procedure:
    1. Discharge and recover the air conditioning system refrigerant.
    2. Remove the refrigerant lines from the evaporator core. Discard the O-rings.
    3. Disconnect the air conditioning cycling switch.
    4. Disconnect the blower motor electrical connectors.
    5. Disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo.
    6. Remove the windshield washer reservoir/coolant recovery reservoir, and move it aside.
    7. Disconnect the air conditioning manifold and tube from the accumulator/drier.
    8. Disconnect the condenser-to-evaporator tube.
    9. Inside the vehicle, disconnect the air conditioning system vacuum harness and the evaporator housing mounting nut.
    10. In the passenger-s compartment, remove the evaporator housing-to-chassis nut.
    11. In the engine compartment, remove the 3 evaporator housing-to-chassis nuts.
    12. Remove the air conditioning accumulator from the evaporator core.
    13. If equipped with a 5.0L engine, remove the evaporator housing heat shield screw, clips and the shield.
    14. Remove the evaporator housing cover screws and the cover.
    15. Remove the evaporator core from the housing.

  3. Remove the PCM ground strap screw and the heat sink.
  4. In the engine compartment, remove the heater housing air plenum nuts.
  5. Remove the heater core-to-air plenum cover screws and the cover.
  6. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel assembly-Ford Explorer



    Click image to see an enlarged view

    Fig. View of the upper series floor console-Ford Explorer



    Click image to see an enlarged view

    Fig. View of the evaporator housing-Ford Explorer



    Click image to see an enlarged view

    Fig. View of the evaporator core-Ford Explorer



    Click image to see an enlarged view

    Fig. View of the heater core-Ford Explorer


To install:

  1. Install the heater core.
  2. Install the heater core-to-air plenum cover and the cover screws.
  3. In the engine compartment, install the heater housing air plenum nuts.
  4. Install the PCM ground strap screw and the heat sink.
  5. Install the evaporator core by perform the following procedure:
    1. Install the evaporator core to the housing.
    2. Install the evaporator housing cover and the cover screws.
    3. If equipped with a 5.0L engine, install the evaporator housing heat shield, clips and the shield screw.
    4. Install the air conditioning accumulator to the evaporator core.
    5. In the engine compartment, install the 3 evaporator housing-to-chassis nuts.
    6. In the passenger-s compartment, install the evaporator housing-to-chassis nut.
    7. Inside the vehicle, connect the air conditioning system vacuum harness and the evaporator housing mounting nut.
    8. Connect the condenser-to-evaporator tube.
    9. Connect the air conditioning manifold and tube to the accumulator/drier.
    10. Install the windshield washer reservoir/coolant recovery reservoir.
    11. Install the speed control servo, the bolt and connect the speed control servo connector.
    12. Connect the blower motor electrical connectors.
    13. Connect the air conditioning cycling switch.
    14. Using new O-rings, install the refrigerant lines to the evaporator core.

  6. Install the PCM, the cover and the PCM cover nuts; then, disconnect the electrical connector.
  7. Install the instrument panel by performing the following procedure:
    1. Using an assistant, install the instrument panel.
    2. Connect the harness and tighten the instrument panel-to-body harness bolt.
    3. Push the instrument panel away toward the dash.
    4. Install the fuse panel door.
    5. Install both the right and left instrument panel-to-cowl bolts.
    6. At both sides, install the windshield side garnish moldings.
    7. Under the steering column, install the instrument panel brace bolt.
    8. If equipped, install the upper series floor console.
    9. Install the upper instrument panel bolts.
    10. Install the instrument panel defroster grille.
    11. Install the glove compartment.
    12. Connect the radio-s antenna connector.
    13. Connect the climate control vacuum harness connector.
    14. Connect the blend door actuator-s electrical connector.
    15. Install the passenger-s side air bag module, connect the electrical connector and install the air bag module-to-instrument panel screws.
    16. Connect the bulkhead electrical connector wiring harness.
    17. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts.
    18. Connect the power distribution box to its bracket.
    19. Install both sides windshield garnish moldings.
    20. At the right side cowl panel, connect the electrical connectors and ground wires.
    21. Install both cowl side trim panels and the push pins.
    22. Connect the Brake Pedal Position (BPP) switch electrical connector.

  8. Install the steering column by performing the following procedure:
    1. Install the lower steering column and the steering column-to-instrument panel nuts; then, torque the nuts to 10-13 ft. lbs. (13-17 Nm).
    2. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt and torque to 19-25 ft. lbs. (26-34 Nm).
    3. Install the air bag sliding contact.
    4. Connect the brake shift interlock solenoid electrical connector.
    5. If equipped with an automatic transmission, connect the shift cable from the steering column shift tube lever and the steering column bracket.
    6. If equipped with an automatic transmission, install the transmission range indicator cable and bolt.
    7. At the base of the steering column, connect the electrical connectors.
    8. Connect the ignition switch electrical connector and install the ignition switch bolt.
    9. Install the instrument panel steering column opening reinforcement and the reinforcement bolts.
    10. Install the instrument panel-to-steering column cover and the 2 cover screws.
    11. Install the hood release and the hood release screws.
    12. Install the parking brake release handle and the release handle screws.
    13. Install the steering wheel to the steering column.
    14. Install the steering wheel-to-steering column nut and torque the nut to 25-34 ft. lbs. (34-46 Nm).
    15. At the both sides of the steering wheel, install the air bag module, connect the air bag electrical connector, install the steering wheel-to-air bag module screws and the cover plugs.

  9. Connect the heater hoses to the heater core.
  10. Refill the cooling system.
  11. Connect the negative battery cable.
  12. Evacuate and charge the air conditioning system.
  13. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

2001 Models
  1. Drain the radiator.
  2. Remove the heater water hoses.
    WARNING
    Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

  3. Remove the steering column.
  4. Disconnect the brake pedal position (BPP) switch electrical connector.
  5. If equipped, disconnect the clutch pedal position (CPP) switch electrical connector.
  6. Remove the LH and RH cowl side trim panels.
  7. Disconnect the electrical connectors and the ground wires on the RH cowl panel.
  8. Disconnect the power distribution box from the bracket and position aside.
  9. Disconnect the bulkhead wiring harness connectors from inside the engine compartment.
  10. Remove the bulkhead connector insulator.
  11. Unclip the bulkhead electrical connectors from the dash panel.
  12. Remove the passenger side air bag module.
  13. Disconnect the blend door actuator electrical connector.
  14. Disconnect the climate control vacuum harness connector.
  15. Disconnect the radio antenna cable in-line connector.
  16. Raise the glove compartment.
  17. Remove the instrument panel defroster opening grille.
  18. Remove the instrument panel cowl top bolts.
  19. If equipped, remove the upper series floor console.
  20. Remove the instrument panel brace bolt from under the steering column opening.
  21. Remove the windshield side garnish moldings.
  22. Remove the RH instrument panel cowl side bolt.
  23. Remove the instrument panel fuse panel door.
  24. Remove the LH instrument panel cowl side bolts.
  25. Position the instrument panel away from the dash panel.
  26. Disconnect the instrument panel to body harness.
    NOTE
    Two technicians are required to carry out this step.

  27. Remove the instrument panel.
  28. Recover the refrigerant.
  29. Disconnect the A/C cycling switch.
  30. Disconnect the blower electrical connectors.
  31. Position the speed control servo aside.
  32. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside.
  33. Disconnect the A/C manifold and tube from the suction accumulator/drier.
  34. Disconnect the condenser to evaporator tube.
  35. Disconnect the A/C system vacuum harness and the A/C evaporator housing mounting nut inside the vehicle.
  36. Remove the A/C evaporator housing.
  37. Remove the powertrain control module (PCM).
  38. Remove the PCM heat sink.
  39. Remove the heater air plenum nuts from the engine side of the dash panel.
  40. Remove the heater core cover to air plenum screws.
  41. Lift off the cover.
  42. Remove the heater core.

To install:

  1. Installation is the reverse of the removal procedure.
  2. Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.

Front



  1. Recover the refrigerant.
    NOTE
    The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.


    NOTE
    After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road.


    NOTE
    The SRS must be fully operational and free of faults before releasing the vehicle to the customer.


    NOTE
    Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.

  2. De-power the system.
  3. Remove the steering wheel back cover plugs.
  4. Remove the driver air bag module bolts.
  5. Remove the driver air bag module connectors.
  6. Remove the horn switch connector.
  7. Remove the driver air bag module.
  8. Open the glove compartment.
  9. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector.
  10. Remove the parts in the order indicated in the following illustration and table.
  11. Remove the passenger air bag module nuts.
  12. Reaching one hand into the glove box opening, push out on the passenger air bag module, releasing the clips at the top and remove the passenger air bag module from the instrument panel. Remove the passenger air bag module.
    WARNING
    Do not handle the passenger air bag module by grabbing the edges of the deployment door.

  13. Remove the A-pillar trim panels and right cowl side trim panel.
    NOTE
    After removing the floor console, reconnect the battery to position the front seats back, then disconnect the battery.

  14. Remove the floor console.
  15. Remove the instrument panel side finish panel (left).
  16. Remove the steering column opening cover screws.
  17. Remove the steering column opening cover
  18. Remove the lower steering column cover.
  19. Remove the steering column electrical connector.
  20. Remove the bulkhead electrical connector.
  21. Remove the body harness electrical connector.
  22. Remove the parking brake release handle screws.
  23. Remove the instrument panel electrical connector.
  24. Remove the instrument panel electrical connector.
  25. Remove the pinch bolt.
    WARNING
    To avoid damage to the clockspring, do not allow the steering column shaft to rotate while the intermediate shaft is disconnected.

  26. Remove the adjustable pedal electrical connector
  27. Remove the instrument panel center brace bolts.
  28. Remove the instrument panel center brace nuts.
  29. Remove the instrument panel center brace.
  30. Remove the transmission range selector lever cable.
  31. Remove the bulkhead electrical connector.
  32. Remove the body harness electrical connector.
  33. Remove the ground strap bolts.
  34. Remove the ground straps.
  35. Remove the inertia switch electrical connector.
  36. Remove the instrument panel electrical connectors.
  37. Remove the instrument panel center brace bolts (right).
  38. Remove the instrument panel center brace nuts (right).
  39. Remove the instrument panel center brace (right).
  40. Remove the instrument panel bolt.
  41. Remove the instrument panel defroster grille.
  42. Remove the sun load sensor electrical connector.
    WARNING
    To avoid damaging the sun load sensor electrical connector, remove the grille just enough to remove the connector.

  43. Remove the instrument panel bolts.
  44. Remove the antenna lead-in cable.
  45. Remove the RCM electrical connector.
  46. Remove the ground strap bolt.
  47. Remove the instrument panel bolts.
    WARNING
    To avoid damage to the instrument panel, an assistant is required to support the panel before carrying out this step.


    WARNING
    Before removing the instrument panel make sure all electrical connector wiring is free and not hindered.

  48. Remove the instrument panel.
  49. Drain the engine coolant.
  50. Remove the engine appearance cover.
  51. Remove the EGR vacuum regulator solenoid electrical connector.
  52. Remove the vacuum hoses.
  53. Remove the EGR vacuum regulator solenoid mounting nuts.
  54. Remove the EGR vacuum regulator solenoid.
  55. Remove the wire harness.
  56. Remove the heater tube bracket nut.
  57. Compress the clamps and disconnect the heater hoses.
  58. Remove the A/C line bracket nut at the inner fender well.
  59. Remove the A/C line bracket nut at the dash panel.
  60. Remove the disconnect the evaporator outlet line fitting.
  61. Remove the vacuum connector.
  62. Remove the heater core and evaporator core housing nut.
  63. Remove the heater core and evaporator core housing.
  64. Remove the floor ducts.
  65. Remove the housing brace.
  66. Remove the heater tube cover.
  67. Remove the heater tube seal.
  68. Remove the heater core cover.
  69. Remove the heater core.

    Click image to see an enlarged view

    Fig. Front heater core


To install:


WARNING
The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module.

  1. Match the electrical connector key to the keyway in the driver air bag module and connect the electrical connectors.
    WARNING
    The passenger air bag module nuts must be torqued in the sequence shown.


    NOTE
    Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure.

  2. Install the components in the order indicated in the following illustration and table.
  3. Install the passenger air bag module.
  4. Connect the passenger air bag module electrical connector.
  5. Close the glove compartment.
  6. Re-power the system.
  7. Make sure the retaining clips are in place before positioning the passenger air bag module to the instrument panel.
  8. Lubricate the refrigerant system with the correct amount of clean PAG oil.
  9. Fill and bleed the engine cooling system.
  10. Evacuate, leak test and charge the refrigerant system.

Mountaineer



2000 Models
  1. Disconnect the negative battery cable.
    CAUTION
    After disconnecting the negative battery cable, wait for 1 minute for the SRS module to deplete its energy.

  2. Drain the cooling system into a clean container for reuse.
  3. Disconnect the heater hoses from the heater core.
  4. Remove the steering column by performing the following procedure:
    1. Position the front wheels in the straight-ahead direction.
    2. At the both sides of the steering wheel, remove the cover plugs, the steering wheel-to-air bag module screws, disconnect the air bag electrical connector and carefully remove the air bag module.
      CAUTION
      Safely store the air bag module with the front side facing upward.

    3. Remove the steering wheel-to-steering column nut.
    4. Using a steering wheel puller, press the steering wheel from the steering column.
    5. Remove the parking brake release handle screws and move the release handle aside.
    6. Remove the hood release screws and move the hood release aside.
    7. Remove the 2 instrument panel-to-steering column cover screws and the cover.
    8. Remove the instrument panel steering column opening reinforcement bolts and the reinforcement.
    9. Remove the ignition switch bolt and disconnect the ignition switch electrical connector.
    10. At the base of the steering column, disconnect the electrical connectors.
    11. If equipped with an automatic transmission, remove the transmission range indicator bolt and the cable.
    12. If equipped with an automatic transmission, disconnect the shift cable from the steering column shift tube lever and the steering column bracket.
    13. Disconnect the brake shift interlock solenoid electrical connector.
    14. Remove the air bag sliding contact.
    15. Remove the upper intermediate steering shaft-to-column shaft bolt and discard the bolt.
    16. Remove the lower steering column-to-instrument panel nuts and the steering column.

  5. Remove the instrument panel by performing the following procedure:
    1. Disconnect the Brake Pedal Position (BPP) switch electrical connector.
    2. Remove the push pins and remove both cowl side trim panels.
    3. At the right side cowl panel, disconnect the electrical connectors and ground wires.
    4. Remove both sides windshield garnish moldings.
    5. Disconnect the power distribution box from its bracket and move it aside.
    6. In the engine compartment, loosen the bulkhead wiring harness bolts and disconnect the electrical connectors.
    7. Pull the bulkhead electrical connector handle and disconnect the wiring harness.
    8. Remove the passenger-s side air bag module-to-instrument panel screws, disconnect the electrical connector and remove the air bag module.


Store the air bag module in a safe location with the front facing upward.

  1. Disconnect the blend door actuator-s electrical connector.
  2. Disconnect the climate control vacuum harness connector.
  3. Disconnect the radio-s antenna connector.
  4. Remove the glove compartment.
  5. Remove the instrument panel defroster grille.
  6. Remove the upper instrument panel bolts.
  7. If equipped, remove the upper series floor console.
  8. Under the steering column, remove the instrument panel brace bolt.
  9. At both sides, remove the windshield side garnish moldings.
  10. Remove both the right and left instrument panel-to-cowl bolts.
  11. Remove the fuse panel door.
  12. Pull the instrument panel away from the dash.
  13. Loosen the instrument panel-to-body harness bolt and disconnect the harness.
  14. Using an assistant, remove the instrument panel.

  1. At the PCM, disconnect the electrical connector; then, remove the 2 PCM cover nuts, the cover and the PCM.
    NOTE
    The PCM is located at the right side of the instrument panel.

  2. Remove the evaporator core by perform the following procedure:
    1. Discharge and recover the air conditioning system refrigerant.
    2. Remove the refrigerant lines from the evaporator core. Discard the O-rings.
    3. Disconnect the air conditioning cycling switch.
    4. Disconnect the blower motor electrical connectors.
    5. Disconnect the speed control servo connector; then, remove the bolt and reposition the speed control servo.
    6. Remove the windshield washer reservoir/coolant recovery reservoir, and move it aside.
    7. Disconnect the air conditioning manifold and tube from the accumulator/drier.
    8. Disconnect the condenser-to-evaporator tube.
    9. Inside the vehicle, disconnect the air conditioning system vacuum harness and the evaporator housing mounting nut.
    10. In the passenger-s compartment, remove the evaporator housing-to-chassis nut.
    11. In the engine compartment, remove the 3 evaporator housing-to-chassis nuts.
    12. Remove the air conditioning accumulator from the evaporator core.
    13. If equipped with a 5.0L engine, remove the evaporator housing heat shield screw, clips and the shield.
    14. Remove the evaporator housing cover screws and the cover.
    15. Remove the evaporator core from the housing.

  3. Remove the PCM ground strap screw and the heat sink.
  4. In the engine compartment, remove the heater housing air plenum nuts.
  5. Remove the heater core-to-air plenum cover screws and the cover.
  6. Remove the heater core.

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel assembly-Mercury Mountaineer



    Click image to see an enlarged view

    Fig. View of the upper series floor console-Mercury Mountaineer



    Click image to see an enlarged view

    Fig. View of the evaporator housing-Mercury Mountaineer



    Click image to see an enlarged view

    Fig. View of the evaporator core-Mercury Mountaineer



    Click image to see an enlarged view

    Fig. View of the heater core-Mercury Mountaineer


To install:

  1. Install the heater core.
  2. Install the heater core-to-air plenum cover and the cover screws.
  3. In the engine compartment, install the heater housing air plenum nuts.
  4. Install the PCM ground strap screw and the heat sink.
  5. Install the evaporator core by perform the following procedure:
    1. Install the evaporator core to the housing.
    2. Install the evaporator housing cover and the cover screws.
    3. If equipped with a 5.0L engine, install the evaporator housing heat shield, clips and the shield screw.
    4. Install the air conditioning accumulator to the evaporator core.
    5. In the engine compartment, install the 3 evaporator housing-to-chassis nuts.
    6. In the passenger-s compartment, install the evaporator housing-to-chassis nut.
    7. Inside the vehicle, connect the air conditioning system vacuum harness and the evaporator housing mounting nut.
    8. Connect the condenser-to-evaporator tube.
    9. Connect the air conditioning manifold and tube to the accumulator/drier.
    10. Install the windshield washer reservoir/coolant recovery reservoir.
    11. Install the speed control servo, the bolt and connect the speed control servo connector.
    12. Connect the blower motor electrical connectors.
    13. Connect the air conditioning cycling switch.
    14. Using new O-rings, install the refrigerant lines to the evaporator core.

  6. Install the PCM, the cover and the PCM cover nuts; then, disconnect the electrical connector.
  7. Install the instrument panel by performing the following procedure:
    1. Using an assistant, install the instrument panel.
    2. Connect the harness and tighten the instrument panel-to-body harness bolt.
    3. Push the instrument panel away toward the dash.
    4. Install the fuse panel door.
    5. Install both the right and left instrument panel-to-cowl bolts.
    6. At both sides, install the windshield side garnish moldings.
    7. Under the steering column, install the instrument panel brace bolt.
    8. If equipped, install the upper series floor console.
    9. Install the upper instrument panel bolts.
    10. Install the instrument panel defroster grille.
    11. Install the glove compartment.
    12. Connect the radio-s antenna connector.
    13. Connect the climate control vacuum harness connector.
    14. Connect the blend door actuator-s electrical connector.
    15. Install the passenger-s side air bag module, connect the electrical connector and install the air bag module-to-instrument panel screws.
    16. Connect the bulkhead electrical connector wiring harness.
    17. In the engine compartment, connect the electrical connectors and tighten the bulkhead wiring harness bolts.
    18. Connect the power distribution box to its bracket.
    19. Install both sides windshield garnish moldings.
    20. At the right side cowl panel, connect the electrical connectors and ground wires.
    21. Install both cowl side trim panels and the push pins.
    22. Connect the Brake Pedal Position (BPP) switch electrical connector.

  8. Install the steering column by performing the following procedure:
    1. Install the lower steering column and the steering column-to-instrument panel nuts; then, torque the nuts to 10-13 ft. lbs. (13-17 Nm).
    2. Using a new bolt, install the upper intermediate steering shaft-to-column shaft bolt and torque to 19-25 ft. lbs. (26-34 Nm).
    3. Install the air bag sliding contact.
    4. Connect the brake shift interlock solenoid electrical connector.
    5. If equipped with an automatic transmission, connect the shift cable from the steering column shift tube lever and the steering column bracket.
    6. If equipped with an automatic transmission, install the transmission range indicator cable and bolt.
    7. At the base of the steering column, connect the electrical connectors.
    8. Connect the ignition switch electrical connector and install the ignition switch bolt.
    9. Install the instrument panel steering column opening reinforcement and the reinforcement bolts.
    10. Install the instrument panel-to-steering column cover and the 2 cover screws.
    11. Install the hood release and the hood release screws.
    12. Install the parking brake release handle and the release handle screws.
    13. Install the steering wheel to the steering column.
    14. Install the steering wheel-to-steering column nut and torque the nut to 25-34 ft. lbs. (34-46 Nm).
    15. At the both sides of the steering wheel, install the air bag module, connect the air bag electrical connector, install the steering wheel-to-air bag module screws and the cover plugs.

  9. Connect the heater hoses to the heater core.
  10. Refill the cooling system.
  11. Connect the negative battery cable.
  12. Evacuate and charge the air conditioning system.
  13. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

2001 Models
  1. Drain the radiator.
  2. Remove the heater water hoses.
    WARNING
    Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

  3. Remove the steering column.
  4. Disconnect the brake pedal position (BPP) switch electrical connector.
  5. If equipped, disconnect the clutch pedal position (CPP) switch electrical connector.
  6. Remove the LH and RH cowl side trim panels.
  7. Disconnect the electrical connectors and the ground wires on the RH cowl panel.
  8. Disconnect the power distribution box from the bracket and position aside.
  9. Disconnect the bulkhead wiring harness connectors from inside the engine compartment.
  10. Remove the bulkhead connector insulator.
  11. Unclip the bulkhead electrical connectors from the dash panel.
  12. Remove the passenger side air bag module.
  13. Disconnect the blend door actuator electrical connector.
  14. Disconnect the climate control vacuum harness connector.
  15. Disconnect the radio antenna cable in-line connector.
  16. Raise the glove compartment.
  17. Remove the instrument panel defroster opening grille.
  18. Remove the instrument panel cowl top bolts.
  19. If equipped, remove the upper series floor console.
  20. Remove the instrument panel brace bolt from under the steering column opening.
  21. Remove the windshield side garnish moldings.
  22. Remove the RH instrument panel cowl side bolt.
  23. Remove the instrument panel fuse panel door.
  24. Remove the LH instrument panel cowl side bolts.
  25. Position the instrument panel away from the dash panel.
  26. Disconnect the instrument panel to body harness.
    NOTE
    Two technicians are required to carry out this step.

  27. Remove the instrument panel.
  28. Recover the refrigerant.
  29. Disconnect the A/C cycling switch.
  30. Disconnect the blower electrical connectors.
  31. Position the speed control servo aside.
  32. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery reservoir. Set the reservoir aside.
  33. Disconnect the A/C manifold and tube from the suction accumulator/drier.
  34. Disconnect the condenser to evaporator tube.
  35. Disconnect the A/C system vacuum harness and the A/C evaporator housing mounting nut inside the vehicle.
  36. Remove the A/C evaporator housing.
  37. Remove the powertrain control module (PCM).
  38. Remove the PCM heat sink.
  39. Remove the heater air plenum nuts from the engine side of the dash panel.
  40. Remove the heater core cover to air plenum screws.
  41. Lift off the cover.
  42. Remove the heater core.

To install:

  1. Installation is the reverse the removal procedure.
  2. Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.

2002 Models
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2. Deactivate the supplemental restraints system (SRS).
  3. Release the two floor console front clips (one each side).
  4. On vehicles with manual transmission, remove the gearshift lever handle.
  5. Remove the console finish panel mat.
  6. On vehicles with automatic transmission:
    1. If equipped, remove the ashtray assembly.
    2. Disconnect the electrical connector.
    3. Remove the console finish panel screw.

  7. Remove the console finish panel by lifting up at the rear and sliding it rearward. Disconnect the electrical connector(s).
  8. Remove the floor console front screws.
  9. If equipped, disconnect the electrical connector and release the wiring harness locators.
  10. Remove the floor console center bolts.
  11. Remove the two floor console access covers (one each side).
  12. Remove the two floor console rear bolts (one each side).
  13. Remove the floor console by lifting up at the rear of the console and sliding it rearward.
  14. Remove the screws and remove the snow shield.
  15. Crimp off the coolant hoses and disconnect from the heater core.
  16. Remove the instrument panel center support brackets.
  17. Remove the assist handle bolt covers.
  18. Remove the bolts and the passenger assist handle.
  19. Remove the windshield side garnish moldings.
  20. Remove the defroster opening grill.
  21. Remove the upper instrument panel support bolts.
  22. Remove the exterior cowl grill.
  23. Remove the instrument panel support bolt.
  24. Remove the two instrument panel side finish panels.
  25. Lower the glove compartment.
  26. Loosen the left instrument panel side support bolts until half the threads are exposed.
    WARNING
    Be sure the instrument panel is properly supported to avoid possible damage to the instrument panel wiring or components. To avoid damage to the instrument panel wiring or components, do not use excessive force when moving the instrument panel away from the dash panel. The instrument panel may be supported by installing threaded rods or equivalent, with the same diameter and thread pitch, in place of the instrument panel support bolts.

  27. Properly support the instrument panel and remove the right instrument panel support bolts to allow the instrument panel to be pulled away from the dash panel.
  28. Remove the center console floor duct.
  29. Remove the screws and remove the right floor duct.
  30. Remove the screws and remove the left floor duct.
  31. Disconnect the electrical connectors and detach the pin-type retainers.
  32. Remove the screws and remove the heater core tube cover.
  33. Remove the right heater core cover screws.
  34. Remove the left heater core cover screws and remove the heater core cover.
    NOTE
    The instrument panel will need to be moved to facilitate removal of the heater core.

  35. Remove the heater core.

To install:

  1. Installation is the reverse of the removal procedure.
  2. Lubricate the coolant hoses with coolant hose lubricant or plain water only if needed.
  3. Top-off the engine coolant level.
  4. Rearm the supplemental restraints system (SRS).

2003-05 Models-Front

NOTE
If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle.


NOTE
Installation of a new accumulator is not required when repairing the air conditioning system except when there is physical evidence of contamination from a failed A/C compressor or damage to the accumulator.


NOTE
New O-ring seals, lubricated in clean mineral oil, must be installed before reconnecting any A/C fitting which has been disconnected.


NOTE
Lubricate the coolant hoses with plain water only if needed.

  1. Recover the refrigerant.
    WARNING
    Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment.


    WARNING
    Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment.


    WARNING
    Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment.


    WARNING
    After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards.


    WARNING
    Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury.


    WARNING
    Air bag modules with discolored or damaged trim covers must be replaced, not repainted.


    WARNING
    The restraint system diagnostic tool is for restraint system service only. Remove from vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle safety standards.


    WARNING
    To reduce the risk of personal injury, do not use any memory saver devices.


    NOTE
    The air bag warning lamp illuminates when the RCM fuse is removed and the ignition switch is ON. This is normal operation and does not indicate a supplemental restraint system (SRS) fault.


    NOTE
    After diagnosing or repairing an SRS, the restraint system diagnostic tools must be removed before operating the vehicle over the road.


    NOTE
    The SRS must be fully operational and free of faults before releasing the vehicle to the customer.


    NOTE
    Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again.

  2. De-power the system.
  3. Remove the steering wheel back cover plugs.
  4. Remove the driver air bag module bolts.
  5. Remove the driver air bag module connectors.
  6. Remove the horn switch connector.
  7. Remove the driver air bag module.
  8. Open the glove compartment.
  9. Through the glove compartment opening, release the tab and disconnect the passenger air bag module electrical connector.
  10. Remove the parts in the order indicated in the following illustration and table.
  11. Remove the passenger air bag module nuts.
  12. Reaching one hand into the glove box opening, push out on the passenger air bag module, releasing the clips at the top and remove the passenger air bag module from the instrument panel. Remove the passenger air bag module.
    WARNING
    Do not handle the passenger air bag module by grabbing the edges of the deployment door.

  13. Remove the A-pillar trim panels and right cowl side trim panel.
    NOTE
    After removing the floor console, reconnect the battery to position the front seats back, then disconnect the battery.

  14. Remove the floor console.
  15. Remove the instrument panel side finish panel (left).
  16. Remove the steering column opening cover screws.
  17. Remove the steering column opening cover
  18. Remove the lower steering column cover.
  19. Remove the steering column electrical connector.
  20. Remove the bulkhead electrical connector.
  21. Remove the body harness electrical connector.
  22. Remove the parking brake release handle screws.
  23. Remove the instrument panel electrical connector.
  24. Remove the instrument panel electrical connector.
  25. Remove the pinch bolt.
    WARNING
    To avoid damage to the clockspring, do not allow the steering column shaft to rotate while the intermediate shaft is disconnected.

  26. Remove the adjustable pedal electrical connector
  27. Remove the instrument panel center brace bolts.
  28. Remove the instrument panel center brace nuts.
  29. Remove the instrument panel center brace.
  30. Remove the transmission range selector lever cable.
  31. Remove the bulkhead electrical connector.
  32. Remove the body harness electrical connector.
  33. Remove the ground strap bolts.
  34. Remove the ground straps.
  35. Remove the inertia switch electrical connector.
  36. Remove the instrument panel electrical connectors.
  37. Remove the instrument panel center brace bolts (right).
  38. Remove the instrument panel center brace nuts (right).
  39. Remove the instrument panel center brace (right).
  40. Remove the instrument panel bolt.
  41. Remove the instrument panel defroster grille.
  42. Remove the sun load sensor electrical connector.
    WARNING
    To avoid damaging the sun load sensor electrical connector, remove the grille just enough to remove the connector.

  43. Remove the instrument panel bolts.
  44. Remove the antenna lead-in cable.
  45. Remove the RCM electrical connector.
  46. Remove the ground strap bolt.
  47. Remove the instrument panel bolts.
    WARNING
    To avoid damage to the instrument panel, an assistant is required to support the panel before carrying out this step.


    WARNING
    Before removing the instrument panel make sure all electrical connector wiring is free and not hindered.

  48. Remove the instrument panel.
  49. Drain the engine coolant.
  50. Remove the engine appearance cover.
  51. Remove the EGR vacuum regulator solenoid electrical connector.
  52. Remove the vacuum hoses.
  53. Remove the EGR vacuum regulator solenoid mounting nuts.
  54. Remove the EGR vacuum regulator solenoid.
  55. Remove the wire harness.
  56. Remove the heater tube bracket nut.
  57. Compress the clamps and disconnect the heater hoses.
  58. Remove the A/C line bracket nut at the inner fender well.
  59. Remove the A/C line bracket nut at the dash panel.
  60. Remove the disconnect the evaporator outlet line fitting.
  61. Remove the vacuum connector.
  62. Remove the heater core and evaporator core housing nut.
  63. Remove the heater core and evaporator core housing.
  64. Remove the floor ducts.
  65. Remove the housing brace.
  66. Remove the heater tube cover.
  67. Remove the heater tube seal.
  68. Remove the heater core cover.
  69. Remove the heater core.

    Click image to see an enlarged view

    Fig. Front heater core


To install:

  1. Installation is the reverse of the removal procedure.
    WARNING
    The clockspring electrical connectors are unique and cannot be reversed when connected to the driver air bag module. Match the electrical connector key to the keyway in the driver air bag module. Do not force the electrical connectors into the driver air bag module.

  2. Match the electrical connector key to the keyway in the driver air bag module and connect the electrical connectors.
    WARNING
    The passenger air bag module nuts must be torqued in the sequence shown.


    NOTE
    Make sure the battery negative cable is still disconnected before continuing with the installation portion of this procedure.

  3. Install the components in the order indicated in the following illustration and table.
  4. Install the passenger air bag module.
  5. Connect the passenger air bag module electrical connector.
  6. Close the glove compartment.
  7. Re-power the system.
  8. Make sure the retaining clips are in place before positioning the passenger air bag module to the instrument panel.
  9. Lubricate the refrigerant system with the correct amount of clean PAG oil.
  10. Fill and bleed the engine cooling system.
  11. Evacuate, leak test and charge the refrigerant system.

2003-05 Models-Rear
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    NOTE
    Lubricate the coolant hoses with plain water only if needed.

  2. Position the vehicle on a hoist with the gear selector in NEUTRAL.
  3. Using suitable tools, clamp-off the underbody heater hoses at the floor pan bracket.
  4. Remove the clamps
  5. Remove the auxiliary line floor pan bracket nuts.
  6. Remove the line bracket screws.
  7. Remove the line bracket.
    NOTE
    The screw and line bracket are located inside the vehicle above the floor pan line bracket.

  8. Remove the auxiliary harness electrical connector.
  9. Remove the auxiliary housing bolts.
  10. Remove the auxiliary housing nut.
  11. Remove the blend door actuator electrical connector.
  12. Remove the blend door actuator screws.
  13. Remove the auxiliary blend door actuator.
  14. Remove the temperature blend door actuator screws.
  15. Remove the auxiliary temperature blend door actuator.
  16. Remove the heater core cover.
  17. Remove the clamps.
  18. Remove the auxiliary heater core.

    Click image to see an enlarged view

    Fig. Rear heater core


To install:

  1. Installation is the reverse of the removal procedure.
  2. Fill the engine cooling system.

Rear



  1. Before servicing the vehicle, refer to the -Precautions- section.
    NOTE
    Lubricate the coolant hoses with plain water only if needed.

  2. Position the vehicle on a hoist with the gear selector in NEUTRAL.
  3. Using suitable tools, clamp-off the underbody heater hoses at the floor pan bracket.
  4. Remove the clamps
  5. Remove the auxiliary line floor pan bracket nuts.
  6. Remove the line bracket screws.
  7. Remove the line bracket.
    NOTE
    The screw and line bracket are located inside the vehicle above the floor pan line bracket.

  8. Remove the auxiliary harness electrical connector.
  9. Remove the auxiliary housing bolts.
  10. Remove the auxiliary housing nut.
  11. Remove the blend door actuator electrical connector.
  12. Remove the blend door actuator screws.
  13. Remove the auxiliary blend door actuator.
  14. Remove the temperature blend door actuator screws.
  15. Remove the auxiliary temperature blend door actuator.
  16. Remove the heater core cover.
  17. Remove the clamps.
  18. Remove the auxiliary heater core.
  19. Installation is the reverse of the removal procedure.
  20. Fill the engine cooling system.
Click image to see an enlarged view

Fig. Rear heater core




This are the sections, you can go through and click the link to read its troubleshooting.

---------

The car will not start?

http://schematicsdiagram.blogspot.com/2011/06/car-will-not-start.html

-----------------

Car will not crank?

http://schematicsdiagram.blogspot.com/2011/06/car-will-not-crank.html

-----------

Car has no spark?

http://schematicsdiagram.blogspot.com/2011/06/car-has-no-spark.html

-------------

How to troubleshoot car battery?

http://schematicsdiagram.blogspot.com/2011/06/how-to-troubleshoot-car-battery.html

-----------------

How to test starter solenoid?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-starter-solenoid.html

--------------------

How to test cars starter?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-cars-starter.html

How to replace starter in car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-starter-in-car.html

-----------

car will turn over but will not start?

http://technoanswers.blogspot.com/2011/05/car-will-turn-over-but-will-not-start.html

-----------------

The Brake Indicator Light Stays On dash of car?

http://schematicsdiagram.blogspot.com/2011/06/brake-indicator-light-stays-on-dash-of.html

The ABS and Traction Control Lights stays ON dash of car?

http://schematicsdiagram.blogspot.com/2011/06/abs-and-traction-control-lights-stays.html

Check Engine Light On car?

http://schematicsdiagram.blogspot.com/2011/06/check-engine-light-on-car.html

-------------------------

How to replace Interior Lights on car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-interior-lights-on-car.html

Car lights not working, even after replacing the bulb/lamp?

Click this link below:--

http://schematicsdiagram.blogspot.com/2011/06/car-lights-not-working-even-after.html

---------------

How to replace head lights on car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-head-lights-on-car.html

--------------------

How to replace Parking, turn, and Brake Lights on car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-parking-turn-and-brake.html


How to remove the door panel on car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-remove-door-panel-on-car.html

How to replace power window motor in car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-replace-power-window-motor-in.html

How to test relays on car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-test-relays-on-car.html

-----------------------------



How to troubleshoot Engine Misfires?

http://schematicsdiagram.blogspot.com/2011/06/how-to-troubleshoot-engine-misfires.html

------------

The spark plug firing order for car?

http://schematicsdiagram.blogspot.com/2011/06/spark-plug-firing-order-for-car.html



------------------------

Where is the Thermostat located in car?

http://schematicsdiagram.blogspot.com/2011/06/where-is-thermostat-located-in-car.html

How to recharge AC on Auto/Truck/car?

http://schematicsdiagram.blogspot.com/2011/06/how-to-recharge-ac-on-autotruckcar.html



-------------------

How to trouble shoot speedometer?

http://schematicsdiagram.blogspot.com/2011/06/speedometer-not-working.html

To Order car parts online:--To get heavy discount on car parts .Click this link below:----

http://technoanswers.blogspot.com/2011/05/from-where-to-order-car-parts-online.html

For car error code diagnosis click the link below:---

http://www.automd.com/diagnose/?amdcid=apwldrbrd1
Posted by Hemant somaiya at 4:20 AM
Labels: Heater Core removal procedure on 2005 Ford Explorer.

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