1999 - 2005 Mercury Grand Marquis
Heater Core Replacement

1999_Mercury_Grand_Marquis.jpg

Source Reference: 

  

Referenced Procedure:  http://www.autozone.com/autozone/repairinfo/repairguide/repairGuideContent.jsp?pageId=0996b43f802e6377

Removal

  1. If equipped, turn the air suspension service switch to the OFF position before raising the vehicle.

  2. Drain the cooling system.

  3.  Remove or disconnect the following: 
  •  
    • Negative battery cable
    • Front seats
    • Carpeting
    • Rear airflow duct
    • Heater hoses

4. Remove the driver's side air bag module by removing or disconnect the following: 

  •  
    •  SRS module-to-steering wheel bolts, from both sides of the steering wheel.
    • SRS module and disconnect the electrical connector
    •  Horn switch electrical connector

    5. Remove the passenger side SRS module by removing or disconnecting the following:  

  •  
    • Open the glove box and disconnect the glove compartment isolator
    •  Push inward on the 2 glove box door tabs and lower the door
    •  Disconnect the SRS module electrical connector
    •  Remove the SRS module-to-instrument panel bolts
    •  Remove the SRS module
    • 6. Remove the instrument panel by removing or disconnecting the following:
    •  
    • Remove the Speed control servo nuts and
    • Move the Speed control servo aside
    • Bolt and disconnect the left side bulkhead connector
    • Left side bulkhead connector from the dash panel
    • Windshield washer fluid reservoir screw, and position the reservoir aside
    • Blower motor electrical connector
    • Air conditioning pressure cut-off switch electrical connector
    • In-line electrical harness connector
    • Electronic Automatic Temperature Control (EATC) variable blower motor controller electrical connector
    • Right front wheel
    • Right front fender splash shield bolts and move the shield away from the cowl
    • Wiring harness from the evaporator case
    • Wiring harness from the cowl
    • Right side instrument panel lower insulator pushpins, disconnect the power point electrical connector, remove the courtesy lamp from the socket and remove the insulator
    • Unseat the wiring grommet and feed the wiring harness through the cowl
    • Cowl side trim panels and the windshield side garnish moldings from both sides 
    • Locking clip and the Electronic Crash Sensor (ECS) module electrical connector
    • Antenna connector
    • Ground wire bolts from the right side
    • EATC hose at the evaporator housing
    • Bolt and disconnect the bulkhead connector from the right side
    • Pull the door weatherstrip seals away from the instrument panel on both sides
    • Tunnel brace trim cover
    • Climate control head vacuum harness connector
    • Instrument panel tunnel brace nuts and the brace
    • Ground wire bolts from the left side
    • Wiring harness connectors from the left side
    • Parking brake switch electrical connector

7. Pry out the instrument panel defroster opening grille, disconnect the electrical connectors and the remove the grille.

 8. Remove or disconnect the following: 

  •  
    • 3 upper instrument panel screws
    • Instrument panel cowl side nut from both sides
    • Instrument panel cowl side bolt from the left side
    • Instrument panel
    • Windshield wiper mounting arm and the pivot shaft
    • Electrical connector and remove the upper cowl extension screw and the extension
    • Vacuum hoses and the wire harness connector from the evaporative emissions canister purge valve
    • Evaporative emissions purge valve nuts and the valve
    • Cowl side nut
    • Right side rear fender apron screws and reposition the apron
    • Evaporator housing nut and screw
    • Vacuum hoses and the wiring harness connectors
    • Plenum chamber-s lower flange nuts
    • Plenum chamber-s upper flange nut and the plenum chamber
    • Heater core cover-to-heater plenum chamber screws and the cover
    • Seal and the heater core 

 

    Click image to see an enlarged view


    Fig. 1. View of the instrument panel finish panels

     

    Click image to see an enlarged view


    Fig. 2. Exploded view of the Grand Marquis instrument panel

     

    Click image to see an enlarged view


    Fig. 3. Exploded view of the heater air plenum chamber, the evaporator housing and the air inlet duct

     

    Click image to see an enlarged view


    Fig 4. View of the heater core


 

To install:

1. Install or connect the following: 

  •  
    • Seal and the heater core
    • Heater core cover and the cover-to-heater plenum chamber screws
    • Plenum chamber and the plenum chamber-s upper flange nut
    • Plenum chamber-s lower flange nuts
    • Vacuum hoses and the wiring harness connectors
    • Evaporator housing nut and screw
    • Right side rear fender apron and the apron screws
    • Cowl side nut
    • Evaporative emissions purge valve and the valve nuts
    • Vacuum hoses and the wire harness connector to the evaporative emissions canister purge valve
    • Electrical connector; then, install the upper cowl extension screw and the extension
    • Windshield wiper mounting arm and the pivot shaft

 

    2. Install the instrument panel by installing or connecting the following: 

  •  
    • Instrument panel
    • At the left side, install the instrument panel cowl side bolt
    • Instrument panel cowl side nut on both sides
    • 3 upper instrument panel screws
    • Electrical connectors and the install the instrument panel defroster opening grille
    • Parking brake switch electrical connector
    • Wiring harness connectors on the left side
    • Ground wire bolts on the left side
    • Instrument panel tunnel brace and the brace nuts
    • Climate control head vacuum harness connector
    • Install the tunnel brace trim cover.
    • Door weatherstrip seals to the instrument panel on both sides
    • Bulkhead connector and tighten the bolt on both sides
    • EATC hose at the evaporator housing
    • Ground wire bolts on the right side
    • Antenna connector
    • ECS module electrical connector and the locking clip
    • Cowl side trim panels and the windshield side garnish moldings on both sides
    • Feed the wiring harness through the cowl and seat the wiring grommet
    • Right side instrument panel lower insulator, connect the power point electrical connector, install the courtesy lamp to the socket and secure the insulator with pushpins
    • Wiring harness from the cowl
    • Wiring harness to the evaporator case
    • Right front fender splash shield and the shield bolts
    • Right front wheel
    • EATC variable blower motor controller electrical connector
    • In-line electrical harness connector
    • Air conditioning pressure cut-off switch electrical connector
    • Blower motor electrical connector
    • Windshield washer fluid reservoir and the reservoir screw
    • Left side bulkhead connector to the dash panel
    • Left side bulkhead connector and tighten the bolt
    • Speed control servo and the servo nuts
    • Right SRS module and torque the module-to-instrument panel bolts to 62-97 inch lbs. (7-11 Nm)
    • Right SRS module electrical connector
    • Glove compartment isolator
    • Glove box door
    • Horn switch electrical connector
    • Electrical connector and install the left SRS module
    • Left SRS module-to-steering wheel bolts on both sides of the wheel, and torque the bolts to 90-122 inch lbs. (10-14 Nm)
    • Rear airflow duct
    • Carpeting
    • Front seats
    • Heater hoses

 3. Refill the cooling system.

 4. Connect the negative battery cable.

 5. Operate the engine to normal operating temperature.

6. Check the climate control operation and check for leaks.

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