How do you change the heater core on a 1997 Mercury Villager?

Answer 1

1. Disconnect the battery cables, negative cable first.
2. Drain and recycle the engine coolant.
3. Disconnect the heater hoses from the heater core at the bulkhead.
4. Remove the four lower center console cover screws or clips and remove the cover.
5. Remove the plastic clip from the side of the glove compartment assembly. Remove the two lower screws, two center bolts, two upper screws, and the screw at the instrument panel bracket. Separate the glove compartment from the instrument panel, disconnect the electrical connector from the latch, and remove the glove compartment.
6. Remove the two screws and plastic nut from both the driver's side and passenger's side lower instrument panel center covers and remove the covers.
7. Disconnect the foot lamp electrical connectors.
8. Slide the ashtray out. Depress the retainer and remove the ashtray.
9. Remove the two upper and two lower screws from the center instrument panel bezel. Pull the bezel evenly away from the instrument panel to release the clips, being careful not to damage the bezel. Disconnect the lighter and lighter lamp electrical connectors and remove the bezel.
10. Remove the four climate control assembly screws. Slide the control assembly out, disconnect the three electrical connectors, and remove the control assembly.
11. Remove the four radio bracket screws. Slide the radio out, disconnect the electrical and antenna connections, and remove the radio and bracket assembly.
12. If equipped with a CD changer, remove the four CD changer bracket screws. Slide the CD changer out, disconnect the electrical connector, and remove the changer.
13. Remove the two heater outlet floor duct screws and remove the duct.
14. Remove the four passenger's side instrument panel lower reinforcement bolts and remove the reinforcement.
15. Remove the four driver's side instrument panel lower reinforcement bolts and remove the reinforcement.
    • Disconnect the electronic door lock timer module electrical connector and remove the module.
16. Remove the three electronic door lock timer module screws.
17. Using a screwdriver, pry back the metal retainer on the anti-lock brake control module electrical harness connector and disconnect the connector and position the harness aside.
18. Disconnect the remaining electrical connectors from the anti-lock brake control module and position them aside.
19. Remove the three anti-lock brake control module screws and remove the module.
20. If the vehicle is equipped with cruise control, disconnect the cruise control amplifier electrical connector.
    • Using a tamper-resistant Torx® T-50 bit, remove the four air bag diagnostic monitor bolts.
21. Remove the two cruise control amplifier bolts and remove the amplifier.
22. Disconnect the air bag diagnostic monitor electrical connector and remove the diagnostic monitor.
    • Remove the two ground wire bolts.
23. Remove the two center duct screws and remove the duct.
24. Remove the three U-bracket-to-chassis nuts.
25. Remove the four U-bracket bolts and remove the bracket.
26. Remove the two bolts from both the driver's side and passenger's side instrument panel brackets and remove the brackets.
27. Remove the passenger's side inner duct.
28. Remove the driver's side inner duct.
29. Remove the two accelerator pedal and shaft assembly bolts and remove the assembly.
30. Remove the accelerator pedal stop screw and remove the stop.
31. Remove the heater outlet duct screw and remove the duct.
32. Remove the three temperature blend/panel bypass door actuator motor bracket bolts.
33. Disconnect the temperature blend/panel bypass door actuator motor electrical connector and remove the motor and bracket assembly.
34. Remove the three panel/floor/defrost door actuator motor bolts.
35. Disconnect the panel/floor/defrost door actuator motor electrical connector.
36. Disengage the control rod from the panel/floor/defrost door actuator motor and remove the motor and bracket assembly.
37. Remove the three A/C evaporator register duct screws and remove the duct.
38. Remove the four A/C evaporator and blower motor assembly screws to allow the heater assembly to be removed. DO NOT remove the A/C evaporator and blower motor assembly.
39. Remove the four heater assembly screws and remove the assembly.
40. Place the heater assembly on a workbench or other suitable working surface.
41. Remove the two screws from the heater pipe plate and remove the plate.
42. Remove the heater core retainer and remove the heater core from the heater assembly.