2002 Ford Windstar heater core

1. Disconnect the negative battery cable.
2. Drain and recycle the engine coolant.
3. Remove the cowl top vent panel.
4. Disconnect the heater hoses from the heater core inlet and outlet tubes.
5. Remove the ground strap from the heater core tube, as required.
6. Remove the center instrument panel trim.
7. Remove the ashtray.
8. Remove the rear seat airflow duct.
9. Label and disconnect the keyless entry wiring harness, as required.
10. Remove the center instrument panel support brackets
11. Label and disconnect the climate control vacuum lines.
12. Remove the heater outlet floor duct.
13. Remove the housing core plate retaining screws and remove the heater housing core plate.
14. Remove the heater core.

To install:

1. Position the heater core.
2. Install the heater housing core plate and tighten the screws securely.
3. Install the heater outlet floor duct.
4. Connect the climate control vacuum lines.
5. Install the center instrument panel support brackets.
6. Connect the keyless entry wiring harness, as required.
7. Install the rear seat airflow duct.
8. Install the ashtray.
9. Install the center instrument panel trim.
10. Install the ground strap to the heater core tube, as required.
11. Connect the heater hoses on the heater core inlet and outlet tubes.
12. Install the cowl top vent panel.
13. Fill and bleed the cooling system.
14. Connect the negative battery cable.

Heater Core
Removal and Installation
NOTE:If a heater core leak is suspected, the heater core must be pressure leak tested before it is removed from the vehicle. Refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION.

Drain the cooling system.
Remove the cowl top vent panel.
Disconnect the heater hoses.

Remove the lower instrument panel utility compartment
Remove the ash receptacle.

Remove the rear seat airflow duct.
Remove the pins.
Remove the duct.
.
Remove the four instrument panel support bolts and detach the electrical connectors.

Remove the nuts and remove the center instrument panel support bracket.

Remove the bolts and remove the support brace.

Remove the screws and remove the floor duct.

Remove the cover screws and remove the cover.

Remove the dash panel seal.

Remove the core.