You are going to need to partly disassemble your dash. It seems like a big job, but if you go at it systematically it's not too bad. <IIRC> You need to disassemble everything to the right of the instrument panel. One thing that helps is to keep your fasteners organized by sticking them on a sheet of cardboard and writing the locations next to the fastener. You'll probably find a lot of dirt & dust in your ducts and you'll find that the duct seals are falling apart. You can replace the seals with self-adhesive weather stripping from your local Home store.




I've still got this '89 4runner donor truck from my EFI upgrade project (see image below). The dash is open so if you need any specific how-to photos I'd be glad to post them up. In fact it might be a good excuse for me to retrieve the heater core out of that for use as a back-up for my pickup -- Matt