HVAC Housing: Removal
WARNING: This page is about a different car, the 2002 Dodge Intrepid, 2002 Chrysler Intrepid, and 2002 Chrysler Concorde. However, it is still accessible from the selected car via links, so may be relevant.
- Open the hood and disconnect the negative battery cable remote terminal from the remote battery post. Remove the instrument panel from vehicle. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. Recover the refrigerant from the system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
- Drain the engine cooling system. Remove the air cleaner hose and air distribution duct from the engine. Remove the spring type heater hose fasteners at the dash panel and remove the hoses from heater core. Plug the heater core inlet and outlet tubes to prevent anti-freeze from spilling on the vehicle interior during removal. If an appropriate plug cannot be found pull back carpet and use caution when removing the HVAC housing. Keep the heater tubes elevated to prevent spillage of coolant.
- Remove one nut at expansion valve retaining both A/C lines to expansion valve. After removing the lines cap the expansion valve openings and the A/C hose openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing. Remove the three retaining nuts from the studs. These studs project through the dash panel into the engine compartment. Remove two screws to the defrost duct and remove.
- Remove 2 nuts, and 2 screws attaching the HVAC housing to the dash panel. Remove 4 nuts retaining the rear seat heat duct, and remove. Remove the rear seat heat duct elbow push pin fastener. Disconnect the HVAC harness connector. Gently pull the HVAC housing rearward from the dash panel, being careful not to spill any coolant into the passenger compartment