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Housing, HVAC: Installation: Housing-HVAC

NOTE: LHD model shown in Fig 1. RHD model similar.
Fig 1: HVAC Housing Passenger Compartment
GC0116542Courtesy of CHRYSLER LLC
  1. Position the HVAC housing assembly to the dash panel (2). Be certain that the condensate drain and the housing mounting studs are inserted into their correct locations.
  2. Install the bolt (3) that secures the air inlet housing (4) to the passenger compartment side of dash panel. Tighten the bolt to 4.5 N.m (40 in. lbs.).
  3. Install the bolt (5) that secures the HVAC housing (7) to the floor bracket (6). Tighten the bolt to 4.5 N.m (40 in. lbs.).
  4. Install the right rear floor duct. See Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Installation .
  5. Reposition the dash panel insulator (1) and install the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Installation .
    Fig 2: Dash Panel
    GC0116541Courtesy of CHRYSLER LLC
  6. Install the three nuts(6) that secure the HVAC housing to the engine compartment side of the dash panel (4). Tighten the nuts to 4.5 N.m (40 in. lbs.).
  7. Remove the previously installed plugs or caps and connect the heater hoses (5) to the heater core tubes.
  8. Install the condensation drain tube (3). See Heating and Air Conditioning/Plumbing/TUBE, Condensation Drain - Installation .
  9. Remove the tape or plugs from the opened refrigerant line fittings and the evaporator ports.
  10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line and tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  11. Engage the accumulator mounting bracket onto the rubber grommet located on the right frame rail. See Heating and Air Conditioning/Plumbing/ACCUMULATOR - Installation .
  12. Connect the accumulator tubes to the evaporator tube tapping block and install the two retaining bolts. Tighten the bolts to 11 N.m (100 in. lbs.). See Heating and Air Conditioning/Plumbing/ACCUMULATOR - Installation .
  13. Install the air intake tube and air filter housing cover. Refer to Engine/Air Intake System/BODY, Air Cleaner - Installation .
  14. Install the coolant recovery container (refer to INSTALLATION ).
  15. If equipped with diesel engine, install the oil separator onto the top of the valve cover. Install five screws and connect hose. Tighten screws securely.
  16. If equipped with diesel engine, install the fuel filter. Refer to Fuel System/Fuel Delivery/FILTER, Fuel - Installation .
  17. Reconnect the negative battery cable.
  18. If the heater core is being replaced, flush the cooling system. Refer to Cooling - Standard Procedure .
  19. Refill the engine cooling system (refer to COOLING SYSTEM FILLING ).
  20. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard Procedure .
  21. Charge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard Procedure .
  22. If equipped, install the engine cover.
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