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Housing, HVAC: Removal: Housing-HVAC

WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible serious or fatal injury.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. See Heating and Air Conditioning/Plumbing - Warning  and Heating and Air Conditioning/Plumbing - Caution . Failure to follow the warnings and cautions could result in possible serious or fatal injury.
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater core, A/C evaporator, air intake housing and the mode-air and blend-air doors.
NOTE: LHD model shown in Fig 1. RHD model similar.
Fig 1: Dash Panel
GC0116541Courtesy of CHRYSLER LLC
  1. Disconnect and isolate the negative battery cable.
  2. If equipped, remove the engine cover.
  3. Recover the refrigerant from the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard Procedure .
  4. Partially drain the engine cooling system (refer to COOLING SYSTEM DRAINING ).
  5. If equipped with diesel engine, remove the fuel filter. Refer to Fuel System/Fuel Delivery/FILTER, Fuel - Removal .
  6. If equipped with diesel engine, remove the oil separator from the top of the valve cover. Disconnect hose and remove five screws.
  7. Remove the coolant recovery container (refer to REMOVAL ).
  8. Remove the air intake tube and air filter housing cover. Refer to Engine/Air Intake System/BODY, Air Cleaner - Removal .
  9. Remove the two bolts that secure the accumulator tubes to the evaporator tube tapping block and disconnect the accumulator tubes from the tapping block. See Heating and Air Conditioning/Plumbing/ACCUMULATOR - Removal .
  10. Disengage the accumulator mounting bracket from the rubber grommet located on the right frame and position the A/C accumulator out of the way. See Heating and Air Conditioning/Plumbing/ACCUMULATOR - Removal .
  11. Remove and discard the O-ring seals and install plugs in, or tape over all of the opened refrigerant line fittings and the evaporator ports.
  12. Remove the condensation drain tube (3). See Heating and Air Conditioning/Plumbing/TUBE, Condensation Drain - Removal .
  13. Disconnect the heater hoses (5) from the heater core tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during housing removal.
  14. Remove three HVAC housing retaining nuts (6) located on the engine compartment side of the dash panel (4).
    Fig 2: HVAC Housing Passenger Compartment
    GC0116542Courtesy of CHRYSLER LLC
  15. Remove the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Removal .
  16. Remove the right rear floor duct. See Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Removal .
  17. Position the dash panel insulator (1) out of the way and remove the bolt (3) that secures the HVAC housing (4) to the passenger compartment side of the dash panel (2).
  18. Remove the bolt (5) that secures the HVAC housing to the floor bracket (6).
    NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and evaporator cores.
  19. Pull the HVAC housing rearward so that the mounting studs and condensate drain clear the dash panel and remove the HVAC housing assembly from the passenger compartment.
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