HVAC Housing: Removal

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: On vehicles equipped with airbags, 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 personal injury or death.

NOTE: The HVAC housing must be removed from the vehicle and the two halves of the housing separated for service of the heater core, A/C evaporator, blend door and each of the various mode doors.

Disconnect and isolate the negative battery cable.
Remove the instrument panel (Refer to INSTRUMENT CLUSTER - REMOVAL).
If the vehicle is not equipped with A/C, go to step 8. If the vehicle is equipped with A/C, recover the refrigerant from the refrigerant system (Refer to HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY) .
Remove the accumulator and mounting bracket from the dash panel.
Remove the nuts that secure the suction and liquid lines to the evaporator tapping block. See Fig 1.
Disconnect the suction and liquid lines from the evaporator tapping block and remove and discard the O-ring seals.
Install plugs in, or tape over the opened suction and liquid line fittings and evaporator tapping block ports.
Drain the engine cooling system (Refer to COOLING - STANDARD PROCEDURE) .
Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.
Disconnect the HVAC system vacuum supply line connector from the engine vacuum harness.
Remove the nuts that secure the HVAC housing to the dash panel in the engine compartment.
Remove the HVAC housing from inside the vehicle taking care not to allow any remaining coolant to drain on the vehicles interior.

Fig 1: HVAC Housing Components

Courtesy of DAIMLERCHRYSLER CORP.

1 - BLOWER MOTOR

2 - RECIRCULATION DOOR LINKAGE

3 - RECIRCULATION DOOR ACTUATOR

4 - HOUSING SCREW

5 - BLEND DOOR ACTUATOR SCREWS (3)

6 - BLEND DOOR ACTUATOR

7 - ELECTRICAL CONNECTOR

8 - HEATER CORE TABS (4) AND SCREWS (2)

9 - HEATER CORE

10 - RETAINER CLIP

11 - HEATER CORE CONNECTIONS

12 - EVAPORATOR TAPPING BLOCK

13 - HOUSING SCREWS

14 - HVAC HOUSING