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HVAC Housing Assembly

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.
Fig 1: HVAC Housing-Passenger Compartment
GC0028337Courtesy of DAIMLERCHRYSLER CORP.
  1. Position the HVAC housing assembly (2) into the passenger compartment side of the dash panel (3). Make sure that the condensate drain tube protrudes through the opening in the floor panel.
  2. Loosely install the nut (1) that secures the HVAC housing to the passenger compartment side of the dash panel.
    Fig 2: HVAC Housing-Engine Compartment
    GC0028338Courtesy of DAIMLERCHRYSLER CORP.
  3. Install the two bolts (1) that secure the HVAC housing assembly (2) to the engine compartment side of the dash panel (3). Tighten the bolts to 7 N.m (62 in. lbs.).
  4. Connect the heater hoses to the heater core tubes.
  5. Connect the A/C suction line and A/C liquid line to the A/C evaporator (Refer to HEATING & AIR CONDITIONING/PLUMBING /LINE-A/C LIQUID - INSTALLATION) .
    Fig 3: HVAC Housing-Passenger Compartment
    GC0028337Courtesy of DAIMLERCHRYSLER CORP.
  6. Tighten the nut (1) that secures the HVAC housing assembly (2) to the passenger compartment side of the dash panel (3) to 7 N.m (62 in. lbs.).
    Fig 4: Floor Distribution Duct
    GC0028323Courtesy of DAIMLERCHRYSLER CORP.
  7. Connect the right front floor duct (5) and left front floor duct (6) to the air distribution housing (4).
  8. Connect the rear floor distribution duct (3) to the air distribution housing.
  9. Connect the left rear floor duct (1) and the right rear floor duct (2) to the rear floor distribution duct.
    Fig 5: Front Console Duct
    GC0028322Courtesy of DAIMLERCHRYSLER CORP.
  10. Position the gear selector (3) to its installed location on the floor panel (6) and securely install the retaining screws (5).
  11. Connect the front console duct (2) to the air distribution housing (4) and engage the push-pin retainer (1) to the gear selector.
  12. Install the instrument panel (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION) .
  13. Install the floor console (Refer to BODY/INTERIOR/FLOOR CONSOLE - INSTALLATION) .
  14. Reconnect the negative battery cable.
  15. If the heater core is being replaced, flush the cooling system (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM CLEANING/REVERSE FLUSHING) .
  16. Refill the engine cooling system (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL) .
  17. Evacuate the refrigerant system. (Refer to REFRIGERANT SYSTEM EVACUATE  ).
  18. Charge the refrigerant system. (Refer to REFRIGERANT SYSTEM CHARGE  ).
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