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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.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (Refer to HEATING & AIR CONDITIONING/PLUMBING - WARNINGS)  and (Refer to HEATING & AIR CONDITIONING/PLUMBING - CAUTIONS) . Failure to follow the warnings and cautions could result in possible personal injury or death.
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 negative battery (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 accidental airbag deployment and possible personal injury or death.
NOTE: The HVAC housing assembly must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.
NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure.
Fig 1: Front Console Duct
GC0028322Courtesy of DAIMLERCHRYSLER CORP.
  1. Recover the refrigerant from the refrigerant system. (Refer to REFRIGERANT SYSTEM RECOVERY ).
  2. Drain the engine cooling system (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN) .
  3. Disconnect and isolate the negative battery cable.
  4. Remove the front floor console (Refer to BODY/INTERIOR/FLOOR CONSOLE - REMOVAL) .
  5. Remove the instrument panel (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL) .
  6. Disengage the push-pin retainer (1) that secures the front console duct (2) to the gear selector (3).
  7. Disconnect the front console duct from the air distribution housing (4) and remove the console duct.
  8. Remove the screws (5) that secure the gear selector to the floor panel (6) and position the gear selector out of the way.
    Fig 2: Floor Distribution Duct
    GC0028323Courtesy of DAIMLERCHRYSLER CORP.
  9. Disconnect the left rear floor duct (1) and the right rear floor duct (2) from the rear floor distribution duct (3).
  10. Disconnect the rear floor distribution duct from the air distribution housing (4) and remove the distribution duct.
  11. Disconnect the right front floor duct (5) and the left front floor duct (6) from the air distribution housing and remove the floor ducts.
    Fig 3: HVAC Housing-Passenger Compartment
    GC0028337Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove the nut (1) that secures the HVAC housing assembly (2) to the passenger side of the dash panel (3).
    Fig 4: HVAC Housing-Engine Compartment
    GC0028338Courtesy of DAIMLERCHRYSLER CORP.
  13. Disconnect the A/C liquid line and the A/C suction line from the A/C evaporator (Refer to HEATING & AIR CONDITIONING/PLUMBING/LINE-A/C LIQUID - REMOVAL) .
  14. Disconnect the heater hoses from the heater core tubes.
  15. Remove the two bolts (1) that secure the HVAC housing assembly (2) to the engine compartment side of the dash panel (3).
  16. Lift the HVAC housing assembly upwards so that the condensate drain tube clears the floor panel and remove the HVAC housing assembly from the passenger compartment.
  17. If required, disassemble the HVAC housing assembly (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC ASSEMBLY - DISASSEMBLY) .
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