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Housing, HVAC: Removal: Housing-HVAC

WARNING: This page is about a different car, the 2016 Jeep Wrangler and 2015 Jeep Wrangler. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:

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. 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 follow these instructions may result in possible serious or fatal injury.

WARNING:

Review the warnings and cautions for this system before performing the procedure. Failure to follow these instructions may result in serious injury or death.

NOTE:

The HVAC housing and instrument panel must be removed from the vehicle as an assembly.

NOTE:

The HVAC housing must be removed from the instrument panel and disassembled for service of the A/C evaporator, air intake housing, mode-air and blend-air doors and the heater core.

NOTE:

3.6L LHD model shown in illustrations. Other models similar.

Fig 1: A/C Lines, Expansion Valve & Nut
GC0153994Courtesy of CHRYSLER GROUP, LLC
  1. Disconnect and isolate the negative battery cable.
  2. Remove the engine trim cover.
  3. Recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  4. Partially drain the engine cooling system. Refer to STANDARD PROCEDURE .
  5. On 3.6L engine models, remove the upper intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL .
  6. Remove the nut (2) that secures the A/C liquid line (3) and A/C suction line (4) to the A/C expansion valve (1).
  7. Disconnect the A/C liquid and suction lines from the A/C expansion valve and remove and discard the O-ring seals.
  8. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve ports.
    Fig 2: Heater Hose Connections
    GC0131437Courtesy of CHRYSLER GROUP, LLC
  9. Using cable-type spring clamp pliers or equivalent, release the hose clamps that secure the heater hoses (2) to the heater core tubes (1) and disconnect the hoses from the tubes. Install plugs in, or tape over the opened heater core tubes to prevent coolant spillage during HVAC housing assembly removal.
    Fig 3: Air Inlet Housing, Instrument Panel Support, Alignment Pin & Bolts
    GC0131681Courtesy of CHRYSLER GROUP, LLC
  10. Remove the instrument panel and place it on a workbench. Refer to PANEL, INSTRUMENT, REMOVAL .
  11. Remove the instrument panel cover. Refer to COVER, INSTRUMENT PANEL, REMOVAL .
  12. Disconnect the instrument panel wire harness connectors from the evaporator temperature sensor, blower motor resistor, blower motor and the recirculation door actuator.
  13. Remove the two bolts (1) that secure the air inlet housing (4) to the passenger side of the instrument panel support (3). Use caution not to damage the housing alignment pin (2) during removal of the HVAC housing assembly from the support.
    Fig 4: HVAC Housing Assembly, Instrument Panel Support, Alignment Pin & Bolts
    GC0131682Courtesy of CHRYSLER GROUP, LLC
  14. Remove the instrument panel ducts. Refer to DUCT, INSTRUMENT PANEL, ASSEMBLY, REMOVAL .
  15. Remove the four bolts (1) that secure the HVAC housing assembly (3) to the center of the instrument panel support (2) and remove the housing from the support. Use caution not to damage the housing alignment pin (4) during removal of the housing from the support.
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