HVAC HOUSING - REMOVAL AND INSTALLATION

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Harold Ward
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1 2005 Jeep Truck Grand Cherokee 4WD V8-4.7L VIN N Vehicle > Heating and Air Conditioning > Housing Assembly HVAC > Service and Repair > Removal and Replacement HVAC HOUSING - REMOVAL AND INSTALLATION REMOVAL WARNING: - REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH. - 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. See: Air Bag(s) Arming and Disarming > Service and Repair 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. - Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure. 1/11

2 1. Recover the refrigerant from the refrigerant system. See: Heating and Air Conditioning > Service and Repair 2. Drain the engine cooling system. See: Cooling System > Service and Repair 3. Disconnect and isolate the negative battery cable. See: Battery Cable > Service and Repair 4. Remove the front floor console. Refer to Instrument Panel, See: Housing Assembly HVAC > Overhaul Gauges and Warning Indicators/ Instrument Cluster / Carrier/ Service and Repair/ Procedures/ Assembly-Instrument Panel. 5. Remove the instrument panel. Refer to Instrument Panel, Gauges and Warning Indicators/ Instrument Cluster / Carrier/ Service and Repair/ Procedures/ Assembly-Instrument Panel. 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. 2/11

3 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. 3/11

4 12. Remove the nut (1) that secures the HVAC housing assembly (2) to the passenger side of the dash panel (3). 4/11

5 13. Disconnect the A/C liquid line and the A/C suction line from the A/C evaporator. 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. See: Housing Assembly HVAC > Overhaul INSTALLATION 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. 5/11

6 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. 6/11

7 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. 7/11

8 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.). 8/11

9 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. 9/11

10 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. 13. Install the floor console. 14. Reconnect the negative battery cable. 15. If the heater core is being replaced, flush the cooling system. See: Cooling System > Service and Repair 16. Refill the engine cooling system. 17. Evacuate the refrigerant system. See: Heating and Air Conditioning > Service and Repair 18. Charge the refrigerant system 10/11

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INSTRUMENT PANEL ASSEMBLY

INSTRUMENT PANEL ASSEMBLY 2003 Dodge or Ram Truck RAM 1500 Truck 2WD V8-4.7L VIN N Vehicle > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Service and Repair > Removal and Replacement INSTRUMENT PANEL