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Home >> Jeep Truck >> 2006 >> TJ (CANADA) L4-2.4L >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Overhaul >> HVAC Housing

HVAC Housing

HVAC HOUSING

DISASSEMBLY

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

1. Remove the HVAC housing assembly and place it on a workbench.

Vacuum Harness And Actuators - LHD Shown, RHD Similar:




2. Disconnect the HVAC vacuum harness connectors from the mode door actuators and the recirculation door actuator, if equipped.
3. Disengage the vacuum harness from any retaining clips located on the HVAC housing and carefully pull the vacuum supply line through the foam seal located at the front of the housing and remove the vacuum harness.
4. Remove the mode door actuators from the HVAC housing.
5. Remove the blend door actuator from the HVAC housing.

HVAC Wire Harness - LHD Shown, RHD Similar:




6. Disconnect the wire harness connectors from the blower motor resistor and the blower motor.
7. Disengage the push-in retainers for the HVAC wire harness connector and the blower motor relay from the HVAC housing.
8. Remove the three screws that secure the HVAC wire harness to the HVAC housing and remove the wire harness.
9. Remove the two screws that secure the blower motor resistor to the HVAC housing and remove the resistor.
10. Disengage the blower motor retaining tab and turn the blower motor counter-clockwise and remove the blower motor from the HVAC housing.

HVAC Air Inlet Housing - LHD Shown, RHD Similar:




11. Remove the five screws that secure the air inlet housing to the top of the HVAC housing and remove the inlet housing.

Floor Distribution Duct And Screw - LHD Shown, RHD Similar:




12. Remove the three screws that secure the floor distribution duct to the bottom of the HVAC housing and remove the duct.
13. Remove the one screw that secures the upper and lower HVAC housing halves together at the bottom of the HVAC housing.

NOTE: If the foam seal for the defrost/demister outlet cover or the panel outlet is deformed or damaged, the seal must be replaced.

Foam Seals And Parting Lines - Typical:




14. Carefully cut the foam seal for the defrost/demister outlet cover along the two parting lines of the outlet cover.
15. Carefully cut the foam seal for the panel outlet along the parting line of the two HVAC housing halves.

NOTE: If the foam seal for the defrost/demister outlet cover is deformed or damaged, the seal must be replaced.

Defrost/Demister Outlet Cover - LHD Shown, RHD Similar:




16. Remove the five screws that secure the defrost/demister outlet cover to the top of the HVAC housing and remove the cover.

NOTE: If the foam seal for the evaporator and heater core tubes is deformed or damaged, the seal must be replaced.

Foam Seal And HVAC Housing Screws - Typical:




17. Carefully cut the foam seal for the evaporator and heater core tubes along the parting line of the two HVAC housing halves.

NOTE: If the foam seal for the evaporator condensate drain tube is deformed or damaged, the seal must be replaced.

18. Remove the foam seal from the evaporator condensate drain tube.
19. Remove the fourteen screws and two clips that secure the upper and lower HVAC housing halves together.
20. Carefully separate the two HVAC housing halves.

NOTE: If either foam seal on the panel-air door is deformed or damaged, the air door must be replaced.

Panel-Air Door - LHD Shown, RHD Similar:




21. Using a pick or similar tool, release the retaining tab that secures panel door lever to the panel-air door and remove the lever.
22. Remove the panel-air door from the lower half of the HVAC housing.

NOTE: If either foam seal on the air doors is deformed or damaged, the air door must be replaced.

Floor/Defrost And Blend - Air Doors - LHD Shown, RHD Similar:




23. Remove the floor/defrost-air door and the blend-air door from the lower half of the HVAC housing.

Heater Core And A/C Evaporator - Typical:




24. Carefully lift the heater core and foam insulator out of the lower half of the HVAC housing.

NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.

25. If equipped with A/C, disengage the rubber seal from around the tubes of the A/C evaporator and carefully lift the A/C evaporator and foam insulator out of the lower half of the HVAC housing.

NOTE: If the rubber seal for the A/C evaporator tubes is deformed or damaged, the seal must be replaced.

26. Remove the rubber seal for the evaporator tubes from the lower half of the HVAC housing, if equipped.
27. If required, remove the screw that secures the evaporator tube clamp to the evaporator tubes and remove the clamp.

ASSEMBLY

NOTE:
- The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, heater core, blend-air and mode-air doors.
- If any foam or rubber seal on the HVAC housing or an air-door is deformed or damaged, it must be replaced.

Heater Core And A/C Evaporator - Typical:




1. Carefully install the A/C evaporator, foam insulator and the rubber seal into the lower half of the HVAC housing. If removed, install the evaporator tube clamp.
2. Carefully install the heater core and foam insulator into the lower half of the HVAC housing.

Floor/Defrost And Blend-Air Doors - LHD Shown, RHD Similar:




3. Install the floor/defroster-air door and the blend-air door into their pivot holes in the lower half of the HVAC housing.

Panel Door Lever - Typical:




4. Position the panel-air door into the pivot hole located in the lower half of the HVAC housing.
5. Align the panel door lever with the panel-air door pivot shaft and install the lever into the shaft. Be sure that the lever retaining tab fully engages the pivot shaft.

Foam Seal And HVAC Housing Screws -Typical:




6. Position the two halves of the HVAC housing together. Be certain that each of the air-door pivot shafts are properly engaged in its pivot hole and, if equipped with A/C, that the evaporator tube rubber seal is properly positioned.
7. Install the fourteen screws and two clips that secure the two housing halves together. Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the foam seal onto the evaporator condensate drain tube.

Defrost/Demister Outlet Cover - LHD Shown, RHD Similar:




9. Position the defrost/demister outlet cover onto the top of the HVAC housing.
10. Install the five screws that secure the defrost/ demister outlet cover to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).

Floor Distribution Duct And Screw - LHD Shown, RHD Similar:




11. Install the one screw that secures the two housing halves together at the bottom of the HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).
12. Position the floor distribution duct onto the bottom of the HVAC housing.
13. Install the three screws that secure the floor distribution duct to the HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).

HVAC Air Inlet Housing - LHD Shown, RHD Similar:




14. Position the air inlet housing onto the top of the HVAC housing.
15. Install the five screws that secure the air inlet housing to the HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).

HVAC Wire Harness - LHD Shown, RHD Similar:




16. Install the HVAC wire harness onto the HVAC housing. Make sure the wires are routed through all wiring retainers.
17. Engage the push-in retainers for the HVAC wire harness connector and the blower motor relay to the HVAC housing.
18. Install the three screws that secure the HVAC wire harness to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
19. Position the blower motor into the HVAC housing and turn it clockwise until the retaining tab is fully engaged.
20. Position the blower motor resistor into the HVAC housing and install the two retaining screws. Tighten the screws to 2 N.m (17 in. lbs.).
21. Connect the HVAC wire harness connectors to the blower motor and the blower motor resistor.

Vacuum Harness And Actuators - LHD Shown, RHD Similar:




22. Install the mode door actuators.
23. Install the blend door actuator.
24. Install the HVAC vacuum harness onto the HVAC housing. Make sure the harness is routed through all the retaining clips located on the HVAC housing.
25. Insert the vacuum supply line through the foam seal located at the front of the HVAC housing and connect the vacuum harness connectors to the mode door actuators and the recirculation door actuator, if equipped.
26. Install the HVAC housing assembly.
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