Housing Assembly HVAC: Service and Repair
HVAC HOUSING
REMOVAL
WARNING
- THE AIR CONDITIONING SYSTEM CONTAINS REFRIGERANT UNDER HIGH PRESSURE. SEVERE PERSONAL INJURY MAY RESULT FROM IMPROPER SERVICE PROCEDURES. REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL.
- AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST. EXPOSURE MAY IRRITATE THE EYES, NOSE, AND/OR THROAT. WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM. SERIOUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT. IF EYE CONTACT OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY.DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME. POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED. AN ELECTRONIC LEAK DETECTOR IS RECOMMENDED.IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE THE WORK AREA BEFORE RESUMING SERVICE. LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION.THE EVAPORATION RATE OF R-134a REFRIGERANT AT AVERAGE TEMPERATURE AND ALTITUDE IS EXTREMELY HIGH. AS A RESULT, ANYTHING THAT COMES IN CONTACT WITH THE REFRIGERANT WILL FREEZE. ALWAYS PROTECT THE SKIN OR DELICATE OBJECTS FROM DIRECT CONTACT WITH THE REFRIGERANT.THE R-134a SERVICE EQUIPMENT OR THE VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR AND R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS, AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.
- ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, DRIVER AIRBAG, PASSENGER AIRBAG, FRONT IMPACT SENSOR, SIDE IMPACT SENSOR, SIDE CURTAIN AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
- AN AIRBAG INFLATOR UNIT MAY CONTAIN SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER, OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. AN AIRBAG INFLATOR UNIT MAY ALSO CONTAIN A GAS CANISTER PRESSURIZED TO OVER 2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN AIRBAG UNIT OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE, OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURES EXCEEDING 93° C (200° F).
- THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE RESTRAINT SYSTEM COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE RESTRAINT SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANY TIME A NEW FASTENER IS NEEDED, REPLACE IT WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE DAIMLERCHRYSLER MOPAR PARTS CATALOG.
- WHEN A STEERING COLUMN HAS AN AIRBAG UNIT ATTACHED, NEVER PLACE THE COLUMN ON THE FLOOR OR ANY OTHER SURFACE WITH THE STEERING WHEEL OR AIRBAG UNIT FACE DOWN.
CAUTION:
- Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with the service equipment being used.
- Never add R-12 to a refrigerant system designed to use R-134a. Damage to the system will result. R-12 refrigerant oil must not be mixed with R-134a refrigerant oil. They are not compatible. Do not use R-12 equipment or parts on the R-134a system. Damage to the system will result. Do not overcharge the refrigerant system. This will cause excessive compressor head pressure and can cause noise and system failure.
- Recover the refrigerant before opening any fitting or connection. Open the fittings with caution, even after the system has been discharged. Never open or loosen a connection before recovering the refrigerant. The refrigerant system must always be evacuated before charging.
- Do not open the refrigerant system or uncap a replacement component until you are ready to service the system. This will prevent contamination in the system. Before disconnecting a component, clean the outside of the fittings thoroughly to prevent contamination from entering the refrigerant system.
- Immediately after disconnecting a component from the refrigerant system, seal the open fittings with a cap or plug.
- Before connecting an open refrigerant fitting, always install a new seal or gasket. Coat the fitting and seal with clean refrigerant oil before connecting. Do not remove the sealing caps from a replacement component until it is to be installed. When installing a refrigerant line, avoid sharp bends that may restrict refrigerant flow. Position the refrigerant lines away from exhaust system components or any sharp edges, which may damage the line. Tighten refrigerant fittings only to the specified torque. The aluminum fittings used in the refrigerant system will not tolerate overtightening.
- When disconnecting a refrigerant fitting, use a wrench on both halves of the fitting. This will prevent twisting of the refrigerant lines or tubes.
- Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do not open a container of refrigerant oil until you are ready to use it. Replace the cap on the oil container immediately after using. Store refrigerant oil only in a clean, airtight, and moisture-free container. Keep service tools and the work area clean. Contamination of the refrigerant system through careless work habits must be avoided.
1. Disconnect the negative battery cable.
2. Evacuate the refrigerant from the A/C system.
CAUTION Do not open cooling system unless coolant temperature is below 90° C. Open cap slowly and release the pressure. Do not pour coolant into beverage bottles. Wear protective gloves, protective clothing and eye protection.
3. Relieve the pressure in the cooling system by turning the cap on supply reservoir to catch "1" and then tightening it back to its rest position.
4. Drain the coolant from the engine cooling system.
5. Remove the hot water hose clamp (1) located inboard from the brake booster on the bulkhead, then remove and plug off the hot water hose.
6. Remove the two hot water hose clamps (1) from hot water hoses located on the right side of the bulkhead, then remove the two hot water hoses.
7. Remove the instrument panel top section (1).
8. Remove the lower instrument panel (2).
9. Remove the lower instrument panel (2).
10. Remove the instrument cluster cover (1).
11. Remove the green insulating mats.
12. Remove the nuts for the instrument cluster holder then remove instrument cluster.
13. Remove the Sentry Key Remote Entry Module (SKREEM) by:
- Disconnect the 2-pin CAN harness connector from the SKREEM (1).
- Disconnect the 2-pin harness connector for the transponder coil (1).
- Disconnect the 18-pin harness connector (1).
- Press the retaining tabs apart (1).
- Remove the SKREEM control module from the base plate.
NOTE: This is necessary to remove the instrument panel support from the vehicle.
14. Remove all of the wiring harness nylon ties attaching the wiring harnesses on the instrument panel support.
15. Remove any harness connectors (1) or electric leads on the body transmission tunnel.
16. Remove the bolts and nuts (1) attaching the steering column to the instrument panel support.
NOTE: It is not necessary to fully remove the steering column from the vehicle.
17. Relocate the steering column out of the working area.
WARNING: BE SURE YOU HAVE TAKEN THE NECESSARY PRECAUTIONS TO DISENGAGE THE AIRBAG SYSTEM.
18. Remove the electrical harness connector (1) on passenger airbag module.
19. Remove the heater ducts on left and right side of the instrument panel support.
20. Remove the nuts (1) on the heater case attaching it to the instrument panel support.
21. Remove the bolts from the instrument panel support attaching it to the body transmission tunnel.
22. Remove the bolts (1) attaching the instrument panel support to the front of the vehicle bulkhead.
23. Remove the bolts (1) attaching the instrument panel support to the A-pillars.
24. Disconnect the connectors (1) from the vacuum reservoir.
CAUTION To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support.
25. Remove the instrument panel support.
26. Remove the electrical harness connector on heater core temperature sensor located on the front of the heater housing and the evaporator temperature sensor (1) located on the left side of the heater case.
27. Disconnect the electrical harness connector from the fresh air/recirculating air flap switchover valve (1) located on the right front of the heater housing where the vacuum lines for the reservoir where removed.
28. Remove all the nylon ties on the heater housing attaching any wiring harnesses.
CAUTION:
- To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support.
- Be sure not to spill any residual coolant from the heater housing into the passenger compartment of the vehicle.
29. Remove the heater housing from the vehicle by tipping it forward and removing through the passenger side door.
INSTALLATION
1. Install the HVAC housing to the vehicle.
2. Install any wiring harnesses associated with the HVAC housing with nylon ties in their respected routing positions.
3. Connect the harness connector (1) to the fresh air/recirculating air flap switchover valve located on the right side of the heater housing.
4. Install the harness connector on heater core temperature sensor located on the front of the HVAC housing. Then install the evaporator temperature sensor (1) to the HVAC case.
CAUTION To avoid any damage to the vehicle a helper may be required to aid in the removal of the instrument panel support.
5. Install the instrument panel support to the vehicle.
6. Install the bolts (1) attaching the instrument panel support to the A-pillars.
7. Connect the connectors (1) to the vacuum reservoir switch over valve.
8. Install the bolts (1) attaching the instrument panel support to the front of the vehicle bulkhead.
9. Install the nuts to the instrument panel support attaching it to the body transmission tunnel.
10. Install the nuts on the heater housing (1) attaching it to the instrument panel support.
11. Install the heater ducts on left and right side of the instrument panel support.
12. Install the harness connector (1) on passenger airbag module.
13. Locate the steering column to its mounting position on the instrument panel support.
14. Install the bolts and nuts (1) attaching the steering column to the instrument panel support.
15. Install the connection (1) for electric leads on body tunnel.
16. Install all of the wiring harnesses to their respected routing positions attaching them with nylon ties on the instrument panel support.
17. Install the Sentry Key Remote Entry Module (SKREEM) by:
- Connecting the 2-pin CAN harness connector to the SKREEM module.
- Connecting the 2-pin harness connector for the transponder coil.
- Connecting the 18-pin connector.
- Installing the SKREEM control module to the base plate.
18. Install instrument cluster holder to the vehicle then install the nuts for the instrument cluster holder.
19. Install the green insulating mats.
20. Install the instrument panel top section (1).
21. Install the left lower instrument panel (2).
22. Install the lower right instrument panel (2).
23. Install the instrument cluster cover (1).
24. Install the two hot water hoses (1) then install the two hot water hose clamps to hot water hoses located on the right side of the bulkhead.
25. Install the hot water hose (1) the install the hot water hose clamp located inboard to the brake booster on the bulkhead.
26. Fill the coolant to the engine cooling system.
27. Connect the negative battery cable.