Jeep Wrangler TJ. Manual — part 595
NOTE: If either foam seal on the panel-air door is
deformed
or
damaged,
the
air
door
must
be
replaced.
(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 (Fig. 17).
(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.
(23) Remove the floor/defrost-air door and the
blend-air door from the lower half of the HVAC hous-
ing (Fig. 18).
NOTE: If the foam insulator around the heater core
is deformed or damaged, the insulator must be
replaced.
(24) Carefully lift the heater core and foam insula-
tor out of the lower half of the HVAC housing (Fig.
19).
NOTE: If the foam insulator around the A/C evapo-
rator 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.
Fig. 17 Panel-Air Door - LHD shown, RHD similar
1 - PANEL-AIR DOOR
2 - PANEL DOOR LEVER RETAINING TAB
3 - HVAC HOUSING (LOWER HALF)
Fig. 18 Floor/Defrost and Blend-Air Doors - LHD
shown, RHD similar
1 - FLOOR/DEFROST-AIR DOOR
2 - BLEND-AIR DOOR
3 - HVAC HOUSING (LOWER HALF)
Fig. 19 Heater Core and A/C Evaporator - Typical
1 - HEATER CORE
2 - RUBBER SEAL
3 - A/C EVAPORATOR (IF EQUIPPED)
4 - HVAC HOUSING (LOWER HALF)
24 - 46
DISTRIBUTION
TJ
HVAC HOUSING (Continued)
AIR INLET HOUSING
NOTE: The recirculation-air door and actuator are
used only on models equipped with A/C.
NOTE: The air inlet housing must be removed from
HVAC housing and disassembled for service of the
recirculation-air door.
(1) Remove the air inlet housing from the HVAC
housing and place it on a workbench (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC
HOUSING
-
AIR
INLET
HOUSING
-
REMOVAL).
(2) Using a small flat bladed tool, gently pry the
recirculation door actuator latch while pulling firmly
outwards on the actuator and remove the actuator
from the HVAC air inlet housing mount (Fig. 20).
(3) Disengage the actuator rod from the push-pin
type retainer located on the end of the recirculation
door actuator lever.
(4) Remove the screw that secures the recircula-
tion door actuator lever to the air inlet housing and
remove the lever (Fig. 21).
(5) Using a pick or similar tool, release the retain-
ing tab of the recirculation door lever located on the
inside surface of the air inlet housing and pull the
lever out of the pivot shaft of the recirculation-air
door (Fig. 22).
Fig. 20 Recirculation Door Actuator
1 - ACTUATOR LATCH
2 - RECIRCULATION DOOR ACTUATOR LEVER
3 - HVAC AIR INLET HOUSING
4 - RECIRCULATION DOOR ACTUATOR
Fig. 21 Recirculation Door Actuator Lever
1 - HVAC AIR INLET HOUSING
2 - RECIRCULATION DOOR LEVER
3 - RECIRCUALTION DOOR ACTUATOR LEVER
4 - SCREW
Fig. 22 Recirculation Door Lever
1 - HVAC AIR INLET HOUSING (INSIDE VIEW)
2 - RECIRCULATION DOOR LEVER RETAINING TAB
3 - RECIRCULATION DOOR PIVOT SHAFT
4 - RECIRCULATION-AIR DOOR
TJ
DISTRIBUTION
24 - 47
HVAC HOUSING (Continued)
(6) Using a pick or similar tool, release the retain-
ing tab of the recirculation door retainer located on
the inside surface of the air inlet housing and pull
the retainer out of the pivot shaft of the recircula-
tion-air door (Fig. 23).
NOTE: If a foam seal on the recirculation-air door is
deformed
or
damaged,
the
air
door
must
be
replaced.
(7) Remove the recirculation-air door from the air
inlet housing.
ASSEMBLY
HVAC HOUSING
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.
NOTE: If any foam or rubber seal on the HVAC
housing or an air-door is deformed or damaged, it
must be replaced.
(1) Carefully install the A/C evaporator, foam insu-
lator and the rubber seal into the lower half of the
HVAC housing. If removed, install the evaporator
tube clamp (Fig. 24).
(2) Carefully install the heater core and foam insu-
lator into the lower half of the HVAC housing.
(3) Install the floor/defroster-air door and the
blend-air door into their pivot holes in the lower half
of the HVAC housing (Fig. 25).
Fig. 23 Recirculation Door Retainer
1 - RETAINING TAB
2 - HVAC AIR INLET HOUSING (INSIDE VIEW)
3 - RECIRCULATION DOOR PIVOT SHAFT
4 - RECIRCULATION-AIR DOOR
Fig. 24 Heater Core and A/C Evaporator - Typical
1 - HEATER CORE
2 - RUBBER SEAL
3 - A/C EVAPORATOR (IF EQUIPPED)
4 - HVAC HOUSING (LOWER HALF)
Fig. 25 Floor/Defrost and Blend-Air Doors - LHD
shown, RHD similar
1 - FLOOR/DEFROST-AIR DOOR
2 - BLEND-AIR DOOR
3 - HVAC HOUSING (LOWER HALF)
24 - 48
DISTRIBUTION
TJ
HVAC HOUSING (Continued)
(4) Position the panel-air door into the pivot hole
located in the lower half of the HVAC housing (Fig.
26).
(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.
(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 (Fig. 27).
(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 con-
densate drain tube.
(9) Position the defrost/demister outlet cover onto
the top of the HVAC housing (Fig. 28).
(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.).
Fig. 26 Panel Door Lever - Typical
1 - PANEL-AIR DOOR PIVOT SHAFT
2 - HVAC HOUSING (LOWER HALF)
3 - PANEL DOOR LEVER
Fig. 27 Foam Seal and HVAC Housing Screws -
Typical
1 - PARTING LINE
2 - FOAM SEAL
3 - HVAC HOUSING (UPPER HALF)
4 - SCREWS (14)
5 - CLIP (2)
6 - FOAM SEAL
7 - HVAC HOUSING (LOWER HALF)
Fig. 28 Defrost/Demister Outlet Cover - LHD shown,
RHD similar
1 - SCREW (5)
2 - DEFROST/DEMISTER OUTLET COVER
3 - HVAC HOUSING
TJ
DISTRIBUTION
24 - 49
HVAC HOUSING (Continued)
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