Jeep Wrangler TJ. Manual — part 594
NOTE: The HVAC housing must be removed from
the vehicle and the two halves of the housing sep-
arated for service of the heater core, A/C evapora-
tor, blend door and each of the various mode
doors.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the instrument panel (Refer to 23 -
BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(3) If the vehicle is not equipped with A/C, go to
Step 6. If the vehicle is equipped with A/C, recover
the refrigerant from the refrigerant system (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - REFRIGERANT SYS-
TEM RECOVERY).
(4) Disconnect the A/C liquid and suction lines
from the A/C evaporator and remove and discard the
O-ring seals (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/REFRIGERANT LINE COU-
PLER - REMOVAL).
(5) Install plugs in, or tape over the opened suc-
tion and liquid line fittings and both evaporator
tubes.
(6) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE).
(7) Disconnect the heater hoses from the heater
core tubes. Install plugs in, or tape over the opened
heater core tubes.
(8) Disconnect the HVAC system vacuum supply
line connector from the tee fitting near the heater
core tubes.
(9) Remove the five nuts that secure the HVAC
housing to the dash panel in the engine compartment
(Fig. 8). If necessary, loosen the battery hold-downs
and reposition the battery for additional access
(Refer to 8 - ELECTRICAL/BATTERY SYSTEM/BAT-
TERY - REMOVAL).
(10) Remove the two push-nuts that secure the
defroster duct to the dash panel in the passenger
compartment and remove the duct.
(11) Remove the bolt that secures the HVAC hous-
ing to the bracket located on the dash panel in the
passenger compartment.
(12) Remove the HVAC housing from inside the
vehicle taking care not to allow any remaining cool-
ant to drain on the vehicles interior.
AIR INLET HOUSING
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNINGS) and (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTIONS). Failure to follow the warnings and cau-
tions could result in possible personal injury or
death.
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing 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 air-
bag system. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.
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 HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - REMOVAL).
(2) If equipped, disconnect the HVAC vacuum har-
ness connector from the recirculation door actuator.
Fig. 8 HVAC Housing - LHD shown, RHD similar
1 - DASH PANEL
2 - NUT (5)
3 - INSTRUMENT PANEL WIRE HARNESS
4 - INSTRUMENT PANEL VACUUM HARHESS
5 - BOLT
6 - HVAC HOUSING
7 - NUT (2)
8 - DEFROSTER DUCT
24 - 42
DISTRIBUTION
TJ
HVAC HOUSING (Continued)
(3) Remove the five screws that secure the air
inlet housing to the top of the HVAC housing and
remove the air inlet housing (Fig. 9).
NOTE: If the foam seal on the air inlet housing is
deformed or damaged, it must be replaced.
(4) If required, disassemble the air inlet housing
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - AIR INLET
HOUSING - DISASSEMBLY).
DISASSEMBLY
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.
(1) Remove the HVAC housing assembly and place
it on a workbench (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/HVAC HOUSING
- REMOVAL).
(2) Disconnect the HVAC vacuum harness connec-
tors from the mode door actuators and the recircula-
tion door actuator, if equipped (Fig. 10).
(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 (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/MODE
DOOR
ACTUA-
TORS - REMOVAL).
(5) Remove the blend door actuator from the
HVAC housing (Refer to 24 - HEATING & AIR CON-
DITIONING/CONTROLS/BLEND
DOOR
ACTUA-
TOR - REMOVAL).
Fig. 9 HVAC Air Inlet Housing - LHD shown, RHD
similar
1 - SCREWS (5)
2 - AIR INLET HOUSING
3 - HVAC HOUSING
Fig. 10 Vacuum Harness and Actuators - LHD
shown, RHD similar
1 - VACUUM HARNESS CONNECTORS
2 - RECIRCULATION DOOR ACTUATOR
3 - HVAC VACUUM HARNESS
4 - BLEND DOOR ACTUATOR
5 - HVAC HOUSING
6 - MODE DOOR ACTUATORS
TJ
DISTRIBUTION
24 - 43
HVAC HOUSING (Continued)
(6) Disconnect the wire harness connectors from
the blower motor resistor and the blower motor (Fig.
11).
(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.
(11) Remove the five screws that secure the air
inlet housing to the top of the HVAC housing and
remove the inlet housing (Fig. 12).
(12) Remove the three screws that secure the floor
distribution duct to the bottom of the HVAC housing
and remove the duct (Fig. 13).
(13) Remove the one screw that secures the upper
and lower HVAC housing halves together at the bot-
tom of the HVAC housing.
NOTE: If the foam seal for the defrost/demister out-
let cover or the panel outlet is deformed or dam-
aged, the seal must be replaced.
(14) Carefully cut the foam seal for the defrost/de-
mister outlet cover along the two parting lines of the
outlet cover (Fig. 14).
(15) Carefully cut the foam seal for the panel out-
let along the parting line of the two HVAC housing
halves.
Fig. 11 HVAC Wire Harness - LHD shown, RHD
similar
1 - HVAC WIRE HARNESS
2 - BLOWER MOTOR RELAY
3 - BLOWER MOTOR RESISTOR
4 - SCREW (2)
5 - BLOWER MOTOR
6 - SCREW (3)
7 - HVAC HOUSING
Fig. 12 HVAC Air Inlet Housing - LHD shown, RHD
similar
1 - SCREWS (5)
2 - AIR INLET HOUSING
3 - HVAC HOUSING
Fig. 13 Floor Distribution Duct and Screw - LHD
shown, RHD similar
1 - SCREW (3)
2 - FLOOR DISTRIBUTION DUCT
3 - HVAC HOUSING (LOWER HALF)
4 - SCREW
24 - 44
DISTRIBUTION
TJ
HVAC HOUSING (Continued)
NOTE: If the foam seal for the defrost/demister out-
let cover is deformed or damaged, the seal must be
replaced.
(16) Remove the five screws that secure the
defrost/demister outlet cover to the top of the HVAC
housing and remove the cover (Fig. 15).
NOTE: If the foam seal for the evaporator and
heater core tubes is deformed or damaged, the seal
must be replaced.
(17) Carefully cut the foam seal for the evaporator
and heater core tubes along the parting line of the
two HVAC housing halves (Fig. 16).
NOTE: If the foam seal for the evaporator conden-
sate 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.
Fig. 14 Foam Seals and Parting Lines - Typical
1 - FOAM SEAL (2)
2 - PARTING LINE
3 - PARTING LINE
4 - HVAC HOUSING HALVES
5 - PARTING LINE
Fig. 15 Defrost/Demister Outlet Cover - LHD shown,
RHD similar
1 - SCREW (5)
2 - DEFROST/DEMISTER OUTLET COVER
3 - HVAC HOUSING
Fig. 16 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)
TJ
DISTRIBUTION
24 - 45
HVAC HOUSING (Continued)
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