Jeep Wrangler TJ. Manual — part 596
(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.) (Fig.
29).
(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.).
(14) Position the air inlet housing onto the top of
the HVAC housing (Fig. 30).
(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.).
(16) Install the HVAC wire harness onto the HVAC
housing. Make sure the wires are routed through all
wiring retainers (Fig. 31).
(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.
(22) Install the mode door actuators (Fig. 32)
(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS/MODE DOOR ACTUATORS - INSTAL-
LATION).
Fig. 29 Floor Distribution Duct and Screw - LHD
shown, RHD similar
1 - SCREW (3)
2 - FLOOR DISTRIBUTION DUCT
3 - HVAC HOUSING (LOWER HALF)
4 - SCREW
Fig. 30 HVAC Air Inlet Housing - LHD shown, RHD
similar
1 - SCREWS (5)
2 - AIR INLET HOUSING
3 - HVAC HOUSING
Fig. 31 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
24 - 50
DISTRIBUTION
TJ
HVAC HOUSING (Continued)
(23) Install the blend door actuator (Refer to 24 -
HEATING
&
AIR
CONDITIONING/CONTROLS/
BLEND DOOR ACTUATOR - INSTALLATION).
(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 actua-
tor, if equipped.
(26) Install the HVAC housing assembly (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/HVAC HOUSING - INSTALLATION).
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.
NOTE: If a foam seal on the recirculation-air door
is deformed or damaged, the air door must be
replaced.
(1) Position the recirculation-air door into the air
inlet housing.
CAUTION: Make sure that the recirculation-air door
pivot shaft is properly seated in the pivot seats
located in the air inlet housing.
(2) Align the recirculation door lever with the
recirculation-air door pivot shaft and install the lever
until the retaining tab is fully engaged to the pivot
shaft (Fig. 33).
Fig. 32 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
Fig. 33 Recirculation Door Lever Installation
1 - RECIRCULATION DOOR PIVOT SHAFT
2 - RECIRCULATION DOOR LEVER
3 - HVAC AIR INLET HOUSING
TJ
DISTRIBUTION
24 - 51
HVAC HOUSING (Continued)
(3) Align the recirculation door retainer with the
recirculation-air door pivot shaft and install the
retainer until the retaining tab is fully engaged to
the pivot shaft (Fig. 34).
(4) Install the recirculation door actuator lever
onto the pivot shaft on the air distribution housing
(Fig. 35).
NOTE: Align the guide pin on the recirculation door
actuator lever with the guides on the recirculation
door lever during installation of the actuator lever.
(5) Connect the recirculation door actuator lever to
the recirculation door lever.
(6) Install the screw that secures the recirculation
door actuator lever to the air distribution housing.
Tighten the screw to 2 N·m (17 in. lbs.).
(7) Install the recirculation door actuator mount
onto the air inlet housing mounting boss (Fig. 36).
Push the actuator onto the mount until it snaps into
the locked position.
(8) Install the air inlet housing onto the HVAC
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING - AIR
INLET HOUSING - INSTALLATION).
INSTALLATION
HVAC HOUSING
NOTE: Use only the specified O-rings as they are
made of special material for R-134a. Use only refrig-
erant oil of the type required for the A/C compres-
sor in the vehicle.
(1) Position the HVAC housing to the dash panel.
Be certain that the evaporator condensate drain tube
and the housing mounting studs are inserted into
their correct mounting holes.
(2) Install the bolt that secures the HVAC housing
to the bracket located on the dash panel in the pas-
Fig. 34 Recirculation Door Retainer Installation
1 - RECIRCULATION DOOR PIVOT SHAFT
2 - RECIRCULATION DOOR RETAINER
3 - HVAC AIR INLET HOUSING
Fig. 35 Recirculation Door Actuator Lever
1 - HVAC AIR INLET HOUSING
2 - RECIRCULATION DOOR LEVER
3 - RECIRCUALTION DOOR ACTUATOR LEVER
4 - SCREW
Fig. 36 Recirculation Door Actuator
1 - ACTUATOR LATCH
2 - RECIRCULATION DOOR ACTUATOR LEVER
3 - HVAC AIR INLET HOUSING
4 - RECIRCULATION DOOR ACTUATOR
24 - 52
DISTRIBUTION
TJ
HVAC HOUSING (Continued)
senger compartment. Tighten the bolt to 3 N·m (27
in. lbs.).
(3) Install the defroster duct onto the top of the
HVAC housing.
(4) Install the two push-nuts that secure the
defroster duct to the dash panel in the passenger
compartment.
(5) Install the five nuts that secure the HVAC
housing to the dash panel in the engine compart-
ment. Tighten the nuts to 6 N·m (53 in. lbs.).
(6) If the battery was repositioned during the
removal procedure, position the battery and tighten
the hold-downs (Refer to 8 - ELECTRICAL/BAT-
TERY SYSTEM/BATTERY - INSTALLATION).
(7) Connect the HVAC system vacuum supply line
connector to the tee fitting near the heater core
tubes.
(8) Unplug or remove the tape from the heater
core tubes and connect the heater hoses to the heater
core tubes.
(9) If the vehicle is not equipped with A/C, go to
Step 15. If the vehicle is equipped with A/C, unplug
or remove the tape from the liquid and suction line
fittings and both evaporator tubes.
(10) Lubricate new rubber O-ring seals with clean
refrigerant oil and install them on the liquid and suc-
tion line fittings.
(11) Connect the A/C liquid and suction lines to
the A/C evaporator (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT LINE
COUPLER - INSTALLATION).
(12) Install the instrument panel (Refer to 23 -
BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION).
(13) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(14) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
(15) Reconnect the negative battery cable.
(16) If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/
REVERSE FLUSHING).
(17) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
AIR INLET HOUSING
NOTE: The recirculation-air door and actuator are
used only on models equipped with A/C.
NOTE: If the foam seal on the air inlet housing is
deformed or damaged, it must be replaced.
(1) Position the air inlet housing onto the top of
the HVAC housing.
(2) Install the five screws that secure the air inlet
housing to the HVAC housing. Tighten the screws to
2 N·m (17 in. lbs.).
(3) If equipped, connect the HVAC vacuum harness
connector to the recirculation door actuator.
(4) Install the HVAC housing (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).
INSTRUMENT PANEL
DEMISTER DUCTS
REMOVAL
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 battery negative (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 two demister ducts can be serviced
without removing the instrument panel. However, if
either of the demister outlets require servicing, the
instrument panel must be removed.
DEMISTER DUCTS
(1) Disconnect and isolate the negative battery
cable.
(2) To gain access to the passenger side demister
duct, remove the glove box from the instrument
panel (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - REMOVAL).
(3) To gain access to the driver side demister duct
remove the top cover, knee blocker and instrument
cluster from the instrument panel (Refer to 23 -
BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL TOP COVER - REMOVAL), (Refer to 23 -
BODY/INSTRUMENT PANEL/KNEE BLOCKER -
REMOVAL) and (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - REMOVAL).
(4) Reach through the glove box opening and/or
the cluster opening of the instrument panel and dis-
TJ
DISTRIBUTION
24 - 53
HVAC HOUSING (Continued)
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