2007 Wrangler JK Factory Service Manual 24 - HEATING & AIR CONDITIONING

DISASSEMBLY

HOUSING-AIR DISTRIBUTION

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.

NOTE: Whenever the control cables are removed from the HVAC housing, new cables must be installed. Failure to replace the control cables when required can result in selected temperatures and operating modes not properly obtained.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.




1. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove the air distribution housing (3) from the HVAC housing (1) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - REMOVAL).
3. Remove the heater core from the air distribution housing (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/CORE HEATER - REMOVAL).
4. If equipped with the 2.8L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing (refer to 24 - HEATING & AIR CONDITIONING/CABIN HEATER/HEATER UNIT - REMOVAL).


5. Remove the temperature control cable (1) from the left side of the air distribution housing (2) and discard the cable (refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/CABLE-TEMPERATURE CONTROL - REMOVAL).
6. Remove the screw and washer (6) that secures the blend door cable lever (7) to the air distribution housing and remove the cable lever.

NOTE: To remove the blend door pivot lever, disengage the retaining tab and pull the lever straight off of the blend door pivot shaft.


7. Remove the blend door pivot lever (4) and washer (3) from the end of the blend door pivot shaft (5).


8. Remove the mode door cable (1) from the right side of the air distribution housing (2) and discard the cable (refer to 24 - HEATING & AIR CONDITIONING/CONTROLS/CABLE-MODE DOOR - REMOVAL).
9. Remove the screw and washer (3) that secure the mode door cam (4) to the air distribution housing and remove the cam.

NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.


10. Carefully cut the foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If a seal is deformed or damaged, it must be replaced.
11. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together.
12. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing.

NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.


13. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5).

NOTE: To remove the mode door levers, disengage the lever retaining tabs located on the inside of the air distribution housing and pull the levers straight out of the housing.


14. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5).

HOUSING-AIR INLET

NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.




1. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove the air inlet housing (2) from the HVAC housing (1) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR INLET - REMOVAL).


3. Remove the two screws (1) that secure the recirculation door actuator (3) to the right side of the air inlet housing (2) and remove the actuator.


4. To remove the recirculation door pivot shaft adapter (1) from the right end of the recirculation-air door, first carefully push down on the tab of the door lever pivot shaft adapter located inside of the air inlet housing (2), then pull the pivot shaft adapter straight out of the end of the recirculation-air door pivot shaft.

NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.

NOTE: If a rubber seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.


5. Carefully pinch the two ends of the recirculation air-door together and remove the air-door from the air inlet housing. If the seal on the recirculation air-door is deformed or damaged, the air-door must be replaced.

HOUSING-HVAC

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.




1. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove the air inlet housing (2) from the HVAC housing (1) (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR INLET - REMOVAL).
3. Remove the air distribution housing (3) from the HVAC housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - REMOVAL).


4. Remove the three screws (1) that secure the blower motor (2) to the bottom of the HVAC housing (3) and remove the blower motor.
5. Remove the two screws (4) that secure the blower motor resistor (5) to the back of the HVAC housing and remove the resistor.


6. Using needle nose pliers (1) , disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.


7. Remove the A/C expansion valve from the A/C evaporator (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/VALVE-A/C EXPANSION - REMOVAL).

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.


8. Remove the foam seal (2) from the flange (3) located on the top of the HVAC housing (4).
9. Remove the four screws (1) that secure the flange to the HVAC housing and remove the flange.

NOTE: If the foam insulator for the evaporator is deformed or damaged, it must be replaced.


10. Carefully remove the A/C evaporator (1) and its insulator (2) from the HVAC housing (3).

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


11. If required, remove the foam seal (1) from around the condensate drain located on the bottom of the HVAC housing (2).


12. Remove the two metal clips (1) and ten screws (2) that secure the two halves of the HVAC housing together (4 and 5).
13. Disengage the eight plastic retaining tabs (4) that secure the two halves of the HVAC housing together and separate the housing.