Operation CHARM: Car repair manuals for everyone.
Home >> Dodge and Ram >> 2005 >> Durango 2WD V6-3.7L VIN K >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Removal and Replacement >> Front HVAC Housing Removal and Installation

Front HVAC Housing Removal and Installation




REMOVAL





WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION AND FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
- ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE, Service and RepairTHEN 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 AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY OR DEATH. Service and Repair

NOTE: The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage. Service and Repair

1. Recover the refrigerant from the refrigerant system. Service and Repair
2. Drain the engine cooling system. Service and Repair
3. Disconnect and isolate the negative battery cable. Service and Repair
4. Disconnect the liquid line and suction line from the expansion valve and install plugs or caps over the fittings and expansion valve ports.
5. Disconnect the heater hoses from the heater core tubes and install plugs or caps over the heater core tube openings.
6. Remove the four nuts (1) that secure the HVAC housing (2) to the engine compartment side of the dash panel(3).




7. Remove the instrument panel from the passenger compartment.Service and Repair Refer to: "Body and Frame, Interior Trim: Dashboard/Instrument Panel" Service and Repair
8. Disconnect the intermediate floor distribution duct from the front floor distribution duct.
9. Remove the two bolts (1) that secure the HVAC housing (2) to the passenger compartment side of the dash panel (3).
10. Pull the HVAC housing rearward so that the mounting studs and condensate drain tube clear the dash panel and remove the front HVAC housing from the passenger compartment.

INSTALLATION




1. Position the HVAC housing (2) into the passenger compartment with the mounting studs and the con-densate drain tube in their proper mounting locations in the dash panel (3).
2. Loosely install the two bolts (1) that secure the HVAC housing to the passenger compartment side of the dash panel.




3. Install the four nuts (1) that secure the HVAC housing (2) to the engine compartment side of the dash panel (3). Tighten the nuts to 7 N.m (62 in.lbs.).
4. Tighten the two bolts that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the bolt(s) to 3 N.m (26 in.lbs.).
5. Connect the intermediate floor distribution duct to front floor distribution duct.
6. Install the instrument panel. Refer to: "Body and Frame, Interior Trim: Dashboard/Instrument Panel" Service and Repair
7. Remove previously installed plugs or caps and reconnect the heater hoses to the heater core tubes.
8. Remove previously installed plugs or caps and reconnect the suction line and liquid line to the expansion valve .
9. Reconnect the negative battery cable.
10. If the heater core is being replaced, flush the cooling system.
11. Refill the engine cooling system. Service and Repair
12. Evacuate the refrigerant system. Service and Repair
13. Charge the refrigerant system.
pro multis · About Operation CHARM