The JEEP LIBERTY 2002 KJ / 1.G Workshop Manual

INSTALLATION
INSTALLATION - PANEL DOOR ACTUATOR
(1) Install the defrost door vacuum actuator by
snapping it into place, engage the hole on the end of
the actuator link with the hooked pin on the end of
the panel/demist door lever.
(2) Plug in the vacuum harness connector to the
defrost door actuator.
(3) Install the instrument panel assembly in the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Connect the battery negative cable.
INSTALLATION - FLOOR - DEFROST DOOR
ACTUATOR
(1) Engage the hole on the end of the actuator
link to the hooked pin. Install the floor-defrost door
vacuum actuator to the HVAC assembly. on the end
of the floor door lever.
(2) Install the floor door vacuum actuator to the
HVAC assembly.
(3) Install the instrument panel assembly into the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL ASSEMBLY - INSTALLA-
TION).
(4) Connect the battery negative cable.
Fig. 17 HVAC DOOR VACUUM ACTUATORS
1 - VACUUM LINE AND CONNECTOR
2 - PANEL DOOR ACTUATOR
3 - VACUUM LINE AND CONNECTOR
4 - FLOOR-DEFROST DOOR ACTUATOR
5 - HVAC ASSEMBLY
Fig. 18 VACUUM ACTUATOR REMOVE/INSTALL -
TYPICAL
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
KJCONTROLS 24 - 25
MODE DOOR ACTUATOR (Continued)

RECIRCULATION DOOR
ACTUATOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the vacuum harness connector from the
recirculation door actuator (Fig. 19).(3) Insert a trim stick or another suitable wide
flat-bladed tool into the latch hole on the HVAC
housing actuator mount (Fig. 20).
(4) Gently pry the actuator latch while pulling
firmly outwards on the actuator to remove the actua-
tor from the mount (Fig. 21).
(5) Disengage the hole on the end of the actuator
link from the hooked pin on the end of the recircula-
tion door lever.
(6) Remove the recirculation door vacuum actuator
from the vehicle.
INSTALLATION
(1) Install the recirculation door vacuum actuator
by slipping the arm on to the hole on the end of the
actuator link with the hooked pin on the end of the
panel/demist door lever.
(2) Snap the actuator back into its mount.
(3) Plug in the vacuum harness connector to the
recirculation door actuator.
(4) Connect the battery negative cable.
Fig. 19 RECIRCULATION DOOR ASSEMBLY
1- INSTRUMENT PANEL ELECTRICAL HARNESS MOUNTING
TABS
2- MOUNTING TAB
3- RECIRCULATION DOOR
4- MOUNTING TAB
5- RECIRCULATION DOOR ASSEMBLY
6- RECIRCULATION DOOR LEVER
Fig. 20 VACUUM ACTUATOR REMOVE/INSTALL -
TYPICAL
1 - ACTUATOR MOUNT LATCH HOLE
2 - TRIM STICK
3 - ACTUATOR LATCH
24 - 26 CONTROLSKJ

VACUUM CHECK VALVE
DESCRIPTION
A vacuum check valve is installed in the accessory
vacuum supply line in the engine compartment, near
the vacuum tap on the engine intake manifold, and
at the HVAC unit takeout. The vacuum check valve
is designed to allow vacuum to flow in only one direc-
tion through the accessory vacuum supply circuits.
OPERATION
The use of a vacuum check valve helps to maintain
the system vacuum needed to retain the selected A/C
Heater mode settings. The check valve will prevent
the engine from bleeding down system vacuum
through the intake manifold during extended heavy
engine load (low engine vacuum) operation.
The vacuum check valve cannot be repaired and, if
faulty or damaged, it must be replaced.
REMOVAL
(1) Unplug the HVAC vacuum supply line connec-
tor at the vacuum check valve. The check valve is
located behind the glove box on the passengers side
of the vehicle (Fig. 22).
(2) Note the orientation of the check valve in the
vacuum supply line for correct reinstallation.
(3) Unplug the vacuum check valve from the vac-
uum supply line fittings.
INSTALLATION
(1) Plug in the vacuum check valve at the vacuum
supply line fittings making sure of proper orienta-
tion.(2) Plug in the vacuum check valve at the HVAC
vacuum supply line connector.
Fig. 22 RECIRCULATION ACTUATOR AND CHECK
VA LV E
1 - RECIRCULATION ACTUATOR
2 - VACUUM LINE TO RESEVOIR
3 - HVAC HOUSING
4 - VACUUM CHECK VALVE
24 - 28 CONTROLSKJ

DISTRIBUTION
TABLE OF CONTENTS
page page
AIR OUTLETS
DESCRIPTION - DEMISTER OUTLETS.......29
REMOVAL - PANEL OUTLET BARRELS......29
INSTALLATION - PANEL OUTLET BARRELS . . . 29
BLOWER MOTOR
DESCRIPTION.........................30
OPERATION...........................30
DIAGNOSIS AND TESTING - BLOWER
MOTOR .............................30
REMOVAL.............................30
INSTALLATION.........................31
FLOOR CONSOLE DUCT
REMOVAL.............................31
INSTALLATION.........................31
FLOOR DUCT
REMOVAL.............................32
INSTALLATION.........................32
DEFROST - DEMISTER DUCT
REMOVAL - DEFROST DUCT/DEMISTER
ADAPTOR...........................32INSTALLATION - DEFROST/DEMISTER DUCT . 32
HVAC HOUSING
REMOVAL.............................33
DISASSEMBLY.........................34
ASSEMBLY............................34
INSTALLATION.........................34
BLEND DOOR
REMOVAL.............................35
INSTALLATION.........................35
MODE DOOR
REMOVAL
REMOVAL - DEFROST DOOR............35
REMOVAL - FLOOR - DEFROST DOOR....36
INSTALLATION
INSTALLATION - PANEL DOOR...........36
INSTALLATION - FLOOR - DEFROST DOO . . 37
RECIRC DOOR
REMOVAL.............................37
INSTALLATION.........................37
AIR OUTLETS
DESCRIPTION - DEMISTER OUTLETS
The side window demister outlets are integral to
the instrument panel end caps(Refer to 23 - BODY/
INSTRUMENT PANEL/INSTRUMENT PANEL END
CAP - REMOVAL) and (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL END CAP -
REMOVAL).
REMOVAL - PANEL OUTLET BARRELS
(1) Use a trim stick or another suitable wide flat-
bladed tool to gently pry the panel outlet barrels out
of the panel outlet housing (Fig. 1). The barrel is
retained by a light snap fit.
INSTALLATION - PANEL OUTLET BARRELS
To install, position the barrel in the panel outlet
housing and press firmly until the barrel snaps into
place.
Fig. 1 DASH PANEL OUTLETS
1 - CENTER OUTLETS
2 - SIDE WINDOW DEMISTER OUTLETS
3 - SIDE OUTLETS
4 - WIRING FOR HVAC CONTROL ASSEMBLY
5 - WINDSHIELD DEFROSTER OUTLET
KJDISTRIBUTION 24 - 29

BLOWER MOTOR
DESCRIPTION
The blower motor and blower wheel are located in
the passenger side end of the HVAC housing, below
the glove box. The blower motor controls the velocity
of air flowing through the HVAC housing by spinning
a squirrel cage-type blower wheel within the housing
at the selected speed. The blower motor and wheel
can be removed from the housing inside the vehicle
without removing the dash or HVAC housing assem-
bly.
OPERATION
The blower motor will only operate when the igni-
tion switch is in the On position, and the A/C Heater
mode control switch knob is in any position, except
Off. The blower motor receives a fused battery feed
through the blower motor relay whenever the igni-
tion switch is in the On position. The blower motor
battery feed circuit is protected by a fuse in the
Power Distribution Center (PDC). Blower motor
speed is controlled by regulating the ground path
through the A/C Heater control blower motor switch
and the blower motor resistor.
The blower motor and blower motor wheel cannot
be repaired and, if faulty or damaged, they must be
replaced. The blower motor and blower wheel are ser-
viced only as a unit.
DIAGNOSIS AND TESTING - BLOWER MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
For circuit descriptions and diagrams, (Refer to
Appropriate Wiring Information). Possible causes of
an inoperative blower motor include:²Faulty fuse
²Faulty blower motor circuit wiring or wire har-
ness connectors
²Faulty blower motor resistor
²Faulty blower motor relay
²Faulty blower motor switch
²Faulty A/C Heater mode control switch
²Faulty blower motor.
Possible causes of the blower motor not operating
in all speeds include:
²Faulty blower motor switch
²Faulty blower motor resistor
²Faulty blower motor circuit wiring or wire har-
ness connectors.
VIBRATION
Possible causes of blower motor vibration include:
²Improper blower motor mounting
²Improper blower wheel mounting
²Blower wheel out of balance or bent
²Blower motor faulty.
NOISE
To verify that the blower is the source of the noise,
unplug the blower motor wire harness connector and
operate the HVAC system. If the noise goes away,
possible causes include:
²Foreign material in the HVAC housing
²Improper blower motor mounting
²Improper blower wheel mounting
²Blower motor faulty.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
24 - 30 DISTRIBUTIONKJ

The blower motor is located on the passenger side
of the vehicle under the dash
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the blower motor wire harness connec-
tor (Fig. 2).
(3) Release the locking tab that secures the blower
motor and wheel assembly to the HVAC housing.
(4) Rotate and tilt the blower motor unit as needed
for clearance to remove the blower motor and wheel
from the HVAC housing.
INSTALLATION
(1) Align and install the blower motor and wheel
assembly into the HVAC housing.
(2) Rotate the blower assembly until the locking
tab secures the blower motor and wheel assembly to
the HVAC housing.
(3) Plug in the blower motor wire harness connec-
tor.
(4) Connect the battery negative cable.
FLOOR CONSOLE DUCT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the floor console from the sled (Fig. 3).
Refer to Floor Console for the procedures(Refer to 23
- BODY/INTERIOR/FLOOR CONSOLE - REMOV-
AL).
(3) Lift the rear of the console duct out of the con-
sole rear mounting bracket on the sled and slide the
duct rearward to disengage it from the floor duct and
adapter.
(4) Remove the console rear duct from the vehicle.
INSTALLATION
(1) Push the console duct forward in place on the
HVAC floor duct.
(2) Align the rear tab of the console duct with the
hole on the sled bracket.
(3) Insert the push pin in the hole on the sled.
(4) Install the floor console on the floor panel
transmission tunnel(Refer to 23 - BODY/INTERIOR/
FLOOR CONSOLE - INSTALLATION).
(5) Connect the battery negative cable.
Fig. 2 HVAC BLOWER MOTOR
1 - HVAC HOUSING
2 - BLOWER MOTOR
3 - RETAINER-LOCKING TAB
4 - BLOWER MOTOR ELECTRICAL CONNECTOR
Fig. 3 CONSOLE DUCT REMOVE/INSTALL
1 - REAR DUCT ASSEMBLY
2 - REAR DUCT RETAINER SCREW
3 - REAR DUCT MOUNTING FLANGE
4 - TRANSMISSION SHIFT LEVER ASSEMBLY
5 - FRONT TO REAR DUCT CONNECTING POINT
KJDISTRIBUTION 24 - 31
BLOWER MOTOR (Continued)

FLOOR DUCT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove the instrument panel from the vehi-
cle(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(2) Remove the three screws that secure the floor
duct to the HVAC housing.
(3) Remove the floor duct from the HVAC housing.
INSTALLATION
(1) Install the floor duct on the HVAC housing.
(2) Install the three screws that secure the floor
duct to the HVAC housing. Tighten the mounting
screws to 2.2 N´m (20 in. lbs.).
(3) Install the instrument panel in the vehicle(Re-
fer to 23 - BODY/INSTRUMENT PANEL - INSTAL-
LATION).
DEFROST - DEMISTER DUCT
REMOVAL - DEFROST DUCT/DEMISTER
ADAPTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) Remove the instrument panel assembly from
the vehicle(Refer to 23 - BODY/INSTRUMENT
PANEL - REMOVAL).
(2) Remove the three screws that secure the
defrost duct/demister adapter to the instrument
panel (Fig. 4).
(3) Remove the defrost duct/demister duct from the
instrument panel.
INSTALLATION - DEFROST/DEMISTER DUCT
(1) Install the defrost/demister duct in the instru-
ment panel.
(2) Install the three screws that secure the defrost/
demister duct to the instrument panel.
(3) Tighten the mounting screws to 2.2 N´m (20 in.
lbs.).
(4) Install the instrument panel assembly in the
vehicle(Refer to 23 - BODY/INSTRUMENT PANEL -
INSTALLATION).
Fig. 4 DEFROST/DEMISTER DUCT
1 - INSTRUMENT PANEL
2 - DEFROST DUCT/ DEMISTER ADAPTOR
3 - SCREW
24 - 32 DISTRIBUTIONKJ

HVAC HOUSING
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.(2) Remove the instrument panel from the vehi-
cle(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(3) If the vehicle is not equipped with air condi-
tioning, go to Step 6. If the vehicle is equipped with
air conditioning, recover the refrigerant from the
refrigerant system. (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line fit-
ting from the evaporator inlet tube (Fig. 5). (Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING
- STANDARD PROCEDURE - A/C LINE COU-
PLERS)
(5) Disconnect the accumulator inlet tube refriger-
ant line fitting from the evaporator outlet tube.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - A/C LINE
COUPLERS) Install plugs in, or tape over all of the
opened refrigerant line fittings.
(6) Drain the engine cooling system(Refer to 7 -
COOLING - STANDARD PROCEDURE).
Fig. 5 HVAC CASE ASSEMBLY
1 - BLOWER MOTOR AND CAGE
2 - RECIRCULATION DOOR ACTUATOR LINKAGE
3 - RECIRCULATION DOOR VACUUM ACTUATOR
4 - CASE RETAINER SCREW
5 - BLEND DOOR ACTUATOR MOUNTING SCREWS
6 - ELECTRIC BLEND DOOR ACTUATOR
7 - ELECTRICAL CONNECTOR FOR BLEND DOOR ACTUATOR
8 - HEATER CORE RETAINER TABS (4) AND SCREWS (2)9 - HEATER CORE
10 - HVAC CASE RETAINER CLIP
11 - HEATER CORE INPUT AND OUTPUT CONNECTIONS
12 - EVAPORATOR CONNECTION FLANGE
13 - HVAC CASE RETAINER SCREWS
14 - HVAC HOUSING
KJDISTRIBUTION 24 - 33

(7) Disconnect the heater hoses from the heater
core tubes. Install plugs in, or tape over the opened
heater core tubes.
(8) Unplug the HVAC system vacuum supply line
connector from the engine side harness.
(9) Remove the nuts from the HVAC housing
mounting studs.
(10) Remove the HVAC housing from inside the
vehicle taking care not to allow any remaining cool-
ant to drain on the vehicles interior.
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle
and place it on the workbench. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - REMOVAL)
(2) Unplug the vacuum harness connectors from
the mode and recirculation door actuators and the
recirculation door actuator.
(3) Disengage the vacuum harness from any rout-
ing clips located on the lower half of the HVAC hous-
ing.
(4) Remove the blower motor and blower wheel
unit from the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/
BLOWER MOTOR - REMOVAL)
(5) Pop out the grommet onl the vacuum supply
line and slide hole in housing.
(6) Carefully remove the foam seals from the
heater core and evaporator coil tube mounting flange
of the HVAC housing. If the either seal is deformed
or damaged it must be replaced.
(7) Use a screwdriver to pry off the four snap clips
that help secure the upper and lower HVAC housing
halves together.
(8) Remove the screws that secure the upper and
lower HVAC housing halves together.
(9) Carefully separate the upper HVAC housing
from the lower half.
ASSEMBLY
(1) Assemble the upper HVAC housing half to the
lower half. During assembly, be certain of the follow-
ing.
(a) That each of the mode door pivot shaft ends
and the two temperature blend door shafts are
properly engaged in there pivot holes.
(b) That the blower motor venturi ring is prop-
erly indexed and installed.
(c) If the unit is equipped with air conditioning,
that the evaporator coil tube rubber seal is prop-
erly positioned in the grooves in both the upper
and lower HVAC housing halves.
(2) Install the screws and four snap clips that
secure the upper and lower HVAC housing halves toeach other. Tighten the screws to 2.2 N´m (20 in.
lbs.).
(3) Install the blower motor and wheel unit in the
HVAC housing. (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/BLOWER MOTOR -
INSTALLATION)
(4) Install the foam seals on the flanges around
the heater core and evaporator coil tube mounting
flange of the HVAC housing.
(5) Insert the vacuum supply line and connector
through the foam seal on the heater core and evapo-
rator coil tube mounting flange of the HVAC housing.
Check that the vacuum grommet is securely seated
into the housing hole flange.
(6) Engage the vacuum harness to the routing
clips and plug in the vacuum harness connector at
the floor door actuator and, if the unit is so equipped,
at the recirculation air door actuator.
INSTALLATION
WARNING: IF THE VEHICLE IS EQUIPPED WITH AIR
CONDITIONING, REVIEW THE WARNINGS AND
CAUTIONS IN PLUMBING BEFORE PERFORMING
THE FOLLOWING OPERATION. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - WARNING)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - CAUTION) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION -
REFRIGERANT HOSES/LINES/TUBES PRECAU-
TIONS)
(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 and tighten the nuts onto the HVAC
housing mounting studs. Tighten the nuts to 6.2 N´m
(55 in.lbs.).
(3) Connect the HVAC system vacuum supply line
connector.
(4) Unplug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
core tubes and fill the engine cooling system(Refer to
7 - COOLING/ENGINE - STANDARD PROCE-
DURE).
(5) If the vehicle is not equipped with air condi-
tioning, go to Step 10.
(6) Unplug or remove the tape from the liquid line
and the evaporator inlet tube fittings. Connect the
liquid line coupler to the evaporator inlet tube. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - STANDARD PROCEDURE - A/C LINE COU-
PLERS)
(7) Evacuate the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
24 - 34 DISTRIBUTIONKJ
HVAC HOUSING (Continued)

STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(8) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
(9) Install the instrument panel in the vehicle(Re-
fer to 23 - BODY/INSTRUMENT PANEL - INSTAL-
LATION).
(10) Connect the battery negative cable.
(11) Start the engine and check for proper opera-
tion of the heating and air conditioning systems.
BLEND DOOR
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Remove and disassemble the HVAC housing.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - DISASSEMBLY)
(2) Lift the blend door pivot shaft out of the pivot
hole in the bottom of the lower half of the HVAC
housing (Fig. 6).
INSTALLATION
(1) Place the blend door pivot shaft in of the pivot
hole in the bottom of the lower half of the HVAC
housing.
(2) Assemble the HVAC housing. (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - ASSEMBLY)
(3) Install the HVAC housing in the vehicle. (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/HVAC HOUSING - INSTALLATION)
MODE DOOR
REMOVAL
REMOVAL - DEFROST DOOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
Fig. 6 Blend Door
1 - DEFROSTER DOOR
2- HEATER CORE
3- BLEND DOORS
4- BLOWER MOTOR HOUSING
5- EVAPORATOR (A/C ONLY)
6- LOWER HVAC CASE ASSEMBLY
KJDISTRIBUTION 24 - 35
HVAC HOUSING (Continued)