Housing Assembly HVAC: Service and Repair

PLENUM CHAMBER

REMOVAL

All vehicles
1. Remove the instrument panel. For additional information, refer to: Dashboard/Instrument Panel. Service and Repair







2. Clamp-off and disconnect the heater hoses.







3. Inside the vehicle, remove the nut.







4. NOTE: Mark the locations of the vacuum hoses.

Disconnect the vacuum hoses.







5. Disconnect the vacuum hose.







6. Remove the pin-type retainers and remove the vacuum harness.







7. Disconnect the connector.







8. Remove the nuts.







9. Disconnect the connectors.


Five passenger/Marauder vehicles







10. Loosen the center console rear footwell duct nuts.

Six passenger vehicles







11. CAUTION: Do not excessively cut the rear footwell duct. Make sure to only cut the rear footwell duct to the point that allows the heater floor duct to be removed with the plenum chamber as an assembly.

Position back the carpet from the plenum chamber. Cut each side of the rear footwell duct and bend back the duct.

All Vehicles







12. Remove the in-car temperature sensor hose (if equipped).







13. Remove the plenum chamber.

INSTALLATION

1. NOTE: Make sure to sufficiently seal the rear footwell duct to the heater outlet floor duct.

To install,reverse the removal procedure.
- Clean and lubricate the coolant hose with coolant hose lubricant or plain water only if needed.
- Close the rear footwell duct around the heater outlet floor duct, install a tie strap, and position back the carpet.

2. Refill the engine coolant to the correct level.