Chrysler Full-Size Trucks 1989-1996 Repair Guide

Heater/Air Conditioning Housing

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REMOVAL & INSTALLATION



1994-96 Pick-Ups

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Take the vehicle to a certified refrigerant recovery/recycling station and have the air conditioning system refrigerant properly recovered.
  4.  



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Fig. Fig. 1: Disconnect the evaporator and heater core lines-1994-96 models

  1. Disconnect the refrigerant lines from the evaporator tubes. Install plugs or tape over all the open refrigerant lines.
  2.  



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Fig. Fig. 2: Remove the defroster duct assembly to access the heater/air conditioning housing

  1. Drain the cooling system.
  2.  
  3. Disconnect the heater hoses from the heater core tubes.
  4.  



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Fig. Fig. 3: Exploded view of the heater/air conditioning housing mounting

  1. Remove the coolant reserve/overflow bottle.
  2.  
  3. Remove the Powertrain Control Module (PCM) and set it aside. Do NOT disconnect the PCM connectors.
  4.  
  5. Remove the heater/air conditioning housing mounting nuts from the studs on the engine compartment side of the dash panel.
  6.  
  7. Remove the instrument panel.
  8.  
  9. Remove the defroster duct.
  10.  
  11. Unplug the electrical connections.
  12.  
  13. Remove the housing mounting nuts from the studs on the passenger compartment side of the dash panel.
  14.  
  15. Remove the heater/air conditioning housing from the vehicle.
  16.  

To install:
  1. Position the heater/air conditioning housing to the dash panel. Make sure the drain tube is positioned in the dash panel drain hole.
  2.  
  3. Install the mounting nuts on the passenger side. Tighten them to 40 inch lbs. (4.5 Nm).
  4.  
  5. Install the mounting nuts to the studs on the engine compartment side of the dash panel. Tighten these to 60 inch lbs. (7 Nm).
  6.  
  7. Connect the heater hoses.
  8.  
  9. Unplug and connect the refrigerant lines.
  10.  
  11. Install the coolant reserve/overflow bottle.
  12.  
  13. Install the PCM.
  14.  
  15. Install the defroster duct.
  16.  
  17. Connect the rear floor heat duct to the center heat duct adapter.
  18.  
  19. Plug in all disconnected electrical connectors.
  20.  
  21. Install the instrument panel.
  22.  
  23. Fill the cooling system.
  24.  
  25. Have the refrigerant system properly evacuated and charged.
  26.  
  27. Connect the negative battery cable.
  28.  

 
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