Liberty, Wrangler, 1997-2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and remove the negative battery.
    CAUTION
    After disconnecting the negative battery cable, wait 2 minutes for the driver-s/passenger-s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the instrument panel by performing the following procedure:
    1. Turn the steering wheel in the straight-ahead position.
    2.  
    3. Remove the knee blocker from the instrument panel.
    4.  
    5. Remove the steering column; do not remove the air bag module, the steering wheel or switches from the steering column.
    6.  
    7. From under the driver-s side of the instrument panel, disconnect the following items:

      Instrument panel wiring harness connector from the 100-way wiring harness connector at the left side of the inner panel.
       
      Side window demister hose at the heater/air conditioning housing demister/defroster duct on the driver-s side.
       

    8.  
    9. Remove the glove box.
    10.  
    11. Reaching through the glove box opening, disconnect the following items:

      Two halves of the heater/air conditioning system vacuum harness connector.
       
      Instrument panel wiring harness connector from the heater/air conditioning system wiring harness connector.
       
      Instrument panel wiring harness connector from the passenger-s side air bag module wiring harness connector.
       
      Side window demister hose at the heater/air conditioning housing demister/defroster duct (passenger-s side).
       
      Two halves of the radio antenna coaxial cable connector.
       
      Two instrument panel wiring harness connectors from the passenger air bag ON/OFF switch wiring harness connector.
       
      Passenger-s side air bag ON/OFF switch wiring harness from the retainer clip on the plenum bracket that supports the heater/air conditioning housing just inboard of the fuse block module.
       
      Two lower passenger-s side air bag module bracket-to-dash panel nuts.
       

    12.  
    13. Remove the upper cover from the instrument panel.
    14.  
    15. Remove the 3 instrument panel-to-door hinge pillar screws.
    16.  
    17. Remove the 4 upper instrument panel-to-dash nuts.
    18.  
    19. Using an assistant, remove the instrument panel from the vehicle.
    20.  

  8.  
  9. If equipped with air conditioning, discharge and recover the air conditioning system refrigerant.
  10.  
  11. Disconnect the refrigerant lines from the evaporator. Plug the refrigerant openings to prevent evaporation.
  12.  
  13. Disconnect the heater hoses from the heater core tubes.
  14.  
  15. Disconnect the heater/air conditioning system vacuum supply line connector from the T-fitting near the heater core tubes.
  16.  
  17. In the engine compartment, remove the 5 heater/air conditioning housing-to-chassis nuts. If necessary, loosen the battery hold-downs and reposition the battery for access.
  18.  
  19. Remove the cowl plenum drain tube from the heater/air conditioning housing stud; it-s located behind the cylinder head on the cowl.
  20.  
  21. From the bottom of the heater/air conditioning housing, remove the floor duct.
  22.  
  23. On the passenger side, remove the heater/air conditioning housing-to-plenum bracket screw.
  24.  
  25. Pull the heater/air conditioning housing down far enough to clear the defrost/demist and fresh air ducts, then, rearward far enough to clear the mounting studs and the evaporator drain tube to clear the dash panel holes.
  26.  
  27. Remove the heater/air conditioning housing assembly from the vehicle.
  28.  
  29. Remove the heater/air conditioning housing upper case.
  30.  
  31. Lift the heater core from the lower half of the heater/air conditioning housing.

    Click image to see an enlarged view

    Fig. View of the instrument panel and fasteners-Wrangler



    Click image to see an enlarged view

    Fig. Exploded view of the heater core assembly-Wrangler



    Click image to see an enlarged view

    Fig. View of the heater core-Wrangler

  32.  

To install:

  1. Assemble the heater core into the lower half of the heater/air conditioning housing.
  2.  
  3. Install the heater/air conditioning housing upper case.
  4.  
  5. Install the heater/air conditioning housing assembly to the vehicle.
  6.  
  7. On the passenger-s side, install the heater/air conditioning housing-to-plenum bracket screw.
  8.  
  9. At the bottom of the heater/air conditioning housing, install the floor duct.
  10.  
  11. Install the cowl plenum drain tube to the heater/air conditioning housing stud; it-s located behind the cylinder head on the cowl.
  12.  
  13. In the engine compartment, install the 5 heater/air conditioning housing-to-chassis nuts.
  14.  
  15. Connect the heater/air conditioning system vacuum supply line connector to the T-fitting near the heater core tubes.
  16.  
  17. Connect the heater hoses to the heater core tubes.
  18.  
  19. Connect the refrigerant lines to the evaporator.
  20.  
  21. If equipped with air conditioning, evacuate and charge the air conditioning system refrigerant.
  22.  
  23. Install the instrument panel by performing the following procedure:
    1. Using an assistant, install the instrument panel to the vehicle.
    2.  
    3. Install the 4 upper instrument panel-to-dash nuts.
    4.  
    5. Install the 3 instrument panel-to-door hinge pillar screws.
    6.  
    7. Install the upper cover to the instrument panel.
    8.  
    9. Reaching through the glove box opening, connect the following items.

      Two lower passenger-s side air bag module bracket-to-dash panel nuts.
       
      Passenger-s side air bag ON/OFF switch wiring harness to the retainer clip on the plenum bracket that supports the heater/air conditioning housing just inboard of the fuse block module.
       
      Two instrument panel wiring harness connectors to the passenger air bag ON/OFF switch wiring harness connector.
       
      Two halves of the radio antenna coaxial cable connector.
       
      Side window demister hose at the heater/air conditioning housing demister/defroster duct (passenger-s side).
       
      Instrument panel wiring harness connector to the passenger-s side air bag module wiring harness connector.
       
      Instrument panel wiring harness connector to the heater/air conditioning system wiring harness connector.
       
      Two halves of the heater/air conditioning system vacuum harness connector.
       

    10.  
    11. Install the glove box.
    12.  
    13. Under the driver-s side of the instrument panel, connect the following items:

      Side window demister hose at the heater/air conditioning housing demister/defroster duct on the driver-s side.
       
      Instrument panel wiring harness connector to the 100-way wiring harness connector at the left side of the inner panel.
       

    14.  
    15. Install the steering column.
    16.  
    17. Install the knee blocker to the instrument panel.
    18.  

  24.  
  25. Connect and remove the negative battery.
  26.  
  27. Refill the cooling system.
  28.  
  29. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
  30.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and remove the negative battery.
    CAUTION
    After disconnecting the negative battery cable, wait 2 minutes for the driver-s/passenger-s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument.

  4.  
  5. Drain the cooling system into a clean container for reuse.
  6.  
  7. Remove the instrument panel by performing the following procedure:
    1. Turn the steering wheel in the straight-ahead position.
    2.  
    3. Remove the A-pillar trim from both sides of the vehicle.
    4.  
    5. Remove the top cover from the instrument panel.
    6.  
    7. Remove the speakers.
    8.  
    9. Remove the floor console.
    10.  
    11. Remove the radio.
    12.  
    13. Remove the center support bracket.
    14.  
    15. Remove the trim panels from both sides of the inner cowl.
    16.  
    17. Remove the fuse cover from the junction box.
    18.  
    19. Remove the instrument panel cluster bezel.
    20.  
    21. Remove the steering column opening cover from the instrument panel.
    22.  
    23. Remove the steering column bracket from the instrument panel column support bracket.
    24.  
    25. Remove the lower steering column shroud cover-to-multifunction switch screw; then, unsnap both halves of the shroud cover from the steering column.
    26.  
    27. Disconnect the instrument panel wiring harness connectors from the following steering column components:

      Both lower clockspring connector receptacles
       
      Left multifunction switch receptacle
       
      Right multifunction switch receptacle
       
      Both ignition switch receptacles
       
      Shifter interlock solenoid receptacle
       
      Sentry Key Immobilizer Module (SKIM) receptacle, if equipped
       

    28.  
    29. Turn the ignition switch to ON position; then, release and remove the shifter interlock cable connector from the ignition lock housing receptacle.
    30.  
    31. Turn the ignition switch to OFF position; this will prevent the steering wheel from turning and the loss of the clockspring centering following steering column removal.
    32.  
    33. Remove the 4 steering column-to-instrument panel steering column bracket nuts.
    34.  
    35. Remove the steering column from the instrument panel.
    36.  

  8.  
  9. Remove the driver-s side cowl trim cover.
  10.  
  11. Disconnect the green and light blue wire harness bulk connectors at the junction block.
  12.  
  13. Disconnect the electrical connector at the inner side of the pedal support bracket.
  14.  
  15. Remove the 2 bolts from the front and the 2 from the side of the pedal support bracket.
  16.  
  17. Remove the glove box.
  18.  
  19. Remove the 2 HVAC mounting bolts behind the center trim.
  20.  
  21. Remove the passenger trim bezel.
  22.  
  23. Remove the HVAC mount bolt above the glove box.
  24.  
  25. Remove the HVAC bolt at the lower outside glove box opening.
  26.  
  27. Remove the passenger trim cover, disconnect the blower resistor, remove the rolldown brackets at the right cowl side panel.
  28.  
  29. Disconnect the vacuum check valve and the vacuum reservoir.
  30.  
  31. Disconnect the blower connectors.
  32.  
  33. Remove the 4 top bolts connecting the instrument panel to the cowl.
  34.  
  35. Roll the instrument panel rearward and disconnect the wiring.
  36.  
  37. Remove the panel.
  38.  
  39. Discharge and recover the air conditioning system refrigerant.
  40.  
  41. Disconnect the air conditioning system lines at the evaporator. Plug the openings to prevent contamination.
  42.  
  43. Disconnect the heater hoses from the heater core. Plug the openings to prevent coolant loss.
  44.  
  45. If equipped with a manual temperature control system, unplug the heater/air conditioning system vacuum supply line connector from the T-fitting located near the heater core tubes.
  46.  
  47. Remove all remaining fasteners and connections and remove the HVAC unit.
  48.  
  49. Disconnect all remaining hoses and wires.
  50.  
  51. Remove the blower motor.
  52.  
  53. Pop out the grommet on the vacuum supply line and slide hole.
  54.  
  55. Remove the foam gasket from around the heater core tubes.
  56.  
  57. Pry off the 4 snap clips that hold the halves of the unit together and separate the unit halves.
  58.  
  59. Installation is the reverse of removal.
  60.  
  61. Refill the cooling system.
  62.  
  63. Connect the negative battery.
  64.  
  65. Evacuate, charge and leak test the system.
  66.  
  67. Run the engine to normal operating temperatures. Check the climate control operation and check for leaks.

    Click image to see an enlarged view

    Fig. HVAC case components-Liberty

  68.  

 
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