2003 JEEP GRAND CHEROKEE door panel removal

HVAC HOUSING
REMOVAL
The HVAC housing assembly must be removed
from the vehicle and the two halves of the housing
separated for service access of the heater core, evap-
orator coil, blend door(s), and each of the various
mode doors.
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.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION)
(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) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line from
the evaporator inlet tube(Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/LIQUID LINE -
REMOVAL) or (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/LIQUID LINE - REMOV-
AL). Install plugs in, or tape over all of the opened
refrigerant line fittings.
(5) Disconnect the suction line refrigerant line
from the evaporator outlet tube(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/SUCTION
LINE - REMOVAL), (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/SUCTION LINE -
REMOVAL) or (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/SUCTION LINE - REMOV-
AL). Install plugs in, or tape over all of the opened
refrigerant line fittings.(6) Disconnect the heater hoses from the heater
core tubes. Clamp off the heater hoses to prevent loss
of coolant. Refer to Cooling for the procedures. Install
plugs in, or tape over the opened heater core tubes.
(7) If the vehicle is equipped with the manual tem-
perature control system, unplug the HVAC system
vacuum supply line connector from the tee fitting
near the heater core tubes.
(8) Remove the coolant reserve/overflow bottle
from the passenger side inner fender shield. Refer to
Cooling for the procedures.
(9) Remove the Powertrain Control Module (PCM)
from the passenger side dash panel in the engine
compartment and set it aside. Do not unplug the
PCM wire harness connectors. Refer to Electronic
Control Modules for the procedures.
(10) Remove the nuts from the HVAC housing
mounting studs on the engine compartment side of
the dash panel (Fig. 9).
(11) Remove the rear floor heat ducts from the
floor heat duct outlets (Fig. 10).
(12) Unplug the HVAC housing wire harness con-
nectors.
(13) Remove the HVAC housing mounting nuts
from the studs on the passenger compartment side of
the dash panel (Fig. 11).
Fig. 9 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
WJDISTRIBUTION 24 - 41

(14) Remove the HVAC housing from the vehicle,
ensuring that the interior is covered in case of loss of
fluids.
DISASSEMBLY
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Place the HVAC housing with the tubing side
down on a work bench, making allowance for leakage
of fluids.
(3) Using a sharp knife, split the foam seal sur-
rounding the panel outlet opening, at the dividing
line of the upper and lower cases (Fig. 12).
(4) Place the HVAC housing in the upright position
on the work bench.
(5) Remove the mode door actuator on the left side
of the housing, which controls the mode door in the
top of the case (Fig. 13) (Fig. 14).
(6) Remove the screw with plastic washer holding
the lever assembly to the upper case section, and
move aside (Fig. 15).
(7) Remove the 5 clips that secure the two housing
halves to each other. There are 2 on either side at
the center, and 1 located at the forward end of the
mode door side of the case (Fig. 16).
Fig. 10 REAR FLOOR DUCTS
1 - LEFT REAR PASSENGER FLOOR AIR DUCT
2 - RIGHT REAR PASSENGER FLOOR AIR DUCT
3 - TO CARPET DUCT
4 - TO CARPET DUCT
Fig. 11 Passenger Side Instrument Panel to
Heater-A/C Housing Mounting
1 - HEATER AND AIR CONDITIONER HOUSING
2 - INSTRUMENT PANEL STRUCTURAL DUCT
3 - SCREW (2)
Fig. 12 SPLIT FOAM SEAL AT PANEL OUTLET
1 - ONE PIECE FOAM SEAL
2 - FLOOR DUCT
3 - TO REAR PASSENGER FLOOR AIR DUCT
24 - 42 DISTRIBUTIONWJ
HVAC HOUSING (Continued)

STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE)
(13) Charge the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
(14) Install the instrument panel in the vehicle(Re-
fer to 23 - BODY/INSTRUMENT PANEL - INSTAL-
LATION).
(15) Connect the battery negative cable.
(16) 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) Remove evaporator from lower case to ease
access to plastic door shaft bushing.
(3) Pinch the retention tabs holding the blend door
pivot shaft to the case. The 3 plastic tabs, located on
the inside of the case, are part of the shaft retainer.
(4) Remove door(s).
INSTALLATION
(1) Install the blend door(s) by snapping the pivot
shaft into the HVAC case.
(2) Install the evaporator in the lower case.
(3) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)NOTE: The blend door sub-assembly is attached to
the housing with 2 screws, and may be removed for
service (Fig. 20).
MODE DOOR
REMOVAL
REMOVAL - PANEL OUTLET 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.
(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)
Fig. 20 BLEND DOOR SUB-ASSEMBLY
1 - PASSENGER SIDE BLEND DOOR
2 - BLEND DOOR SUB-ASSEMBLY
3 - DOOR PIVOT SHAFT BUSHING
4 - DOOR SHAFT LEVER
5 - DRIVER SIDE BLEND DOOR
24 - 46 DISTRIBUTIONWJ
HVAC HOUSING (Continued)

(2) Pinch the retention tabs holding the panel out-
let door pivot shaft to the case. The 3 plastic tabs,
located on the inside of the case, are part of the shaft
retainer (Fig. 21).
(3) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the panel outlet door pivot
shaft retainer from the pivot shaft.
(4) Remove the panel outlet door from the HVAC
housing.
REMOVAL - HEAT/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.(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) Remove the evaporator, and styrofoam tray
from the lower case.
(3) Place the HVAC housing upside down on a
work bench.
(4) Unscrew and remove the 2 floor heat ducts.
(5) Unsnap and remove the duct adapter from the
bottom of the heat/defrost door sub-assembly (Fig.
22).
(6) Gently pry the metal linkage from the heat/de-
frost door lever.
(7) Remove the heat/defrost door sub-assembly,
which is attached to the housing with 4 screws (Fig.
23).
(8) Pinch the retention tabs holding the heat/de-
frost door pivot shaft lever to the case. The 3 plastic
tabs, located on the inside of the case, are part of the
shaft retainer.
(9) Remove the heat/defrost door (Fig. 24).
Fig. 21 PANEL OUTLET DOOR
1 - PANEL/OUTLET DOOR
2 - DOOR SHAFT
3 - FOAM SEAL
(SPLIT)
4 - LOWER HOUSING
5 - PANEL OUTLET DOOR LEVER
6 - LEVER
Fig. 22 HEAT/DEFROST DOOR DUCTS, AND
ADAPTER
1 - FLOOR DUCT ADAPTER
2 - HEAT/DEFROST DOOR SUB-ASSEMBLY
3 - DOOR LEVERS
4 - LOWER HOUSING
5 - FLOOR DUCTS
6 - LINKAGE
7 - RETAINING TABS
WJDISTRIBUTION 24 - 47
MODE DOOR (Continued)

REMOVAL - PANEL/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.
(1) Remove and disassemble the HVAC housing.
See HVAC Housing in this group for the procedures.
(2) Pinch the retention tabs holding the panel/de-
frost door pivot shaft to the case. The 3 plastic tabs,
located on the inside of the case, are part of the shaft
retainer (Fig. 25).
(3) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the panel/defrost door
pivot shaft retainer from the pivot shaft.
(4) Remove the panel/defrost door from the HVAC
housing.
Fig. 23 HEAT/DEFROST DOOR SUB-ASSEMBLY
REMOVAL
1 - HEAT/DEFROST DOOR SUB-ASSEMBLY
2 - LEVERS
3 - LOWER HOUSING
4 - SCREWS
5 - LINKAGE
Fig. 24 HEAT/DEFROST DOOR REMOVAL
1 - HEAT/DEFROST DOOR
2 - LOWER HOUSING
3 - HEAT/DEFROST DOOR SUB-ASSEMBLY
4 - FLOOR DUCTS
5 - DOOR LEVER
Fig. 25 PANEL/DEFROST DOOR
1 - UPPER HOUSING
2 - LEVER
3 - PANEL/DEFROST MODE DOOR
24 - 48 DISTRIBUTIONWJ
MODE DOOR (Continued)

INSTALLATION
INSTALLATION - PANEL OUTLET DOOR
(1) Snap the panel outlet door pivot shaft retainer
on the pivot shaft.
(2) Attach the panel outlet door pivot shaft to the
HVAC case.
(3) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
INSTALLATION - HEAT/DEFROST DOOR
(1) Install the heat/defrost door by snapping the
heat/defrost door pivot shaft into the HVAC case.
(2) Install the heat/defrost door sub-assembly and
tighten the mounting screws to 2.2 N´m (20 in. lbs.).
(3) Attach the metal linkage to the heat/defrost
door lever.
(4) Snap the duct adapter to the bottom of the
heat/defrost door sub-assembly.
(5) Install the 2 floor heat ducts and tighten the
mounting screws to 2.2 N´m (20 in. lbs.)..
(6) Install the evaporator, and styrofoam tray in
the lower case.
(7) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
INSTALLATION - PANEL/DEFROST DOOR
(1) Snap the panel/defrost door pivot shaft retainer
on the pivot shaft.
(2) Attach the panel/defrost door pivot shaft to the
HVAC case.
(3) Reassemble the HVAC housing and install in
the vehicle. (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HVAC HOUSING -
ASSEMBLY) (Refer to 24 - HEATING & AIR CON-
DITIONING/DISTRIBUTION/HVAC HOUSING -
INSTALLATION)
RECIRCULATION 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 the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Place the HVAC housing right side up on the
work bench.
(3) Unplug the wire/vacuum connector from the
recirculation door actuator.
(4) Remove the 2 screws fastening the recircula-
tion door sub-assembly to the main housing (Fig. 26).
Fig. 26 RECIRCULATION DOOR HOUSING
1 - RECIRCULATION DOOR HOUSING
2 - ATTACHING SCREWS
WJDISTRIBUTION 24 - 49
MODE DOOR (Continued)

HEATER CORE
DESCRIPTION
The heater core is located in the HVAC housing,
under the instrument panel. It is a heat exchanger
made of rows of tubes and fins.
OPERATION
Engine coolant is circulated through heater hoses
to the heater core at all times. As the coolant flows
through the heater core, heat removed from the
engine is transferred to the heater core fins and
tubes. Air directed through the heater core picks up
the heat from the heater core fins. The temperature
control door allows control of the heater output air
temperature by controlling how much of the air flow-
ing through the HVAC housing is directed through
the heater core. The blower motor speed controls the
volume of air flowing through the HVAC housing.
The heater core cannot be repaired and, if faulty or
damaged, it must be replaced. Refer to Cooling for
more information on the engine cooling system, the
engine coolant and the heater hoses.
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.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Remove the HVAC housing from the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/HVAC HOUSING - REMOVAL)
(2) Remove the foam gasket surrounding the core
tubes.
NOTE: Notice the orientation of the irregularly
shaped gasket on the tubes. The gasket must be
placed correctly to ensure proper sealing against
the body during reinstallation.(3)
Remove the screws and retainers that secure the
heater core and tubes to the HVAC housing (Fig. 12).
(4) Remove the mode door actuator if necessary,
for clearance to remove the core.
(5) Lift the heater core straight up and out of the
HVAC housing (Fig. 13).
(6) When replacing individual tubes, loosen and
remove the round tube-to-core clamp, and pull tube
from core.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
Fig. 12 HEATER CORE, TUBES, AND RETAINERS
1 - TUBE-TO-CORE CLAMPS
2 - GROUND STRAP
3 - HVAC HOUSING
4 - TUBE RETAINERS AND SCREWS
5 - HEATER CORE
WJPLUMBING 24 - 71