Once you get the dash assembly removed, the HVAC air box is exposed and can be removed. The below photo shows after the box is removed, there are 5 mounting points. The top two points are 10mm nuts that are accessed from inside the car. The bottom 3 are 10mm nuts that are accessed from the engine bay. The bottom right nut is behind the cabin air filter intake assembly. This assembly must be removed from inside the hood area to access this nut.
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Here is a view of that bottom right nut location after the cabin air filter intake assembly is removed.
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Here is a view of the HVAC box out of the car, upside down. You can see the PAG oil residue at the condensation drain port for the evap core. This is evidence that the oil and refrigerant drained out slowly over time from the evap core.
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Here is the HVAC box split open. There are tons of little screws that hold it together, and you also need to remove the expansion valve from the evap core inlet.
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Now onto the rebuilding phase of the project. My plan was to replace all of the main AC system components, all seals, and all poppet/Schrader valves. I intend to have this car forever and I want the AC system to last at least another 18 years.
I opted to replace the compressor because it was completely empty of PAG oil. My theory is that all the PAG oil leaked out through the hole in the evap core, and the compressor was running for some time perhaps with little or no oil. I managed to find the OEM Denso “Made in Japan” compressor on Rockauto for cheap.
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I also chose to replace the AC condenser, for two reasons. Firstly, the drier assembly is integral to the condenser and does not appear to be separately replaceable. Secondly, my condenser was packed with small gravel and road debris, likely reducing its cooling capacity. Also, I found the Denso unit on Rockauto, so it was a no-brainer. You can see the close-up below of the condenser.
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In parallel with the AC system, there are a few heater system items that could/should be replaced at this same time. I ordered new heater hose assemblies from Rockauto, to replace the 18-year old hoses on the car. I trashed those terrible spring clamps, and bought some new stainless steel screw-drive hose clamps. I opted to leave the factory heater core in-place, and not replace it. I couldn’t find an OEM heater core (only cheap knock-off brands) and I don’t have any reason to believe it needs to be replaced.
While everything was disassembled, I took the time to repair broken plastic tabs and deteriorated foam. I used plastic epoxy and metal ribbon to make new mounting tabs. I also used new weatherstripping seal for the foam seals around the vents, as shown below.
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Here is the parts list that I ordered for the re-assembly of the system:
Here is a view of that bottom right nut location after the cabin air filter intake assembly is removed.
Here is a view of the HVAC box out of the car, upside down. You can see the PAG oil residue at the condensation drain port for the evap core. This is evidence that the oil and refrigerant drained out slowly over time from the evap core.
Here is the HVAC box split open. There are tons of little screws that hold it together, and you also need to remove the expansion valve from the evap core inlet.
Now onto the rebuilding phase of the project. My plan was to replace all of the main AC system components, all seals, and all poppet/Schrader valves. I intend to have this car forever and I want the AC system to last at least another 18 years.
I opted to replace the compressor because it was completely empty of PAG oil. My theory is that all the PAG oil leaked out through the hole in the evap core, and the compressor was running for some time perhaps with little or no oil. I managed to find the OEM Denso “Made in Japan” compressor on Rockauto for cheap.
I also chose to replace the AC condenser, for two reasons. Firstly, the drier assembly is integral to the condenser and does not appear to be separately replaceable. Secondly, my condenser was packed with small gravel and road debris, likely reducing its cooling capacity. Also, I found the Denso unit on Rockauto, so it was a no-brainer. You can see the close-up below of the condenser.
In parallel with the AC system, there are a few heater system items that could/should be replaced at this same time. I ordered new heater hose assemblies from Rockauto, to replace the 18-year old hoses on the car. I trashed those terrible spring clamps, and bought some new stainless steel screw-drive hose clamps. I opted to leave the factory heater core in-place, and not replace it. I couldn’t find an OEM heater core (only cheap knock-off brands) and I don’t have any reason to believe it needs to be replaced.
While everything was disassembled, I took the time to repair broken plastic tabs and deteriorated foam. I used plastic epoxy and metal ribbon to make new mounting tabs. I also used new weatherstripping seal for the foam seals around the vents, as shown below.
Here is the parts list that I ordered for the re-assembly of the system:
- New AC evap core, Mopar P/N: 05061585AA
- New AC compressor, Denso P/N: 4710810. 180ml of PAG oil added with dye.
- New AC condenser, Denso P/N: 4770829. New dryer included.
- New AC Schrader valves installed, FOUR SEASONS P/N: 26779.
- All AC o-rings and metal flange gaskets replaced, GPD P/N: 1321312.
- New heater hose assemblies installed, Gates P/N: 24364 & 24365. New worm-drive hose clamps installed.
- New heater core o-ring seals, Mopar P/N: 68239586A
