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HVAC Housing: Assembly

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the two blend-air doors and levers into the HVAC housing.
    NOTE: Rotate the blend door cam until it fully seats into the HVAC housing. The cam followers must be in the correct position to properly install the cam.
  2. Align the blend door cam followers to the blend door cam and install the cam into the HVAC housing. See Fig 1.
    Fig 1: Blend Door Cam
    GC0031883Courtesy of DAIMLERCHRYSLER CORP.
    1 - CAM FOLLOWER GUIDE (2)
    2 - CAM FOLLOWER (2)
    3 - BLEND DOOR CAM
  3. Align the blend door actuator spline with the spline in the blend door cam and install the blend door actuator. See Fig 2.
  4. Install the three screws that secure the blend door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 2: Blend Door Actuator
    GC0031837Courtesy of DAIMLERCHRYSLER CORP.
    1 - BLEND DOOR ACTUATOR
    2 - DOOR CAM SPLINE
    3 - ACTUATOR SPLINE
    NOTE: The center vain of the air deflector must seat into the locating tabs of the bottom HVAC housing.
  5. Install the air deflector vanes and panel door into the bottom half of the HVAC housing. See Fig 3.
    Fig 3: Air Deflector Vanes
    GC0031880Courtesy of DAIMLERCHRYSLER CORP.
    1 - PANEL DOOR
    2 - AIR DEFLECTOR VANES
    3 - LOCATING TABS
  6. Install the panel door lever to the panel door. See Fig 4.
  7. Install the floor/defrost door cam, link and door onto the HVAC housing as an assembly.
  8. Install the screw that secures the floor/defrost door cam to the HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).
    Fig 4: Mode Door Levers
    GC0031885Courtesy of DAIMLERCHRYSLER CORP.
    1 - FLOOR/DEFROST LEVER
    2 - PANEL LEVER
    NOTE: The mode door cam followers must be in the correct position to properly install the cam.
  9. Align the mode door cam followers to the mode door cam and install the cam onto the HVAC housing. See Fig 5.
    Fig 5: Mode Door Cam
    GC0031881Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE DOOR CAM
    2 - CAM FOLLOWER GUIDE (2)
    3 - CAM FOLLOWER (2)
  10. Align the mode door actuator spline with the spline in the mode door cam and install the mode door actuator. See Fig 6.
  11. Install the three screws that secure the mode door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 6: Mode Door Actuator Spline
    GC0031846Courtesy of DAIMLERCHRYSLER CORP.
    1 - ACTUATOR SPLINE
    2 - DOOR CAM SPLINE
    3 - MODE DOOR ACTUATOR
  12. Position the floor distribution duct to the bottom half of the HVAC housing. See Fig 7.
  13. Install the screws that secure the floor distribution duct to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 7: Floor Distribution Duct and Actuators
    GC0031858Courtesy of DAIMLERCHRYSLER CORP.
    1 - FLOOR DISTRIBUTION DUCT
    2 - MODE DOOR ACTUATOR
    3 - BLEND DOOR ACTUATOR
    4 - HVAC HOUSING
    NOTE: Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator is properly installed.
  14. Install the A/C evaporator into the bottom half of the HVAC housing. See Fig 8.
    NOTE: The A/C evaporator is manufactured with three holes for evaporator temperature sensor probe insertion. Always insert the probe into the uppermost hole.
  15. Install the evaporator temperature sensor probe into the A/C evaporator.
  16. Install the access plate to the HVAC housing.
    Fig 8: A/C Evaporator
    GC0031876Courtesy of DAIMLERCHRYSLER CORP.
    1 - A/C EVAPORATOR
    2 - HVAC HOUSING (LOWER HALF)
  17. Install the heater core into the bottom half of the HVAC housing. See Fig 9.
    Fig 9: Heater Core
    GC0031869Courtesy of DAIMLERCHRYSLER CORP.
    1 - HEATER CORE
    2 - HVAC HOUSING (BOTTOM HALF)
  18. Align the blend and mode door shafts with the holes in the HVAC housing and install the top half of the housing to the bottom half of the housing. See Fig 10.
  19. Install the screws that secure the two halves of the HVAC housing together. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 10: Blend And Mode Door Shafts
    GC0031879Courtesy of DAIMLERCHRYSLER CORP.
    1 - PANEL DOOR SHAFT
    2 - BLEND DOOR SHAFT
    3 - BLEND DOOR SHAFT
  20. Install the foam seals on the heater core and evaporator coil tube mounting flange. See Fig 11.
    Fig 11: HVAC Housing Seals
    GC0031877Courtesy of DAIMLERCHRYSLER CORP.
    1 - EVAPORATOR SEAL
    2 - A/C EXPANSION VALVE
    3 - HVAC HOUSING
    4 - HEATER CORE TUBES
    5 - HVAC HOUSING STUD
    6 - HVAC HOUSING STUD
    7 - EXPANSION VALVE BOLT (2)
  21. Install the recirculation-air door into the air inlet housing.
  22. Install the recirculation door gear onto the recirculation door shaft. See Fig 12.
    NOTE: The recirculation door actuator gear and door gear must be properly aligned to operate correctly.
  23. Align and install the recirculation door actuator gear with the door gear.
  24. Install the screw that secure the recirculation door actuator gear to the air inlet housing. Tighten the screw to 2 N.m (17 in. lbs.).
    Fig 12: Recirculation Door Actuator Gear
    GC0031849Courtesy of DAIMLERCHRYSLER CORP.
    1 - DOOR GEAR
    2 - ACTUATOR GEAR
    3 - HVAC AIR INLET HOUSING
  25. Align the recirculation door actuator spline with the spline in the recirculation door gear and install the recirculation door actuator. See Fig 13.
  26. Install the three screws that secure the recirculation door actuator to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 13: Recirculation Door Actuator
    GC0031848Courtesy of DAIMLERCHRYSLER CORP.
    1 - HVAC AIR INLET HOUSING
    2 - RECIRCULATION DOOR ACTUATOR
  27. Install the air inlet housing onto the HVAC housing.
  28. Install the screws that secure the air inlet housing to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
  29. If removed, install the blower motor resistor or power module (depending on application). Install and tighten the screws to 2 N.m (17 in. lbs.).
  30. If removed, install the blower motor. Install and tighten the screws to 2 N.m (17 in. lbs.).
    NOTE: Make sure that all HVAC wire harness leads are routed through all HVAC housing wiring retainers.
  31. Install the HVAC wire harness onto the HVAC housing.
  32. Install the two screws that secure the HVAC wire harness connector to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
  33. Connect the HVAC wire harness connectors to the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
  34. Install the HVAC housing (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - INSTALLATION) .
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