HVAC Housing: Disassembly

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.

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, heater core and the mode-air and blend-air doors.

Remove the HVAC housing from the vehicle and place it on the workbench (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HVAC HOUSING - REMOVAL) .
Disconnect the HVAC wire harness connectors from the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
Remove the two screws that secure the HVAC harness connector to the HVAC housing and remove the HVAC wire harness. See Fig 1.

Fig 1: HVAC Wire Harness Connector
Courtesy of DAIMLERCHRYSLER CORP.

1 - WIRE HARNESS CONNECTOR

2 - SCREW (2)
Remove the screws that secure the blower motor to the HVAC housing and remove the blower motor.
Remove the screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove it from the housing.
Remove the screws that secure the air inlet housing to the HVAC housing and remove the air inlet housing.
Remove the three screws that secure the recirculation door actuator to the air inlet housing and remove the actuator. See Fig 2.

Fig 2: Recirculation Door Actuator
Courtesy of DAIMLERCHRYSLER CORP.

1 - HVAC AIR INLET HOUSING

2 - RECIRCULATION DOOR ACTUATOR

Remove the screw that secures the recirculation door actuator gear to the air inlet housing and remove the gear. See Fig 3.

Fig 3: Recirculation Door Actuator Gear

Courtesy of DAIMLERCHRYSLER CORP.

1 - DOOR GEAR

2 - ACTUATOR GEAR

3 - HVAC AIR INLET HOUSING

Using a small screwdriver, depress the recirculation door gear release and remove the recirculation door gear from the recirculation door shaft. See Fig 4.

Fig 4: Recirculation Door Release

Courtesy of DAIMLERCHRYSLER CORP.

1 - RECIRCULATION DOOR

2 - SCREWDRIVER

3 - DOOR GEAR RELEASE

NOTE: If the seals on the recirculation-air door is deformed or damaged, the air door must be replaced.

Tilt the gear end of the recirculation-air door up and pull the door out of the air inlet housing.
NOTE: If either foam seal is deformed or damaged, it must be replaced.

Carefully remove the foam seals from the heater core and the evaporator tube mounting flange of the HVAC housing. See Fig 5.

Fig 5: HVAC Housing Seals

Courtesy 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)

Remove the screws that secure the upper and lower HVAC housing halves together and separate the housing halves. See Fig 6.

Fig 6: HVAC Housing

Courtesy of DAIMLERCHRYSLER CORP.

1 - HVAC HOUSING (TOP HALF)

2 - HEATER CORE

3 - HVAC HOUSING (BOTTOM HALF)

4 - A/C EVAPORATOR

Using a flat blade pry tool, disengage the locking tab on the access plate of the evaporator temperature sensor. Turn the access plate clockwise one-quarter turn and push the access plate inside of the HVAC housing, then orientate the plate in such a way that it can be removed from the housing. See Fig 7.

Fig 7: Evaporator Temperature Sensor
Courtesy of DAIMLERCHRYSLER CORP.

1 - ACCESS PLATE
Remove the evaporator temperature sensor probe from the A/C evaporator and remove the sensor. See Fig 8.

Fig 8: Evaporator Temperature Sensor Probe
Courtesy of DAIMLERCHRYSLER CORP.

1 - EVAPORATOR TEMPERATURE SENSOR PROBE
Lift the A/C evaporator out of the bottom half of the HVAC housing. See Fig 9.

Fig 9: A/C Evaporator
Courtesy of DAIMLERCHRYSLER CORP.

1 - A/C EVAPORATOR

2 - HVAC HOUSING (LOWER HALF)
Lift the heater core out of the bottom half of the HVAC housing. See Fig 10.

Fig 10: Heater Core
Courtesy of DAIMLERCHRYSLER CORP.

1 - HEATER CORE

2 - HVAC HOUSING (BOTTOM HALF)
Remove the screws that secure the floor distribution duct to the bottom half of the HVAC housing and remove the duct. See Fig 11.

Remove the screws that secure the blend and mode door actuators to the HVAC housing and remove the actuators.

Fig 11: Floor Distribution Duct and Actuators

Courtesy of DAIMLERCHRYSLER CORP.

1 - FLOOR DISTRIBUTION DUCT

2 - MODE DOOR ACTUATOR

3 - BLEND DOOR ACTUATOR

4 - HVAC HOUSING

Remove the mode door cam from the HVAC housing. See Fig 12.

Fig 12: Mode Door Cam
Courtesy of DAIMLERCHRYSLER CORP.

1 - MODE DOOR CAM

2 - CAM SPLINE

Remove the screw that secures the floor/defrost door cam to the HVAC housing. See Fig 13.

Fig 13: Floor/Defrost Door Cam

Courtesy of DAIMLERCHRYSLER CORP.

1 - FLOOR/DEFROST-AIR DOOR

2 - LINK

3 - PANEL DOOR LEVER

4 - FLOOR/DEFROST DOOR CAM

Remove the floor/defrost door cam, link and door as an assembly. See Fig 14.

Fig 14: Floor/Defrost-Air Door

Courtesy of DAIMLERCHRYSLER CORP.

1 - FLOOR/DEFROST-AIR DOOR

2 - LINK

3 - FLOOR/DEFROST DOOR CAM

Remove the panel door lever from the panel-air door. See Fig 15.

Fig 15: Panel Door Lever
Courtesy of DAIMLERCHRYSLER CORP.

Remove the panel-air door and air deflector vanes from the bottom half of the HVAC housing. See Fig 16.

Fig 16: Panel-Air Door and Deflector Vane

Courtesy of DAIMLERCHRYSLER CORP.

1 - PANEL-AIR DOOR

2 - AIR DEFLECTOR VANES

3 - HVAC HOUSING (BOTTOM HALF)

NOTE: The blend door cam must be in the correct position for removal from the HVAC housing.

Rotate the blend door cam and remove the cam from the HVAC housing. See Fig 17.

Fig 17: Blend Door Cam
Courtesy of DAIMLERCHRYSLER CORP.
Using a small screw driver, depress blend door lever release and remove the blend door lever and blend-air door from the HVAC housing. See Fig 18.
Remove the second blend door lever and blend-air door from the HVAC housing.

Fig 18: Blend Door Lever Release

Courtesy of DAIMLERCHRYSLER CORP.

1 - BLEND-AIR DOOR

2 - DOOR LEVER RELEASE

3 - SCREWDRIVER