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HVAC Housing: Disassembly

WARNING: This page is about a different car, the 2002 Dodge Intrepid, 2002 Chrysler Intrepid, 2002 Chrysler Concorde, and 2002 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the HVAC housing from the vehicle. Place HVAC housing on a workbench. Remove the heater core retaining screws. Pull back on the retaining tabs and remove the heater core from the housing.
  2. Remove the recirculation door actuator wiring. Remove the actuator from the recirculation housing. See RECIRCULATION DOOR ACTUATOR  . Remove the lower distribution housing. Remove the mode door actuator. See MODE DOOR ACTUATOR  .
  3. Remove the blend door actuator. See BLEND DOOR ACTUATOR  . Remove the recirculation housing screws and clip. Remove the blower motor wiring at the blower motor resistor block/power module.
  4. Squeeze the blower motor wiring grommet and push the grommet through the blower motor cover. Remove the blower motor cover. Remove the blower motor retaining screws and remove the motor. Remove the blower motor resistor block/power module. Remove the evaporator temperature sensor. See EVAPORATOR TEMPERATURE SENSOR  .
  5. Remove the vent door seal from the HVAC housing. Remove the evaporator seal from the HVAC housing. Remove the upper housing screws and clips. Separate the upper half of the HVAC housing from the lower half.
  6. Remove the evaporator assembly from the lower housing. Remove the blend door from the lower housing. Using a flat blade screwdriver, pinch in the retaining tab at the base of the vent door. Pull up on door and remove it from the HVAC housing. Remove the mode door actuating cam. Remove the screw at defrost door actuating arm. Remove the defrost door link from the arm.
  7. Remove the defrost door arm from the lower HVAC housing. Remove the link and defrost door from the HVAC housing. Remove the vent door actuating arm from the lower HVAC housing.
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