Housing-Air Inlet

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the recirculation-air door.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.

Fig 1: HVAC Housing Assembly Components

Courtesy of CHRYSLER LLC

Remove the HVAC housing assembly and place it on a workbench. See REMOVAL .
Remove the air inlet housing (3) from the HVAC housing (1). See REMOVAL .

Fig 2: Actuator - Recirculation Door
Courtesy of CHRYSLER LLC
Remove the three screws (1) that secure the recirculation door actuator (2) to the left side of the air inlet housing (3) and remove the actuator.

Fig 3: Removing Recirculation Door Pivot Lever
Courtesy of CHRYSLER LLC

NOTE: Remove the recirculation door pivot lever by carefully pulling it straight out from the end of the recirculation door pivot shaft.
Remove the recirculation door pivot lever (1) from the end of the recirculation door pivot shaft on the driver side of the air inlet housing (2).

Fig 4: Air Inlet Housing - Fasteners
Courtesy of CHRYSLER LLC

NOTE: If the foam seal on the air inlet housing is deformed or damaged, the seal must be replaced.
Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air inlet housing (5). If the seal is deformed or damaged, it must be replaced.
Remove the screws (4) that secure the two halves of the air inlet housing together.
Carefully separate the two halves of the air inlet housing and remove the recirculation-air door (3).