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Housing, HVAC: Disassembly: Housing-HVAC

WARNING: This page is about a different car, the 2010 Dodge Charger and 2010 Chrysler 300. 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.
NOTE: LHD model shown in illustrations. RHD model similar.
Fig 1: Housing-HVAC Description
GC0081031Courtesy of CHRYSLER LLC
  1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  2. Remove the air distribution housing (3) from the HVAC housing (1). See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  3. Remove the air inlet housing (2) from the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
    Fig 2: HVAC Housing-Flange R and I
    GC0081043Courtesy of CHRYSLER LLC
  4. Remove the two screws (1) that secure the flange (2) to the front of the HVAC housing (3).
  5. Remove the flange and the heater core tubes (4) from the HVAC housing.
    Fig 3: HVAC Housing-Controls R and I
    GC0081044Courtesy of CHRYSLER LLC
  6. Disconnect the HVAC wiring harness (1) from the evaporator temperature sensor (2), blower motor resistor or power module (3) (depending on application) and the blower motor (4).
  7. Disengage the two HVAC wire harness retainers (5) from the blower motor and remove the blower motor from the HVAC housing. See Heating and Air Conditioning/Distribution/MOTOR, Blower - Removal .
  8. Remove the blower motor resistor or power module, depending on application. See Heating and Air Conditioning/Controls/RESISTOR, Blower Motor - Removal  or. See Heating and Air Conditioning/Controls/MODULE, Power - Removal .
  9. Remove the evaporator temperature sensor. See Heating and Air Conditioning/Controls/SENSOR, Evaporator Temperature - Removal .
    Fig 4: Valve-A/C Expansion R and I
    GC0081045Courtesy of CHRYSLER LLC
  10. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block located within the foam seal (3).
  11. Remove the A/C expansion valve from the evaporator tube tapping block and foam seal.
  12. Remove the O-ring seals from the evaporator tube fittings and discard.
  13. Install plugs in, or tape over the opened evaporator tube fittings and all expansion valve ports.
    Fig 5: Housing-HVAC D and A
    GC0081046Courtesy of CHRYSLER LLC
  14. Remove the HVAC wiring harness (1).
  15. Remove the ten screws (2) that secure the upper half of the HVAC housing (3) to the lower half of the HVAC housing (4).
  16. Separate the two halves of the HVAC housing.
    Fig 6: Evaporator-A/C R and I
    GC0081047Courtesy of CHRYSLER LLC
  17. Carefully lift the A/C evaporator (1) and foam seal (2) out of the lower half of the HVAC housing (3).
  18. If required, remove the foam seal from the tapping block of the A/C evaporator. If the seal is deformed or damaged, it must be replaced.
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