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Housing-HVAC Assembly

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (Refer to HEATING & AIR CONDITIONING/PLUMBING - WARNINGS)  and (Refer to HEATING & AIR CONDITIONING/PLUMBING - CAUTIONS) . Failure to follow the warnings and cautions could result in possible personal injury or death.
WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.
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: Remove/Install Housing-HVAC-Exterior
GC0039744Courtesy of DAIMLERCHRYSLER CORP.
  1. Recover the refrigerant from the refrigerant system (Refer to REFRIGERANT SYSTEM RECOVERY ).
  2. Drain the engine cooling system (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN) .
  3. Disconnect and isolate the negative battery cable.
  4. Remove the fresh air inlet housing from the dash panel (HOUSING-AIR INLET ).
  5. Disconnect the A/C liquid line and the A/C suction line from the A/C evaporator (Refer to HEATING & AIR CONDITIONING/PLUMBING/LINE-A/C LIQUID - REMOVAL) .
  6. Disconnect the heater hoses from the heater core tubes.
  7. Remove the three nuts (1 and 3) that secure the HVAC housing to the engine compartment side of the dash panel (2).
    Fig 2: Remove/Install Housing-HVAC-Interior
    GC0013961Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the instrument panel from the passenger compartment (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL) .
  9. Disconnect the floor console duct (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-FLOOR CONSOLE - REMOVAL) .
  10. Disconnect the rear floor distribution ducts (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-FLOOR DISTRIBUTION - REMOVAL) .
  11. Remove the defroster ducts (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-DEFROSTER - REMOVAL) .
  12. Remove the two nuts (1) that secure the HVAC housing (2) to the passenger compartment side of the dash panel (5).
  13. Pull the HVAC housing assembly rearward so that the mounting studs clear the dash panel.
  14. Lift the HVAC housing assembly upwards so that the condensate drain tube clears the grommet (4) in the floor panel (3) and remove the HVAC housing assembly from the passenger compartment.
  15. If required, disassemble the HVAC housing assembly (Refer to HOUSING-HVAC .
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