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Housing, HVAC: Assembly: Housing-HVAC

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
Fig 1: A/C Evaporator
GC0084676Courtesy of CHRYSLER LLC
  1. If removed, install the seal (4) onto the evaporator tube tapping block (5).
    NOTE: Make sure that the foam insulator is properly positioned in the HVAC housing.
  2. Carefully install the A/C evaporator (1) and foam insulator (2) into the lower half of the HVAC housing (3).
    Fig 2: HVAC Housing-Separate
    GC0084675Courtesy of CHRYSLER LLC
  3. Install the two halves of the HVAC housing (4) together and engage the nine plastic retaining tabs (1). Make sure the retaining tabs are fully engaged.
  4. Install the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together. Tighten the screws to 1.2 N.m (10 in. lbs.). Make sure the metal clips are fully engaged to the housing halves.
  5. Install the foam seal (2) onto the front of the two HVAC housing halves.
    Fig 3: Evaporator Temperature Sensor
    GC0082713Courtesy of CHRYSLER LLC
  6. Install the evaporator temperature sensor (1) into the driver side of the HVAC housing (2). Make sure the retaining tabs (3) are fully engaged to the housing.
    Fig 4: Blower Motor and Resistor
    GC0082729Courtesy of CHRYSLER LLC
  7. Position the blower motor (3) into the bottom of the HVAC housing (4).
  8. Install the wire lead bracket (2) and the three screws (1) that secure the blower motor to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
  9. Position the blower motor resistor (6) into the HVAC housing.
  10. Install the two screws (5) that secure the blower motor resistor to the HVAC housing. Tighten the screws to 1.2 N.m (10 in. lbs.).
    Fig 5: HVAC Housing
    GC0084670Courtesy of CHRYSLER LLC
  11. Install the air inlet housing (3) onto the HVAC housing (1). See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Installation .
  12. Install the air distribution housing (2) onto the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Installation .
    NOTE: If the heater core is being replaced, flush the cooling system. Refer to Cooling - Standard Procedure .
  13. Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Installation .
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