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Housing, HVAC: Disassembly: 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: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
Fig 1: HVAC Housing
GC0084670Courtesy 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 (2) from the HVAC housing (1). See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  3. Remove the air inlet housing (3) from the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
    Fig 2: Blower Motor and Resistor
    GC0082729Courtesy of CHRYSLER LLC
  4. Remove the three screws (1) that secure the wire lead bracket (2) and the blower motor (3) to the bottom of the HVAC housing (4) and remove the blower motor and wire lead bracket.
  5. Remove the two screws (5) that secure the blower motor resistor (6) to the bottom of the HVAC housing and remove the resistor.
    Fig 3: Evaporator Temperature Sensor-Removal
    GC0082730Courtesy of CHRYSLER LLC
  6. Using needle nose pliers (1), disengage the two retaining tabs (2) that secure the evaporator temperature sensor (3) to the driver side of the HVAC housing (4) and remove the sensor.
    Fig 4: HVAC Housing-Separate
    GC0084675Courtesy of CHRYSLER LLC
    NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
  7. Carefully remove the foam seal (2) from the front of the two halves of the HVAC housing (4). If the seal is deformed or damaged, it must be replaced.
  8. Remove the nine screws (3) and three metal clips (5) that secure the two halves of the HVAC housing together.
  9. Disengage the nine plastic retaining tabs (1) that secure the two halves of the HVAC housing together and separate the housing.
    Fig 5: A/C Evaporator
    GC0084676Courtesy of CHRYSLER LLC
    NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
  10. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3).
    NOTE: If the seal around the evaporator tube tapping block is deformed or damaged, the seal must be replaced.
  11. If required, remove the seal (4) from around the evaporator tube tapping block (5).
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