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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 shown in illustrations. RHD model similar.
Fig 1: HVAC Housing to Dash Panel Nut
GC0082723Courtesy of CHRYSLER LLC
  1. Position the HVAC housing assembly (2) to the dash panel (3). Be certain that the passenger side of the HVAC housing is correctly located over the dash panel mounting stud.
  2. Install the nut (1) that secures the HVAC housing to the passenger compartment side of dash panel. Tighten the nut to 4.5 N.m (40 in. lbs.).
  3. Install the condensation drain tube. See Heating and Air Conditioning/Plumbing/TUBE, Condensation Drain - Installation .
  4. Install the rear floor ducts. See Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Installation .
  5. Install the instrument panel. Refer to Body/Instrument Panel/PANEL, Instrument - Installation .
    Fig 2: Refrigerant Lines to Evaporator Bolt
    GC0084672Courtesy of CHRYSLER LLC
  6. Remove the previously installed plugs or caps and connect the heater hoses (4) to the heater core tubes.
  7. Remove the tape or plugs from the refrigerant line fittings and the evaporator ports.
  8. Lubricate the rubber O-rings on new dual-plane seals with clean refrigerant oil and install the seals onto the liquid and suction line fittings. Use only the specified seals as they are made of special materials compatible to the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  9. Connect the A/C liquid and suction line assembly (2) to the A/C evaporator (3).
  10. Install the bolt (1) that secures the A/C liquid and suction line assembly to the A/C evaporator. Tighten the bolt to 12 N.m (105 in. lbs.).
    Fig 3: Heat Shield
    GC0083943Courtesy of CHRYSLER LLC
  11. Position the heat shield (3) onto the studs (2) located on the dash panel in the engine compartment.
  12. Install the three nuts (1) that secure the heat shield to the dash panel. Tighten the nuts to 1 N.m (10 in. lbs.).
  13. Reconnect the negative battery cable.
  14. If the heater core is being replaced, flush the cooling system. Refer to Cooling - Standard Procedure .
  15. Refill the engine cooling system. Refer to Cooling - Standard Procedure .
  16. Evacuate the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard Procedure .
  17. Charge the refrigerant system. See Heating and Air Conditioning/Plumbing - Standard Procedure .
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