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Home >> Chrysler >> 2009 >> PT Cruiser Limited >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> HVAC Systems (Service Information) >> Distribution >> Housing, HVAC >> Disassembly >> Housing-Air Distribution

Housing-Air Distribution

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.
NOTE: LHD model with A/C shown in Fig 1. RHD and heater-only models similar.
Fig 1: HVAC Housing Assembly
GC0116536Courtesy 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 .
    Fig 2: Blend Door Levers Removal
    GC0116543Courtesy of CHRYSLER LLC
  3. Remove the temperature control cable from the driver side of the air distribution housing. See Heating and Air Conditioning/Controls/CABLE, Temperature Control - Removal .
  4. Remove the screw and washer (1) that secures the blend door lever (2) to the driver side of the air distribution housing (4) and remove the lever.
    NOTE: Remove the blend door pivot lever by carefully pulling it straight out from the end of the blend door pivot shaft.
  5. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft.
    Fig 3: Mode Door Cable Lever
    GC0116544Courtesy of CHRYSLER LLC
  6. Remove the mode door cable from the passenger side of the air distribution housing. See Heating and Air Conditioning/Controls/CABLE, Mode Door - Removal .
  7. Remove the screw (2) that secures the mode door cable lever (1) to the passenger side of the air distribution housing (3) and remove the lever.
    Fig 4: Mode Door Pivot Levers Removal
    GC0116545Courtesy of CHRYSLER LLC
    NOTE: Remove the two mode door pivot levers by carefully pulling them straight out from the end of the mode door pivot shafts.
  8. Remove the two mode door pivot levers (1 and 2) from the end of the mode door pivot shafts on the passenger side of the air distribution housing (3).
    Fig 5: Air Distribution Housing Seal and Screws
    GC0116546Courtesy of CHRYSLER LLC
    NOTE: If the foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
  9. Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air distribution housing (3). If the seal is deformed or damaged, it must be replaced.
  10. Remove the seven screws and one clip (4) that secure the two halves of the air distribution housing together.
  11. Carefully separate the left half of the air distribution housing from the right half of the housing.
    Fig 6: Air Doors
    GC0116547Courtesy of CHRYSLER LLC
  12. Remove the air deflector (2) from inside of the air distribution housing (3).
    NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
  13. Remove the air door(s) (1, 4 and 5) from the air distribution housing, as required.
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