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HVAC Housing: Disassembly

WARNING: This page is about a different car, the 2004 Dodge Dakota. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the HVAC housing from the vehicle and place it on the workbench (Refer to REMOVAL  ).
  2. Disconnect the electrical connectors from the blower motor, blower motor resistor block, evaporator temperature sensor and each actuator ( Figure ).
  3. Remove the HVAC wiring harness from the HVAC housing.
  4. If necessary, remove the blower motor from the HVAC housing (Refer to REMOVAL  ).
    Fig 1: Identifying HVAC Housing
    G03489470Courtesy of DAIMLERCHRYSLER CORP.
  5. If necessary, remove the blower motor resistor block from the HVAC housing (Refer to BLOWER MOTOR RESISTOR BLOCK ).
  6. Carefully remove the foam seals from the heater core and evaporator coil tube mounting flange of the HVAC housing. If the either seal is deformed or damaged, it must be replaced.
  7. Use a screwdriver to pry off any snap clips that may secure the upper and lower HVAC housing halves together.
  8. Remove the screws that secure the upper and lower HVAC housing halves to each other and those that secure the air inlet housing to the HVAC housing.
  9. Carefully separate the air inlet housing and the upper HVAC housing from the lower housing.
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