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Housing, HVAC: Assembly: Housing-HVAC

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NOTE:

All of the linkage and gear to gear contact points on the HVAC housing should be adequately lubricated, as well as the air door pivot shaft to HVAC housing contact points using Molykote® Grease, available through Mopar. Do not get grease on the air door seals, as this could cause unwanted flap noises and impairs the durability of the seal. Lubrication should be performed if there is a concern or complaint of linkage chatter, grinding, or other movement derived noises that are detectable in the cabin.

NOTE:

If the A/C evaporator is being replaced, add 17 cc (0.6 fluid oz.) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

NOTE:

Make sure that the evaporator drain within the HVAC housing is clean and unrestricted and that the insulator is properly positioned.

NOTE:

A/C equipped model shown in illustrations. Heater only model similar.

Fig 1: Mode Air Doors
GC0152598Courtesy of CHRYSLER GROUP, LLC
NOTE:

If a rubber seal (2) on a mode air door is deformed or damaged, the door must be replaced.

NOTE:

Use care when lubricating the air door pivot shafts and linkage. Do not get lubricant on the air door seals. Lubricant on the seals may result in

  1. Lightly lubricate the ends of the mode air door pivot shafts with Molykote® Grease, available through Mopar. Be sure not to get any grease on the air door seals.
  2. If removed, install the three mode air doors (1, 3 and 4) into the left half of the HVAC housing (5).
    Fig 2: Mode Door Gears & Tabs
    GC0152593Courtesy of CHRYSLER GROUP, LLC
  3. If removed, install mode door gears (1 and 3) onto the mode air doors (2 and 4) and engage the retaining tabs (5 and 7). Make sure the tabs are fully engaged.
    Fig 3: Mode Door Gears, Lever, Tab & Screw
    GC0152590Courtesy of CHRYSLER GROUP, LLC
  4. Lightly lubricate all the mode door gears and linkage contact points with Molykote® Grease, available through Mopar.
  5. Perform the following if the mode air doors were removed from the left side of the HVAC housing (9).
    • Install the mode door lever (4) onto the mode air doors (5) and engage the retaining tab (6). Make sure the tab is fully engaged.
    • Rotate the mode door gears (1 and 3) to the positions shown.
    • Rotate the mode door cam (8) so that the two arrows (2 and 11) align with the tabs on the two mode door gears and install the cam and rod (7).
    • Install the screw (10) that secures the cam to the housing. Tighten the screw to 0.8 N.m (7 in lbs.).
    Fig 4: Blend Air Doors
    GC0152599Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If a rubber seal on a blend air door is deformed or damaged, the door must be replaced.

  6. Lightly lubricate the ends of the blend air door pivot shafts with Molykote® Grease, available through Mopar. Be sure not to get any grease on the air door seals.
  7. If removed, install the two blend air doors (1 and 2) into the right half of the HVAC housing (3).
    Fig 5: Blend Door Gear, Lever & Tabs
    GC0152587Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Manual Temperature Control (MTC) shown. Automatic Temperature Control (ATC) similar.

  8. Lightly lubricate all the blend door gears and linkage contact points with Molykote® Grease, available through Mopar.
  9. If removed, install the blend door gear (1), rod (2) and lever (3) onto the blend air doors (5 and 8) and engage the retaining tabs (4 and 7). Make sure the tabs are fully engaged.
    Fig 6: Evaporator & Expansion Valve
    GC0152589Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the foam insulator for the evaporator is deformed or damaged, it must be replaced.

  10. Install the A/C evaporator (1) into the left side of the HVAC housing (3). Make sure that the insulator around the evaporator and the foam seal around the tubes are properly positioned.
  11. If required, install the A/C expansion valve (2). Refer to EVAPORATOR, A/C, INSTALLATION .
    Fig 7: HVAC Housing Screws
    GC0152588Courtesy of CHRYSLER GROUP, LLC
  12. Align the air doors to the openings on each side of the HVAC housing (1) and install the two halves of the housing together.
  13. Install the ten screws (2) that secure the housing together. Tighten the screws to 0.8 N.m (7 in lbs.).
    Fig 8: HVAC Housing & Heater Core
    GC0152538Courtesy of CHRYSLER GROUP, LLC
    WARNING:

    Use care when installing the heater core. Do not force the heater core into the housing. Do not push on the heater core tubes. Apply pressure on the heater core side tank only. Failure to follow these instructions can result in a possible engine coolant leak and serious or fatal injury.

    NOTE:

    If the foam seal around the heater core is deformed or damaged, it must be replaced.

  14. Carefully install the heater core (1) into the left side of the HVAC housing (2). Do not force the heater core into the housing. Do not push on the heater core tubes. Apply pressure on the heater core side tank only.
    Fig 9: Heater Core Cover Screws
    GC0152537Courtesy of CHRYSLER GROUP, LLC
  15. Install the heater core cover (3) onto the left side of the HVAC housing.
  16. Install the three screws (1 and 2) that secure the cover to the housing. Tighten the screws to 0.8 N.m (7 in. lbs.).
    Fig 10: Foam Seal At Front Of HVAC Housing
    GC0152536Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    If the foam seal at the front of the HVAC housing is deformed or damaged, it must be replaced.

  17. Install the foam seal (1) onto the flange at the front of the HVAC housing (2).
    Fig 11: Evaporator & Temperature Sensor
    GC0152586Courtesy of CHRYSLER GROUP, LLC
  18. Install the evaporator temperature sensor (1) onto the A/C evaporator (2). Refer to SENSOR, EVAPORATOR TEMPERATURE, INSTALLATION .
    Fig 12: Condensation Drain, HVAC Housing & Screws
    GC0152585Courtesy of CHRYSLER GROUP, LLC
  19. Install the condensate drain (2) onto the bottom of the HVAC housing (3). Make sure the evaporator drain is clean and unrestricted.
  20. Install the six screws (1) that secure the drain to the housing. Tighten the screws to 0.8 N.m (7 in. lbs.).
    Fig 13: Particulate Air Filter Air Flow Direction
    GC0152584Courtesy of CHRYSLER GROUP, LLC
  21. Install the cabin air filter (1) into the right side of the HVAC housing (3). Make note of the air flow direction (2).
    Fig 14: Particulate Air Filter Cover Screws
    GC0152583Courtesy of CHRYSLER GROUP, LLC
  22. Install the cabin air filter cover (2) onto the right side of the HVAC housing (4).
  23. Install the two screws (1 and 3) that secure cover to the housing. Tighten the screws to 0.8 N.m (7 in. lbs.).
    Fig 15: A/C Control Module Screws
    GC0152582Courtesy of CHRYSLER GROUP, LLC
  24. When equipped with MTC, install the A/C control module (2) and the three screws (1 and 3) onto the right side of the HVAC housing (4). Tighten the screws to 0.8 N.m (7 in. lbs.).
    Fig 16: A/C Heater Module, Evaporator Temperature Sensor, Wire Harness, Brackets & Screw
    GC0152581Courtesy of CHRYSLER GROUP, LLC
  25. Position the wire harness (1) to the right side of the HVAC housing (7) and engage the harness to the two plastic retaining brackets (3 and 8).
  26. Position the HVAC wire harness bracket (4) to the HVAC housing and install the retaining screw (6). Tighten the screw to 0.8 N.m (7 in. lbs.).
  27. Connect the HVAC wire harness to the evaporator temperature sensor (5) and the MTC A/C heater module (2), when equipped.
    Fig 17: Blower Motor Power Module, Connectors & Screws
    GC0152851Courtesy of CHRYSLER GROUP, LLC
  28. When equipped with ATC, install the blower motor power module (1) onto the right side of the HVAC housing (5) and connect the wire harness connectors (3). Tighten the two screws (2 and 4) to 0.8 N.m (7 in. lbs.).
    Fig 18: Air Outlet Temperature Sensor & Connector
    GC0152818Courtesy of CHRYSLER GROUP, LLC
  29. When equipped with ATC, install the floor air outlet temperature sensor (2) into the right side of the HVAC housing (3) and connect the HVAC wire harness (1).
    Fig 19: Air Outlet Temperature Sensor, Housing & Wire Harness
    GC0152938Courtesy of CHRYSLER GROUP, LLC
  30. When equipped with ATC, install the instrument panel air outlet temperature sensor (2) into the right side of the HVAC housing (3) and connect the HVAC wire harness (1).
    Fig 20: Aligning Blend Door Actuator
    GC0152832Courtesy of CHRYSLER GROUP, LLC
  31. Lightly lubricate the blend door actuator to linkage contact point with Molykote® Grease, available through Mopar.
  32. When equipped with ATC, position the blend door actuator (2) to the right side of the HVAC housing (1) and align the notch in the actuator output shaft (3) with the flat on the splines (4) of the blend door linkage (5).
    Fig 21: Blend Door Actuator, Connector & Screws
    GC0152823Courtesy of CHRYSLER GROUP, LLC
  33. When equipped with ATC, install the blend door actuator onto the right side of the HVAC housing and connect the wire harness connector (2) Tighten the two screws (3 and 4) to 0.8 N.m (7 in. lbs.).
    Fig 22: Temperature Control Cable, Blend Door Gear & Clip
    GC0152663Courtesy of CHRYSLER GROUP, LLC
  34. Lightly lubricate all the blend door cable to gear contact point with Molykote® Grease, available through Mopar.
  35. When equipped with MTC, connect the temperature control cable (4) to the blend door gear (2) and install the retaining clip (1) onto the right side of the HVAC housing (3). Make sure the retaining clip is fully engaged to the housing. Make sure the blend door cable and gear move freely thoughout the entire operating range. Adjust cable as required.
    Fig 23: Blower Motor, Connector & Screws
    GC0152528Courtesy of CHRYSLER GROUP, LLC
  36. Position the blower motor (4) into the left side of the HVAC housing (5) and install the three retaining screws (1 and 3). Tighten the screws to 0.8 N.m (7 in. lbs.).
  37. Connect the wire harness connector (2) to the blower motor.
    Fig 24: Actuator Gear, Bracket & Screws
    GC0152844Courtesy of CHRYSLER GROUP, LLC
  38. Lightly lubricate all the mode door gear contact points with Molykote® Grease, available through Mopar.
  39. When equipped with ATC, install the actuator bracket (2) onto the left side of the HVAC housing (4). Tighten the three screws (1, 3 and 5) to 0.8 N.m (7 in. lbs.).
  40. When equipped with ATC, position the actuator gear (6) to the HVAC housing.
    Fig 25: Mode Door Actuator Gear & Arrows
    GC0152834Courtesy of CHRYSLER GROUP, LLC
  41. When equipped with ATC, align the two arrows (3 and 4) to each other.
    Fig 26: Aligning Mode Door Actuator
    GC0152836Courtesy of CHRYSLER GROUP, LLC
  42. Lightly lubricate the mode door actuator to linkage contact point with Molykote® Grease, available through Mopar.
  43. When equipped with ATC, position the mode door actuator (1) to the left side of the HVAC housing (3) and align the notch in the actuator output shaft (5) with the flat on the splines (4) of the mode door actuator gear (2).
    Fig 27: Mode Door Actuator, Connector & Screws
    GC0152833Courtesy of CHRYSLER GROUP, LLC
  44. When equipped with ATC, install the mode door actuator (2) onto the bracket (3), located on the left side of the HVAC housing (1) and connect the wire harness connector (5). Tighten the two screws (4 and 6) to 0.8 N.m (7 in. lbs.).
    Fig 28: Mode Control Cable, Cam & Clip
    GC0152662Courtesy of CHRYSLER GROUP, LLC
  45. Lightly lubricate all the mode door cable to gear contact point with Molykote® Grease, available through Mopar.
  46. When equipped with MTC, connect the mode control cable (2) to the mode door cam (3) and install the retaining clip (1) onto the left side of the HVAC housing (4). Make sure the retaining clip is fully engaged to the housing. Make sure the mode door cable and gear move freely thoughout the entire operating range. Adjust cable as required.
  47. Install the air inlet housing. Refer to HOUSING, HVAC, INSTALLATION .
  48. Install the HVAC housing assembly. Refer to HOUSING, HVAC, INSTALLATION .
    NOTE:

    If the heater core is being replaced, flush the cooling system. Refer to STANDARD PROCEDURE .

  49. Initiate the Actuator Calibration function using a scan tool. Refer to STANDARD PROCEDURE .
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