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Housing, HVAC: Disassembly: Housing-HVAC

WARNING: This page is about a different car, the 2015 Fiat 500. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

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

Fig 1: Mode Control Cable, Cam & Clip
GC0152662Courtesy of CHRYSLER GROUP, LLC
  1. Remove the HVAC housing assembly and place it on a workbench. Refer to HOUSING, HVAC, REMOVAL .
  2. Remove the air inlet housing from the HVAC housing. Refer to HOUSING, HVAC, REMOVAL .
  3. When equipped with MTC, use a small screwdriver or similar tool and carefully remove the retaining clip (1) from the left side of the HVAC housing (4) and disconnect the mode control cable (2) from the mode door cam (3).
    Fig 2: Mode Door Actuator, Connector & Screws
    GC0152833Courtesy of CHRYSLER GROUP, LLC
  4. When equipped with ATC, disconnect the wire harness connector (5) and remove the two screws (4 and 6) and the mode door actuator (2) from the bracket (3) on the left side of the HVAC housing (1).
    Fig 3: Actuator Gear, Bracket & Screws
    GC0152844Courtesy of CHRYSLER GROUP, LLC
  5. When equipped with ATC, remove the three screws (1, 3 and 5), actuator bracket (2) and actuator gear (6) from the left side of the HVAC housing (4).
    Fig 4: Blower Motor, Connector & Screws
    GC0152528Courtesy of CHRYSLER GROUP, LLC
  6. Disconnect the wire harness connector (2) from the blower motor (4).
  7. Remove the three screws (1 and 3) that secure the blower motor to the HVAC housing (5) and remove the blower motor.
    Fig 5: Temperature Control Cable, Blend Door Gear & Clip
    GC0152663Courtesy of CHRYSLER GROUP, LLC
  8. When equipped with MTC, use a small screwdriver or similar tool and carefully remove the retaining clip (1) from the right side of the HVAC housing (3) and disconnect the temperature control cable (4) from the blend door cam (3).
    Fig 6: Blend Door Actuator, Connector & Screws
    GC0152823Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Use care when removing the blend door actuator to prevent damage to the blend door linkage. If required, disconnect the blend door linkage from the blend doors and then separate the linkage from the blend door actuator.

  9. When equipped with ATC, disconnect the wire harness connector (2) and remove the two screws (3 and 4) and the blend door actuator (1) from the right side of the HVAC housing (5).
    Fig 7: Trim Stick, Air Outlet Temperature Sensor, Housing & Wire Harness
    GC0152845Courtesy of CHRYSLER GROUP, LLC
  10. When equipped with ATC, remove the instrument panel air outlet temperature sensor (3) from the right side of the HVAC housing (4) using Trim Stick (special tool #C-4755, Trim Stick) (1) or equivalent, and disconnect the HVAC wire harness (2) from the sensor.
    Fig 8: Removing Floor Air Outlet Temperature Sensor
    GC0152849Courtesy of CHRYSLER GROUP, LLC
  11. When equipped with ATC, remove the floor air outlet temperature sensor (3) from the right side of the HVAC housing (2) using Trim Stick (special tool #C-4755, Trim Stick) (4) or equivalent, and disconnect the HVAC wire harness (1) from the sensor.
    Fig 9: Blower Motor Power Module, Connectors & Screws
    GC0152851Courtesy of CHRYSLER GROUP, LLC
  12. When equipped with ATC, disconnect the wire harness connectors (3) and remove the two screws (2 and 4) and the blower motor power module (1) from the right side of the HVAC housing (5).
    Fig 10: A/C Heater Module, Evaporator Temperature Sensor, Wire Harness, Brackets & Screw
    GC0152581Courtesy of CHRYSLER GROUP, LLC
  13. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (5) and the MTC A/C heater module (2), when equipped.
  14. Remove the screw (6) that secures the HVAC wire harness bracket (4) to the HVAC housing.
  15. Disengage the HVAC wire harness from the plastic retaining brackets (3 and 8) and remove the HVAC wire harness.
    Fig 11: A/C Control Module Screws
    GC0152582Courtesy of CHRYSLER GROUP, LLC
  16. When equipped with MTC, remove the three screws (1 and 3) that secure the A/C control module (2) to the right side of the HVAC housing (4) and remove the module.
    Fig 12: Particulate Air Filter Cover Screws
    GC0152583Courtesy of CHRYSLER GROUP, LLC
  17. Remove the two screws (1 and 3) that secure the cabin air filter cover (2) to the right side of the HVAC housing (4) and remove the cover.
    Fig 13: Particulate Air Filter Air Flow Direction
    GC0152584Courtesy of CHRYSLER GROUP, LLC
  18. Remove the cabin air filter (1) from the right side of the HVAC housing (3). Make note of the air flow direction (2).
    Fig 14: Condensation Drain, HVAC Housing & Screws
    GC0152585Courtesy of CHRYSLER GROUP, LLC
  19. Remove the six screws (1) that secure the condensate drain (2) to the bottom of the HVAC housing (3) and remove the drain.
    Fig 15: Evaporator & Temperature Sensor
    GC0152586Courtesy of CHRYSLER GROUP, LLC
  20. Using needle nose pliers, remove the evaporator temperature sensor (1) and retaining clip from the A/C evaporator (2).
    Fig 16: 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.

  21. Remove the foam seal (1) from the flange at the front of the HVAC housing (2).
    Fig 17: Heater Core Cover Screws
    GC0152537Courtesy of CHRYSLER GROUP, LLC
  22. Remove the three screws (1 and 2) that secure the heater core cover (3) to the left side of the HVAC housing.
  23. Remove the heater core cover from the HVAC housing.
    Fig 18: HVAC Housing & Heater Core
    GC0152538Courtesy of CHRYSLER GROUP, LLC
    WARNING:

    Use care when removing the heater core. Do not apply excessive force to the heater core tubes. 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.

  24. Carefully pull the heater core (1) out of the left side of the HVAC housing (2).
    Fig 19: HVAC Housing Screws
    GC0152588Courtesy of CHRYSLER GROUP, LLC
  25. Remove the ten screws (2) that secure the two halves of the HVAC housing together (1).
  26. Carefully separate the two halves of the HVAC housing.
    Fig 20: Evaporator & Expansion Valve
    GC0152589Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

    NOTE:

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

  27. Remove the A/C evaporator (1) and the A/C expansion valve (2) as an assembly from the left side of the HVAC housing (2).
  28. If required, remove the A/C expansion valve from the A/C evaporator. Refer to EVAPORATOR, A/C, REMOVAL .
    Fig 21: Blend Door Gear, Lever & Tabs
    GC0152587Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

    NOTE:

    For ease of reassembly, make note of the installed position of the two blend air doors, prior to removal.

    NOTE:

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

  29. Perform the following if removal of the blend air doors from the right side of the HVAC housing (6) is required.
    • Using a small flat bladed tool, carefully disengage the retaining tabs (4 and 7) that secure the blend door gear (1) and the blend door lever (3) to the blend air doors (5 and 8).
    • Remove the blend door gear, rod (2), lever and blend air doors.
    Fig 22: Mode Door Gears, Lever, Tab & Screw
    GC0152590Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    For ease of reassembly, make note of the installed position of the floor mode air door, prior to removal.

    NOTE:

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

  30. Perform the following if removal of the mode air doors from the left side of the HVAC housing (9) is required.
    • Rotate the mode door cam (8) so that the two arrows (2 and 11) align with the tabs on the two mode door gears (1 and 3).
    • Remove the screw (10) that secures the mode door cam to the left side of the HVAC housing.
    • Using a small flat bladed tool and carefully disengage the retaining tab (6) that secures the mode door lever (4) to the floor mode air door (5).
    • Remove the mode door cam, mode door rod (7), mode door lever and the floor mode air door.
    Fig 23: Mode Door Gears & Tabs
    GC0152593Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    For ease of reassembly, make note of the installed position of the mode air doors, prior to removal.

    NOTE:

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

  31. Using a small flat bladed tool, carefully disengage the retaining tabs (5 and 7) that secure the mode door gears (1 and 3) to the mode air doors (2 and 4) and remove the gears and doors from the left side of the HVAC housing (6).
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