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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.

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.).
  14. Install the PTC heater. Refer to HEATER, BATTERY COOLANT (BCH), INSTALLATION .
  15. Install the foam seal (1) onto the flange at the front of the HVAC housing (2).
    Fig 8: Evaporator & Temperature Sensor
    GC0152586Courtesy of CHRYSLER GROUP, LLC
  16. Install the evaporator temperature sensor (1) onto the A/C evaporator (2). Refer to SENSOR, EVAPORATOR TEMPERATURE, INSTALLATION  .
    Fig 9: Condensation Drain, HVAC Housing & Screws
    GC0152585Courtesy of CHRYSLER GROUP, LLC
  17. Install the condensate drain (2) onto the bottom of the HVAC housing (3). Make sure the evaporator drain is clean and unrestricted.
  18. Install the six screws (1) that secure the drain to the housing. Tighten the screws to 0.8 N.m (7 in. lbs.).
    Fig 10: Particulate Air Filter Air Flow Direction
    GC0152584Courtesy of CHRYSLER GROUP, LLC
  19. Install the cabin air filter (1) into the right side of the HVAC housing (3). Make note of the air flow direction (2).
    Fig 11: Particulate Air Filter Cover Screws
    GC0152583Courtesy of CHRYSLER GROUP, LLC
  20. Install the cabin air filter cover (2) onto the right side of the HVAC housing (4).
  21. 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 12: A/C Heater Module, Evaporator Temperature Sensor, Wire Harness, Brackets & Screw
    GC0152581Courtesy of CHRYSLER GROUP, LLC
  22. 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).
  23. 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.).
  24. Connect the HVAC wire harness to the evaporator temperature sensor (5) and the MTC A/C heater module (2), when equipped.
    Fig 13: Blower Motor Power Module, Connectors & Screws
    GC0152851Courtesy of CHRYSLER GROUP, LLC
  25. 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 14: Air Outlet Temperature Sensor & Connector
    GC0152818Courtesy of CHRYSLER GROUP, LLC
  26. 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 15: Air Outlet Temperature Sensor, Housing & Wire Harness
    GC0152938Courtesy of CHRYSLER GROUP, LLC
  27. 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 16: Aligning Blend Door Actuator
    GC0152832Courtesy of CHRYSLER GROUP, LLC
  28. Lightly lubricate the blend door actuator to linkage contact point with Molykote® Grease, available through Mopar.
  29. 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 17: Blend Door Actuator, Connector & Screws
    GC0152823Courtesy of CHRYSLER GROUP, LLC
  30. 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.).
  31. Lightly lubricate all the blend door cable to gear contact point with Molykote® Grease, available through Mopar.
    Fig 18: Blower Motor, Connector & Screws
    GC0152528Courtesy of CHRYSLER GROUP, LLC
  32. 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.).
  33. Connect the wire harness connector (2) to the blower motor.
    Fig 19: Actuator Gear, Bracket & Screws
    GC0152844Courtesy of CHRYSLER GROUP, LLC
  34. Lightly lubricate all the mode door gear contact points with Molykote® Grease, available through Mopar.
  35. 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.).
  36. Position the actuator gear (6) to the HVAC housing.
    Fig 20: Mode Door Actuator Gear & Arrows
    GC0152834Courtesy of CHRYSLER GROUP, LLC
  37. Align the two arrows (3 and 4) to each other.
    Fig 21: Aligning Mode Door Actuator
    GC0152836Courtesy of CHRYSLER GROUP, LLC
  38. Lightly lubricate the mode door actuator to linkage contact point with Molykote® Grease, available through Mopar.
  39. 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 22: Mode Door Actuator, Connector & Screws
    GC0152833Courtesy of CHRYSLER GROUP, LLC
  40. 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.).
  41. Lightly lubricate all the mode door cable to gear contact point with Molykote® Grease, available through Mopar.
  42. Install the air inlet housing. Refer to HOUSING, HVAC, INSTALLATION  .
  43. Install the HVAC housing assembly. Refer to HOUSING, HVAC, INSTALLATION  .
  44. Initiate the Actuator Calibration function using a scan tool. Refer to STANDARD PROCEDURE .
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