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Housing, HVAC: Disassembly: Housing-HVAC

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  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  .
    Fig 1: Mode Door Actuator, Connector & Screws
    GC0152833Courtesy of CHRYSLER GROUP, LLC
  3. 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 2: Actuator Gear, Bracket & Screws
    GC0152844Courtesy of CHRYSLER GROUP, LLC
  4. 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 3: Blower Motor, Connector & Screws
    GC0152528Courtesy of CHRYSLER GROUP, LLC
  5. Disconnect the wire harness connector (2) from the blower motor (4).
  6. Remove the three screws (1 and 3) that secure the blower motor to the HVAC housing (5) and remove the blower motor.
    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.

    Fig 4: Blend Door Actuator, Connector & Screws
    GC0152823Courtesy of CHRYSLER GROUP, LLC
  7. 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 5: Trim Stick, Air Outlet Temperature Sensor, Housing & Wire Harness
    GC0152845Courtesy of CHRYSLER GROUP, LLC
  8. 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 6: Removing Floor Air Outlet Temperature Sensor
    GC0152849Courtesy of CHRYSLER GROUP, LLC
  9. 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 7: Blower Motor Power Module, Connectors & Screws
    GC0152851Courtesy of CHRYSLER GROUP, LLC
  10. 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 8: A/C Heater Module, Evaporator Temperature Sensor, Wire Harness, Brackets & Screw
    GC0152581Courtesy of CHRYSLER GROUP, LLC
  11. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (5) and the MTC A/C heater module (2), when equipped.
  12. Remove the screw (6) that secures the HVAC wire harness bracket (4) to the HVAC housing.
  13. Disengage the HVAC wire harness from the plastic retaining brackets (3 and 8) and remove the HVAC wire harness.
    Fig 9: Particulate Air Filter Cover Screws
    GC0152583Courtesy of CHRYSLER GROUP, LLC
  14. 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 10: Particulate Air Filter Air Flow Direction
    GC0152584Courtesy of CHRYSLER GROUP, LLC
  15. Remove the cabin air filter (1) from the right side of the HVAC housing (3). Make note of the air flow direction (2).
    Fig 11: Condensation Drain, HVAC Housing & Screws
    GC0152585Courtesy of CHRYSLER GROUP, LLC
  16. Remove the six screws (1) that secure the condensate drain (2) to the bottom of the HVAC housing (3) and remove the drain.
    Fig 12: Evaporator & Temperature Sensor
    GC0152586Courtesy of CHRYSLER GROUP, LLC
  17. Using needle nose pliers, remove the evaporator temperature sensor (1) and retaining clip from the A/C evaporator (2).
    18. NOTE:

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

  18. Remove the foam seal (1) from the flange at the front of the HVAC housing (2).
  19. Remove the PTC heater. Refer to HEATER, AIR ELECTRIC (AEH), REMOVAL .
    20. Fig 13: HVAC Housing Screws
    GC0152588Courtesy of CHRYSLER GROUP, LLC
  21. Remove the ten screws (2) that secure the two halves of the HVAC housing together (1).
  22. Carefully separate the two halves of the HVAC housing.
    Fig 14: Evaporator & Expansion Valve
    GC0152589Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  23. 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).
  24. If required, remove the A/C expansion valve from the A/C evaporator. Refer to EVAPORATOR, A/C, REMOVAL  .
    Fig 15: 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.

  25. 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 16: 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.

  26. 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 17: 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.

  27. 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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