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Housing, HVAC: Disassembly: Housing-HVAC

WARNING: This page is about a different car, the 2009 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.
NOTE: LHD model shown in illustrations. RHD model similar.
Fig 1: Identifying HVAC Housing - LHD Shown
GC0086378Courtesy of CHRYSLER LLC
  1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  2. Remove the air distribution housing (1) from the HVAC housing (2). See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  3. Remove the air inlet housing (3) from the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  4. Remove the passenger side lower front floor duct. See Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Removal .
    Fig 2: Blower Motor & Resistor
    GC0086392Courtesy of CHRYSLER LLC
  5. Remove the two screws (1) that secure the blower motor resistor (5) to the rear of the HVAC housing (2) and remove the resistor.
  6. Remove the three screws (3) that secure the blower motor (4) to the bottom of the HVAC housing and remove the blower motor.
    Fig 3: Removing/Installing Evaporator Temperature Sensor
    GC0086368Courtesy of CHRYSLER LLC
  7. Remove the evaporator temperature sensor (1) from the front of the HVAC housing (2).
    Fig 4: Separating HVAC Housing Halves
    GC0086393Courtesy of CHRYSLER LLC
    NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
  8. Carefully remove the foam seal (1) from the front of the two halves of the HVAC housing (2 and 6). If the seal is deformed or damaged, it must be replaced.
    NOTE: Be sure to remove the screws that secure the two halves of the HVAC housing together located at the bottom of the HVAC housing.
  9. Remove the seven screws (5) and two metal clips (4) that secure the two halves of the HVAC housing together.
  10. Disengage the four plastic retaining tabs (4) that secure the two halves of the HVAC housing together and separate the housing halves.
    Fig 5: Removing/Installing A/C Evaporator
    GC0086394Courtesy of CHRYSLER LLC
    NOTE: If the foam insulator around the A/C evaporator is deformed or damaged, the insulator must be replaced.
  11. Carefully lift the A/C evaporator (1) and the foam insulator (2) out of the lower half of the HVAC housing (3).
    NOTE: If the rubber seal around the evaporator tubes and tapping block is deformed or damaged, the seal must be replaced.
  12. If required, remove the rubber seal (4) from around the evaporator tubes and tapping block (5).
    Fig 6: Air Deflector Vane
    GC0086395Courtesy of CHRYSLER LLC
  13. Disengage the retainers that secure the air deflector vane (1) to the lower half of the HVAC housing (2) and remove the deflector vane.
  14. If required, remove the foam seal (3) from around the condensate drain located at the bottom of the HVAC housing.
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