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HVAC Housing: Assembly

WARNING: This page is about a different car, the 2004 Dodge Intrepid, 2004 Chrysler Intrepid, 2004 Chrysler Concorde, and 2004 Chrysler 300M. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the vent door actuating arm to the lower HVAC housing.
  2. Install the defrost door link to the defrost door.
  3. Install the defrost door and link into the HVAC housing.
  4. Install the defrost door actuating arm and retaining screw to the HVAC housing.
  5. Install the defrost door link to the actuating arm.
  6. Line up the slots to the pegs on the mode door cam, and install the mode door cam.
  7. Turn the HVAC housing over and snap in the vent door to the vent door arm.
  8. Install the blend door in the HVAC housing.
  9. Install the evaporator into the lower HVAC housing.
  10. Install the upper housing onto the lower housing.
  11. Install the screws that Secure the two housing halves to each other and tighten to 2.2 N.m (20 in. lbs.).
  12. Install the evaporator and vent door seals on the HVAC housing.
  13. Insert the evaporator temperature sensor in the evaporator. (Refer to INSTALLATION ) If the same evaporator is being used, the new probe must not go into the same hole (in the evaporator coil) that the old probe was removed.  The evaporator is manufactured with three holes for probe insertion. Insert the probe in the uppermost hole. If a new evaporator is installed, place the evaporator probe in the same location as on the previous evaporator.
  14. Install the wiring at the evaporator temperature probe.
  15. Install the blower motor resistor block/power module.
  16. Install the blower motor in the HVAC housing. Install the blower motor mounting screws and tighten to 2.2 N.m (20 in. lbs.).
  17. Thread the blower motor wiring through the blower motor cover, and install the blower motor housing cover.
  18. Seat the blower motor wiring grommet in the blower motor housing cover.
  19. Install the blower motor wiring to the blower motor resistor.
  20. Position the recirculation housing to the HVAC housing. Install the retaining screws and clip.
  21. Install the blend door actuator. (Refer to INSTALLATION )
  22. Install the mode door actuator. (Refer to INSTALLATION )
  23. Install the lower distribution housing.
  24. Install the recirculation door actuator and wiring. (Refer to INSTALLATION )
  25. Install heater core in the HVAC housing. Tighten; the retaining screws to 2.2 N.m (20 in. lbs.).
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