Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 738
(12) Position the floor distribution duct to the bot-
tom half of the HVAC housing (Fig. 33).
(13) Install the screws that secure the floor distri-
bution duct to the HVAC housing. Tighten the screws
to 2 N·m (17 in. lbs.).
NOTE: Make sure that the evaporator drain is clean
and unrestricted and that the evaporator insulator
is properly installed.
(14) Install the A/C evaporator into the bottom
half of the HVAC housing (Fig. 34).
NOTE: The A/C evaporator is manufactured with
three holes for evaporator temperature sensor
probe insertion. Always insert the probe into the
uppermost hole.
(15) Install the evaporator temperature sensor
probe into the A/C evaporator.
(16) Install the access plate to the HVAC housing.
(17) Install the heater core into the bottom half of
the HVAC housing (Fig. 35).
Fig. 33 Floor Distribution Duct
1 - FLOOR DISTRIBUTION DUCT
2 - MODE DOOR ACTUATOR
3 - BLEND DOOR ACTUATOR
4 - HVAC HOUSING
Fig. 34 A/C Evaporator
1 - A/C EVAPORATOR
2 - HVAC HOUSING (LOWER HALF)
Fig. 35 Heater Core
1 - HEATER CORE
2 - HVAC HOUSING (BOTTOM HALF)
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DISTRIBUTION
24 - 51
HVAC HOUSING (Continued)
(18) Align the blend and mode door shafts with the
holes in the HVAC housing and install the top half of
the housing to the bottom half of the housing (Fig.
36).
(19) Install the screws that secure the two halves
of the HVAC housing together. Tighten the screws to
2 N·m (17 in. lbs.).
(20) Install the foam seals on the heater core and
evaporator coil tube mounting flange (Fig. 37).
(21) Install the recirculation-air door into the air
inlet housing.
(22) Install the recirculation door gear onto the
recirculation door shaft (Fig. 38).
NOTE: The recirculation door actuator gear and
door gear must be properly aligned to operate cor-
rectly.
(23) Align and install the recirculation door actua-
tor gear with the door gear.
(24) Install the screw that secure the recirculation
door actuator gear to the air inlet housing. Tighten
the screw to 2 N·m (17 in. lbs.).
Fig. 36 Blend And Mode Door Shafts
1 - PANEL DOOR SHAFT
2 - BLEND DOOR SHAFT
3 - BLEND DOOR SHAFT
Fig. 37 HVAC Housing Seals
1 - EVAPORATOR SEAL
2 - A/C EXPANSION VALVE
3 - HVAC HOUSING
4 - HEATER CORE TUBES
5 - HVAC HOUSING STUD
6 - HVAC HOUSING STUD
7 - EXPANSION VALVE BOLT (2)
Fig. 38 Recirculation Door Actuator Gear
1 - DOOR GEAR
2 - ACTUATOR GEAR
3 - HVAC AIR INLET HOUSING
24 - 52
DISTRIBUTION
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HVAC HOUSING (Continued)
(25) Align the recirculation door actuator spline
with the spline in the recirculation door gear and
install the recirculation door actuator (Fig. 39).
(26) Install the three screws that secure the recir-
culation door actuator to the HVAC housing. Tighten
the screws to 2 N·m (17 in. lbs.).
(27) Install the air inlet housing onto the HVAC
housing.
(28) Install the screws that secure the air inlet
housing to the HVAC housing. Tighten the screws to
2 N·m (17 in. lbs.).
(29) If removed, install the blower motor resistor
or power module (depending on application). Install
and tighten the screws to 2 N·m (17 in. lbs.).
(30) If removed, install the blower motor. Install
and tighten the screws to 2 N·m (17 in. lbs.).
NOTE: Make sure that all HVAC wire harness leads
are routed through all HVAC housing wiring retain-
ers.
(31) Install the HVAC wire harness onto the HVAC
housing.
(32) Install the two screws that secure the HVAC
wire
harness
connector
to
the
HVAC
housing.
Tighten the screws to 2 N·m (17 in. lbs.).
(33) Connect the HVAC wire harness connectors to
the blower motor, blower motor resistor or power
module (depending on application), evaporator tem-
perature sensor and each actuator.
(34) Install the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
HVAC HOUSING - INSTALLATION).
INSTALLATION
NOTE: The HVAC housing must be removed from
the vehicle and disassembled for service of the A/C
evaporator, heater core and the mode-air and blend-
air doors.
(1) Position the HVAC housing to the instrument
panel. Make sure that all air ducts are properly
aligned or connected.
(2) Install the two nuts and bolts that secure the
HVAC housing to the instrument panel. Tighten the
nuts and bolts securely.
(3) Connect the HVAC wire harness to the instru-
ment panel wire harness connector.
NOTE: Verify that the evaporator drain tube and
evaporator seals are properly seated to the HVAC
housing before installing the instrument panel and
HVAC Housing into the vehicle.
(4) Install the instrument panel and HVAC hous-
ing as an assembly (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
INSTALLATION).
(5) Reconnect the negative battery cable.
(6) If the heater core is being replaced, flush the
cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/
REVERSE FLUSHING).
(7) Refill the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM REFILL).
(8) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM EVACUATE).
(9) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE).
Fig. 39 Recirculation Door Actuator
1 - HVAC AIR INLET HOUSING
2 - RECIRCULATION DOOR ACTUATOR
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DISTRIBUTION
24 - 53
HVAC HOUSING (Continued)
INSTRUMENT PANEL DUCTS
REMOVAL
WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. Disconnect and
isolate the battery negative (ground) cable, then
wait two minutes for the airbag system capacitor to
discharge before performing further diagnosis or
service. This is the only sure way to disable the air-
bag system. Failure to take the proper precautions
could result in accidental airbag deployment and
possible personal injury or death.
(1) Remove the instrument panel and HVAC hous-
ing from the vehicle as an assembly and separate the
HVAC housing from the instrument panel (Refer to
23 - BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(2) Remove the instrument panel top cover from
the instrument panel (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL TOP COVER
- REMOVAL).
(3) Remove the defroster duct from the instrument
panel (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/DEFROSTER
DUCT
-
REMOVAL).
(4) Remove the speakers from the instrument
panel (Refer to 8 - ELECTRICAL/AUDIO/SPEAKER
- REMOVAL).
(5) If equipped, remove the sun sensor from the
instrument panel (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/SUN
SENSOR
-
REMOVAL).
(6) Remove the instrument cluster from the instru-
ment panel (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(7) Remove the passenger side air bag from the
instrument panel (Refer to 8 - ELECTRICAL/RE-
STRAINTS/PASSENGER AIRBAG - REMOVAL).
(8) Remove the screws that secure the center dis-
tribution duct to the instrument panel support (Fig.
40).
(9) Remove the center distribution duct from the
instrument panel support and disconnect it from the
panel and demister duct assembly.
(10) Remove the center instrument panel duct
from the instrument panel
(11) Remove the screws that secure the panel and
demister duct assembly to the instrument panel sup-
port and remove the duct assembly.
INSTALLATION
(1) Install the panel and demister duct assembly
into the instrument panel.
(2) Install the screws that secure the panel and
demister duct assembly to the instrument panel sup-
port. Tighten the screws to 2 N·m (17 in. lbs.).
(3) Install the center instrument panel duct into
the instrument panel.
(4) Install the center distribution duct into the
instrument panel and connect it to the panel and
demister duct assembly.
(5) Install the screws that secure the center distri-
bution duct to the instrument panel support. Tighten
the screws to 2 N·m (17 in. lbs.).
(6) Install the passenger side air bag into the
instrument panel (Refer to 8 - ELECTRICAL/RE-
STRAINTS/PASSENGER
AIRBAG
-
INSTALLA-
TION).
(7) Install the instrument cluster into the instru-
ment panel (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - INSTALLATION).
(8) If equipped , install the sun sensor onto the
instrument panel (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/SUN
SENSOR
-
INSTALLATION).
(9) Install the speakers into the instrument panel
(Refer to 8 - ELECTRICAL/AUDIO/SPEAKER -
INSTALLATION).
(10) Install the defroster duct onto the instrument
panel (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/DEFROSTER
DUCTS
-
INSTALLATION).
Fig. 40 Instrument Panel Ducts - Removed
1 - PANEL AND DEMISTER DUCT ASSEMBLY
2 - CENTER PANEL DUCT
3 - CENTER DISTRIBUTION DUCT
24 - 54
DISTRIBUTION
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