Chrysler Sebring, Stratus sedan, Sebring Convertible. Manual — part 736
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 negative battery (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.
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.
NOTE: The instrument panel and HVAC housing are
removed from the vehicle together as an assembly.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING
-
STANDARD
PROCEDURE
-
REFRIGERANT SYSTEM RECOVERY).
(2) Drain the engine cooling system (Refer to 7 -
COOLING - STANDARD PROCEDURE - COOLING
SYSTEM DRAIN).
(3) Disconnect and isolate the negative battery
cable.
(4) Remove the instrument panel and HVAC hous-
ing from the vehicle as an assembly (Refer to 23 -
BODY/INSTRUMENT
PANEL/INSTRUMENT
PANEL ASSEMBLY - REMOVAL).
(5) Disconnect
HVAC
wire
harness
from
the
instrument panel wire harness connector at the left
side of the HVAC housing.
(6) Remove the two nuts and two bolts that secure
the HVAC housing to the instrument panel (Fig. 8).
(7) Separate the HVAC housing from the instru-
ment panel.
DISASSEMBLY
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) Remove the HVAC housing from the vehicle
and place it on the workbench (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - REMOVAL).
(2) Disconnect the HVAC wire harness connectors
from the blower motor, blower motor resistor or
power module (depending on application), evaporator
temperature sensor and each actuator.
Fig. 8 HVAC Housing
1 - HVAC HOUSING
2 - INSTRUMENT PANEL
3 - MOUNTING STUD (2)
4 - NUT (2)
5 - BOLT (2)
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DISTRIBUTION
24 - 43
HVAC HOUSING (Continued)
(3) Remove the two screws that secure the HVAC
harness connector to the HVAC housing and remove
the HVAC wire harness (Fig. 9).
(4) Remove the screws that secure the blower
motor to the HVAC housing and remove the blower
motor.
(5) Remove the screws that secure the blower
motor resistor or power module (depending on appli-
cation) to the HVAC housing and remove it from the
housing.
(6) Remove the screws that secure the air inlet
housing to the HVAC housing and remove the air
inlet housing.
(7) Remove the three screws that secure the recir-
culation door actuator to the air inlet housing and
remove the actuator (Fig. 10).
(8) Remove the screw that secures the recircula-
tion door actuator gear to the air inlet housing and
remove the gear (Fig. 11).
Fig. 9 HVAC Wire Harness Connector
1 - WIRE HARNESS CONNECTOR
2 - SCREW (2)
Fig. 10 Recirculation Door Actuator
1 - HVAC AIR INLET HOUSING
2 - RECIRCULATION DOOR ACTUATOR
Fig. 11 Recirculation Door Actuator Gear
1 - DOOR GEAR
2 - ACTUATOR GEAR
3 - HVAC AIR INLET HOUSING
24 - 44
DISTRIBUTION
JR
HVAC HOUSING (Continued)
(9) Using a small screwdriver, depress the recircu-
lation door gear release and remove the recirculation
door gear from the recirculation door shaft (Fig. 12).
NOTE: If the seals on the recirculation-air door is
deformed
or
damaged,
the
air
door
must
be
replaced.
(10) Tilt the gear end of the recirculation-air door
up and pull the door out of the air inlet housing.
NOTE: If either foam seal is deformed or damaged,
it must be replaced.
(11) Carefully remove the foam seals from the
heater core and the evaporator tube mounting flange
of the HVAC housing (Fig. 13).
(12) Remove the screws that secure the upper and
lower HVAC housing halves together and separate
the housing halves (Fig. 14).
Fig. 12 Recirculation Door Release
1 - RECIRCULATION DOOR
2 - SCREWDRIVER
3 - DOOR GEAR RELEASE
Fig. 13 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. 14 HVAC Housing
1 - HVAC HOUSING (TOP HALF)
2 - HEATER CORE
3 - HVAC HOUSING (BOTTOM HALF)
4 - A/C EVAPORATOR
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DISTRIBUTION
24 - 45
HVAC HOUSING (Continued)
(13) Using a flat blade pry tool, disengage the lock-
ing tab on the access plate of the evaporator temper-
ature sensor. Turn the access plate clockwise one-
quarter turn and push the access plate inside of the
HVAC housing (Fig. 15), then orientate the plate in
such a way that it can be removed from the housing.
(14) Remove the evaporator temperature sensor
probe from the A/C evaporator and remove the sensor
(Fig. 16).
(15) Lift the A/C evaporator out of the bottom half
of the HVAC housing (Fig. 17).
(16) Lift the heater core out of the bottom half of
the HVAC housing (Fig. 18).
Fig. 15 Evaporator Temperature Sensor
1 - ACCESS PLATE
Fig. 16 Remove Probe
1 - EVAPORATOR TEMPERATURE SENSOR PROBE
Fig. 17 A/C Evaporator
1 - A/C EVAPORATOR
2 - HVAC HOUSING (LOWER HALF)
Fig. 18 Heater Core
1 - HEATER CORE
2 - HVAC HOUSING (BOTTOM HALF)
24 - 46
DISTRIBUTION
JR
HVAC HOUSING (Continued)
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