Chrysler RG Voyager. Manual — part 1222
HVAC HOUSING
WARNING: Refer to the applicable warnings and
cautions for this system before performing the fol-
lowing operation (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - FRONT - WARNINGS)
and (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - FRONT - CAUTIONS). Failure to follow
the warnings and cautions could result in possible
personal injury or death.
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.
NOTE: The HVAC housing must be removed from
the vehicle and disassembled for service of the air
inlet housing, air distribution housing and the A/C
evaporator.
NOTE: Take the proper precautions to protect the
front face of the instrument panel from cosmetic
damage while performing this procedure.
NOTE: LHD model shown in illustrations. RHD
model similar.
(1) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT - STANDARD PROCE-
DURE - 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) Disconnect the liquid and suction lines from
the A/C expansion valve (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - FRONT/LIQ-
UID LINE - REMOVAL).
(5) Disconnect the heater hoses from the heater
core (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - FRONT/HEATER INLET HOSE -
REMOVAL) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING
-
FRONT/HEATER
RETURN HOSE - REMOVAL).
(6) Remove the three nuts that secure the HVAC
housing to the engine compartment side of the dash
panel (Fig. 18).
(7) Remove the instrument panel from the passen-
ger compartment (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL ASSEMBLY -
REMOVAL).
(8) Remove the nut and bolt that secure the HVAC
housing to the passenger compartment side of the
dash panel (Fig. 19).
Fig. 16 Blower Motor Wire Lead Grommet
1 - BLOWER MOTOR WIRE LEAD GROMMET
Fig. 17 Upper Air Inlet Housing
1 - HVAC HOUSING
2 - PARTING LINE
3 - UPPER AIR INLET HOUSING
4 - RECIRCULATION-AIR DOOR
5 - SCREW (3)
6 - SCREW
RS
DISTRIBUTION - FRONT
24 - 53
HVAC HOUSING (Continued)
(9) Pull the HVAC housing rearward to clear the
dash panel and remove the HVAC housing from the
passenger compartment.
(10) If required, disassemble the HVAC housing
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION -FRONT/HVAC HOUSING - DISAS-
SEMBLY).
DISASSEMBLY
AIR DISTRIBUTION HOUSING
NOTE:
The
air
distribution
housing
must
be
removed from the HVAC housing and disassembled
for service of the mode-air and blend-air doors.
NOTE: LHD model shown in illustrations. RHD
model similar.
(1) Remove the air distribution housing from the
HVAC housing and place it on a workbench (Refer to
24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION - FRONT/HVAC HOUSING - AIR DISTRIBU-
TION HOUSING - REMOVAL).
(2) Remove the two screws that secure the heater
core to the driver side of the air distribution housing
and carefully remove the heater core (Fig. 20).
(3) Remove the screws that secure the mode door
actuator and the blend door actuator(s) to the driver
side of the air distribution housing and remove the
actuators.
(4) Remove the defrost door linkage arm, instru-
ment panel door linkage arm, mode door cam, floor
door gear, driver side blend door gear (if equipped)
and the passenger side blend door stop from the
driver side of the air distribution housing (Fig. 21).
Fig. 18 HVAC Housing-Engine Compartment
1 - NUT (3)
2 - HVAC HOUSING MOUNTING STUDS
3 - DASH PANEL
Fig. 19 HVAC Housing-Passenger Compartment
1 - NUT
2 - BOLT
3 - HVAC HOUSING ASSEMBLY
4 - DASH PANEL
Fig. 20 Actuators and Heater Core
1 - AIR DISTRIBUTION HOUSING
2 - MODE DOOR ACTUATOR
3 - BLEND DOOR ACTUATOR (DRIVER)
4 - SCREW (2)
5 - SCREWS
6 - HEATER CORE
7 - BLEND DOOR ACTUATOR (PASSENGER)
24 - 54
DISTRIBUTION - FRONT
RS
HVAC HOUSING (Continued)
(5) Remove the six screws that secure the floor dis-
tribution ducts to the air distribution housing and
remove the ducts (Fig. 22).
(6) Remove the screw from the center of the driver
side of the air distribution housing (Fig. 23).
(7) Carefully cut the foam seal along the parting
line of the two halves of the air distribution housing.
If the seal is deformed or damaged, it must be
replaced.
(8) Remove the seven screws that secure the two
halves of the air distribution housing together and
carefully separate the housing.
(9) If equipped with dual zone heating -A/C sys-
tem, push down on the retaining tab of the driver
side blend door gear and carefully pull the gear out
of the blend door pivot shaft (Fig. 24).
NOTE: If the seal on the air door is deformed or
damaged, the air door must be replaced.
(10) Remove the blend-air door from the driver
side of the air distribution housing.
(11) Remove the screw that secures the driver side
air vane to the passenger side of the air distribution
housing and remove the vane (Fig. 25).
NOTE: If the seal on any air door is deformed or
damaged, the air door must be replaced.
(12) Remove the air doors and the partition from
the air distribution housing.
(13) Remove the screw that secures the passenger
side air vane to the passenger side of the air distri-
bution housing and remove the vane (Fig. 26).
NOTE: If the seal on any air door is deformed or
damaged, the air door must be replaced.
Fig. 21 Air Door Linkage
1 - DEFROST DOOR LINKAGE ARM
2 - INSTRUMENT PANEL DOOR LINKAGE ARM
3 - MODE DOOR CAM
4 - FLOOR DOOR GEAR
5 - DRIVER SIDE BLEND DOOR GEAR
6 - PASSENGER SIDE BLEND DOOR STOP
7 - AIR DISTRIBUTION HOUSING
Fig. 22 Front Floor Distribution Duct
1 - SCREWS (6)
2 - FLOOR DISTRIBUTION DUCTS
3 - HVAC HOUSING
Fig. 23 Air Distribution Housing Screws
1 - SCREW
2 - AIR DISTRIBUTION HOUSING
3 - FOAM SEAL
4 - PARTING LINE
5 - SCREWS (7)
RS
DISTRIBUTION - FRONT
24 - 55
HVAC HOUSING (Continued)
(14) Remove the air doors from the passenger side
of the air distribution housing.
HVAC HOUSING
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.
(1) Remove the HVAC housing from the vehicle
and place it on a workbench (Refer to 24 - HEATING
& AIR CONDITIONING/DISTRIBUTION - FRONT/
HVAC HOUSING - REMOVAL).
(2) Remove the air distribution housing from the
HVAC housing (Fig. 27) (Refer to 24 - HEATING &
AIR
CONDITIONING/DISTRIBUTION
-
FRONT/
HVAC HOUSING - AIR DISTRIBUTION HOUSING
- REMOVAL).
(3) Remove the air inlet housing from the HVAC
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION - FRONT/HVAC HOUS-
ING - AIR INLET HOUSING - REMOVAL).
(4) Remove the A/C expansion valve from the A/C
evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - FRONT/A/C EXPANSION
VALVE - REMOVAL).
(5) Disconnect the HVAC wiring harness from the
blower motor resistor or power module (depending on
application) (Fig. 28).
Fig. 24 Dual Zone Driver Side Blend-Air Door
1 - BLEND-AIR DOOR (DRIVER SIDE)
2 - AIR DISTRIBUTION HOUSING
3 - GEAR RETAINING TAB
4 - BLEND DOOR GEAR
Fig. 25 Air Doors and Partition - Driver Side
1 - AIR VANE (DRIVER SIDE)
2 - DEFROST-AIR DOORS
3 - PANEL-AIR DOOR (DRIVER SIDE)
4 - SCREW
5 - FLOOR-AIR DOOR (DRIVER SIDE)
6 - AIR DISTRIBUTION HOUSING (PASSENGER SIDE)
7 - PARTITION
Fig. 26 Air Doors and Vane - Passenger Side
1 - AIR VANE (PASSENGER SIDE)
2 - PANEL-AIR DOOR (PASSENGER SIDE)
3 - FLOOR-AIR DOOR (PASSENGER SIDE)
4 - AIR DISTRIBUTION HOUSING (PASSENGER SIDE)
5 - BLEND-AIR DOOR (PASSENGER SIDE)
24 - 56
DISTRIBUTION - FRONT
RS
HVAC HOUSING (Continued)
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