Dodge Caliber. Manual — part 1420
1. Remove the HVAC housing assembly and place it
on a workbench (refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION /HOUSING-HVAC
- HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove the air distribution housing (2) from the
HVAC housing (1) (refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/HOUSING-HVAC
- HOUSING-AIR DISTRIBUTION - REMOVAL).
3. If equipped with the 2.0L diesel engine, remove the
electric
positive
temperature
coefficient
(PTC)
heater unit from the air distribution housing (refer to
24 - HEATING & AIR CONDITIONING/CABIN
HEATER/HEATER UNIT - REMOVAL).
4. Remove the heater core from the air distribution
housing (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/CORE
HEATER
-
REMOVAL).
5. Remove the temperature control cable (1) from the
left side of the air distribution housing (2) (refer to
24
-
HEATING
&
AIR
CONDITIONING/CON-
TROLS/CABLE-TEMPERATURE
CONTROL
-
REMOVAL).
6. Remove the screw and washer (5) that secures the
blend door cable lever (6) to the air distribution
housing and remove the cable lever.
NOTE: To remove the blend door pivot lever, dis-
engage the retaining tab and pull the lever straight
out of the air distribution housing.
7. Remove the blend door pivot lever (3) from the end
of the blend door pivot shaft (4) and remove the
pivot lever.
8. Remove the mode door cable (1) from the right
side of the air distribution housing (2) (refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/CA-
BLE-MODE DOOR - REMOVAL).
9. Remove the screw and washer (3) that secure the
mode door cam (4) to the air distribution housing
and remove the cam.
PM
DISTRIBUTION
24 - 97
NOTE: If any foam seal on the air distribution
housing outlets is deformed or damaged, the seal
must be replaced.
10. Carefully cut the two foam seals (1) along the
parting line (2) of the two halves of the air distri-
bution housing (3). If either seal is deformed or
damaged, it must be replaced.
11. Remove the five screws (4) and one metal clip (5)
that secure the two halves of the air distribution
housing together.
12. Disengage the three plastic retaining tabs (6) that
secure the two halves of the air distribution hous-
ing together and carefully separate the housing.
NOTE: If a seal on an air door is deformed or dam-
aged, the air door must be replaced.
13. Disengage the air door(s) (1, 2, 3 and 4) from the
mode door levers and remove the air doors from
the air distribution housing (5).
NOTE: To remove the mode door levers, disen-
gage the retaining tabs on the inside of the air dis-
tribution housing and pull the levers straight out
of the housing.
14. Remove the four mode door levers (1, 2, 3 and 4)
from the right side of the air distribution housing
(5).
24 - 98
DISTRIBUTION
PM
HOUSING-AIR INLET
NOTE: The air inlet housing must be removed from HVAC housing and disassembled for service of the
recirculation-air door.
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
1. Remove the HVAC housing assembly and place it
on a workbench (refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION /HOUSING-HVAC
- HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove the air inlet housing (3) from the HVAC
housing (1) (refer to 24 - HEATING & AIR CONDI-
TIONING/DISTRIBUTION/HOUSING-HVAC
-
HOUSING-AIR INLET - REMOVAL).
3. Remove the two screws (1) that secure the recircu-
lation door actuator (2) to the right side of the air
inlet housing (3) and remove the actuator.
PM
DISTRIBUTION
24 - 99
4. To remove the recirculation door pivot shaft adapter
from the right end of the recirculation-air door, first
carefully push down on the tab of the door lever
pivot shaft adapter located inside of the air inlet
housing, then pull the pivot shaft adapter straight
out of the end of the recirculation-air door pivot
shaft.
NOTE: If the foam seal on the air inlet housing is
deformed or damaged, the seal must be replaced.
NOTE: If a rubber seal on the recirculation air-door
is deformed or damaged, the air-door must be
replaced.
5. Carefully pinch the two ends of the recirculation air-
door together and remove the air-door from the air
inlet housing. If the seal on the recirculation air-
door is deformed or damaged, the air-door must be replaced.
ASSEMBLY
HOUSING-HVAC
NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.
1. If removed, install the seal (4) onto the evaporator
tube tapping block (5).
NOTE: Make sure that the foam insulator is prop-
erly positioned in the HVAC housing.
2. Carefully install the A/C evaporator (1) and foam
insulator (2) into the lower half of the HVAC hous-
ing (3).
24 - 100
DISTRIBUTION
PM
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