Dodge Caliber. Manual - part 1418

2. Position the particulate air filter cover (2) to the

HVAC housing (3) and engage the four retaining
tabs (1) that secure the cover to the housing. Make
sure the retaining tabs are fully engaged.

3. Install the glove box bin (refer to 23 - BODY/IN-

STRUMENT

PANEL/BIN-GLOVE

BOX

INSTALLATION).

DISTRIBUTION

24 - 89

HOUSING-HVAC

DESCRIPTION

NOTE: LHD model shown RHD model similar.

All models are equipped with a common HVAC hous-
ing assembly that combines A/C and heating capabili-
ties into a single unit mounted within the passenger
compartment. The HVAC housing assembly consists
of three separate housings:

•

HVAC housing — The HVAC housing (1) is
mounted to the dash panel behind the instrument
panel and contains the A/C evaporator. The
HVAC housing consists of a upper and a lower
housing that are attached together and has
mounting provisions for the air inlet housing,
blower motor and the air distribution housing.

•

Air distribution housing — The air distribution
housing (2) is mounted to the rear of the HVAC
housing and contains the heater core, blend-air
and mode-air doors and door linkage.

•

Air inlet housing — The air inlet housing (3) is
mounted to the passenger side end of the HVAC housing. The air inlet housing contains the recirculation-air
door and actuator when equipped with A/C.

The heating-A/C system is a blend-air type system. The blend-air door controls the amount of conditioned air that is
allowed to flow through, or around, the heater core.

The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator to cool and
dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge
air temperature by operating the temperature control cable, which moves the blend-air door. This allows an almost
immediate control of the output air temperature of the system. The mode door cable operates the mode-air doors
which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. When
equipped with A/C, the recirculation door actuator operates the recirculation-air door which closes off the fresh air
intake and recirculates the air already inside the vehicle. The electric recirculation door actuator and the blower
motor are connected to the vehicle electrical system by the instrument panel wire harness. The blower motor con-
trols the velocity of air flowing through the HVAC housing assembly by spinning the blower wheel within the HVAC
housing at the selected speed by use of the blower motor resistor, which is located in the dash panel in the engine
compartment.

The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air
and mode-air doors. The air inlet housing must be removed from HVAC housing and disassembled for service of the
recirculation-air door. The HVAC housing must be removed from the vehicle and disassembled for service of the A/C
evaporator.

REMOVAL

HOUSING-HVAC

WARNING: Disable the airbag system before attempting any steering 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 airbag system. Failure to take the proper precautions could result
in an accidental airbag deployment and possible personal injury or death.

24 - 90

DISTRIBUTION

WARNING: Refer to the applicable warnings and cautions for this system before performing the following
operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in
possible personal injury or death.

NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the heater
core, A/C evaporator, air intake housing and the mode-air and blend-air doors.

NOTE: LHD model shown in illustrations. RHD model similar.

1. Disconnect and isolate the negative battery cable.

2. Recover the refrigerant from the refrigerant system

(refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING

STANDARD

PROCEDURE

REFRIGERANT SYSTEM RECOVERY).

3. Partially drain the engine cooling system (refer to 7

COOLING/ENGINE/COOLANT

STANDARD

PROCEDURE - DRAINING COOLING SYSTEM).

4. Remove the three nuts (1) that secure the heat

shield (3) to the studs (2) located on the dash
panel in the engine compartment and remove the
heat shield.

5. Remove the bolt (1) that secures the A/C liquid and

suction line assembly (2) to the A/C evaporator (3).

6. Disconnect the A/C liquid and suction line assem-

bly from the A/C evaporator and remove and dis-
card the dual-plane seals.

7. Install plugs in, or tape over the opened refrigerant

line fittings and the evaporator ports.

8. Disconnect the heater hoses (4) from the heater

core tubes. Install plugs in, or tape over the
opened heater core tubes to prevent coolant spill-
age during housing removal.

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24 - 91

NOTE: Make sure to remove the five bolts that
secure the HVAC housing to the instrument panel
support prior to removing the instrument panel
from the vehicle.

9. Remove the instrument panel (refer to 23 - BODY/

INSTRUMENT

PANEL/ASSEMBLY-INSTRUMENT

PANEL - REMOVAL).

10. Remove the rear floor ducts (refer to 24 - HEAT-

ING

AIR

CONDITIONING/DISTRIBUTION/

DUCTS-FLOOR DISTRIBUTION - REMOVAL).

11. Remove the condensation drain tube (refer to 24 -

HEATING

& AIR

CONDITIONING/PLUMBING/

TUBE-CONDENSATION DRAIN - REMOVAL).

12. Remove the nut (1) that secures the passenger

side of the HVAC housing (2) to the dash panel
(3).

NOTE: Use care to ensure that the interior is covered in case of loss of residual fluids from the heater and
evaporator cores.

13. Pull the HVAC housing rearward and remove the HVAC housing assembly from the passenger compartment.

HOUSING-AIR DISTRIBUTION

WARNING: Disable the airbag system before attempting any steering 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 airbag system. Failure to take the proper precautions could result
in accidental airbag deployment and possible personal injury or death.

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service
of the blend-air and mode-air doors.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.

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DISTRIBUTION

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