Sebring 2006

Removal & Installation

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CAUTION
On vehicles equipped with airbags, 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 instrument panel and HVAC housing are removed from the vehicle together as an assembly.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Recover the refrigerant from the refrigerant system.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Disconnect and isolate the negative battery cable.
  8.  
  9. Remove the 1 bolt retaining the A/C lines to the right strut tower.
  10.  
  11. Remove the 2 top HVAC housing retaining nuts in the engine compartment.
  12.  
  13. Raise and safely support the vehicle.
  14.  
  15. Remove the lower HVAC housing retaining nut.
  16.  
  17. Lower the vehicle.
  18.  
  19. Remove the driver-s and passenger-s seats:
    1. Position the seat far enough forward to gain access to the rear mount bolts on the floor.
    2.  
    3. Remove the bolts holding the rear of the seat track to the floor.
    4.  
    5. Slide the seat rearward.
    6.  
    7. Remove the bolts attaching the front of the seat track to the floor kick up.
    8.  
    9. Disconnect the front seat wire harness connector from the body harness connector.
      CAUTION
      Do not handle the seat by the adjuster release bar when removing the spring loaded seat from the vehicle.

    10.  
    11. Remove the front seat from the vehicle.
    12.  

  20.  
  21. Remove the screw-to-shift knob and transmission range indicator bezel from the floor console.
  22.  
  23. Remove the floor center console. Remove the 2 mounting screws in the front and the 2 mounting screws inside the console storage bin.
  24.  
  25. Remove the amplifier retaining fasteners.
  26.  
  27. Disconnect the wire harness connector.
  28.  
  29. Remove the amplifier.
  30.  
  31. Using a trim stick, or equivalent, gently pry out on the left and right rear floor heat ducts and remove.
  32.  
  33. Disconnect the console wiring connectors and unclip the push-in fasteners.
  34.  
  35. Using a trim stick, or equivalent, gently pry up and remove the right sill plate.
  36.  
  37. Remove the 2 screws to the right cowl kick panel and remove the kick panel from the vehicle.
  38.  
  39. Using a trim stick, or equivalent, gently pry out on the right end cover and remove the end cover from the vehicle.
  40.  
  41. Using a trim stick, or equivalent, gently pry out on the right A-pillar trim and remove it from the vehicle.
  42.  
  43. Open the glove box. Pinch in on the sides and drop to the floor. Pull down to disengage the hinges.
  44.  
  45. Disconnect the right door harness connectors located within the A-pillar.
  46.  
  47. Remove the 4 right A-pillar instrument panel retainers.
  48.  
  49. Remove the right silencer.
  50.  
  51. Remove the 1 right side, center instrument panel support bolt.
  52.  
  53. Using a trim stick, or equivalent, gently pry up on and remove the left sill plate.
  54.  
  55. Remove the 2 screws to the left cowl kick panel and remove it from the vehicle.
  56.  
  57. Using a trim stick, or equivalent, gently pry out on the left end cover and remove it from the vehicle.
  58.  
  59. Using a trim stick, or equivalent, gently pry out on the left A-pillar trim and remove it from the vehicle.
  60.  
  61. Disconnect the left door harness connectors located within the A-pillar.
  62.  
  63. Remove the 4 left A-pillar instrument panel retainers.
  64.  
  65. Remove the 5 screws and one wire connector to the left lower instrument panel trim bezel.
  66.  
  67. Remove the left silencer.
  68.  
  69. Remove the 1 left side, center instrument panel support bolt.
  70.  
  71. Remove the 1 bolt to the left side support strut to the bulkhead.
  72.  
  73. Disconnect the junction block wiring connectors.
  74.  
  75. Remove the 2 screws to the steering column shrouds and remove the steering column shrouds.
  76.  
  77. Disconnect all the column wiring and unclip the harness from the steering column.
  78.  
  79. Disconnect the transaxle shift interlock and the wire connector.
  80.  
  81. Remove the 4 steering column retaining bolts and drop the column to the floor.
  82.  
  83. Using a trim stick, or equivalent, pry up on the rear of the top cover and pull rearward as you lift it off of the instrument panel.
  84.  
  85. Remove the instrument panel pad.
  86.  
  87. Remove the 7 bolts and 5 screws attaching the instrument panel to the fence line and the cowl side.
  88.  
  89. With the help of an assistant, lift up the instrument panel and move it rearward to remove. Tilt the panel rearward to prevent the coolant from leaking out. If replacing the instrument panel, transfer all the non-damaged parts and wiring harness to the new instrument panel assembly.
  90.  
  91. Disconnect the HVAC wire harness from the instrument panel wire harness connector at the left side of the HVAC housing.
  92.  
  93. Remove the 2 nuts and 2 bolts that secure the HVAC housing to the instrument panel.
  94.  
  95. Separate the HVAC housing from the instrument panel.
  96.  
  97. 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.
  98.  
  99. Remove the 2 screws that secure the HVAC harness connector to the HVAC housing and remove the HVAC wire harness.
  100.  
  101. Remove the screws that secure the blower motor to the HVAC housing and remove the blower motor.
  102.  
  103. Remove the screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove it from the housing.
  104.  
  105. Remove the screws that secure the air inlet housing to the HVAC housing and remove the air inlet housing.
  106.  
  107. Remove the 3 screws that secure the recirculation door actuator to the air inlet housing and remove the actuator.
  108.  
  109. Remove the screw that secures the recirculation door actuator gear to the air inlet housing and remove the gear.
  110.  
  111. Using a small screwdriver, depress the recirculation door gear release and remove the recirculation door gear from the recirculation door shaft.
    NOTE
    If the seal on the recirculation-air door is deformed or damaged, the air door must be replaced.

  112.  
  113. 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.

  114.  
  115. Carefully, remove the foam seals from the heater core and the evaporator tube mounting flange of the HVAC housing.
  116.  
  117. Remove the screws that secure the upper and lower HVAC housing halves together and separate the housing halves.
  118.  
  119. Using a flat blade pry tool, disengage the locking tab on the access plate of the evaporator temperature sensor. Turn the access plate clockwise 1 / 4 turn and push the access plate inside of the HVAC housing, then orientate the plate in such a way that it can be removed from the housing.
  120.  
  121. Remove the evaporator temperature sensor probe from the A/C evaporator and remove the sensor.
  122.  
  123. Lift the A/C evaporator out of the bottom half of the HVAC housing.
  124.  
  125. Lift the heater core out of the bottom half of the HVAC housing.

    Click image to see an enlarged view

    Fig. HVAC housing



    Click image to see an enlarged view

    Fig. Heater core

  126.  

To install:

  1. Install the heater core into the bottom half of the HVAC housing.
  2.  
  3. 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.
  4.  
  5. Install the screws that secure the two halves of the HVAC housing together. Tighten the screws to 18 inch lbs. (2 Nm).
  6.  
  7. Install the foam seals on the heater core and evaporator coil tube mounting flange.
  8.  
  9. Install the recirculation-air door into the air inlet housing.
  10.  
  11. Install the recirculation door gear onto the recirculation door shaft.
    NOTE
    The recirculation door actuator gear and door gear must be properly aligned to operate correctly.

  12.  
  13. Align and install the recirculation door actuator gear with the door gear.
  14.  
  15. Install the screw that secures the recirculation door actuator gear to the air inlet housing. Tighten the screw to 18 inch lbs. (2 Nm).
  16.  
  17. Align the recirculation door actuator spline with the spline in the recirculation door gear and install the recirculation door actuator.
  18.  
  19. Install the 3 screws that secure the recirculation door actuator to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
  20.  
  21. Install the air inlet housing onto the HVAC housing.
  22.  
  23. Install the screws that secure the air inlet housing to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
  24.  
  25. If removed, install the blower motor resistor or power module (depending on application). Install and tighten the screws to 18 inch lbs. (2 Nm).
  26.  
  27. If removed, install the blower motor. Install and tighten the screws to 18 inch lbs. (2 Nm).
    NOTE
    Make sure that all HVAC wire harness leads are routed through all HVAC housing wiring retainers.

  28.  
  29. Install the HVAC wire harness onto the HVAC housing.
  30.  
  31. Install the 2 screws that secure the HVAC wire harness connector to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
  32.  
  33. Connect the HVAC wire harness connectors to the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor, and each actuator.
  34.  
  35. Position the HVAC housing to the instrument panel. Make sure that all air ducts are properly aligned or connected.
  36.  
  37. Install the 2 nuts and bolts that secure the HVAC housing to the instrument panel. Tighten the nuts and bolts securely.
  38.  
  39. Connect the HVAC wire harness to the instrument 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.

  40.  
  41. With the help of an assistant, place the instrument panel in the vehicle, carefully guiding the HVAC housing studs through the bulkhead and into position.
  42.  
  43. Install the 7 bolts and 5 screws attaching instrument panel to fence line and cowl side.
  44.  
  45. Place the instrument panel pad into position.
  46.  
  47. Place the instrument panel top cover in position on the vehicle.
  48.  
  49. Push the top cover forward to engage the hooks to hold the front of the top cover to the instrument panel.
  50.  
  51. Engage the clips to hold the rear edge of the top cover to the instrument panel.
  52.  
  53. Pull the top cover rearward as you firmly push down and snap into it place.
  54.  
  55. Install the A-pillar trim.
  56.  
  57. Install the 4 steering column retaining bolts.
  58.  
  59. Connect the transaxle shift interlock and wire connector.
  60.  
  61. Connect all the column wiring and clip the harness to the steering column.
  62.  
  63. Install the 2 screws to the steering column shrouds.
  64.  
  65. Connect the junction block wiring connectors.
  66.  
  67. Install the 1 bolt to the left side support strut to bulkhead.
  68.  
  69. Install the 5 screws and 1 wire connector to the left lower instrument panel trim bezel.
  70.  
  71. Install the 1 left side, center instrument panel support bolt.
  72.  
  73. Install the left silencer.
  74.  
  75. Install the 4 left A-pillar instrument panel retainers.
  76.  
  77. Connect the right door harness connectors located within the A-pillar.
  78.  
  79. Install the left end cover.
  80.  
  81. Install the 2 screws to the left cowl trim panel.
  82.  
  83. Install the left door sill plate.
  84.  
  85. Install the 1 right side, center instrument panel support bolt.
  86.  
  87. Install the right silencer.
  88.  
  89. Install the 4 right A-pillar instrument panel retainers.
  90.  
  91. Connect the right door harness connectors located within the A-pillar.
  92.  
  93. Install the glove box.
  94.  
  95. Install the right A-pillar trim.
  96.  
  97. Install the right end cover.
  98.  
  99. Install the 2 screws to the right cowl trim panel.
  100.  
  101. Install the right door sill plate.
  102.  
  103. Connect the console wiring connectors and clip the push in fasteners in.
  104.  
  105. Install the left and right rear floor heat ducts.
  106.  
  107. Connect the 2 harness connectors to the amplifier.
  108.  
  109. Connect the wire harness connector to the amplifier.
  110.  
  111. Install the amplifier. Tighten the forward screw to 27 inch lbs. (3 Nm) and the rear nut to 18 inch lbs. (2 Nm).
  112.  
  113. Install the floor center console. Install the 2 mounting screws in the front and 2 mounting screws inside console storage bin.
  114.  
  115. Install the transmission range indicator bezel and 1 screw to the shift knob.
  116.  
  117. Connect the battery negative remote cable.
    CAUTION
    Do not handle the seat by the seat adjuster release bar.


    NOTE
    Ensure that the seat tracks are rearward. Ensure the seat tracks on the right and left are in equal latch positions.

  118.  
  119. Place the front seat in position in the vehicle.
  120.  
  121. Connect the front seat wire harness connector to the body harness connector.
  122.  
  123. Install the bolts to attach the front of seat track to the floor kick up. Tighten the bolts to 45 ft. lbs. (61 Nm).
  124.  
  125. Slide the seat forward and install the bolts attaching the rear of the seat track to the floor. Tighten the bolts to 45 ft. lbs. (61 Nm).
  126.  
  127. Verify the front seat operation.
  128.  
  129. Raise and safely support the vehicle.
  130.  
  131. Install the lower HVAC housing retaining nut.
  132.  
  133. Lower the vehicle.
  134.  
  135. Install the 2 top HVAC housing retaining nuts in the engine compartment.
  136.  
  137. Install the 1 bolt retaining the A/C lines to the right strut tower.
  138.  
  139. Connect the negative battery cable.
  140.  
  141. If the heater core is being replaced, flush the cooling system.
  142.  
  143. Refill the engine cooling system to the proper level.
  144.  
  145. Evacuate the refrigerant system. Refer to Evacuating the System.
  146.  
  147. Charge the refrigerant system. Refer to Charging the System.
  148.  

 
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