Housing-Air Distribution

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

Fig 1: Air Distribution Housing - Air Doors & Deflector

Courtesy of DAIMLERCHRYSLER CORP.

NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.

Install the air door(s) (1, 4 and 5) into the air distribution housing (3), as required. Align the air door(s) with the pivot shaft hole(s) in the housing.
Install the air deflector (2) into the air distribution housing.

Fig 2: Housing - Air Distribution - Fasteners
Courtesy of DAIMLERCHRYSLER CORP.
Align the air door pivot shafts the pivot shaft holes in the air distribution housing (3) and carefully install the left half of the air distribution housing to the right half of the housing.
Install the seven screws and one clip (4) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 N.m (20 in. lbs.).
NOTE: If the foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
Inspect the foam seal (1), especially at the parting line (2). If the foam seal is deformed or damaged, it must be replaced.

Fig 3: Installing Mode Door Pivot Lever
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Install the two mode door pivot levers by carefully pushing them straight into the end of the mode door pivot shafts.
Install the two mode door pivot levers (1 and 3) into the end of the mode door pivot shafts (2) on the passenger side of the air distribution housing (4). Make sure the levers are fully engaged to the shafts.

Fig 4: Installing Mode Door Cable Lever
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Align the pins on the mode door pivot levers with the grooves in the cable lever prior to installation of the cable lever.
Position the mode door cable lever (1) onto the passenger side of the air distribution housing (3). Make sure the pins on the mode door pivot levers are positioned in the grooves of the cable lever.
Install the screw and washer (2) that secure the mode door cable lever to the air distribution housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
Install the mode door cable onto the passenger side of the air distribution housing (Refer to HEATING & AIR CONDITIONING/CONTROLS/CABLE-MODE DOOR - INSTALLATION) .

Fig 5: Installing Mode Door Pivot Lever
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Install the blend door pivot lever by carefully pushing it straight into the end of the blend door pivot shaft.
Install the blend door pivot lever (3) into the end of the blend door pivot shaft on the driver side of the air distribution housing (4). Make sure the lever is fully engaged to the shaft.
NOTE: Align the pin on the blend door lever with the grooves in the blend door pivot lever prior to installation of the blend door lever.
Position the blend door lever (2) onto the driver side of the air distribution housing. Make sure the pin on the blend door lever is positioned in the grooves of the pivot lever.
Install the screw (1) that secures the blend door lever to the air distribution housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
Install the temperature control cable onto the driver side of the air distribution housing (Refer to HEATING & AIR CONDITIONING/CONTROLS/CABLE-TEMPERATURE CONTROL - INSTALLATION) .

Fig 6: HVAC Housing Assembly
Courtesy of DAIMLERCHRYSLER CORP.
Install the air distribution housing (2) onto the HVAC housing (1) (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - INSTALLATION) .
Install the HVAC housing assembly (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - INSTALLATION) .