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Housing-Air Distribution

WARNING: This page is about a different car, the 2007 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
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.
Fig 1: HVAC Housing Assembly Components
GC0043307Courtesy of CHRYSLER LLC
  1. Remove the HVAC housing assembly and place it on a workbench. See REMOVAL .
  2. Remove the air distribution housing (2) from the HVAC housing (1). See REMOVAL .
    Fig 2: Removing Blend Door Levers
    GC0043314Courtesy of CHRYSLER LLC
  3. Remove the temperature control cable from the driver side of the air distribution housing. See REMOVAL .
  4. Remove the screw and washer (1) that secures the blend door lever (2) to the driver side of the air distribution housing (4) and remove the lever.
    NOTE: Remove the blend door pivot lever by carefully pulling it straight out from the end of the blend door pivot shaft.
  5. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft.
    Fig 3: Mode Door Cable Lever
    GC0043315Courtesy of CHRYSLER LLC
  6. Remove the mode door cable from the passenger side of the air distribution housing. See REMOVAL .
  7. Remove the screw (2) that secures the mode door cable lever (1) to the passenger side of the air distribution housing (3) and remove the lever.
    Fig 4: Removing Mode Door Pivot Levers
    GC0043316Courtesy of CHRYSLER LLC
    NOTE: Remove the two mode door pivot levers by carefully pulling them straight out from the end of the mode door pivot shafts.
  8. Remove the two mode door pivot levers (1 and 2) from the end of the mode door pivot shafts on the passenger side of the air distribution housing (3).
    Fig 5: Housing - Air Distribution - Fasteners
    GC0043317Courtesy of CHRYSLER LLC
    NOTE: If the foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
  9. Carefully cut the foam seal (1) along the parting line (2) of the two halves of the air distribution housing (3). If the seal is deformed or damaged, it must be replaced.
  10. Remove the seven screws and one clip (4) that secure the two halves of the air distribution housing together.
  11. Carefully separate the left half of the air distribution housing from the right half of the housing.
    Fig 6: Air Distribution Housing - Air Doors & Deflector
    GC0043318Courtesy of CHRYSLER LLC
  12. Remove the air deflector (2) from inside of the air distribution housing (3).
    NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
  13. Remove the air door(s) (1, 4 and 5) from the air distribution housing, as required.
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