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Housing-Air Distribution

WARNING: This page is about a different car, the 2010 Dodge Charger and 2010 Chrysler 300. 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 mode-air and blend-air doors.
NOTE: LHD model shown in illustrations. RHD model similar.
Fig 1: Air Housing-Air Doors Install
GC0081048Courtesy of CHRYSLER LLC
  1. Install the air door(s) (1) into the air distribution housing (2) as required. Align the air door with the pivot shaft hole in the housing.
  2. Align and install the air door lever (4) into the pivot shaft of the air door. Make sure that the tab (3) on the door lever is securely engaged to the pivot shaft.
    Fig 2: Air Housing-Partition R and I
    GC0081040Courtesy of CHRYSLER LLC
  3. Align the air door pivot shafts with the pivot holes in the center partition (3) and install the partition onto the left half of the air distribution housing (1).
  4. Align the air door pivot shafts to each other and carefully install the left half of the air distribution housing to the right half of the housing (2).
    Fig 3: Air Housing-Seal and Screws R and I
    GC0081039Courtesy of CHRYSLER LLC
  5. Install the screws (4) that secure the two halves of the air distribution housing (3) together. Tighten the screws to 2.2 N.m (20 in. lbs.).
  6. Inspect the foam seal (1), especially at the parting line (2). If the seal is deformed or damaged, it must be replaced.
    Fig 4: Duct-Front Floor Distribution
    GC0081026Courtesy of CHRYSLER LLC
  7. Position the front floor distribution duct (2) onto the air distribution housing (3).
  8. Install the six screws (1) that secure the front floor distribution duct to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 5: Air Housing-Blend Actuator Cam-RH R and I
    GC0081038Courtesy of CHRYSLER LLC
  9. If equipped with dual zone heating-A/C, install the blend door cam (1) onto the blend door lever (2) and the pivot shaft located on the passenger side of the air distribution housing (3).
    Fig 6: Air Housing-Blend Actuator and Bracket-RH R and I
    GC0096066Courtesy of CHRYSLER LLC
  10. If equipped with dual zone heating-A/C, position the blend door actuator mounting bracket (5) onto the passenger side of the air distribution housing (3).
  11. Install the screws (4) that secure the blend door actuator mounting bracket to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  12. Position the blend door actuator (1) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door cam. See Heating and Air Conditioning/Controls/ACTUATOR, Blend Door - Installation .
  13. Install the screws (2) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
    Fig 7: Air Housing-Actuator Linkages-LH R and I
    GC0081037Courtesy of CHRYSLER LLC
  14. Install the blend door cam (9) onto the blend door lever (10) and the pivot shaft located on the driver side of the air distribution housing (8).
  15. Install the floor door linkage (5) onto the floor door lever (4) and the pivot shaft on air distribution housing.
    NOTE: Align the guide pin on the floor door linkage with the guides on the mode door cam during installation of the floor door linkage.
  16. Install the mode door cam (6) onto the pivot shaft on air distribution housing.
  17. Connect the defrost/demister door linkage rod (12) onto the defrost/demister door lever (11).
    NOTE: Align the guide pin on the defrost/demister linkage with the guides on the mode door cam during installation of the defrost/demister linkage.
  18. Install the defrost/demister linkage (7) onto the pivot shaft on air distribution housing.
  19. Connect the instrument panel door linkage rod (2) onto the instrument panel door lever (1).
    NOTE: Align the guide pin on the instrument panel linkage with the guides on the mode door cam during installation of the instrument panel linkage.
  20. Install the instrument panel linkage (3) onto the pivot shaft on air distribution housing.
    Fig 8: Air Housing-Actuators and Brackets-LH R and I
    GC0096065Courtesy of CHRYSLER LLC
  21. Position the blend door actuator mounting bracket (6) and the mode door actuator mounting bracket (3) onto the driver side of the air distribution housing (1).
  22. Install the screws (5) that secure the mounting brackets to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  23. Position the blend door actuator (7) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door cam. See Heating and Air Conditioning/Controls/ACTUATOR, Blend Door - Installation .
  24. Position the mode door actuator (4) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the mode door cam. See Heating and Air Conditioning/Controls/ACTUATOR, Mode Door - Installation .
  25. Install the screws (2) that secure the blend door actuator to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  26. Position the mode door actuator mounting bracket (6) onto the driver side of the air distribution housing (1).
  27. Install the screws that secure the blend door actuator mounting bracket to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  28. Position the blend door actuator (7) onto the air distribution housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend-air door linkage. See Heating and Air Conditioning/Controls/ACTUATOR, Blend Door - Installation .
  29. Install the screws (2) that secure the blend door and mode door actuators to the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  30. Install the air distribution housing onto the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Installation .
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