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Housing-Air Distribution

WARNING: This page is about a different car, the 2006 Dodge Magnum, 2006 Dodge Charger, and 2006 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: LHD model shown in illustrations. RHD model similar.
Fig 1: Housing-Air Distribution Install
GC0013958Courtesy of DAIMLERCHRYSLER CORP.
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
  1. Position the air distribution housing (1) into the vehicle.
  2. Install the air distribution housing onto the rear of the HVAC housing (2) by inserting the tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing and tipping the distribution housing forward until it is properly aligned with the HVAC housing.
  3. Connect the floor distribution ducts to the air distribution housing.
  4. Install the screws (3) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
    Fig 2: Remove/Install Retainer-Heater Core Tube
    GC0013955Courtesy of DAIMLERCHRYSLER CORP.
  5. Remove the tape or plugs from the heater core tubes and heater core ports.
  6. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as they are made of a special material for the engine cooling system.
  7. Install the heater core tubes (2) onto the heater core (3).
  8. Install the two retaining clamps (1) that secure the heater core tubes to the heater core. Make sure that the clamps are installed correctly and securely.
    Fig 3: Remove/Install HVAC Housing-Flange
    GC0013957Courtesy of DAIMLERCHRYSLER CORP.
  9. Install the heater core tubes (4) and the flange (2) to the front of the HVAC housing (3).
  10. Install the two screws (1) that secure the flange to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
    Fig 4: Remove/Install HVAC Wire Harness Actuators
    GC0013954Courtesy of DAIMLERCHRYSLER CORP.
  11. Connect the HVAC wire harness (1) to the mode door actuator (2) and the blend door actuator (3) located on the driver side of the air distribution housing (4).
  12. If equipped with dual zone heating-A/C, connect the HVAC wire harness to the blend door actuator (5) located on the passenger side of the air distribution housing.
  13. Install the floor console duct (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-FLOOR CONSOLE - INSTALLATION) .
  14. Install the defroster ducts (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-DEFROSTER - INSTALLATION) .
  15. Install the instrument panel (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - INSTALLATION) .
  16. Reconnect the negative battery cable.
  17. Refill the engine cooling system (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM REFILL) .
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