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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.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (Refer to HEATING & AIR CONDITIONING/PLUMBING - WARNINGS)  and (Refer to HEATING & AIR CONDITIONING/PLUMBING - CAUTIONS) . Failure to follow the warnings and cautions could result in possible personal injury or death.
WARNING: 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 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: Remove/Install HVAC Wire Harness Actuators
GC0013954Courtesy of DAIMLERCHRYSLER CORP.
  1. Drain the engine cooling system (Refer to COOLING - STANDARD PROCEDURE - COOLING SYSTEM DRAIN) .
  2. Disconnect and isolate the negative battery cable.
  3. Remove the instrument panel from the passenger compartment (Refer to BODY/INSTRUMENT PANEL/INSTRUMENT PANEL ASSEMBLY - REMOVAL) .
  4. Remove the defroster ducts (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-DEFROSTER - REMOVAL) .
  5. Remove the floor console duct (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/DUCT-FLOOR CONSOLE - REMOVAL) .
  6. Disconnect the HVAC wire harness (1) from the mode door actuator (2) and the blend door actuator (3) located on the driver side of the air distribution housing (4).
  7. If equipped with dual zone heating-A/C, disconnect the HVAC wire harness from the blend door actuator (5) located on the passenger side of the air distribution housing.
    Fig 2: Remove/Install HVAC Housing-Flange
    GC0013957Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove the two screws (1) that secure the flange (2) to the front of the HVAC housing (3).
  9. Remove the flange and the heater core tubes (4) from the HVAC housing.
    Fig 3: Remove/Install Retainer-Heater Core Tube
    GC0013955Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Take proper precautions to protect the carpeting from spilled engine coolant. Have absorbent toweling readily available to clean up any spills.
  10. Remove the two retaining clamps (1) that secure the heater core tubes (2) to the heater core (3).
  11. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
  12. Install plugs in, or tape over the opened heater core tubes and heater core ports.
    Fig 4: Housing-Air Distribution Removal
    GC0013956Courtesy of DAIMLERCHRYSLER CORP.
  13. Remove the two screws (1) that secure the air distribution housing (2) to the rear of the HVAC housing (3).
  14. Tilt the top of the air distribution housing rearward to disconnect the distribution housing from the tab-and-slot type retainers located at the bottom of the housing.
  15. Disconnect the air distribution housing from rear floor distribution ducts.
  16. Remove the air distribution housing from the vehicle.
  17. If required, disassemble the air distribution housing (Refer to HOUSING-AIR DISTRIBUTION ).
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