Housing-Air Distribution

WARNING: This page is about a different car, the 2009 Dodge Caliber. However, it is still accessible from the selected car via links, so may be relevant.

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

Fig 1: Mode Door Levers

Courtesy of CHRYSLER LLC

Install the four mode door levers (1, 2, 3 and 4) onto the right side of the air distribution housing (5) Make sure the lever retaining tabs are fully engaged to the housing.

Fig 2: Air Doors
Courtesy of CHRYSLER LLC

NOTE: Properly position the air doors within the air distribution housing by first aligning the four mode door levers to the scribe lines located on the right outer side of the air distribution housing. Then, install the air doors onto the mode door levers with the UP mark on each air door facing toward the top of the housing.

NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.
Align the four mode door levers to the scribe lines on the right outer side of the air distribution housing (5) and install the air door(s) (1, 2, 3 and 4) onto the mode door levers with the UP mark on each air door facing toward the top of the housing.

Fig 3: Parting Line and Retainers
Courtesy of CHRYSLER LLC
Align the air door(s) with the pivot shaft hole(s) in the air distribution housing (3) and install the two halves of the housing together. Make sure the three plastic retaining tabs (6) are fully engaged.
Install the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together. Tighten the screws to 2.2 N.m (20 in lbs.). Make sure the metal clip is fully engaged to the housing halves.
NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.
Inspect the foam seals (1), especially at the parting line (2). If a foam seal is deformed or damaged, it must be replaced.

Fig 4: Mode Door Cable and Cam
Courtesy of CHRYSLER LLC

NOTE: Align the pins on the mode door levers with the grooves in the back of the mode door cam prior to installation of the cam.
Align the mode door levers on the right side of the air distribution housing (2) to the mode door cam (4) and install the cam onto the housing. Make sure the levers are correctly engaged to the cam.
Install the screw and washer (3) that secure the mode door cam to the air distribution housing. Tighten the screw to 0.6 N.m (5 in. lbs.).
Install the mode door cable (1). See Heating and Air Conditioning/Controls/CABLE, Mode Door - Installation .

Fig 5: Temperature Control Cable and Levers
Courtesy of CHRYSLER LLC
Install the blend door pivot lever (3) onto the end of the blend door pivot shaft (4) located on the left side of the air distribution housing (2). Make sure the lever retaining tab is fully engaged to the pivot shaft.
NOTE: Align the pin on the blend door lever with the groove in the pivot lever prior to installation of the blend door lever.
Install the blend door lever (6) onto the air distribution housing. Make sure the levers are correctly aligned to each other.
Install the screw and washer (5) that secure the blend door lever to the air distribution housing. Tighten the screw to 0.6 N.m (5 in. lbs.).
Install the temperature control cable (1). See Heating and Air Conditioning/Controls/CABLE, Temperature Control - Installation .

Fig 6: HVAC Housing
Courtesy of CHRYSLER LLC
If equipped with the 2.0L diesel engine, install the electric positive temperature coefficient (PTC) heater unit into the air distribution housing. See Heating and Air Conditioning/Cabin Heater/UNIT, Heater - Installation .
Install the heater core into the air distribution housing (2). See Heating and Air Conditioning/Plumbing/CORE, Heater - Installation .
Install the air distribution housing onto the HVAC housing (1). See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Installation .
Install the HVAC housing assembly. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Installation .