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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.
WARNING: 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 follow these instructions may result in accidental airbag deployment and possible serious or fatal injury.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation. See Heating and Air Conditioning/Plumbing - Warning  and Heating and Air Conditioning/Plumbing - Caution . Failure to follow these instructions may result in possible serious or fatal injury.
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: Heater Core
GC0084671Courtesy of CHRYSLER LLC
  1. Remove the HVAC housing assembly and place it on a workbench. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
  2. Remove all of the floor distribution ducts from the air distribution housing (5). See Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Removal .
    NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
  3. Remove the foam seal (1) from the flange (2) located on the front of the HVAC housing (9).
  4. Remove the screw (10) that secures the flange to the front of the HVAC housing and remove the flange.
  5. Remove the screw (3) that secures the retaining bracket (4) for the heater core tubes (8) to the left side of the air distribution housing.
  6. On RHD models, remove the air distribution housing from the HVAC housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal 
  7. Carefully pull the heater core (6) out of the driver side of the air distribution housing.
    Fig 2: Air Distribution Housing
    GC0082720Courtesy of CHRYSLER LLC
    NOTE: Illustration shown with heater core and tubes removed from view for clarity.
  8. Remove the two metal retaining clips (3) that secure the bottom of air distribution housing (2) to the HVAC housing (4).
  9. Remove the seven screws (1) that secure the air distribution housing to the rear of the HVAC housing.
  10. Remove the air distribution housing from the rear of the HVAC housing.
  11. If required, disassemble the air distribution housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Disassembly .
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