Housing-Air Distribution

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 Fig 1. RHD and heater-only models similar.

Fig 1: Heater Core Cover Removal/Installation

Courtesy of CHRYSLER LLC

Remove the HVAC housing assembly and place it on a workbench. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal .
Remove the left and right floor distribution ducts. See Heating and Air Conditioning/Distribution/DUCT, Floor Distribution - Removal .
Remove the three screws (1) that secure the heater core cover (2) to the driver side of the air distribution housing (3) and the HVAC housing (4) and remove the cover.

Fig 2: Heater Core Removal/Installation
Courtesy of CHRYSLER LLC

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.
Remove the foam seal (1) from the flange (2) located on the driver side of the HVAC housing (6).
Remove the two screws (4) that secure the heater core (5) to the driver side of the air distribution housing (3).
Carefully pull the heater core out of the driver side of the air distribution housing.

Fig 3: Air Distribution Housing Removal/Installation
Courtesy of CHRYSLER LLC
Remove the screws (1) that secure the air distribution housing (2) to the rear of the HVAC housing (3).
Remove air distribution housing from the HVAC housing by tilting the top of the air distribution housing rearward and disconnecting the distribution housing from the tab-and-slot type retainers located at the bottom of the housing.
If required, disassemble the air distribution housing. See Heating and Air Conditioning/Distribution/HOUSING, HVAC - Disassembly .