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Air Distribution Housing

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
Fig 1: Driver Side Air Doors
GC0028347Courtesy of DAIMLERCHRYSLER CORP.
  1. Install the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3) and the blend-air door (4) into the driver side air distribution housing (5) as required. Align the air doors with the pivot shaft holes in the housing.
    Fig 2: Passenger Side Air Doors
    GC0028346Courtesy of DAIMLERCHRYSLER CORP.
  2. Install the upper defrost/panel-air door (1), lower defrost/panel-air door (2), directional vane (3), rear outlet-air door (4) and the blend-air door (5) into the passenger side air distribution housing (6) as required. Align the air doors with the pivot shaft holes in the housing.
    Fig 3: Center Partition
    GC0028345Courtesy of DAIMLERCHRYSLER CORP.
  3. If removed, align the front floor-air doors (1 and 3) with each other and install then into the center partition (2). Make sure that the air door retaining tabs (4) are fully engaged.
    Fig 4: Housing-Seperate
    GC0028344Courtesy of DAIMLERCHRYSLER CORP.
  4. Install the center partition (3) into the right half of the air distribution housing (2).
  5. Install the left half of the air distribution housing (1) onto the right half of the air distribution housing. Align the air door pivot shafts with each other and with the pivot shaft holes in the housing.
    Fig 5: Housing Retainers-R and I
    GC0028343Courtesy of DAIMLERCHRYSLER CORP.
  6. Install the eight screws (5) that secure the two halves of the air distribution housing (3) together. Tighten the screws to 2.2 N.m (20 in. lbs.).
  7. Install the four metal clips (4) that secure the two halves of the air distribution housing together.
  8. Inspect the foam seal (1), especially at the parting line (2). If the seal is deformed or damaged, it must be replaced.
    Fig 6: Heater Core and Stop-R and I
    GC0028342Courtesy of DAIMLERCHRYSLER CORP.
  9. Carefully install the heater core (3) into the passenger side of the air distribution housing (2).
  10. If equipped with dual zone heating-A/C, install the blend door stop (1) onto the passenger side of the air distribution housing.
    Fig 7: Actuators and Bracket-RH
    GC0028341Courtesy of DAIMLERCHRYSLER CORP.
  11. Position the rear floor/console door actuator (2) onto the passenger side of the air distribution housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the floor/console door pivot shaft. (Refer to HEATING & AIR CONDITIONING/CONTROLS/ACTUATOR-MODE DOOR - INSTALLATION) .
  12. Install the screws (1) that secure the rear floor/console door actuator onto the passenger side of the air distribution housing. Tighten the screws to 2 N.m (17 in. lbs.).
  13. If equipped with dual zone heating-A/C, position the blend door actuator mounting bracket (5) onto the passenger side of the air distribution housing and install the retaining screws (4). Tighten the screws to 2 N.m (17 in. lbs.).
  14. If equipped with dual zone heating-A/C, position the blend door actuator (7) onto the blend door actuator mounting bracket and install the retaining screws (6). Tighten the screws to 2 N.m (17 in. lbs.). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those on the blend door stop. (Refer to HEATING & AIR CONDITIONING/CONTROLS/ACTUATOR-BLEND DOOR - INSTALLATION) .
    Fig 8: Door Linkage-LH-R and I
    GC0028340Courtesy of DAIMLERCHRYSLER CORP.
  15. Install the front floor door linkage rod (6) and the lower defrost/panel door pivot gear (2) onto the driver side of the air distribution housing (3).
    NOTE: Align the arrow on the lower defrost/panel door pivot gear with the locator in the window of the mode door cam during installation of the mode door cam.
  16. Align and install the mode door cam (7) onto the driver side of the air distribution housing.
    NOTE: Align the guide pin on the upper defrost/panel door linkage rod with the guides in the mode door cam during installation of the upper defrost/panel door linkage rod.
  17. Align and install the upper defrost/panel door linkage rod (8) onto the driver side of the air distribution housing.
    NOTE: Align the detent in the upper defrost/panel door pivot gear with the locator in the upper defrost/panel door linkage rod during installation of the upper defrost/panel door pivot gear.
  18. Align and install the blend door stop (5), front floor door pivot gear (4) and the upper defrost/panel door pivot gear (1) onto the driver side of the air distribution housing.
    Fig 9: Actuators and Brackets-LH-R and I
    GC0028339Courtesy of DAIMLERCHRYSLER CORP.
  19. Position the blend door actuator mounting bracket (5) and the mode door actuator mounting bracket (8) onto the driver side of the air distribution housing (1) and install the retaining screws (3 and 6). Tighten the screws to 2 N.m (17 in. lbs.).
  20. Position the blend door actuator (4) and the mode door actuator (7) onto the mounting brackets and install the retaining screws (2). Tighten the screws to 2 N.m (17 in. lbs.). If necessary, rotate the actuators slightly to align the splines on the actuator output shaft with those on the mode door cam and the blend door stop (Refer to HEATING & AIR CONDITIONING/CONTROLS/ACTUATOR-BLEND DOOR - INSTALLATION)  and (Refer to HEATING & AIR CONDITIONING/CONTROLS/ACTUATOR-MODE DOOR - INSTALLATION) .
  21. Install the air distribution housing onto the HVAC housing (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - AIR DISTRIBUTION HOUSING - INSTALLATION) .
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