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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: Air Distribution Housing R and I
GC0028335Courtesy of DAIMLERCHRYSLER CORP.
  1. Position the air distribution housing (2) onto the rear of the HVAC housing (3) by inserting the tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing.
  2. Tip the air distribution housing upward until it is properly aligned with the HVAC housing and the locking tabs at the top of the distribution housing are fully engaged.
  3. Install the seven screws (1) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
    Fig 2: Heater Core Tubes
    GC0028334Courtesy of DAIMLERCHRYSLER CORP.
  4. Remove the tape or plugs from the heater core tubes (2) and the heater core (5).
  5. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-rings as they are made of a special material for the engine cooling system.
  6. Install the heater core tubes onto the heater core and loosely install the bolt (4) that secures the tubes to the heater core.
  7. Install the screw (1) that secures the heater core tubes to the HVAC housing. Tighten the screw to 2.2 N.m (20 in. lbs.).
  8. Tighten the bolt that secures the heater core tubes to the heater core to 3 N.m (27 in. lbs.).
    Fig 3: Heater Core and Tube Cover
    GC0028333Courtesy of DAIMLERCHRYSLER CORP.
  9. Install the heater core and tube cover (2) onto the HVAC housing (3).
  10. Install the five screws (1) that secure the heater core and tube cover to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
    Fig 4: HVAC Wire Harness Connections-Right Side
    GC0028332Courtesy of DAIMLERCHRYSLER CORP.
  11. Connect the HVAC wire harness (1) to the mode door actuator (2) located near the bottom of the air distribution housing (3).
  12. If equipped with dual zone heating-A/C, connect the HVAC wire harness to the blend door actuator (4) located on the passenger side of the air distribution housing.
    Fig 5: HVAC Wire Harness Connections-Left Side
    GC0028331Courtesy of DAIMLERCHRYSLER CORP.
  13. Connect the HVAC wire harness (3) to the blend door actuator (4) and the mode door actuator (5) located on the driver side of the air distribution housing (2).
  14. Engage the HVAC wire harness retainer (1) to the rear of the air distribution housing.
  15. Install the HVAC housing assembly (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HVAC HOUSING ASSEMBLY - INSTALLATION) .
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