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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.
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (Refer to HEATING & AIR CONDITIONING/PLUMBING - WARNINGS)  and (Refer to HEATING & AIR CONDITIONING/PLUMBING - CAUTIONS) . Failure to follow the warnings and cautions could result in possible personal injury or death.
WARNING: On vehicles equipped with airbags, 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 take the proper precautions could result in accidental airbag deployment and possible personal injury or death.
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: HVAC Wire Harness Connections-Left Side
GC0028331Courtesy of DAIMLERCHRYSLER CORP.
  1. Remove the HVAC housing assembly and place it on a workbench (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HVAC HOUSING ASSEMBLY - REMOVAL) .
  2. Disengage the HVAC wire harness retainer (1) from the rear of the air distribution housing (2).
  3. Disconnect the HVAC wire harness (3) from the blend door actuator (4) and the mode door actuator (5) located on the driver side of the air distribution housing.
    Fig 2: HVAC Wire Harness Connections-Right Side
    GC0028332Courtesy of DAIMLERCHRYSLER CORP.
  4. Disconnect the HVAC wire harness (1) from the mode door actuator (2) located near the bottom of the air distribution housing (3).
  5. If equipped with dual zone heating-A/C, disconnect the HVAC wire harness from the blend door actuator (4) located on the passenger side of the air distribution housing.
    Fig 3: Heater Core and Tube Cover
    GC0028333Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove the five screws (1) that secure the heater core and tube cover (2) to the HVAC housing (3).
  7. Remove the heater core and tube cover from the HVAC housing.
    Fig 4: Heater Core Tubes
    GC0028334Courtesy of DAIMLERCHRYSLER CORP.
    NOTE: Take proper precautions to protect the carpeting from spilled engine coolant. Have absorbent toweling readily available to clean up any spills.
  8. Remove the screw (1) that secures the heater core tubes (2) to the HVAC housing (3).
  9. Remove the bolt (4) that secures the heater core tubes to the heater core (5).
  10. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
  11. Install plugs in, or tape over the opened heater core tubes and heater core ports.
    Fig 5: Air Distribution Housing R and I
    GC0028335Courtesy of DAIMLERCHRYSLER CORP.
  12. Remove the seven screws (1) that secure the air distribution housing (2) to the HVAC housing (3).
  13. Release the locking tabs located at the top of the distribution housing and tilt the distribution housing downward to disengage the tab-and-slot type retainers located at the bottom of the housing.
  14. Remove the air distribution housing from the HVAC housing.
  15. If required, disassemble the air distribution housing (Refer to HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - AIR DISTRIBUTION HOUSING - DISASSEMBLY) .
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