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Home >> Dodge >> 2006 >> Charger V6-2.7L VIN R >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Removal and Replacement >> Air Distribution Housing Removal and Installation

Air Distribution Housing Removal and Installation


HOUSING-AIR DISTRIBUTION

NOTE:
- The air distribution housing must be removed from the HVAC housing and disassembled for service of the mode-air and blend-air doors.
- LHD model shown in illustrations. RHD model similar.

REMOVAL

WARNING:
- REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
- 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. Air Bag(s) Arming and Disarming




1. Drain the engine cooling system. Service and Repair
2. Disconnect and isolate the negative battery cable. Service and Repair
3. Remove the instrument panel from the passenger compartment. Service and Repair
4. Remove the defroster ducts.
5. Remove the floor console duct. Service and Repair
6. Disconnect the HVAC wire harness (1) from the mode door actuator (2) and the blend door actuator (3) located on the driver side of the air distribution housing (4).




7. If equipped with dual zone heating-A/C, disconnect the HVAC wire harness from the blend door actuator (5) located on the passenger side of the air distribution housing.
8. Remove the two screws (1) that secure the flange (2) to the front of the HVAC housing (3).
9. Remove the flange and the heater core tubes (4) from the HVAC housing.






NOTE: Take proper precautions to protect the carpeting from spilled engine coolant. Have absorbent toweling readily available to clean up any spills.

10. Remove the two retaining clamps (1) that secure the heater core tubes (2) to the heater core (3).
11. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
12. Install plugs in, or tape over the opened heater core tubes and heater core ports.




13. Remove the two screws (1) that secure the air distribution housing (2) to the rear of the HVAC housing (3).
14. Tilt the top of the air distribution housing rearward to disconnect the distribution housing from the tab-and-slot type retainers located at the bottom of the housing.
15. Disconnect the air distribution housing from rear floor distribution ducts. Service and Repair
16. Remove the air distribution housing from the vehicle.
17. If required, disassemble the air distribution housing. Service and Repair

INSTALLATION




1. Position the air distribution housing (1) into the vehicle.
2. Install the air distribution housing onto the rear of the HVAC housing (2) by inserting the tabs on the bottom of the distribution housing into the slots located on the bottom of the HVAC housing and tipping the distribution housing forward until it is properly aligned with the HVAC housing.
3. Connect the floor distribution ducts to the air distribution housing.
4. Install the screws (3) that secure the air distribution housing to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).




5. Remove the tape or plugs from the heater core tubes and heater core ports.
6. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as they are made of a special material for the engine cooling system.
7. Install the heater core tubes (2) onto the heater core (3).
8. Install the two retaining clamps (1) that secure the heater core tubes to the heater core. Make sure that the clamps are installed correctly and securely.




9. Install the heater core tubes (4) and the flange (2) to the front of the HVAC housing (3).
10. Install the two screws (1) that secure the flange to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).




11. Connect the HVAC wire harness (1) to the mode door actuator (2) and the blend door actuator (3) located on the driver side of the air distribution housing (4).
12. If equipped with dual zone heating-A/C, connect the HVAC wire harness to the blend door actuator (5) located on the passenger side of the air distribution housing.
13. Install the floor console duct.
14. Install the defroster ducts.
15. Install the instrument panel.
16. Reconnect the negative battery cable.
17. Refill the engine cooling system.
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