Dodge Viper SRT-10 (ZB). Manual - part 264

FLOOR DISTRIBUTION DUCT

REMOVAL

WARNING: On vehicles equipped with airbags, dis-
able the airbag system before attempting any steer-
ing wheel, steering column, or instrument panel
component diagnosis or service. Disconnect and
isolate the battery negative (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 air-
bag system. Failure to take the proper precautions
could result in an accidental airbag deployment and
possible personal injury or death.

(1) Remove the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - REMOVAL).

(2) Remove the one screw and one nut that secure

the floor distribution duct to the dash panel (Fig. 6).

(3) Disconnect the floor distribution duct from

HVAC housing.

(4) Remove the floor distribution duct from the

vehicle.

INSTALLATION

(1) Position the floor distribution duct into the

vehicle.

(2) Connect the floor distribution duct to the

HVAC housing.

(3) Install the one screw and one nut that secure

the floor distribution duct to the dash panel. Tighten
the screw and nut to 2 N·m (17 in. lbs.).

(4) Install the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - INSTALLATION).

(5) Reconnect the negative battery cable.

HVAC HOUSING

REMOVAL

NOTE: The HVAC housing must be removed from
the vehicle and the two halves of the housing sep-
arated for service access of the A/C evaporator,
floor/defrost door, panel door, blend door and the
recirculation door.

(1) Disconnect and isolate the negative battery

cable.

(2) Recover refrigerant from the refrigerant system

(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM RECOVERY).

(3) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE).

(4) Remove the four scews that secure the air inlet

plenum to the dash panel in the engine compartment
(Fig. 7).

(5) Remove the air inlet plenum from the engine

compartment.

(6) Disconnect the liquid and suction line from the

A/C evaporator (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/LIQUID

LINE

REMOVAL) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/SUCTION

LINE

REMOVAL).

(7) Disconnect the heater hoses from the heater

core tubes (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/HEATER

INLET

HOSE

REMOVAL) and (Refer to 24 - HEATING & AIR

Fig. 6 Floor Distribution Duct

1 - DASH PANEL
2 - LOWER DEFROSTER DUCT
3 - SCREW (2)
4 - NUT
5 - FLOOR DISTRIBUTION DUCT

24 - 30

DISTRIBUTION

CONDITIONING/PLUMBING/HEATER

RETURN

HOSE - REMOVAL).

(8) Remove the two nuts and one bolt that secure

the HVAC housing to the dash panel in the engine
compartment (Fig. 8).

(9) Remove the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - REMOVAL).

(10) Disconnect the evaporator drain tube from the

fitting on the dash panel in the passenger compart-
ment (Fig. 9).

(11) Disconnect the lower defroster duct and the

floor distribution duct from the HVAC housing (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/DEFROSTER DUCTS - REMOVAL) and
(Refer to 24 - HEATING & AIR CONDITIONING/
DISTRIBUTION/FLOOR DISTRIBUTION DUCTS -
REMOVAL).

(12) Remove the one nut that secures the HVAC

housing to the dash panel in the passenger compart-
ment and remove the housing.

DISASSEMBLY

(1) Remove the HVAC housing from the vehicle

and place it on the workbench (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - REMOVAL).

(2) Disconnect the electrical connectors from the

blower motor, blower motor resistor and each actua-
tor (Fig. 10).

Fig. 7 Air Inlet Plenum

1 - AIR INLET PLENUM
2 - SCREW (4)
3 - DASH PANEL

Fig. 8 HVAC Housing - Engine Compartment

1 - NUT (2)
2 - DASH PANEL
3 - HVAC HOUSING
4 - BOLT

Fig. 9 HVAC Housing - Passenger Compartment

1 - DASH PANEL
2 - NUT
3 - EVAPORATOR DRAIN TUBE
4 - DRAIN TUBE FITTING
5 - HVAC HOUSING
6 - FLOOR DISTRIBUTION DUCT
7 - DEFROSTER DUCT (LOWER)

DISTRIBUTION

24 - 31

HVAC HOUSING (Continued)

(3) Remove the HVAC wiring harness from the

HVAC housing.

(4)

If necessary, remove the blower motor from

the HVAC housing (Refer to 24 - HEATING & AIR
CONDITIONING/DISTRIBUTION/BLOWER
MOTOR - REMOVAL).

(5) If necessary, remove the blower motor resistor

from the HVAC housing (Refer to 24 - HEATING &
AIR

CONDITIONING/CONTROLS/BLOWER

MOTOR RESISTOR - REMOVAL).

(6) Carefully remove the foam seals from the

heater core and evaporator coil tube mounting flange
of the HVAC housing. If the either seal is deformed
or damaged, it must be replaced.

(7) Remove the screws that secure the upper and

lower HVAC housing halves to each other.

(8) Carefully separate the upper HVAC housing

from the lower HVAC housing.

ASSEMBLY

(1) Position the upper HVAC housing to the lower

housing. During assembly, be certain of the following:

(a) That each of the door pivot shaft ends are

properly engaged in there pivot holes.

(b) That the evaporator drain opening is clean

and the evaporator seal is properly installed.
(2) Install the screws that secure the upper and

lower HVAC housing halves to each other. Tighten
the screws to 2 N·m (17 in. lbs.).

(3) Install the foam seals on the heater core and

evaporator coil tubes.

(4) If removed, install the blower motor resistor

(Refer to 24 - HEATING & AIR CONDITIONING/
CONTROLS/BLOWER

MOTOR

RESISTOR

INSTALLATION).

(5) If removed, install the blower motor (Refer to

24 - HEATING & AIR CONDITIONING/DISTRIBU-
TION/BLOWER MOTOR - INSTALLATION).

(6) Install the HVAC wire harness. Make sure the

wires are routed through all wiring retainers.

(7) Connect the wire harness to the blower motor,

blower motor resistor and each actuator.

(8) Install the HVAC housing (Refer to 24 - HEAT-

ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION).

INSTALLATION

(1) Position the HVAC housing into the vehicle.

Fig. 10 HVAC Housing - Disassembled

1 - PANEL MODE DOOR ACTUATOR
2 - FLOOR/DEFROST MODE DOOR ACTUATOR
3 - UPPER HVAC HOUSING
4 - RECIRCULATION-AIR DOOR
5 - RECIRCULATION DOOR ACTUATOR
6 - FOAM SEAL
7 - A/C EVAPORATOR
8 - HVAC WIRE HARNESS
9 - LOWER HVAC HOUSING

10 - BLOWER MOTOR AND WHEEL
11 - BLOWER MOTOR RESISTOR BLOCK
12 - HEATER CORE
13 - BLEND-AIR DOOR
14 - BLEND DOOR ACTUATOR
15 - FOAM SEAL
16 - PANEL-AIR DOOR
17 - FLOOR/DEFROST-AIR DOOR

24 - 32

DISTRIBUTION

HVAC HOUSING (Continued)

(2) Install the one nut that secures the HVAC

housing to the dash panel in the passenger compart-
ment. Tighten the nut to 7 N·m (60 in. lbs.).

(3) Connect lower defroster duct and the floor dis-

tribution duct to the HVAC housing (Refer to 24 -
HEATING & AIR CONDITIONING/DISTRIBUTION/
DEFROSTER DUCTS - INSTALLATION) and (Refer
to 24 - HEATING & AIR CONDITIONING/DISTRI-
BUTION/FLOOR

DISTRIBUTION

DUCTS

INSTALLATION).

(4) Connect the evaporator drain tube to the fit-

ting on the dash panel.

(5) Install the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - INSTALLATION).

(6) Install the two nuts and one bolt that secure

the HVAC housing to the dash panel in the passen-
ger compartment. Tighten the nuts and bolt 7 N·m
(60 in. lbs.).

(7) Connect the heater hoses to the heater core

tubes (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/HEATER INLET HOSE - INSTAL-
LATION) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/HEATER

RETURN

HOSE - INSTALLATION).

(8) Connect the suction and liquid line to the A/C

evaporator (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING/SUCTION LINE - INSTAL-
LATION) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/LIQUID

LINE

INSTALLATION).

(9) Position the air inlet plenum into the engine

compartment.

(10) Install the four screws that secure the air

inlet plenum to the dash panel. Tighten the screws to
2 N·m (17 in. lbs.).

(11) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT

STANDARD

PROCEDURE

REFRIGERANT SYSTEM EVACUATE).

(12) Recharge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT

STANDARD

PROCEDURE

REFRIGERANT SYSTEM CHARGE).

(13) Reconnect the negative battery cable.
(14) If the heater core is being replaced, flush the

cooling system (Refer to 7 - COOLING - STANDARD
PROCEDURE - COOLING SYSTEM CLEANING/
REVERSE FLUSHING).

(15) Refill the cooling system (Refer to 7 - COOL-

ING - STANDARD PROCEDURE).

INSTRUMENT PANEL DUCTS

REMOVAL

(1) Disconnect the negative battery cable.
(2) Remove the instrument panel from the vehicle

and place it on a workbench (Refer to 23 - BODY/IN-
STRUMENT

PANEL/INSTRUMENT

PANEL

ASSEMBLY - REMOVAL).

(3) Remove the screws that secure the left and

right side instrument panel ducts and the center dis-
tribution duct to the instrument panel.

(4) Remove the left and right side instrument

panel ducts and the center distribution duct from the
instrument panel (Fig. 11).

INSTALLATION

(1) Position the left and right side instrument

panel ducts and the center distribution duct to the
instrument panel.

(2) Install the screws that secure the left and right

side instrument panel ducts and the center distribu-
tion duct to the instrument panel. Tighten the screws
to 2 N·m (17 in. lbs.).

(3) Install the instrument panel (Refer to 23 -

BODY/INSTRUMENT

PANEL/INSTRUMENT

PANEL ASSEMBLY - INSTALLATION).

(4) Reconnect the negative battery cable.

Fig. 11 Instrument Panel Ducts

1 - SCREW (3)
2 - LH INSTRUMENT PANEL DUCT
3 - CENTER DISTRIBUTION DUCT
4 - RH INSTRUMENT PANEL DUCT
5 - INSTRUMENT PANEL ASSEMBLY

DISTRIBUTION

24 - 33

HVAC HOUSING (Continued)

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