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My interior work as started and one of the items on the list was to replace a broken (missing the close-able vanes) air vent on the passenger dash. I got a replacement part, made in China..., and well it doesn't fit. Seems to be 1-2mm too small for the opening? The original housing had a 1 inch gap on the inner ring and I couldn't get the inner housing of the new part to fit right, it ended up breaking off more of the inner lip in the process. Pulling out the outer housing I fond the vent was glued/stuck to the yellow foam in one of the pictures below. The fit was much tighter however and you can see the indents from the 6 prongs on the outer ring. The fit to so loose you can push it all the way into the dash and the actual air vent.
I ordered the Doorman p/n 74935 from StockWise Auto and their car picker stated it fits, however after going back and checking again I see that is listed as "Location - Center". Are the center air vents smaller the 2 side dash vents? The listed OEM P/N is 17997681 and I haven't found anything stating the outer AC vents are larger then the center console vents. I doused that area of the dash with 303 hoping the vinyl will "relax" and the foam inside the dash can expand a little. I know Doorman makes good parts, I have used some of their replacements in the past without issue (lug nut covers and power window motor). Should I try to "massage" that part of the dash and hope it can relax enough to hold onto the new part? Use some thin weather-seal/strip and adhesive to expand the outer diameter enough to be a secure fit? The gap is a little too much for epoxy or glues to work I am afraid.
Dash after removing the OEM vent, it was so brittle it just crumbled when taking it out
Where the vent should be, notice the gap at the top, at least 1mm possibly more
When aligning everything up to where it should be , better view of the gap
The vent can be pushed in so far only the duct stops it, it can freely spin too
Yup the outer ones are slightly larger. I haven't seen any new either. I bought a Dorman replacement and used it as parts to replace broken/missing slats on the driver side and a center. It was close enough and still better than broken/missing slats.
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Problem with replacement air vent fit 
