Rear
DISASSEMBLYNOTE: The rear HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, heater core, mode-air door, blend-air door and blower motor.
1. Remove the rear HVAC housing (1) and place it on a workbench .
2. Disconnect the rear HVAC wire harness (2) from the rear blower motor (3) and the rear blower motor resistor (4).
3. If necessary, remove the rear blower motor.
4. If necessary, remove the rear blower motor resistor.
5. Remove the screws (5) that secure the rear air inlet housing (6) to the rear HVAC housing.
6. Remove the rear air inlet housing from the rear HVAC housing.
7. Disconnect the rear HVAC wire harness (1) from rear blend door actuator (2) and mode door actuator (3).
8. Remove the rear blend door actuator and mode door actuator from the rear HVAC housing (4).
9. Carefully remove the foam seal (1) from the rear heater core and evaporator extension line flange (3). If the seal is deformed or damaged, it must be replaced.
10. Remove the screws (2) that secure the two halves of the rear heater core and evaporator extension line flange together.
11. Remove the outer half of the rear heater core and evaporator extension line flange.
12. Disconnect the condensate drain tube (1) from the rear HVAC housing (2).
13. Remove the screw (3) that secures the rear heater core tube retaining bracket (4) to the rear HVAC housing.
14. Remove the rear heater core tube retaining bracket.
15. Carefully pull the rear heater core (5) out of the side of the rear HVAC housing.
16. Remove the two screws (6) that secure the rear extension line flange bracket (7) to the bottom of the rear HVAC housing.
17. Carefully lift the rear A/C evaporator (1), rear expansion valve (2) and the rear extension line bracket (3) as an assembly out of the top of the rear HVAC housing (4).
18. Remove the rear HVAC wiring harness (1) from the rear HVAC housing (2).
19. Remove the screws (3) that secure the two halves of the rear HVAC housing together.
20. Separate the two halves of the rear HVAC housing.
21. Remove the blend-air door (4) and mode-air door (5) from the rear HVAC housing.
22. If necessary, remove the actuator couplers (6) from the rear HVAC housing.
ASSEMBLY
1. If removed, install the two actuator couplers (1) into the rear HVAC housing. Be sure to install the couplers with the coupler arm (3) located between the two stop tabs (4) on the HVAC housing.
2. Install the blend-air door (1) and the mode-air door into the rear HVAC housing (2).
3. Align the pivot shafts of the blend-air door (4) and the mode-air door (5) to the actuator couplers (6) and install the two halves of the rear HVAC housing (2) together.
4. Install the screws (3) that secure the two halves of the rear HVAC housing together. Tighten the screws to 2 N.m (17 in. lbs.).
5. Install the HVAC wire harness (1). Make sure the harness is routed through all wiring retainers.
6. Install the rear A/C evaporator (1), rear expansion valve (2) and the rear extension line bracket (3) as an assembly into the top of the rear HVAC housing (4). Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator is properly installed.
7. Install the two screws (6) that secure the rear extension line flange bracket (7) to the bottom of the rear HVAC housing (2). Tighten the screws to 2 N.m (17 in. lbs.).
8. Install the rear heater core (5) into the side of the rear HVAC housing. Make sure that the insulator is properly installed.
9. Install the rear heater core retaining bracket (4).
10. Install the screw (3) that secures the rear heater core retaining bracket to the rear HVAC housing. Tighten the screw to 2 N.m (17 in. lbs.).
11. Connect the condensate drain tube (1) to the rear HVAC housing.
12. Install the outer halve of the rear heater core and evaporator extension line flange (3).
13. Install the screws (2) that secure the two halves of the rear heater core and evaporator extension line flange together. Tighten the screws to 2 N.m (17 in. lbs.).
14. Install the foam seal (1) to the rear heater core and evaporator extension line flange.
15. Install the blend door actuator (2) and the mode door actuator (3) to the rear HVAC housing (4).
16. Connect the rear HVAC wire harness (1) to the rear blend door actuator and mode door actuator.
17. Install the rear air inlet housing (6) onto the rear HVAC housing (1).
18. Install the screws (5) that secure the rear air inlet housing to the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
19. If removed, install the rear blower motor resistor (4).
20. If removed, install the rear blower motor (3).
21. Connect the rear HVAC wire harness (2) to the rear blower motor and the rear blower motor resistor.
22. Install the rear HVAC housing.