Rear HVAC Housing Removal and Installation

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.

NOTE: 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. Service and Repair




1. Recover the refrigerant from the refrigerant system. Service and Repair
2. Drain the engine cooling system. Service and Repair
3. Disconnect and isolate the negative battery cable. Service and Repair
4. Raise and support the vehicle.
5. Remove the nut (1) that secures the rear suction line (2) and the rear liquid line (3) to the rear evaporator extension line tapping plate that extends through the rear floor panel (4) behind the right rear wheel housing.
6. Disconnect the rear suction line and liquid line from the rear evaporator extension line tapping plate.
7. Remove the O-ring seals from the rear suction line and liquid line fittings and discard.
8. Install plugs in, or tape over the opened refrigerant lines and tapping plate ports.
9. Disconnect the rear heater hoses (5) from the rear heater core tubes that extend through the rear floor panel behind the right rear wheel housing.




10. Lower the vehicle.
11. Remove right rear quarter panel trim. Service and Repair
12. Remove the rear distribution ducts from the rear HVAC housing (1).
13. Disconnect the body wire harness connector (2) from the rear HVAC wire harness connector (3).




14. Remove the three bolts (1) that secure the rear HVAC housing (2) to the rear interior quarter panel (3).
15. Remove the rear HVAC housing from the vehicle.

INSTALLATION




1. Position the rear HVAC housing (2) into the vehicle.
2. Install the three bolts (1) that secure the rear HVAC housing to the rear interior quarter panel (3). Tighten the bolts to 3 N.m (26 in. lbs.).




3. Connect the body wire harness connector (2) to the rear HVAC wire harness connector (3).
4. Install the rear distribution ducts to the rear HVAC housing (1).
5. Install the right rear quarter panel trim.




6. Raise and support the vehicle.
7. Connect the rear heater hoses (5) to the rear heater core tubes that extend through the rear floor panel (4) behind the right rear wheel housing.
8. Remove the tape or plugs from fittings on the rear suction line (2) and the rear liquid line (3) and the rear evaporator extension line tapping plate ports.
9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear suction and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
10. Connect the rear suction and liquid line fittings to the rear evaporator extension line tapping plate.
11. Install the nut (1) that secures the rear suction and liquid lines to the rear evaporator extension line tapping plate. Tighten the nut to 23 N.m (17 ft. lbs.).
12. Lower the vehicle.
13. Reconnect the negative battery cable.
14. If the heater core is being replaced, flush the cooling system. Service and Repair
15. Fill the engine cooling system.
16. Evacuate the refrigerant system. Service and Repair
17. Charge the refrigerant system.