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 for service of the mode door actuator, blend door actuator, blower motor, heater core, blower motor resistor or power module and it must be disassembled for service of the A/C evaporator, mode-air door and the blend-air door.
- To prevent any contaminates from entering the rear heating and A/C system, make sure that the area around the underbody line connections is clean of any dirt or foreign residue prior to disconnecting the underbody lines.

1. Recover the refrigerant from the refrigerant system.
2. Drain the engine cooling system.
3. Disconnect and isolate the negative battery cable.
4. Raise and support the vehicle.

Underbody Refrigerant Lines And Sealing Plate:

5. Remove the nut that secures the underbody refrigerant extension lines and sealing plate to the rear A/C expansion valve which extend through the rear floor panel behind the right rear wheel housing.
6. Disengage the metal retaining strap from the sealing plate and disconnect the underbody refrigerant extension lines from the rear A/C expansion valve.
7. Remove and discard the O-ring seals from the underbody refrigerant line fittings.
8. Install plugs in, or tape over the opened underbody refrigerant line fittings and rear expansion valve ports.

Underbody Heater Line Rear Quick Connect Fittings:

9. Disconnect the underbody heater lines from the rear heater core tubes which extend through the rear floor panel in front of the right rear wheel housing by releasing the insert in each rear quick connect fitting and carefully pulling downward on the fittings while using a slight twisting motion.
10. Lower the vehicle.
11. Remove right rear quarter panel and D-pillar trim panels.
12. Remove the metal support strap from the rear quarter panel and floor.
13. Remove the rear floor distribution duct.
14. Remove the rear ceiling distribution ducts.

Rear HVAC Housing:

15. Disconnect the body wire harness from the rear HVAC wire harness connector.
16. Remove the two nuts that secure the rear heater core tubes to the floor panel.
17. Remove the bolt that secures the rear heater core tubes to the right inner quarter panel.
18. Remove the two bolts that secure the rear HVAC housing to the two metal brackets located on the rear inner quarter panel.
19. Remove the rear HVAC housing from the vehicle.

INSTALLATION
1. Position the rear HVAC housing into the vehicle.
2. Install the two bolts that secure the rear HVAC housing to the two brackets located on the rear inner quarter panel. Tighten the bolts to 3 N.m (27 in. lbs.).
3. Install the two nuts that secure the rear heater core tubes to the floor panel. Tighten the nuts to 3 N.m (27 in. lbs.).
4. Install the bolt that secures the rear heater core tubes to the rear inner quarter panel. Tighten the bolt to 3 N.m (27 in. lbs.).
5. Connect the body wire harness to the rear HVAC wire harness connector.
6. Install the rear ceiling distribution ducts.
7. Install the rear floor distribution duct.
8. Install the metal support strap to the rear quarter panel and floor. Tighten the fasteners securely.
9. Install the right D-pillar and rear quarter panel trim.
10. Raise and support the vehicle.
11. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the rear heater core tube fittings which extend through the rear floor panel in front of the right rear wheel housing. Use only the specified O-rings as they are made of a special material designed for use with engine coolant.
12. Connect the underbody heater line quick connect fittings to the rear heater core tubes. Make sure the inserts are fully engaged to the quick connect fittings.
13. Remove the tape or plugs from underbody refrigerant line fittings and rear expansion valve ports.
14. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear underbody extension 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.

CAUTION: The metal retaining strap which engages the sealing plate must be positioned so that the notch in the strap is facing the rear refrigerant liquid extension line. Failure to properly orient the retaining strap prior to extension line installation will cause a refrigerant leak and possible damage to the liquid extension line.

15. Connect the underbody refrigerant extension lines to the rear A/C expansion valve and engage the metal retaining strap to the sealing plate.
16. Install the nut that secures the underbody refrigerant extension lines and sealing plate to the rear A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
17. Lower the vehicle.
18. Reconnect the negative battery cable.
19. If the heater core is being replaced, flush the cooling system.
20. Fill the engine cooling system.
21. Evacuate the refrigerant system.
22. Charge the refrigerant system.
23. Initiate the Actuator Calibration function using a scan tool. Refer to HVAC System Test.