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Rear HVAC Housing







ASSEMBLY

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Capacity .

NOTE: If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.






NOTE: Blend door actuator coupler shown. Mode door coupler similar.

1. Install the two actuator couplers (1) into the rear heater-A/C housing. Be sure to install the couplers with the coupler arm (3) located between the two stop tabs (4) on the rear heater-A/C housing.






NOTE: If a foam seal on an air door is deformed or damaged, the air door must be replaced.

2. Install the blend-air door (1) and the mode-air door (2) the rear heater-A/C housing (3). Align the notch in the air doors with the coupler and fully engage the door to the coupler.






NOTE: If the insulator around the A/C evaporator or evaporator tubes is deformed or damaged, the insulator must be replaced.

3. Carefully install the rear A/C evaporator (1) into the outboard half of the rear heater-A/C housing (3).

NOTE: If the rubber seal is deformed or damaged, the seal must be replaced.

4. Install the rubber seal (2) into the groove on the rear heater-A/C housing.





5. Align the pivot shafts of the air doors located in the inboard half on the rear heater-A/C housing (1) to the openings located in outboard half of the rear heater-A/C housing (2) and install the two halves of the rear housing together.
6. Install the twenty screws (3) that secure the two halves of the rear heater-A/C housing together. Tighten the screws to 2 Nm (17 in. lbs.).





7. Remove the tape or plugs from the rear evaporator tube and extension line fittings and all rear expansion valve ports.
8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto rear evaporator tube and 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.
9. Install the rear A/C expansion valve (2) onto the rear A/C evaporator tube tapping block (4).
10. Connect the rear evaporator extension lines (3) to the rear A/C expansion valve and install the two retaining bolts (1). Tighten the bolts to 11 Nm (97 in. lbs.).






NOTE: If a foam seal on the rear heater core is deformed or damaged, the seal must be replaced.

11. Install the rear heater core (2) into the inboard side of the rear heater-A/C housing (1). Make sure that the foam seals around the heater core are properly installed.
12. Install the rear heater core retaining bracket (4).
13. Install the screw (3) that secures the rear heater core retaining bracket to the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.).





14. Position the rear heater core tube and evaporator line flange (2) to the outboard side of the rear heater-A/C housing (5) and engage the retaining tab (1). Make sure the tab is fully engaged to the housing.
15. Install the screw (4) that secures the rear heater core tube and evaporator line flange to the inboard side of the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.).

NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced.

16. Carefully install the foam seal (3) onto the rear heater core tube and evaporator line flange.





17. Install the blend door actuator (5) and the mode door actuator (1) onto the rear heater-A/C housing (6) Blend Door Actuator - Installation and Mode Door Actuator - Installation.
18. Position the rear heater-A/C wire harness (3) to the top of the rear heater-A/C housing and engage the wiring harness to the two retaining tabs (2 and 4). Make sure the harness is fully engaged to the housing.
19. Disconnect the rear heater-A/C wire harness to rear blend door actuator and mode door actuator.





20. Install the rear blower motor resistor (4) .
21. Install the rear blower motor (2) .
22. Connect the rear heater-A/C wire harness (3) to the rear blower motor and the rear blower motor resistor.
23. Install the rear heater-A/C housing (1) Front HVAC Housing Installation.
24. If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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