Rear HVAC Housing

DISASSEMBLY

NOTE: The rear heater-A/C housing must be removed from the vehicle for service of the blower motor and disassembled for service of the A/C evaporator, heater core, mode-air door and blend-air door.





1. Remove the rear heater-A/C housing (1) and place it on a workbench Front HVAC Housing Removal.
2. Disconnect the rear heater-A/C wire harness (3) from the rear blower motor resistor (4) and the rear blower motor (2).
3. Remove the rear blower motor resistor .
4. Remove the rear blower motor .





5. Disconnect the rear heater-A/C wire harness (3) from rear blend door actuator (5) and mode door actuator (1).
6. Disengage the rear heater-A/C wire harness from two retaining tabs (2 and 4) located on the top of the rear heater-A/C housing (6) and remove the wire harness.
7. Remove the rear blend door actuator and mode door actuator Blend Door Actuator - Removal and Mode Door Actuator - Removal.






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

8. Carefully remove the foam seal (3) from the rear heater core tube and evaporator line flange (2).
9. Remove the screw (4) that secures the rear heater core tube and evaporator line flange to the outboard side of the rear heater-A/C housing (5).
10. Disengage the retaining tab (1) that secures the rear heater core tube and evaporator line flange to the rear heater-A/C housing and remove the flange.





11. Remove the screw (3) that secures the rear heater core retaining bracket (4) to the rear heater-A/C housing (1) and remove the bracket.

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

12. Carefully pull the rear heater core (2) out of the inboard side of the rear heater-A/C housing.





13. Remove the two bolts (1) that secure the rear evaporator extension lines (3) and the rear A/C expansion valve (2) to the rear evaporator tapping block (4).
14. Disconnect the rear evaporator extension lines from the rear A/C expansion valve (2) and remove the lines from the rear heater-A/C housing.
15. Disconnect the rear A/C expansion valve from the rear evaporator tapping block.
16. Remove and discard the O-ring seals and install plugs in, or tape over the opened extension line fittings and expansion valve and evaporator ports.





17. Remove the twenty screws (3) that secure the two halves of the rear heater-A/C housing (1 and 2) together.
18. Separate the two halves of the rear heater-A/C housing from each other.






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

19. Carefully remove the rear A/C evaporator (1) out of 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.

20. Remove the rubber seal (2) from 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.

21. Disengage the blend-air door (1) and the mode-air door (2) from the actuator couplers located on the inboard side of the rear heater-A/C housing (3) and remove the air doors.






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

22. Disengage the retaining tabs that secure each actuator coupler (1) to the inside of the rear heater-A/C housing (2) and remove the actuator couplers from the housing.