Rear HVAC Housing

ASSEMBLY

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Level . 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, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level .

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 the A/C expansion valve is removed from the A/C evaporator. Failure to replace the rubber O-ring seals may result in a refrigerant system leak.





1. Install the blend-air door (1) and the mode-air door (2) into the outboard side of the rear heater-A/C housing (3).





2. Position the rear A/C evaporator (1) into the outboard half of the rear heater-A/C housing (2).
3. Lubricate new rubber O-ring seals (3) with clean refrigerant oil and install them onto the evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.





4. Align the pivot shafts of the air doors located in the outboard half on the rear heater-A/C housing (3) to the openings located in inboard half of the rear heater-A/C housing (4) and install the two halves of the rear housing together. Make sure the three plastic retaining tabs (2) are aligned and fully engaged.
5. Install the fifteen screws (1) that secure the two halves of the rear heater-A/C housing together. Tighten the screws to 2.2 Nm (20 in. lbs.).






NOTE: Make sure the evaporator drain tube is clean and free of any debris prior to installing the lower housing.

6. Install the lower heater-A/C housing (4). Make sure the two plastic retaining tabs (1) are aligned and fully engaged.
7. Install the six screws (3). Tighten the screws to 2.2 Nm (20 in. lbs.).





8. Install the rear A/C expansion valve (2) onto the rear evaporator tubes.
9. Install the two retaining bolts (1). Tighten the bolts to 11 Nm (97 in. lbs.).





10. Install the rear heater core (1) into the inboard side of the rear heater-A/C housing (2). Make sure that the foam seals around the heater core are properly installed.





11. Align the retaining tabs and install the flange (1) onto the bottom of the rear heater-A/C housing (3). Make sure the retaining tabs are fully engaged.
12. Install the screw (2) that secures the flange to the rear heater-A/C housing. Tighten the screw to 2.2 Nm (17 in. lbs.).
13. Install the foam seal (4) onto the flange. If the seal is deformed or damaged, it must be replaced.





14. Position the rear heater-A/C wire harness (1) to the rear heater-A/C housing (2) and engage the harness to the retaining tabs (3).
15. Engage the rear heater-A/C wire harness connector (4) to the retaining tab (5).





16. Position the rear mode door actuator (1) onto the rear heater-A/C housing (4). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (2) with those in the mode door coupler (3).





17. Install the three screws (4) that secure the rear mode door actuator (1) to the rear heater-A/C housing (3). Tighten the screws to 2 Nm (17 in. lbs.).
18. Connect the wire harness connector (2) to the rear mode door actuator.





19. Position the rear blend door actuator (1) onto the rear heater-A/C housing (3). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (4) with those on the blend door coupler (2).





20. Install the three screws (1) that secure the rear blend door actuator (4) to the rear heater-A/C housing (2). Tighten the screws to 2 Nm (17 in. lbs.).
21. Connect the wire harness connector (3) to the rear blend door actuator.





22. Position the rear blower motor power module (3) into the rear heater-A/C housing (1). Make sure the module retaining tabs are fully engaged to the housing.
23. Install the screw (2) that secures the rear blower motor power module to the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.).
24. Connect the wire harness connector (4) to the rear blower motor power module.





25. Position the rear blower motor (2) into the rear heater-A/C housing (4).
26. Install the three screws (3) that secure the rear blower motor to the housing. Tighten the screws to 2.2 Nm (20 in. lbs.).
27. Connect the wire harness connector (1) to the blower motor.
28. Install the rear heater-A/C housing HVAC Housing - Installation.
29. 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, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Level. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
30. If the heater core is being replaced, flush the cooling system Service and Repair.