Rear
HOUSING-HVACDISASSEMBLY
NOTE: The rear HVAC housing must be removed from the vehicle for service of the mode door actuator, blend door actuator, blower motor and blower motor resistor and, it must be disassembled for service of the A/C evaporator, heater core, mode-air door and blend-air door.
1. Remove the rear HVAC housing and place it on a workbench.
2. Carefully remove the foam seal (1) from the flange (2) located at the bottom of the rear HVAC housing (3). If the seal is deformed or damaged, it must be replaced.
3. Partially bend the inner half of the flange downward and remove the heater core tubes (4) from the flange.
4. Release the two tabs (1) that secure the rear heater core (2) in the rear HVAC housing (3).
5. Carefully pull the rear heater core out of the end of the rear HVAC housing. If the foam seals on the heater core are deformed or damaged, they must be replaced.
6. If required, remove the rear A/C expansion valve (1) from the rear A/C evaporator.
7. Remove the four clips (2) and four screws (4) that secure the flange (5) to the bottom of the rear HVAC housing (3) and remove the flange.
8. Disconnect the rear HVAC wire harness (3) from the rear blower motor resistor (1), rear blower motor (2), rear mode door actuator (4) and the rear blend door actuator (6) and remove the wire harness from the rear HVAC housing (5).
9. Remove the rear blower motor resistor.
10. Remove the rear blower motor.
11. Remove the rear mode door actuator and rear blend door actuator.
12. Remove the 15 screws (2) and three metal clips (4) that secure the two halves of the rear HVAC housing (3) together.
13. Release the three plastic retaining tabs (1) that secure the two halves of the rear HVAC housing together and separate the housing halves.
14. Carefully lift the rear A/C evaporator (2) out of the inboard half of the rear HVAC housing (3).
15. Remove the mode-air door (4) and blend-air door (1) from the inboard half of the rear HVAC housing. If the foam seal on any air-door is deformed or damaged, the air door must be replaced.
ASSEMBLY
1. Install the blend-air door (1) and the mode-air door (4) onto the pivots located in the inboard half of the rear HVAC housing (3).
2. Install the rear A/C evaporator (2) into the inboard half of the rear HVAC housing.
3. Align the pivot shafts of the blend-air door and the mode-air door to the pivot holes located in the outboard half of the rear HVAC housing and install the two halves of the rear housing (3) together. Make sure the three plastic retaining tabs (1) are fully engaged.
4. Install the 15 screws (2) and three metal clips (4) that secure the two halves of the rear HVAC housing together. Tighten the screws to 2 N.m (17 in. lbs.).
5. Install the rear blend door actuator (6) and the rear mode door actuator (4) to the rear HVAC housing (5).
6. Install the rear blower motor (2).
7. Install the rear blower motor resistor (1).
8. Install the rear HVAC wire harness (3) onto the rear HVAC housing and connect it to the rear blower motor resistor, rear blower motor, rear blend door actuator and the rear mode door actuator. Make sure the harness is routed through all wiring retainers
9. Position the flange (5) onto the bottom of the rear HVAC housing (3). Make sure that the evaporator drain is clean and unrestricted.
10. Install the four screws (4) and four clips (2) that secure the flange to the bottom of the rear HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
11. If removed, install the rear A/C expansion valve (1) onto the rear A/C evaporator.
12. Install the rear heater core (2) into the end of the rear HVAC housing (3). Make sure that the foam seals are properly installed and that the two retaining tabs (1) are fully engaged.
13. Partially bend the inner half of the flange (2) located at the bottom of the rear HVAC housing (3) downward and install the heater core tubes (4) into the flange.
14. Install the foam seal (1) onto the flange. If the seal is deformed or damaged, it must be replaced.
15. Install the rear HVAC housing.