Rear HVAC Housing Removal and Installation
HOUSING-HVACREMOVAL
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 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.
- Illustration shown with rear body cradle removed for clarity.
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.
5. Remove the nut (1) that secures the underbody refrigerant lines (2) to the rear A/C expansion valve (3) which extends through the rear floor panel (4) behind the right rear wheel housing.
6. Disconnect the rear underbody refrigerant lines from the rear A/C expansion valve and remove and discard the O-ring seals.
7. Install plugs in, or tape over the opened underbody refrigerant line fittings and rear expansion valve ports.
8. Disconnect the rear heater hoses (6) from the rear heater core tubes (5) which extends through the rear floor panel.
9. Lower the vehicle.
10. Remove right rear quarter panel trim.
11. Disengage the retainer that secures the distribution duct (1) to the rear of the HVAC housing (2) and remove the duct
12. Disconnect the rear HVAC wire harness connector (3) from the body wire harness connector (4).
13. Remove the one nut and one bolt (2) that secure the rear HVAC housing (3) to the rear interior quarter panel (1).
14. Remove the rear HVAC housing from the vehicle and if required, remove the distribution duct (4) from the front of the HVAC housing.
INSTALLATION
1. If removed, install the distribution duct (4) onto the front of the rear HVAC housing (3).
2. Position the rear HVAC housing into the vehicle.
3. Install the one nut and one bolt (2) that secure the rear HVAC housing to the rear interior quarter panel (1). Tighten the fasteners to 3 N.m (27 in. lbs.).
4. Connect the rear HVAC wire harness connector (3) to the body wire harness connector (4).
5. Install the distribution duct (1) onto the rear of the HVAC housing (2) and engage the retainer to the housing.
6. Install the right rear quarter panel trim.
NOTE: Illustration shown with rear body cradle removed for clarity.
7. Raise and support the vehicle.
8. Connect the rear heater hoses (6) to the rear heater core tubes (5) which extend through the rear floor panel (4) behind the right rear wheel housing and install the heater hose clamps securely.
9. Remove the tape or plugs from rear underbody refrigerant line fittings and rear expansion valve ports.
10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear underbody refrigerant 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.
11. Connect the underbody refrigerant lines to the rear A/C expansion valve (3).
12. Install the nut (1) that secures the underbody refrigerant lines to the to the rear A/C expansion valve. Tighten the nut to 23 N.m (17 ft. lbs.).
13. Lower the vehicle.
14. Reconnect the negative battery cable.
15. If the heater core is being replaced, flush the cooling system.
16. Fill the engine cooling system.
17. Evacuate the refrigerant system.
18. Charge the refrigerant system.
19. Initiate the Actuator Calibration function using a scan tool. Refer to HVAC System Test.