Overhaul

Rear HVAC Housing

Disassembly

• The rear HVAC housing must be removed from the vehicle for service of the mode door actuator, blend door actuator, blower motor, heater core, blower motor resistor or power module and it must be disassembled for service of the A/C evaporator, mode-air door and the blend-air door.

- Remove the rear HVAC housing and place it on a workbench. Refer to => [ Rear HVAC Housing ] Rear HVAC Housing.






- Carefully remove the foam seal (1) from the flange (5) located at the bottom of the rear HVAC housing (3). If the seal is deformed or damaged, it must be replaced.

- If required, remove the rear A/C expansion valve (6) from the rear A/C evaporator. Refer to => [ Rear A/C Expansion Valve ] Rear A/C Expansion Valve.

- Remove the four retaining clips (2) and four screws (4) that secure the flange to the rear HVAC housing and remove the flange.






- Remove the screw (5) that secures the rear heater core tube bracket (4) to the rear HVAC housing (1).

- Release the two retaining tabs (2) that secure the rear heater core and tubes (3) in the rear HVAC housing.

- 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.






- Disconnect the rear HVAC wire harness (5) from the rear blower motor resistor or power module (1) (depending on application), rear blower motor (2), rear mode door actuator (3) and the rear blend door actuator (4).

- Release the retaining tab that secures the connector of the rear HVAC wire harness to the rear HVAC housing and remove the wire harness from the housing.

- Remove the rear blower motor resistor or power module (depending on application).

- Remove the rear blower motor. Refer to => [ Rear Blower Motor ] Rear Blower Motor.

- Remove the rear mode door actuator. Refer to => [ Rear Mode Door Actuator ] Rear Mode Door Actuator and rear blend door actuator, refer to => [ Rear Blend Door Actuator ] Rear Blend Door Actuator.






- Remove the 15 screws (2) and three metal retaining clips (4) that secure the two halves of the rear HVAC housing (3) together.

- Release the three plastic retaining tabs (1) that secure the two halves of the rear HVAC housing together and separate the housing halves.






- Carefully lift the rear A/C evaporator (2) out of the inboard half of the rear HVAC housing (3).

- Remove the mode-air door (4) and blend-air door (1) from the rear HVAC housing. If the foam seal on any air-door is deformed or damaged, the air door must be replaced.

Assembly






- 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).

- Install the rear A/C evaporator (2) into the rear HVAC housing.






- 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.

- Install the 15 screws (2) and three metal retaining clips (4) that secure the two halves of the rear HVAC housing together. Tighten the screws to 2 Nm (17 in lbs).






- Install the rear blend door actuator (4). Refer to => [ Rear Blend Door Actuator ] Rear Blend Door Actuator and the rear mode door actuator (3), refer to => [ Rear Mode Door Actuator ] Rear Mode Door Actuator to the rear HVAC housing.

- Install the rear blower motor (2). Refer to => [ Rear Blower Motor ] Rear Blower Motor.

- Install the rear blower motor resistor or power module (1) (depending on application).

- Install the rear HVAC wire harness (5) onto the rear HVAC housing and connect it to the rear blower motor resistor or power module (depending on application), rear blower motor, rear blend door actuator and the rear mode door actuator. Make sure the harness connector is properly secured to the side of the rear HVAC housing.






- Install the rear heater core (3) into the end of the rear HVAC housing (1). Make sure that the foam seals are properly installed and that the two retaining tabs (2) are fully engaged.

- Install the screw (5) that secures the heater core tube bracket (4) to the rear HVAC housing. Tighten the screw to 2 Nm (17 in lbs).






- Position the flange (5) onto the bottom of the rear HVAC housing (3). Make sure that the evaporator drain is clean and unrestricted.

- Install the four screws (4) and four retaining clips (2) that secure the flange to the bottom of the rear HVAC housing. Tighten the screws to 2 Nm (17 in lbs).

- If removed, install the rear A/C expansion valve (6) onto the rear A/C evaporator. Refer to => [ Rear A/C Expansion Valve ] Rear A/C Expansion Valve.

- Install the foam seal (1) onto the flange. If the seal is deformed or damaged, it must be replaced.

- Install the rear HVAC housing. Refer to => [ Rear HVAC Housing ] Rear HVAC Housing.