Rear HVAC Housing Removal and Installation

REMOVAL
1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the battery negative cable.

Rear Roof Duct Panel:

3. Remove the rear dome light from the rear roof duct panel.
4. Disconnect the dome light wire harness connector and remove the dome light from vehicle.
5. Remove the six push-pin roof duct panel fasteners and remove the duct panel from the vehicle.
6. Remove the five evaporator panel screws at the front of the panel.

Rear Evaporator Panel:

7. If equipped, remove the interior motion sensor from the evaporator panel, disconnect the wire harness connector and remove the motion sensor from the vehicle.
8. Remove the three push-pin evaporator panel fasteners at the rear of the panel.
9. Remove the rear evaporator panel from the vehicle.

Rear Refrigerant Line Connections:

10. Remove the refrigerant line from the solenoid valve inlet port.
11. Remove the refrigerant line from the expansion valve outlet port.
12. Install plug in, or tape over the refrigerant line fittings and the solenoid and expansion valve ports.

Rear Evaporator Housing:

13. Disconnect and plug the two evaporator drain hoses.
14. Disconnect the wire harness connectors as required and position the wire harness out of the way.
15. Support the rear evaporator housing and remove the one screw and four retaining bolts and washers.
16. Remove the rear evaporator housing from the vehicle.

INSTALLATION
1. Install the rear evaporator housing into the vehicle and support the rear evaporator housing.
2. Install the one screw and four retaining bolts and washers. Tighten the screw to 5 N.m (45 in. lbs.) and the bolts to 20 N.m (15 ft. lbs.).
3. Connect the wire harness connectors as required.
4. Unplug and connect the two evaporator drain hoses.
5. Remove the tape or plugs from the refrigerant line fittings and the solenoid and expansion valve ports.
6. Install the suction line to the expansion valve outlet port. Tighten the retainer to 10 N.m (89 in. lbs.).
7. Install the refrigerant line to the solenoid valve inlet port. Tighten the retainer to 16 N.m (142 in. lbs.).
8. Install the rear evaporator panel and the three push-pin fasteners.
9. If equipped, connect the interior motion sensor wire harness connector and install the interior motion sensor into the evaporator panel.
10. Install the five evaporator panel screws at the front of the panel. Tighten the screws to 2 N.m (17 in. lbs.).
11. Install the roof duct panel and six push-pin fasteners.
12. Connect the dome light wire harness connector and install the dome light into the rear roof duct panel.
13. Reconnect the battery negative cable.
14. Evacuate the refrigerant system.
15. Charge the refrigerant system.