CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. 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, refer to the REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the refrigerant system. NOTE: If only 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 a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.

Fig. 291: Rear Evaporator Install

1. Install the rear A/C evaporator (4) into the rear heater-A/C housing (3). Guide the evaporator tubes (2) past the rear heater core tubes (1). Make sure that the foam seals are properly installed on the evaporator.

Fig. 292: Rear Evaporator Cover Removal/Installation

2. Install the evaporator cover (3) onto the outboard side of the rear heater-A/C housing (2) and install the retaining screw (1). Tighten the screw to 1.2 N.m (10 in. lbs.).

Fig. 293: Lower Rear Housing Removal/Installation

3. Install the lower rear heater-A/C housing (6) onto the rear heater-A/C housing (4). Rotate and tilt the lower housing as necessary for installation.

4. Install the five screws (1 and 5) that secure the lower housing to the rear heater-A/C housing. Tighten the screws to 1.2 N.m (10 in. lbs.).

5. Install the metal retaining clip (2) that secures the lower housing to the rear heater-A/C housing.

6. Close the evaporator tube retaining bracket (3). Make sure the bracket retainers are fully engaged.

7. Install the wire harness connector (7) onto the lower rear heater-A/C housing.

Fig. 294: Rear Expansion Valve Removal/Installation Bench

8. Remove the tape or plugs from the rear evaporator tubes and expansion valve ports.

9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear 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.

10. Install the rear A/C expansion valve (3) onto the tapping plate located on the end of the rear evaporator tubes (2) 11. Install two bolts (1) that secure the rear A/C expansion valve to the taping plate. Tighten the bolts to 11 N.m (97 in. lbs.).

Fig. 295: Rear Housing Flange

12. Position the flange (1) to the bottom of the rear heater-A/C housing (3) and install the three retaining screws (2). Tighten the screws to 1.2 N.m (10 in. lbs.).

Fig. 296: Rear Housing Flange Seal

13. Install the foam seal (2) onto the flange (1) at the bottom of the rear heater-A/C housing (3). Make sure that the foam seal is properly installed.

14. Install the rear heater-A/C housing.

15. Reconnect the negative battery cable.

16. 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, refer to the REFRIGERANT OIL CAPACITIES to determine how much oil should be added to the refrigerant system.Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.