Evaporator Housing Disassembly and Assembly

Use this procedure if any or all of the following items require service:
- Heater core
- Temperature door
- Mode door
- Heat/Defrost door
- Assembly housing
The unit housing must be removed from the vehicle before beginning with this procedure.

DISASSEMBLE
For Right Hand Drive (RHD) vehicles, the Unit Housing does not separate. It is a one piece unit and must be replaced as a whole.

Air Distribution Module Separation:

1. Remove the clips and screws that hold the Air Distribution Module to the Evaporator/Blower Module. Then separate the two units.
2. Remove the panel opening foam seal, demister opening foam seal, and heater core tube foam seals from unit.

Retaining Clip Removal:

3. Remove the retaining clips and screws that hold the upper and lower housings together.

Case Separation:

4. Place the unit in the upside down position. Then separate the two halves of the module.

Heater Core Removal:

5. Lift the heater core out of the case.

Temperature Door Removal:

6. Press tab in at base of temperature door and release door from lever. Then remove the door.

Mode Door Removal:

7. Press tab in at base of mode door and release door from lever.

Cam Screw Removal:

8. Remove Heat/Defrost door cam screw.

Cam And Lever Removal:

9. Lift the cam and mode door lever off of the housing.

Pivot Screw Removal:

10. Remove the Heat/Defrost link pivot screw.
11. Lift the Heat/Defrost link and the door as an assembly. Then separate the link from the door.

ASSEMBLE
To reassemble, reverse the above procedures.