How to remove evaporator core from under dash

AIR CONDITIONING: AIR CONDITIONING UNIT: REMOVAL

REMOVAL
HINT:

Installation is in the reverse order of removal.
COMPONENTS for instrument panel safety pad sub-assembly:

See: Body and Frame Interior Moulding / Trim Dashboard / Instrument Panel Service and Repair Components.

DISCONNECT BATTERY NEGATIVE TERMINAL

(a) Wait for 90 seconds after disconnecting the cable to prevent the airbag working.

REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH See: Wiper and Washer Systems Wiper Motor Service and Repair Removal
REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH See: Wiper and Washer Systems Wiper Motor Service and Repair Removal
REMOVE COWL TOP VENTILATOR LOUVER RH See: Wiper and Washer Systems Wiper Motor Service and Repair Removal
REMOVE WINDSHIELD WIPER MOTOR AND LINK See: Wiper and Washer Systems Wiper Motor Service and Repair Removal
REMOVE COWL TOP OUTSIDE PANEL FRONT

(a) Remove the 4 bolts, 2 nuts and cowl top outside panel front.

DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM See: Service and Repair
DISCONNECT SUCTION HOSE SUB-ASSEMBLY

(a) Remove the bolt, and slide the hook connector.
(b) Disconnect the suction hose sub-assembly.
(c) Remove the O-ring from the suction hose sub-assembly.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

DISCONNECT AIR CONDITIONER TUBE AND ACCESSORY

(a) Disconnect the air conditioner tube & accessory.
(b) Remove the O-ring from the air conditioner tube & accessory.
NOTICE: Seal the openings of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT)

(a) Slide the clip and disconnect the heater water outlet hose A.
NOTICE:

Do not apply excessive force to the heater water outlet hose A.
Prepare a drain pan or cloth in case the cooling water leaks.

DISCONNECT HEATER WATER INLET HOSE A

(a) Slide the clip and disconnect the heater water inlet hose A.
NOTICE:

Do not apply excessive force to the heater water inlet hose A.
Prepare a drain pan or cloth in case the cooling water leaks.

REMOVE INSTRUMENT PANEL SAFETY PAD SUB-ASSEMBLY

See: Body and Frame Interior Moulding / Trim Dashboard / Instrument Panel Service and Repair Removal
HINT: Refer to the removal procedures for the instrument panel safety pad sub-assembly w/ front passenger airbag assembly.

REMOVE HEATER TO REGISTER DUCT NO.2

(a) Remove the 3 clips and heater to register duct No.2.

REMOVE HEATER TO REGISTER DUCT ASSEMBLY NO.6

(a) Disengage the 4 claws and then remove the heater to register duct No.6.

REMOVE CONSOLE BOX DUCT NO.1

(a) Remove the clip and console box duct No.1.

REMOVE FLOOR CARPET BRACKET LH

(a) Release the 2 clamps.
(b) Turn back the floor carpet.

(c) Remove the 3 clips.
(d) Remove the floor carpet bracket LH.

REMOVE FLOOR CARPET BRACKET RH

(a) Release the 3 clamps.
(b) Turn back the floor carpet.

(c) Remove the 3 clips.
(d) Remove the floor carpet bracket RH.

REMOVE AIR DUCT REAR NO.2

(a) Release the 2 claws and remove the air duct rear No.2.

REMOVE AIR DUCT REAR NO.1

(a) Release the 2 claws and remove the air duct rear No.1.

REMOVE AIR DUCT SUB-ASSEMBLY NO.1 See: Steering and Suspension Steering Steering Column Service and Repair Removal
SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY See: Steering and Suspension Steering Steering Column Service and Repair Removal
REMOVE STEERING COLUMN ASSEMBLY See: Steering and Suspension Steering Steering Column Service and Repair Removal
REMOVE INSTRUMENT PANEL REINFORCEMENT ASSEMBLY

(a) Disconnect each connector and remove each clamp. Disconnect the wire harness.
(b) Remove the 6 nuts and 3 bolts.

(c) Remove the 3 bolts and nut.
(d) Using a "Torx" socket wrench (T40), remove the 5 "Torx" bolts.
HINT: The "Torx" bolts on the passenger side can be removed with the collar or for adjustment.
(e) Using a hexagon wrench 12 mm, remove the 2 collars and instrument panel reinforcement assembly with the air conditioner unit assembly.

(f) Remove the 3 bolts, 2 screws and instrument panel reinforcement assembly.

It pays over 9 hours in a shop, double or triple the time if you are going to try it yourself

Roy