REMOVAL

WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.

WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal injury or death.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.

1. Remove the HVAC housing assembly and place it on a workbench (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION /HOUSING-HVAC - HOUSING-HVAC ASSEMBLY - REMOVAL).
2. Remove the air distribution housing from the HVAC housing (refer to 24 - HEATING & AIR CONDITIONING/DISTRIBUTION/HOUSING-HVAC - HOUSING-AIR DISTRIBUTION - REMOVAL).
3. Remove the A/C expansion valve from the A/C evaporator (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/VALVE-A/C EXPANSION - REMOVAL).

NOTE: If the foam seal for the flange is deformed or damaged, it must be replaced.

4. Remove the foam seal (2) from the flange (3) located on the top of the HVAC housing (4).
5. Remove the four screws (1) that secure the flange to the HVAC housing and remove the flange.

NOTE: If the foam insulator for the evaporator is deformed or damaged, it must be replaced.

6. Carefully remove the A/C evaporator (1) and its insulator (2) from the HVAC housing (3).