<BLOCKQUOTE class="ip-ubbcode-quote"><font size="-1">quote:</font><HR>Originally posted by V. Threlkeld:
My Bentley seem quite vague when it come to removing the evaporator housing in the Westfalia. Thanks for any suggestions.<HR></BLOCKQUOTE>
This is how I lower the evaporator cover on my 1987 Vanagon Camper.
Remove the duct housing (with the vents) above the rear seat. I use a razor blad and a small screwdriver to pry the covers off of the screws. Remember the four Phillips screws that hold it in from the upper bunk. I ususally do those first so I don't forget them.
Remove the two Phillips head screws on the front of the evaporator cover.
Remove the rearmost bolt holding the evaporator cover to the rear cabinet.
Remove the rear grill cover.
Remove the front bolt holding the evaporator cover to the rear cabinet.
Disconnect the drain hoses from the drip pan and pull them out of the holes in the evaporator cover.
Support the bottom of the evaporator cover. (I use a large hydraulic jack with a laundry basket on top of it.)
Remove the two Phillips screws on the bottom of the evaporator cover.
Lower the cover 4-6".
Disconnect the wiring to the blower motors and the speakers. (remember to fish the speaker wire out of the cover)
Unbolt the blower resistors from the evaporator cover.
Lower the evaporator cover and remove it from the van. (the cover weighs about 20 lbs)
Remove the inner housing and deflector from the front of the evaporator, it should pull straight out from the front.
You should be able to see whats left of the old foam weatherstriping now on the inside of the outer cover.
I used 1-1/2"w x 1/4"d foam weatherstripping used to seal bed toppers to the back of pickup trucks as a replacement for the original foam.
You also need to pay special attention to where the A/C pressure hoses and evaporator drain hoses enter the inner housing. I wrapped layers of the same foam around the hoses in order to build them up enough to seal the gaps.
I took the time to clean and oil the blower fans as well. This is also a great time to upgrade your rear speakers.
Re-installation is, of course, the reverse of removal. I used a stainless duct tape to seal the rear sides of the inner housing to the brackets that the bottom of the outer housing screw into.
Before I re-installed the duct housing, I put in some foam rubber channels inside it to divert all of the air to the front vents. A photo is here:
http://home.earthlink.net/~tjhannink/photos/Additional_Air_Channels2.jpg
The foam came from Walmart and is part of a window A/C insulation kit. I glued it to the cover with 3M spray adhesive.
I also have a post in the "Demystifying Vanagon heater & fresh air controls" which has more info about improving the performance of the Vanagon Camper air conditioning system.
BTW, the best tool to have when doing this is a fully charged cordless screwdriver with a good #2 Phillips bit.
Good luck,
Tim Hannink
Goldibox - 1987 Vanagon Camper, Wolfsburg Edition
Winter Park, Florida
http://home.earthlink.net/~tjhannink/
http://groups.yahoo.com/group/wolfsburg_campers
http://photos.yahoo.com/tjhannink Vanagon Album