HVAC System (Heater, Ventilator And A/C): Evaporator: Removal

Disconnect the ground cable from battery.
Using the refrigerant recovery system, discharge refrigerant. Refer to PROCEDURE .
Drain the coolant from the radiator.
- H4 model: Refer to DRAINING OF ENGINE COOLANT .
- H6 model: Refer to DRAINING OF ENGINE COOLANT .
Remove the connector and bolts, and remove the high-pressure hose and AC pipe from the expansion valve.
Loosen the heater hose clamps and remove the hoses.
NOTE: Put alignment marks to hoses, clamps, etc. and remove them.

Fig 1: Removing Connector
Courtesy of SUBARU OF AMERICA, INC.
Remove the instrument panel assembly. Refer to REMOVAL .
Remove the engine control module (ECM).
1. Release the lock and remove the relay holder.
2. Remove the nuts, and remove the engine control module (ECM).
  
  Fig 2: Locating Engine Control Module Relay And Nuts
  Courtesy of SUBARU OF AMERICA, INC.
Remove the heater and cooling unit.
1. Remove the clip, and remove the rear center duct.
2. Turn over the floor carpet and remove the rear heater duct slide locks on the left and right.
3. Remove the bolt and remove the heater and cooling unit.
  
  Fig 3: Locating Heater And Cooling Unit Bolts
  Courtesy of SUBARU OF AMERICA, INC.
Remove the blower motor unit assembly.
1. Release the claws and remove the bolts.
  
  Fig 4: Locating Blower Motor Unit Assembly Bolts
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the blower motor unit assembly as shown in the figure.
  
  Fig 5: Removing Blower Motor Unit Assembly
  Courtesy of SUBARU OF AMERICA, INC.
Disconnect the claws and then remove the aspirator hose.

Fig 6: Identifying Aspirator Hose Claws
Courtesy of SUBARU OF AMERICA, INC.
Remove the screw, and then remove the foot duct (RH).

Fig 7: Locating Foot Duct Screws (RH)
Courtesy of SUBARU OF AMERICA, INC.
Remove the screws and remove the foot duct (LH).

Fig 8: Locating Foot Duct Screws (LH)
Courtesy of SUBARU OF AMERICA, INC.
Pull out the heater core.
1. Remove the screw and remove the heater pipe clamp.
  
  Fig 9: Locating Heater Core Screw
  Courtesy of SUBARU OF AMERICA, INC.
2. Pull out the heater core from the heater and cooling unit assembly.
  
  Fig 10: Pulling Out Heater Core
  Courtesy of SUBARU OF AMERICA, INC.
Remove the heater case lower.
1. Remove the clip, and remove the evaporator connector.
2. Remove the gasket.
3. Remove the screw and lock, then remove the heater case lower.
  
  Fig 11: Locating Heater Case Lower Clip, Screw And Lock
  Courtesy of SUBARU OF AMERICA, INC.
Remove the evaporator.

Fig 12: Locating Evaporator
Courtesy of SUBARU OF AMERICA, INC.
Remove the bolt and detach the expansion valve from the evaporator. Refer to REMOVAL .
Remove the evaporator sensor from the evaporator.

Fig 13: Removing Evaporator Sensor
Courtesy of SUBARU OF AMERICA, INC.