To avoid dropping the evaporator housing....
Use a large cardboard box, or two, and some flat cardboard "shims".

1. Measure the distance from the deck lid (or mattress pad if it is a Westy,
as mine was) to the underside of the evaporator housing.

2. Get a box that is as close to that height as possible (or multiple boxes
stacked up, duct taped together).

3. Shim the box up further with more cardboard sheets or similar flat
material (blankets work too) until the box assembly is jammed tight against
the housing.  You should also put a few of these shims on the bottom at
first.

4. Then, remove *all* the housing screws (I did this from above with the
pop-top up, in the Westy.  I'm not sure how it works in non-Westy vans).  If
the box assembly is nicely jammed up in there, the housing won't drop down.

5. Pull out the shims carefully, one at a time.  The housing will lower a
bit with each removal.

6. You can figure out the rest :-)  The reverse process worked well for me
too, when I put a non-AC cabinet up there.

Chris Radcliffe
chris_radcliffe@mindspring.com
'90 Westy Auto "Blue Whale"

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com]On Behalf
Of Kun Chang
Sent: Sunday, May 11, 2003 9:07 AM
To: vanagon@GERRY.VANAGON.COM
Subject: 91 Multivan lowering A/C evaporator housing

My weekend project run into a little problem. I am trying to lower the
evaporator housing before sending the van to the shop Monday morning. I have
successfully removed the front housing, but the back evaporator housing
seems
a little complicated, and found the Bentley not very helpful. Most of all, I
am afraid of dropping the evaporator unit on the floor, if all the screws
are
not removed properly.
Any suggestion will be greatly appreciated.

Albert
91 Multivan, 99,9100mls