I tried your suggestion and guess what I was looking at wihen I took out the blower motor - the evaporator. Oh well.

Anyway, I had already taken out the dash and console, and was glad I did. It is MUCH easirt to see things and much less contorting to see them. I reworked all the vacuum lines, adjusted all the levers, etc. such that now the climate control system works as it is supposed to work. I also took out the fresh air vent flaps and reworked them so that they shut off the air when they are supposed to. Those tiny little vacuum valves operated by the heat levers are a trip anren't they?

But...I still have the problem with the messed up air deflector, so my next step (today) is to remove (or at least attempt to) the heat box; get it out on the bench and figure out how this monstrosity works (or in my case - doesn't). I took a bunch of pictures that I thought I would post once I'm through with this journey in hopes they will perhaps help someone else.

Regards,

Dave

__________________
92 300E - 116K miles - Sold
77 Euro 350SL - 67k miles
94 Explorer 147k miles
2009 Hyundai Genesis - 65k miles