I've replaced a few evaporators at work before, and it always ranked as one of my least favorite jobs. On a newer car, you have to remove a lot of crap such as the center console and steering wheel, along with the entire dash assembly, then the HVAC housing itself, which then has to be taken apart as well.

So, what all has to be removed on a third gen to replace the core? How big a pain is this job?

 

It's simple. You can remove the lines from the evap and take off the whole evap housing, which is about 6 or 7 screws & nuts, and work on it on the workbench. To get it out they're all about 10mm screws and about 12mm nuts, you don't have to fool with any of the smaller ones. About 2 or 3 of them are in the interior, just under the very top edge of the carpet. If you just look around the edges of it you'll see how easy it really is.

Use Window-Weld type butyl windshield sealer in about a 1/4" thickness (thin stuff) to seal it back to the firewall when you put it back on.

 

oooh...... I'll need to re-seal mine then. should i seal the front too? and on my 82, there's no fasteners in the interior. just 8-10 on the outside. this may be different on a newer car.... everything else seems to be.

 

Thanks for this post. I recently replaced my Condensor, and my AC was running fine for a couple months, and then stopped. I broke out my UV light and goggles (I had added dye when I charged it) and now my Evaporator is leaking. If I had to pull my dash apart, I seriously doubt I would fix it. And my Haynes manual doesn't even mention the Evaporator !!!!