Build Thread Enola- Finishing touches

I was asked to give a detailed explanation of how i went about replacing the heater core and evaporator with the air box still inside the car.
Here goes nothing.

This write-up assumes you did not fully remove the dash. I simply removed the center console, glove box, and the panel below the steering wheel. After pulling the screws that bolt the dash to the firewall and drop the steering column, the dash will pull just far enough back to make this possible. This cuts the time required to do the installation down dramatically.

Once the airbox has been freed from the firewall and placed on the floorboard, you will see 4- screws holding the panel lid on the heater core. They will be 5/16 hex head screws remove them and pull the heater core lid free, the heater core is now easily removed.
The evaporator core is a bit more involved, the photo below was taken right after cutting the flap in the evap case. I used a wood flute bit in a dremel tool and took my time, after about 2 mins i had the flap made and the Evaporator removed.




You can clearly see the outline i followed, when you get to the tabs on the right be sure to cut them directly in half up the middle this is important for the clip used to hold the flap closed. Dont forget to clean the loose plastic off the lid surround and vacuum out the air box.




Another shot of the airbox so you can clearly see the flap, and heater core location.



Most replacement evaporators from the auto parts store wont come with the foam installed, carefully peel it off and install it on the new one. I used a small amount of spray adhesive to ensure it would stay in place during installation.




This step is by far the hardest part, DO NOT FORCE the evaporator core into place. If you can have a helper hold the dash away some from the airbox while you fiddle with the evaporator core do so. I did not have any help so i just took my time, after some finagling it slide right in.