I have to replace the evaporator and i'm looking for some insite or directions on this AC surgery.

I'm a lil nervous taking out the dash.


Any Advise Would be Great.

Short of somebody writing one up here, I think you may only have a couple of options:

1. If you are going to keep and work on your SSEi for a while, your best bet is to get an OEM Factory Service Manual from http://www.helminc.com. It usually comes in 2 volumes, is just for your year and model and probably has thousands of pages. But it will run you $105. Well worth it though.

2. Another option is a pay site called alldata.com. You do a yearly membership for ONE model and year. Add'l vehicles are discounted. BUT... The info is not as detailed (basic steps sometimes) but it does have drawings. But I think it is $44.95 (price increase).

Having experienced both, I would definitely go with #1 if you can come up with the bucks. You will be amazed if you are not already familiar with these. Most everybody on here will agree and reference them frequently.

_________________

1993 Red SSE - Bone-Stock except for High Perf. (LOL) Power Antenna-Original Owner. Pushing 140K - It's the love of my wife.
'05 Magnum Hemi R/T "Great White" - Classic VW Beetles

Sometimes Helm used factory service manuals are on Ebay. But I only found one and it's being offered separately. It's a two book set.

http://cgi.ebay.com/ebaymotors/_Manuals ... .m20.l1116

http://cgi.ebay.com/ebaymotors/_Manuals ... .m20.l1116

At $35 EACH and $10 shipping for each one (I'd guess 15 for both). that's $85

I'd pick up new ones at Helminc.com. New is $105 which may include the shipping.

I bought both of my 94's FSMs on eBay for ~$70, shipped. If you have a look around on there and be patient, something good will come up. Good luck!

_________________
94 SSEi - Project car
99 SLE - Tuned with different parts and such
85 Porsche 944 - Daily driver
68 Chevy C-10 - Free truck! Needs parts.

This is currently listed on E-bay

http://cgi.ebay.com/94-Pontiac-Bonnevil ... dZViewItem

70.00 + 10.00 shipping

I'm guessing your 94 is the same as 93. A bit of good news is that, according to the procedure, it comes out through the firewall (under hood). It is still not a cake walk, but not as bad as I would assume.Here is a high level step by step:
REMOVE OR DISCONNECT
• Recover refrigerant from A/C system, Refer to Refrigerant Recovery and Recycling.
1. Accumulator.
2. Blower Control Module (on top of blower housing).

It may help get at things if you take the Fuse/Relay Center loose from the top of the firewall.
There is a 10mm nut on each end of it
And also take the battery cable loose at the top of the Fuse center

You will be able to peek through the BCM hole and see the evaporator at this point
3. Vacuum tank which is between the blower housing and master cylinder.
4. High-side (liquid) refrigerant line.
5. Blower motor.
6. Screws and wire harness retaining clips.
7. Screws and accumulator bracket.
8. Bolts, and heater and A/C module assembly heat shield (see diagram below).
9. Bolts attaching heater and A/C module assembly to front of dash (I think this is the same as "firewall").
10. Cut module assembly insulator along cut one, raising vehicle to access underside of insulator (I have no idea what this is)... hopefully yo will know it when you see it.
11. Heater and A/C module assembly insulator.
12. Electronic Brake Control Module (EBCM) and bracket. This is inside, above the "hump." You have to take off the heat diverter to see it. It is mounted in a bracket. Removing this allows you to get at the bolt in the next step, which screws into the blower housing.
13. Bolt attaching heater and A/C module assembly to rear of dash (firewall).
14. Heater and A/C module assembly (blower portion). (through the under hood)
15. Evaporator.
Special Tool required is:
Dual 0-Ring Joint Separator (or equivalent)

_________________

1993 Red SSE - Bone-Stock except for High Perf. (LOL) Power Antenna-Original Owner. Pushing 140K - It's the love of my wife.
'05 Magnum Hemi R/T "Great White" - Classic VW Beetles