When working on mine a pro mechanic friend pointed out that the evap lines are made of a very hard aluminum which will withstand considerable force. It could help to put some kind of clamp around the lines that remain in the car (to give you a bearing surface for applying force). Just put the clamp at a little distance from the mating parts where the evaporator enters. This worked for the accumulator line which was stuck fast.


He said if you don't distort the lines (making them out-of-round) it is no problem to bend them a bit so they meet up squarely with the lines in the car. I inserted a thin metal dowel covered with electrical tape to aim the new evaporator's lines to the proper angles.

You have already removed your dash but my son and I found it helpful to keep a little notebook with all the steps written down in order. The only issue we had getting everything back together and running was the large red connector under the dasth - at first it did not seat properly and we got all kinds of drivability symptoms and warning lights. We secured it with plastic ties and it has not given further problems.