Are you sure about the labor time? To me it doesnt sound like the dash has to come apart. I just read another posting that claims that it can be done in under an hour to 1.5 hours. The other post on this board seems to think that the dash does not need to come apart. Below is a post from Nov 2002 that talks about replacing the Heater Core in a 1998 model. I do believe that to replace the evaporator you do have to take the dash apart. Any other feedback on this would be greatly appreciated. I also have found the heater core for $120.00 online at FCPG.
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ORIGINAL POST
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Smell of antifreeze in cabin, fog in windshield.
New Behr heater core from AutohausAZ.com cost $77
The only tool required is a Torx screwdriver with assorted sized bits.
You also need some old towels to catch the coolant that will spill out when you pull the heater core free.
It is NOT necessary to remove the dash or console.
Takes only an hour to R&R the heater core. May take the rest of the day to get the coolant out of your carpet. We were lucky and caught it early.
1) Squeeze the plastic latches where the heater hoses plug in to the fire wall and pull them out, noting which hose went in which hole. Secure them up high enough so no coolant spills out.
2) Loosen or remove the two screws in the galvanized plate where you just removed the heater hoses. Those screws hold the water tubes to the cabin side of the firewall.
3) Remove the screw below the steering colum that holds the lower shroud under the dash. Drop it down, unplug the courtesy light, and pull it free.
4) Pull the carpet away from the side of the console up next to the gas pedal. Pull it back as far as you can. Check for coolant under carpet.
5) Snap the black plastic panel off its snap under the console 'skin', then slide it toward the rear of the car to disengage it from the heater core housing. You should now clearly see the white plastic heater core housing, and the two water tubes coming down from the firewall.
6) On the passenger side, loosen the glove box and then remove the lower shroud and the black plastic panel, just as you did on the driver side.
7) Remove two Torx screws from each side of the heater core housing that hold the bottom half to the top half. (one horizonal and one vertical). Remove the Torx screw between the water pipes that hold them to the bottom of the heater core.
8) Get your towels ready. Now pull the bottom of the heater core housing down and rearward so that it disingages from the water tubes. Unplug the A/C drain hose from the floor and pull it aside so that the heater core will slide out easily toward the passenger side.
9) Unscrew the heater core from the bottom half of the heater core housing and, like the books say, assembly is the opposite of disassembly.
10) To remove the coolant from your carpet, a carpet shampoo machine with an upholstery attachment is useful. You may need to remove your front seats if it is bad.
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