Front seat, glove compartment and an air duct removed, foam to lay on, it was not bad at all removing the screws to the lower cover. Thanks for the warning on that passenger side corner screw and the tip on taping the extensions and sockets on. Loosening the evaporator and filter-drier was not bad. I have a bunch of large wrenches but the best tool was a neighbor's Am Pro brand crescent wrench which was very tight, no slop. I'm still not sure if the nuts are metric or SAE. I used what I had and what a neighbor had and what ever fit I used. I remember using a 19mm on the evaporator pipe which fit almost too tight. The coil was in the way but loosening the coil clamp and pushing the coil forward allowed enough room for the typically longer 19mm combination wrench to slip behind it and under a wire bundle.

All the above was step by step, almost easy. Now I am stuck as with the lower cower:

There was no other way but destroy the gasket at the drain pipe, inside and out and there seems to be a large enough hole in the firewall to allow the pipe to come out. That is some good glue and will be there forever. It looks like the evaporator has to come out as the lower cover is removed. The lower cover will even rotate slightly around the drain pipe area. I refused to believe the upper half of the box, the plenum, has to be loosened, but maybe not now. How much movement down will I need? I'm still not sure what that buys me. Logic says if it could be lifted up, I'd get more room. Two easy access screws above the blower motor holes and one more on the firewall? There is a 10 or 12mm nut on a overly long threaded bolt with a gasketed 2" dia washer a few inches directly above the A/C drain pipe.

I think I still have to cut out a little more foam and check for glued stuff around the tube area on the inside of the car.

Any fine tuned advice would help.

Tom