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I have a '95 850 Turbo. My evaporator went about a year ago. I bought the kit and replaced myself over the past weekend. The kit consists of; a new evaporator, receiver dryer can, and pollen filter and filter holder. The 'upgrade' to the blower motor is a cover (1 inch piece of plastic) to lower the air that is re-circulated to the blower motor, some upgrade! Once the system was apart, I ended up getting a new blower motor. The old one was squeaking, but the real issue was the brushes on the motor were worn. And when you spend 8 hours getting the dash and heater core out, you better take the opportunity to change it while it is easy. It was a lot of work, but turned out great. The advantage of doing it yourself is you tend to fix everything you find along the way. After 114k miles, there’s a lot of broken mounting connections under the dash. The dash squeaks less now than it did before thanks to lots of Teflon tape. The disadvantage is it takes a really long time to do and is a very hard job. The entire job took me 20 hours. I am sure the dealer will do it quicker, but they won't take the time to fix all the broken stuff and tighten all the loose screws.
There is no kit/fix I know of to fix it without replacing the evaporator. The seal kits don't work; I tried the cryo-chem one. And once you see what a leaking evaporator looks like, you understand why it can't be sealed from the outside, very ugly!
I am just praying that the new evaporator does not leak EVER!!!
-Joe Gerber
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