Abatta,

You can not just pull the evaporator out of the heater box, it needs to be completely freed from the firewall and the floor as the pipes from the evaporator pass through into the engine bay.

You need to pull the heater core/box far enough from the firewall to slide the evaporator out, then slide in the new one and then push the whole unit back into position. However, I would take this opportunity to clean all the leaves and debris out of the fresh air vent and heater box.

Just my two cents.

Matt
--
1989 - 245, 1990 - 245, 1991 - 245, and 1993 - 245

Prefacing this with "I haven't done it" I still can assure you the mechanical part of replacing the evaporator is not as involved as replacing a blower motor, or even a heater core done by chopping up the housing. In fact, I think it will be 5x as easy as finding an acceptable set of leather skins on the used market.

The evaporator comes out the side. What I can't tell you about is how much work it is to get the hard line aluminum plumbing out of the way. You can see something of what this looks like if you wanted to get the climate box out of the car without disconnecting the evaporator by scrolling through these pics of a heater core done on a '91.

http://cleanflametrap.com/heater_core/



It just has to be easier.
--
Art Benstein near Baltimore

"It's so much darker when a light goes out than it would have been if it had never shone." John Steinbeck