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Most of the AC components on a 2002 Civic are relatively easy to access - compressor, drier, condensor.

Turns out, gaining access to the evaporator isn't too bad, once you've learned the hundred ways not to do it. It looked it was going to be a pain to replace and I was thinking of skipping it, except that the threads for the line to the evaporator had gotten galled up.



Once I got the hose assembly removed at the firewall, it became obvious where the leak was. Good thing I decided to change the hose and evaporator after all!

• Remove glove box
• Remove bottom plastic kick shield
• Remove the kick shield panel on the passenger side.
• Remove the blower motor.

• Remove the metal bracket that stiffens the dash board at the bottom of the glove box.
• Disconnect all the harness plugs going into the ECM module, and disconnect the large harness connecting the engine harness to the interior harness
• Remove the ECM module. This will take a long set of extensions. You'll also need a 10mm deep well socket.
• Remove the bolts holding the blower module. I think there are 5 of them. One hidden behind the dash at the lower left; one way up top on the right hand side, one at the bottom middle that is actually accessible, one that bridges a bracket to the ECM module and holds the harness and the last one really deep straight in just right of the ECM module.

• Remove the plastic cover for the evaporator core
• Remove the hose assembly at the firewall if you haven't already.
• Slide out the evaporator and the expansion valve assembly

A few notes on reassembly.

• It was really hard to push the hoses in to the expansion valve. To get it started, I first assembled the connection with a M6 x 40mm long bolt, then I took that bolt and used a M6 x 30mm to make the final connection. I didn't trust the limited threads of the stock bolt.
• Make sure to connect the harness to the blower control unit before the ECM module and everything else is installed.

 
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Mini spray dryer machine