I did this job on my 1987 wagon several years ago. I used the ACM evaporator with pre-installed expansion valve. It fit just fine, no finagling required. I recommend going this route, saves some hassle of installing the TXV.

You must replace the o-rings at the TXV. They are just standard metric o-rings, nothing exotic. Unfortunately I have forgotten the sizing. A good auto parts store or a/c shop will have them in stock.

Replacement of dryer is mandatory. You'll lose the new parts warranty if it's not replaced.

I didn't remove the steering wheel, just extended it all the way out. Several other folks here have done the same.

It's a tedious job, but I wouldn't rate all that high on the difficulty scale. There are not any impossible to reach fasteners, special tools, or huge torque values. Just lots of dissasembly and reassembly. It took me about 20 hours of labor over 3 days.

- JimY