This weekend I got the old compressor out and the new compressor in place. I still need to tension the belt and torque everything. I have been using some old touch-up paint to mark across the threads of each bolt and the nut to indicate that it has been torqued properly and give a visual indication if anything starts to loosen.
Also pulled the dash, this is the second time I've done that, so its down to about a 1.5hr job. Roughly followed dmorrison's excellent guide at
PeachPartsWiki: Replacing the A/C Evaporator.
Pulling the evaporator housing was a bit more of a challenge. Again followed the same guide. The biggest problem I ran into was getting the heater hoses off at the firewall. I am pretty sure they have never been disconnected. I ended up cutting the three hoses so I could work a small screwdriver in to break them loose. Since I am also switching to zerex, now is a great time to replace all the hoses, although I haven't found a source for the hoses to/from the aux water pump. Hopefully that part is available somewhere.
Next up was dismantling the evap housing. My heater core looks brand new. Unfortunately the evaporator is not so lucky. I would guess that it was 40% clogged. Clearly the foaming cleaner I used was nowhere near adequate. I don't see any obvious damage, besides for quite a few bent fins. I have the behr housing, but have not found a part number on the evap itself. I am still waiting on my new evap to make it from Germany, but I think it is for the other housing. I measured the previous new one (which was damaged in shipping) and it's dimensions are within about 1/4" of the original part. I am hoping it will fit without too much modification. If not I will have to source the other brand housing, or worst case clean, flush, and pressure test mine.
Will post some pictures shortly
Edit: pulling and dismantling the evap housing was roughly a four hour job after the dash was out. Probably an hour was spent trying to get the heater hoses disconnected. One tip is to use some compressed air to blow out the heater core so you dont have to worry about it draining on the floor.