How do i remove evaporator core from a 1999 chrysler 300m. was changing the expansion valve and dryer accumlator, the bolts that connected the valve both broke and need to remove complete thing to be able to heat and release from the core, dash is apart but can't figure out how to get out of the housing that surrounds it.

how did you discount the compressor?
is it turning?
is the fan blowing
is the compressor clutch closed.? and the compressor shaft spinning at full speed.>?

the evap core is covered in all FSM for this car. and and at alldata.com
its not a tube its an expansion VALVe

ill first list the exp, valve steps (then the harder part)

1. Disconnect the negative battery cable.
2. Discharge the air conditioning system.
3. Remove the evaporator assembly from the vehicle.
4. Remove the clamps to separate the upper and lower halves.
5. Using backup wrenches, remove the expansion valve from the evaporator.

now the part about #3 list

1. Disconnect the negative battery cable.
2. Discharge the air conditioning system.
3. Remove the glove compartment, as required.
4. Disconnect all electrical wiring and cables from the blower case.
5. Remove the blower case retaining bolts and case assembly.
6. Disconnect and plug the inlet and outlet lines to the evaporator.
7. Remove the upper and lower housing retaining bolts and remove the evaporator assembly from the vehicle.
8. Separate the case housing and remove the evaporator core.

The expansion valve is bolted directly to the evaporator core. You will need to recover the Freon before attempting to remove this. Once the Freon has been recovered, and the expansion valve removed, be sure to cap off any and all a/c lines to prevent excess air/moisture from entering the system. Once the new valve is installed, you will need to pull a 30 hg vacuum on the system for at least 30 minutes then recharge with the proper amount of Freon.

{: ) You didn't mention your vehicle model. But anyway, the a/c expansion valve can be usually found at the engine compartment firewall, just a division away where it connects with the evaporator inside the dashboard. Just follow the trail of the two a/c pipes from the a/c compressor going towards the engine firewall, and there youl'll find a small rectangular block that serves as the junction point. That is the expansion valve.
The two pipes are mounted to the expansion by one or two bolts, depending on the model. Before you begin removing a/c components, make sure the surfaces especially the area of concern are cleaned, this is to prevent dirt or dust entering the a/c system. If possible, cover the pipes and openings. After removing the bolts, separate by pulling the two pipes aside. The expansion valve is mounted to the evaporator bracket, it's either a torx or an allen type bolts. You need to remove these bolts to separate the expansion valve from the evaporator bracket. Cover all openings of a/c lines to prevent contamination.
With the expansion valve removed, have time also to check the quality and color of the refrigerant oil. Check for possible contamination, flush the system if needed and reevaluate the condition of the compressor and condenser.
If everything seem to be fine, proceed with the new replacement of the expansion valve. It is also advisable not to reuse the old o-rings. Use new o-rings whenever possible.
Installation is just the reverse of the removal, so goodliuck.
I

Heater Core Removal & Installation Front To Remove:

1. Make sure you have the anti-theft codes for the audio and the navigation system, and then write down the audio presets.
2. Disconnect the negative cable from the battery.
3. From under the hood, disconnect the heater valve cable from the heater valve. Turn the heater valve arm to the fully opened position.
4. When the engine is cool, drain the engine coolant from the radiator.
5. Disconnect the inlet heater hose and the outlet heater hose from the heater core.
6. Remove the mounting nut from the heater unit. Take care not to damage or bend the fuel lines, the brake lines, and related parts.
7. Remove the dashboard.
8. Remove the evaporator.
9. Remove the mounting bolts and remove the heater unit. Front heater unit
   
   
10. Remove the self-tapping screws and the clamp.
11. Carefully pull out the heater core so you don't bend the inlet and outlet pipes.

Front heater core

To Install:

1. Using care, install the heater core to the heater unit and secure.
2. Using care, install the heater unit and tighten mounting nuts and bolts to 7 ft-lb (10 Nm).
3. Install the evaporator.
4. Install the dashboard.
5. Connect the inlet heater hose and the outlet heater hose to the heater core.
6. Connect the heater valve cable to the heater valve.
7. Refill the cooling system with engine coolant.
8. Adjust the heater valve cable.
9. Make sure that there is no coolant leakage.
10. Make sure that there is no air leakage.
11. Connect the negative battery cable.
12. Perform the power window control unit resetting procedure.
13. Enter the anti-theft codes for the audio and the navigation system, and then enter the audio presets.

Rear To Remove:
NOTE: The rear blower motor, the rear heater core, the blower screen, the rear blower resistor (heating/air conditioning system) and the rear power transistor (climate control system), the rear air mix control motor (climate control system) , the rear mode control motor and the rear expansion valve can be replaced without removing the rear heater-A/C unit.

1. Remove the self-tapping screws and the clamp, and then remove the bolts and the rear evaporator lines with the rear expansion valve. If necessary, remove the rear expansion valve. Use a second wrench to hold the other fitting on the valve so the rear evaporator lines won't twist. Leave the first fitting loosely connected so you can use it to hold the valve while you loosen the second fitting.
2. Remove the rear heater hoses.
3. If necessary, remove the rear blower motor, the rear heater core, the blower screen, the rear blower resistor (heating/air conditioning system), the rear power transistor (climate control system), the rear air mix control motor and the rear mode control motor.
4. Remove the self-tapping screws and the lower housing.
5. Remove the self-tapping screws, and carefully separate the left upper housing from the right upper housing. Remove the rear heater core.

Rear evaporator assembly

To Install:

1. Replace the rear heater core.
2. Attach the heater hoses.
3. Make sure no air is leaking from the left upper housing and the right upper housing fitting and from the upper housings and the lower housing fitting.
4. Before reassembly, make sure that the rear air mix control linkage and door move smoothly without binding.
5. Before reassembly, make sure that the rear mode control linkage and door move smoothly without binding.
6. Reassemble the housing.
7. After reassembly, make sure the rear air mix control motor runs smoothly.
8. After reassembly, make sure the rear mode control motor runs smoothly.
9. Refill the cooling system and make sure that there is no coolant leakage.

you need to remove upper radiator core support set on engine loosen 15mm bolt on front of alternator tensioner and 13mm bolt behind the tensioner pulley remove this belt then go under passenger front and you will see the tensioner bolt for the ac belt turn until tension is released remove belt replace belt and reverse instructions to put back together

the entire dash, door to door top to bottem has to be removed to be able to take out hvac housing so you can take apart to get at the core [recomend do heater core at same time] the dash comes out as an entire unit guages and all. bolts on ends under plastic covers,on top near winshield under vent trim.,bolts on floor in center below radio and a/c controlls,steering column has to come out. multiple wire connectors etc. its an all day job for a pro so its going to take awhile but its pretty straight forward

Removal & Installation

1. Disconnect the negative battery cable.
   
2. Disconnect the IAC electrical connector.
   
3. Remove the IAC mounting screws.
   
4. Remove the IAC.
   

To install:

1. Install the IAC to the throttle body.
   
2. Tighten mounting screws to 5.1 Nm (45 inch lbs.) torque.
   
3. Attach electrical connector to the IAC.
   
4. Connect the negative battery cable.
   

1. Disconnect electrical connector from IAC motor.
   
2. Disconnect air plenum (where applicable).
   
3. Remove two mounting bolts (screws).
   
4. Remove IAC motor from throttle body.
   

To install:

1. Install IAC motor to throttle body.
   
2. Install and tighten two mounting bolts (screws) to 60 inch lbs. (7 Nm) torque.
   
3. Install electrical connector.
   
4. Connect air plenum (where applicable).
   

check valve at and before fire wall penetration should be in line with heater hose 

YOU HAVE TO HAVE THE AIR CONDITIONER SYSTEM DISCHARGED AT THE DEALERSHIP. OR AIR CONDITIONER REPAIR SHOP.YOU ALSO HAVE TO DISABLE YOUR AIR BAGS.YOU HAVE TO REMOVE THE EVAPORATOR HOUSING TO GET TO THE EXPANSION VALVE.YOU HAVE TO REMOVE THE GLOVE BOX AND GLOVE BOX FRAME.TO GET OUT THE EVAPORATOR HOUSING.REMOVE EVAPORATOR CORE FROM HOUSING TO REMOVE EXPANSION VALVE.THIS JOB IS REALLY A DEALERSHIP JOB.YOUR AC SYSTEM HAS TO BE EVACUATED CHARGED AND LEAK TEST.BEFORE YOUR AC SYSTEM WORK PROPERLY.