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My '00 9-3 needed an evaporator and I was faced with the same dilemna. I didn't want to pony up the $972 for the OEM version, so the aftermarket one was purchased at $169. I called eEuroparts ahead of time and they assured me that they would take the unit back for full refund if it was undamaged.
The install was no problem with the aftermarket evaporator. It fit fine, in fact it was about 1/8 smaller in height and slid right in. I used some memory foam type weatherstripping I had on hand to create a seal at the top, bottom and left side since the aftermarket one does not come with a seal. The tubes were just about in the correct locations, but I did have to bend them maybe 1/4" to fit the cover back on the heater box.
Some thoughts on the install. To get to the box:
Remove glovebox, remove side and floor ducts, remove metal support crossbar, pull the carpet back, unclip the control module from bracket in firewall and let dangle, remove this bracket (it is in the way of the evaporator removal), cut zipties and let cables dangle out of the way. Remove the bracket at the top of the heaterbox cover. The cover for the heater box has four screws, the one at the firewall is a pain to get to, but you can pull out the squishy insulation that is under and behind the heater. This makes it much easier to get the cover on/off. remove the inlet/outlet tube clamp at the expansion valve on the engine side before you cut the evaporator tubes so they don't twist on you. Cut the evap tubes close enough to the firewall so that you can slide the evaporator out. I used a tin snips. Its thin aluminum and cuts easily.
No special tools needed, just T10/15 torx, 10mm socket, 4mm hex wrench, tin snips or shears or hacksay and about 5 hours. I could probably do it in 2.5 hours now that I know what is involved.
So yes, the Aftermarket version for $169 that eEuroparts is selling
(http://www.eeuroparts.com/Main/PartDetail.aspx?id=5047931A)
fits without any problems on a '00 9-3 auto transmission, non ACC.
Good luck its hot out there.
Sandor (who thought that after two years of lurking I should post something usefull!)
posted by 108.16.5...
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