I did not use two wrenches - like an idiot. How screwed am I? Am I "it's going to be hard to get the orifice tube out" screwed, "order a new evaporator" screwed, or is it somewhere in between like "you don't have to replace the evap, but you'll probably have to take it out in an attempt to untwist the port" screwed?

Pic is a view of the damage.

 

I think as long as there isnt any leak, you might be able to get away with leaving it.

but that's just me, maybe wait to see if someone with more experience on those parts to respond...

 

use 2 wrenches and try and pull the orfice tube out..Like DonL said...It may come out and perhaps you can insert in the new tube...tighten everything down and be good to go..Changing the evaporator will be a big job...Do you really need to replace it? (orfice tube)...Jerry

 

The plan is to use 2 wrenches, remove tube, try to twist it back (is this a bad idea?), insert new tube.

I REALLY do not want to swap the evap. I was just going to flush it and the evaporator hose since I am replacing every other component in the AC system.

 

I think I proceed would to try and A) get it apart and B) replace the orfice filter (if you can). I would not attempt to straighten it as this may create an issue. You may already have an issue but until you vacuum it down/recharge it, you don't know...Jerry

 

So I got the evap hose off of both, the condenser and evaporator. I need to pull the filter out since I am flushing the evaporator. I tried to pull it out using a tool and needle nose pliers with no luck. Then I tried to twist the port back to at least straighten it out (maybe the tube was wedged in because of the twists and bends), and the port actually does look better than the pic above, however still no luck pulling the tube out, although pieces did start to chip off, which is just great.

I have been trying to follow the advice of this thread where someone was facing a similar issue. Essentially the advice came down to heating up the evap port while blowing compressed air through the other end. My only issues are: I don't know how hot I am supposed to get it, seeing as I don't want to melt anything; and, I don't want the remaining piece of orifice tube to shoot out and damage anything else around the engine. At one point, I think something shot out, but I couldn't find it, and after trying to get a better view with my camera, it seems that half of it is still in there (Pics below). Or maybe that's what an empty port looks like and I have just been clawing at the inside of it with a pair of needle nose pliers for nothing - which would be ideal.

If I started to flush the evaporator, would the flush pressure be enough to push out the tube/remaining plastic chunks that are lodged in there? I'm sure it'll handle the loose ones fine, just wondering how clear the port needs to be before installing a fresh tube.

 

Thinking back to how deep the pliers were able to get and looking at my new orifice tube, I'm starting to realize that the pliers were not going nearly deep enough for the port to be cleared and, in the pics, that brass circle in the center is almost certainly part of the tube.

Seems like I will try the advice mentioned in video, was also mentioned in the previously linked thread, where you screw into the brass and try to yank it out. Since I am going to flush the evaporator, is spraying PB blaster safe?