I replaced evaporator in my 99 and I cannot for the life of me get the damn seal in place. I'm tempted to just get some expansion insulation and call it done...

This is the plastic and foam seal which is supposed to snap on the evap lines to separate the engine compartment from the cooled air.

Anyone have suggestions on how they've taken care of this?

 

That seal is a nightmare. The trick is to lube it up. Use a little silicone spray on the foam and the edges of the case. Don't use anything petroleum-based. Then, work it on from one corner and use a flathead screwdriver to gently pry and push the lip over the edge of the case. It takes patience and a lot of swearing, but it will eventually pop on.

 

My plastic piece broke in half to help add to the issue, heh
I thought I had cussed enough, that damn part is easily taking as long as the whole rest of the job.

. I have decided to fabricate an aluminum "E" shaped plate with some pipe insulation I can slide in.