BIGSLVRXJ
NAXJA Forum User
- Location
- Des Moines, Iowa
Here is my pictureless write-up on how to change a 1997-2001 XJ’s heater core or evaporator...
1.If it hasn’t all leaked out…have a shop discharge your A/C system.
2.Disconnect negative battery cable as always.
3.Slide seats all the way back.
4.Remove console (Phillips screwdriver).
5.Remove 2 bolts holding dash bracket under where console was (13mm).
6.Remove dash bezel, cluster surround and dash pad (defroster panel) (Phillips).
7.Remove kneeblocker under steering column (Phillips).
8.Lower steering column as far as it will go by removing nuts on each side (Deep 14mm).
9.Remove the kickpanels on each side (Phillips screwdriver and deep 10mm or 11mm).
10.Remove bolts behind kick panels securing dash (15mm on some 13mm on other years).
11.Remove all bolts/nuts along windshield (10mm socket, wobble extensions)
12.At this point the dash should be free to be pulled out enough.
13.In the engine bay remove all 5 nuts securing heater box to the firewall (deep 11mm).
14.Remove hoses from heater core and using disconnect tool remove A/C lines from evaporator tubes. Also unplug vacuum line that’s coming out of the heater box foam block.
15.Back inside, unplug antenna connection and vacuum harness connection that comes from the climate control panel.
16.At this point the dash should be out far enough to jiggle the heater box out of the vehicle. If not, either try removing the steering wheel or whole column, but I’ve been able to do it without that being necessary. It is only the right side that needs to be pulled out, but the column does restrict it to a point.
17.Once the heater box is out set it on a stable surface. Start removing all bolts around the perimeter of it and on the top. Also remove the blower motor (All 8mm screws).
18.Slice the foam gaskets along the seam in the heater box with a razor blade or utility knife.
19.Open the box and replace the evaporator and/or heater core.
20.Installation is reverse of removal. I would be sure to use a little bit of sealant where the foam gaskets had to be sliced.
Disclaimer: This is only intended to be a guide to this project. I obviously may have forgotten a step and a bolt size may vary on your particular vehicle, this was done on a 2001 Cherokee Sport. Length of time to complete may vary from 5 hours if someone competent is doing it to 10 hours if the dealer is doing it…or wait, maybe they just charge you for 10 hours. There will be cussing during this project, unless you are a more patient person than I, and I have been told I am actually very patient. It is always a good idea to do a reality check to make sure the road still exists before you plan a trip on it being there, unless you’re in an XJ; drive on it anyways
. Lastly, I absolutely am not affiliated with Chrysler LLC or whatever they’re going by these days. Good luck with this fun project!
-Collin
1.If it hasn’t all leaked out…have a shop discharge your A/C system.
2.Disconnect negative battery cable as always.
3.Slide seats all the way back.
4.Remove console (Phillips screwdriver).
5.Remove 2 bolts holding dash bracket under where console was (13mm).
6.Remove dash bezel, cluster surround and dash pad (defroster panel) (Phillips).
7.Remove kneeblocker under steering column (Phillips).
8.Lower steering column as far as it will go by removing nuts on each side (Deep 14mm).
9.Remove the kickpanels on each side (Phillips screwdriver and deep 10mm or 11mm).
10.Remove bolts behind kick panels securing dash (15mm on some 13mm on other years).
11.Remove all bolts/nuts along windshield (10mm socket, wobble extensions)
12.At this point the dash should be free to be pulled out enough.
13.In the engine bay remove all 5 nuts securing heater box to the firewall (deep 11mm).
14.Remove hoses from heater core and using disconnect tool remove A/C lines from evaporator tubes. Also unplug vacuum line that’s coming out of the heater box foam block.
15.Back inside, unplug antenna connection and vacuum harness connection that comes from the climate control panel.
16.At this point the dash should be out far enough to jiggle the heater box out of the vehicle. If not, either try removing the steering wheel or whole column, but I’ve been able to do it without that being necessary. It is only the right side that needs to be pulled out, but the column does restrict it to a point.
17.Once the heater box is out set it on a stable surface. Start removing all bolts around the perimeter of it and on the top. Also remove the blower motor (All 8mm screws).
18.Slice the foam gaskets along the seam in the heater box with a razor blade or utility knife.
19.Open the box and replace the evaporator and/or heater core.
20.Installation is reverse of removal. I would be sure to use a little bit of sealant where the foam gaskets had to be sliced.
Disclaimer: This is only intended to be a guide to this project. I obviously may have forgotten a step and a bolt size may vary on your particular vehicle, this was done on a 2001 Cherokee Sport. Length of time to complete may vary from 5 hours if someone competent is doing it to 10 hours if the dealer is doing it…or wait, maybe they just charge you for 10 hours. There will be cussing during this project, unless you are a more patient person than I, and I have been told I am actually very patient. It is always a good idea to do a reality check to make sure the road still exists before you plan a trip on it being there, unless you’re in an XJ; drive on it anyways
. Lastly, I absolutely am not affiliated with Chrysler LLC or whatever they’re going by these days. Good luck with this fun project!-Collin
