318SixPack

Of all the heater core threads I've read here, I haven't seen the relevant instructions from the manual posted. Maybe I missed that one.

I am tackling this job in a few days. Ordered UAC EV4178PFXC evaporator core from Rock Auto
https://www.rockauto.com/en/moreinfo.php?pk=9797456

Heater core from RadiatorExpress.Com part #229873 And that was quite the annoyance.

Below are the pages from the 1996 Jeep Cherokee Field Service Manual that is available on Archive.Org
https://archive.org/details/96-jeep-...ith-supplement

Important note: When they say "remove the center console" they mean remove the floor console, since I didn't find "center console" used anywhere in that section.

I am wondering how much of this stuff does not really need to be disconnected. Like if the Center Cluster Assembly of gauges can be left in there, but disconnect all the HVAC related stuff, and the items attached to the firewall, of course, and then remove the dash mounting bolts and hold it all up with ratchet straps.








Going to shop for the foam this week/weekend.

Will come back here with update.

318SixPack

This looks like it might work to replace the foam on the face of the evaporator core that seems to be gone whenever anybody cracks one of these air boxes open.
https://www.lowes.com/pd/Frost-King-...Filter/1196229

318SixPack

Evaporator mentioned above is in. A couple of mangled fins.

kmessinger

Probably don't need to drain the coolant, that seems like more work than necessary. I just unplugged the hoses 1 at a time and caught the coolant that dripped in a container, and then plugged the hoses. Didn't lose that much honestly, a couple fluid oz maybe.

On my '01 I also got away with unbolting the dash and swinging it out rather than completely disassembling and removing it. You have to take the kick plates off underneath the steering wheel, unbolt the column, and unplug a few harnesses but it's doable.


The HVAC box is a PITA to get out but if you rotate it a bit you can get an angle. Just use caution swinging the dash out that you don't stress anything too much, it'll be tight but it shouldn't feel like you're going to break something.

Hope this helps, best of luck!

318SixPack

Foam supplies from Lowe's, just over $20.

From these threads https://www.cherokeeforum.com/f2/tip...r-core-264319/
https://www.cherokeeforum.com/f2/hea...cement-151110/
https://www.cherokeeforum.com/f2/stuff-vents-230151/
Plus the one I can't find that suggested rubber kneeling pads to make the big gaskets for the firewall. Not sure why they said the got 2, it looks like one is enough material for that.

318SixPack

Yes, I have had the bypass on the heater hoses since early in the year so no need to fuss with coolant.
I was planning on nylon ratchet straps rather than bungees, unless there is a specific reason for bungees.

318SixPack

Was it necessary to remove the center console?

awg

Hi Mate, good thread

Are you please imagine you are doing this job on a RHD drive vehicle, and imagine if there would be a significant differences ?

The reason I say that is I have heard the job can be done on a RHD (mine) using a LHD core from Rock Auto

(RH new cores are hard to obtain and expensive )

I cant remember what they said they did about the pipes, and it would imply the holes un the firewall are centrally located ?

Thank you in anticipation for your indulgence

Its hot for 6mths of the year here, very humid in summer, working A/C is a neccesity

I have already swapped the compressor, condensor and other parts from a previous XJ to keep this one cold, eventually I will need to fit a new evaporator, and probably heater matrix, so I need to work out in advance

318SixPack

I have no idea. The manual on Archive.Org is linked above, but I didn't notice if RHD was addressed in that manual. The pipes are definitely not centrally located on my LHD Jeep, they are on the passenger side and the blower motor is behind the washer fluid bottle.

awg

thankyou,

I will observe your pics if you post

Perhaps the unit may be mounted "upside down" so to speak to use a LHD part in a RHD.

I will try to dig up the original info source

The piping is somehow modified to suit

In summer here, you would do most anything to have A/C

318SixPack

Looks like this project is delayed a week or so. Weather too hot for this stuff this week.

kmessinger

In my case it was, I couldn't get the trim panel that goes around the radio and HVAC controls off without removing the center console first due to clearance. It's pretty simple and just held on by a few screws.

Another note when removing the console, make sure you're in the right gear to get the gearshifter in a place where you can get the console off. I believe (double check this) that I had to be in 1-2 on the gearshifter and at least 4H or N on the t case shifter so that when you get the center console loose you can lift it up over these handles. In their P and 2H state, they are both angled too far forward to allow you to maneuver the console up and over them.

awg

one trick I learned is to have my digicam handy and take sequential pics of each fastener as it is about to come out, even one when it is out, interspersed with video clips for wiring harness etc etc

This has saved my backside so many times, even on simple jobs

For this job, its a 100% needed imo, (I did find it disturbing how much I sound like a moron on my videos)

kmessinger

Yeah definitely second this, I ziploc bagged up each set of fasteners, labeled, and taped them to whatever they came off of. Organization can kill you on this one.

hcole

Did you ever get the evaporator core in?

I used the same one and it the lines are different lengths so it won’t thread into the expansion valve