G'day all, wow this is a useful site, been reading threads with some interest

I'm in the same boat as most here in this thread that I have a '97 ZJ grand (200,000 miles, owned since new) that needs the evaporator cooler replaced. I was hoping someone here with experience doing this could give me a little advice as the shop has told me it's quite expensive to do due to labor. I'm not very mechanical but my brother-in-law is a retired mechanic and could help me provided I had the right info.

I do have the official factory service manual for the car, and the info in it is fairly detailed on how to pull out the dash (and indeed it sounds like a big job). What I guess I need to know is if, firstly, the details in the manual are accurate and there is no alternative or shortcuts to doing it; secondly, if it's something that I could do if I had the help of someone with some mechanical knowledge (but who has never serviced a jeep or any American car for that matter), and, finally, approximately how long it should take someone not experienced with doing it.

On a related topic, too, the shop (aircon place I normally go to, not the dealer) has said they can't be 100% sure of the exact core needed until they open it up (unless they buy the genuine part, which over here in Australia will cost a fortune - to give you an idea, once when I needed to replace a headlight, Jeep here wanted to charge $900 for it - I found out that can be bought from them in the USA for $130 or so [with generics starting at about $30] at the time. I eventually found a local generic that was "only" $250). I was hoping someone might be able to confirm by a photograph or pointer at a generic supplier part that would have the part that is definitely correct for a right-hand drive '97 grand limited?

TIA! :=)

 

I need instructions for replacing the evaporator core in a 1999 jeep cherokee, 4 cylinder. manual transmission.

 

I've obviously been gone for awhile, and my printer/scanner is down right now. So I until I get it fixed I can't offer help as in the past. Sorry.

 

I have been having the same problem as many here.

2000 Jeep Grand Cherokee LMT v8 Auto

condensation/strange residue on the windshield
not so much with the wetness on the passenger side rug
slight stench coming from the vents

I have this heater core leak sealer stuff I got from Walmart. I haven't put it in the antifreeze yet though.

Thanks in advance!

 

JMO but I wouldn't use sealer, I'd replace the heater core.
And Welcome to CF!
Dan

 

G'day mate, was wondering nevertheless if you know if it is actually possible to replace the core without ripping out the entire dash; I do have the full workshop manuals so don't need scans - can you clarify this point?

TIA:0

 

I think there was a thread on here where the guy lifted the dash up after unhooking the attachments and removed the heater box and r&r'd the core that way. He claimed it was the only way for him to accomplish the task solo. There were pics included. So I guess it's possible, but it seemed like more work to me though. I'll follow the manual myself.
Sorry but I can't find the post or remember the person.
Dan

 

Hi, new to the site. Found it doing research on doing an evap core replacement. wjjeeps.com has a lot of info on this, including a step by step tutorial with pics on removing the dash and removing the ac/heating unit. Obviously I have a WJ, 2000 GC Laredo, so wjjeeps was great for me. If you have a ZJ or an XJ you might have to do a little extra searching but I'm sure you can find a lot of info as well. Having the Haynes manual as a cross reference was also helpful. Thanks to Ol Blue for the hookup I took the whole weekend for this project. I worked about 4.5 hours on the removal the first day and about 3 hours on the install the next day. First things first I would say, TAKE YOUR TIME! This is why the removal took a little longer for me, I didn't want to go in there tearing things apart. Some ziploc bags and a sharpie go a long way. Write down your steps as you go, adding whatever notes you feel will help you in the process and label the hardware for each part in a ziploc bag. Then work your way backwards on the list. It's good to do this with someone, you will at least need an extra hand carrying the dash out of the truck. Just make sure you aren't both taking things apart at the same time, it will only add to the confusion as to how things go back together and in what order. One of you do the wrenching and the other one can do the bagging and tagging. The removal of the steering column is very helpful and easy. It's just one 13mm bolt holding it on and it only goes back in one way. Very dummy proof. Take the extra 5 mins. to take it out and save a couple of headaches. Mine would not lock for some reason so I was very careful not to let it turn when I took it out, hopefully I didn't cause damage to the centerspring in the airbag assy. I'm not sure how I would know if this was damaged or not, I drove the jeep today with no consequences. Moving on, You will need to replace the rubber gasket material around the core. No local parts store had anything close so I bought some foam AC insulating tape from Lowes. 30 foot roll for 7 bucks well worth it. Just peel and wrap like the factory unit. You can even use the excess to snug up any trim pieces as you see fit. Make sure your unit came with new orings/gaskets. I also invested in a new set of hose clamps for the heater core inlet/outlet lines. You do NOT need to pull the radio or AC controls. I think the haynes manual points you in this direction but it's not necessary. I also invested in a set of ac/fuel line disconnect tools that I didn't even need. Check the evap lines at your firewall under the hood and check the style. If they have nuts on them they are the new style and you will not need the special tool. In all I used a rachet, deep well 10mm, 13mm sockets, shallow sockets of the same, Combo wrenches of the same, Screwdrivers, channel locks and a couple of torx bits. My evap lines were mated together by a metal plate with torx head screws holding it in place. Oh and my evap unit did not come with studs installed. I took the ones from the factory unit. Don't panic. I used a 7/32 socket to get em out, I sprayed a little penetrating oil on them to loosen them up just to be safe but they were not on there tight. I read the couple of posts where ppl are saying you don't have to take the dash completely out and I can't even begin to understand how that would be possible. Unless their model jeeps are different somehow, you cannot get to the ac unit without removing the whole dash, and then you will need to split the unit to get to the core. You cannot split the unit without removing it from the vehicle. Good luck, and like I said, TAKE YOUR TIME!!!

 

I'm glad you were able to accomplish the job yourself and save some hard earned dough. Thanks for the tips also.
And Welcome to CF!
Dan

 

I'm preparing to replace the evap core and heater core in my '97 JGC. It has ATC, 5.2 L Auto. Do you have photos you can send of the procedure? I appreciate any help you can provide. Thanks.

 

I'll send you a Private Message.
And Welcome to CF!
Dan

 

Check your Private Messages. Hope it helps.

Dan

 

Got the PM. Thank you very much! Looks like this will keep me busy for awhile.

 

Glad to be of help anytime I can. That's what this site is all about, helping each other. Spread the good will whenever you get a chance.
Dan

 

I was wondering if someone could help with instructions for doing the 99 WJ evaporator core replacement project. My WJ has the ATC. I will be printing the write up from wjjeeps.com but was interested in additional information just in case. Thank you.