A/C Evaporator Core repair
CF Veteran
Joined: Mar 2009
Posts: 28,068
Likes: 6
From: Tenn. and Mich.
Year: 2004
Model: Grand Cherokee
Engine: 4.7L V8
Hi,
I am thinking instead of pulling the dash, why can't I cut the firewall?
The hvac box will be exposed. I then just cut the HVAC box as well to get to the evaporator directly. The replacement will be simply to swap in a new one, insulate it, patch the HVAC box with silicone and the firewall with a little soldering. Can this be done? The jeep isn't worth 1000 anyway Unless there is any screw or bolts fixing the evaporator to the HVAC box that cannot be reached when the box is cut
need inputs
I am thinking instead of pulling the dash, why can't I cut the firewall?
The hvac box will be exposed. I then just cut the HVAC box as well to get to the evaporator directly. The replacement will be simply to swap in a new one, insulate it, patch the HVAC box with silicone and the firewall with a little soldering. Can this be done? The jeep isn't worth 1000 anyway Unless there is any screw or bolts fixing the evaporator to the HVAC box that cannot be reached when the box is cut
need inputs
Hank
Junior Member
Joined: Sep 2009
Posts: 34
Likes: 0
From: Pittsburgh, PA
Year: 2000
Model: Cherokee
Engine: 4.0L
I have a soaked passenger floorboard, missing coolant and lack of heat telling me it's time for a new heater core in my 2000 xj. I plan on doing the evap core while I'm in there, can you help me out with the procedure as well?
I'm ready for the assembly/disassembly part but it's the refrigerant part that scares me. What do I do about evacuating the pressure? Some of the other how-tos mention adding PAG 100 oil, how much do I add and where?
I'm ready for the assembly/disassembly part but it's the refrigerant part that scares me. What do I do about evacuating the pressure? Some of the other how-tos mention adding PAG 100 oil, how much do I add and where?
Newbie
Joined: Oct 2010
Posts: 6
Likes: 0
From: Corrales, NM
Year: 1999
Model: Grand Cherokee
Engine: 4.7L
Gentlemen - I'm on my second go-round fixing my GC heater and a/c. Last year I had no heat, so got a used heater-a/c box from a junkyard and took the blend-doors out (before I found out about heatertreater.net). Took the dash out completely (such fun) and, because I didn't want to remove the box at that point, I ended up cutting into the box to replace the doors, (which I found out now you can do without removing the dash(!)).
Long story short, the junkyard door(s) failed again, so I got the heatertreater fix and replaced them. Unfortunately when making their cut, I nicked the A/C evaporator (clouds of freon - more fun). Now I need to repeat the process and remove the dash and the heater-a/c box to replace the evaporator (which I still have from the junkyard box, fortunately).
I can get the dash out again (I think), but could use some advice on disconnecting the A/C and heater lines so I can remove the box completely. Special tools needed? Best way to get to them? Help?
Long story short, the junkyard door(s) failed again, so I got the heatertreater fix and replaced them. Unfortunately when making their cut, I nicked the A/C evaporator (clouds of freon - more fun). Now I need to repeat the process and remove the dash and the heater-a/c box to replace the evaporator (which I still have from the junkyard box, fortunately).
I can get the dash out again (I think), but could use some advice on disconnecting the A/C and heater lines so I can remove the box completely. Special tools needed? Best way to get to them? Help?
CF Veteran
Joined: Mar 2009
Posts: 28,068
Likes: 6
From: Tenn. and Mich.
Year: 2004
Model: Grand Cherokee
Engine: 4.7L V8
Gentlemen - I'm on my second go-round fixing my GC heater and a/c. Last year I had no heat, so got a used heater-a/c box from a junkyard and took the blend-doors out (before I found out about heatertreater.net). Took the dash out completely (such fun) and, because I didn't want to remove the box at that point, I ended up cutting into the box to replace the doors, (which I found out now you can do without removing the dash(!)).
Long story short, the junkyard door(s) failed again, so I got the heatertreater fix and replaced them. Unfortunately when making their cut, I nicked the A/C evaporator (clouds of freon - more fun). Now I need to repeat the process and remove the dash and the heater-a/c box to replace the evaporator (which I still have from the junkyard box, fortunately).
I can get the dash out again (I think), but could use some advice on disconnecting the A/C and heater lines so I can remove the box completely. Special tools needed? Best way to get to them? Help?
Long story short, the junkyard door(s) failed again, so I got the heatertreater fix and replaced them. Unfortunately when making their cut, I nicked the A/C evaporator (clouds of freon - more fun). Now I need to repeat the process and remove the dash and the heater-a/c box to replace the evaporator (which I still have from the junkyard box, fortunately).
I can get the dash out again (I think), but could use some advice on disconnecting the A/C and heater lines so I can remove the box completely. Special tools needed? Best way to get to them? Help?
And Welcome to CF.
Newbie
Joined: Oct 2010
Posts: 6
Likes: 0
From: Corrales, NM
Year: 1999
Model: Grand Cherokee
Engine: 4.7L
Boy, that's what I call a quick response...! I'll let you know how it goes if you're interested. Wish I'd found out about the heatertreater last year before I got in to all of this - hopefully other members will when their blend doors fail... Thanks a bunch!
CF Veteran
Joined: Mar 2009
Posts: 28,068
Likes: 6
From: Tenn. and Mich.
Year: 2004
Model: Grand Cherokee
Engine: 4.7L V8
I'm glad to be of help when/if I can.
CF Veteran
Joined: Mar 2009
Posts: 28,068
Likes: 6
From: Tenn. and Mich.
Year: 2004
Model: Grand Cherokee
Engine: 4.7L V8
I know this post is kind of old but I came across it when the same happened to me while replacing the evaporator core in my 2000 xj, It took me like 2 hours to figure it out but finally got it so I took some pics to share with the good people at cherokee forum for which by the way is my first post but I have visited many times previously and found the help I needed... So it's time to pay back.
Newbie
Joined: Oct 2010
Posts: 6
Likes: 0
From: Corrales, NM
Year: 1999
Model: Grand Cherokee
Engine: 4.7L
After spending half of Saturday and half of Sunday, mission accomplished. I've done this before, but followed most of the steps on the GC Dash removal video on Youtube (for security!). Found out I didn't need to do quite a few of those steps, such as dropping the steering column or disconnecting wiring harness clips. I removed the outer dashboard cover first, then the dashboard itself. I just raised up out of the way so I could get to the heater box:
(white pole is holding up the dashboard so I can get under it to the heater box)

and

(a little fuzzy - pix are from my cell phone)
Hardest part of the whole job was disconnecting the heater hoses next to the firewall under the hood. Didn't have the special tool for those $@%*! clamps, so bought a needle-nosed Vice-Grip. Found the best way was to loosen the clamps and slide them towards the firewall, off of the hose, rather than trying to get it over the bump. Next hardest part was getting the hoses off of the pipes after they've been cooked on for 10 yrs. After all that, undid the 3 bolts inside the car and One bolt under the hood to the right of the heater hoses, and the heater box came right out (manual says there are 3 bolts going through the firewall behind the computer -at least on a '99 GC, these do not exist)
-just replaced the a/c evaporator and the recirc-door (which had already broken the white tab off the axel hub and starting to crack).

Got it all back together in a few hours with only 1 surplus bolt(!).
One strange thing though, the car started up just fine last night after everything was back together, then just fine this morning for work. It started again at lunch, but now it's sitting at a restaurant parking lot. When I was headed back after lunch, car would not start, even with a jump-start. Turning the ignition just makes one soft "click", then nothing. Voltage indicator on dashboard says right around 12V (if it's accurate). Jumping to another batter brings it up to 14V. Anyone have any thoughts about this? I'm thinking starter solenoid...
(white pole is holding up the dashboard so I can get under it to the heater box)

and

(a little fuzzy - pix are from my cell phone)
Hardest part of the whole job was disconnecting the heater hoses next to the firewall under the hood. Didn't have the special tool for those $@%*! clamps, so bought a needle-nosed Vice-Grip. Found the best way was to loosen the clamps and slide them towards the firewall, off of the hose, rather than trying to get it over the bump. Next hardest part was getting the hoses off of the pipes after they've been cooked on for 10 yrs. After all that, undid the 3 bolts inside the car and One bolt under the hood to the right of the heater hoses, and the heater box came right out (manual says there are 3 bolts going through the firewall behind the computer -at least on a '99 GC, these do not exist)
-just replaced the a/c evaporator and the recirc-door (which had already broken the white tab off the axel hub and starting to crack).

Got it all back together in a few hours with only 1 surplus bolt(!).
One strange thing though, the car started up just fine last night after everything was back together, then just fine this morning for work. It started again at lunch, but now it's sitting at a restaurant parking lot. When I was headed back after lunch, car would not start, even with a jump-start. Turning the ignition just makes one soft "click", then nothing. Voltage indicator on dashboard says right around 12V (if it's accurate). Jumping to another batter brings it up to 14V. Anyone have any thoughts about this? I'm thinking starter solenoid...
Newbie
Joined: Oct 2010
Posts: 6
Likes: 0
From: Corrales, NM
Year: 1999
Model: Grand Cherokee
Engine: 4.7L
By the way, I have some extra parts from the heaterbox I got from the junkyard, if anyone needs them: Blower motor, heater core, various actuator motors for the vent operations.


