Motojunky

Just did my 99 XJ heater core in my spare time over the last couple of days. Thanks to the many tips from this forum, it was a breeze. I picked at it between other things, so I'm not exactly sure how long it took. I'd guess around 6 hours. I realize that I got lucky in that I didn't run into any notable snags, but this is a job that anyone who's reasonably competent can do. As long as you are patient and organized, you can do it.

Thought I'd do a quick brain dump for the next person while it's fresh in my mind. Hopefully this helps someone.

In no particular order:

I removed the passenger seat but not the driver seat. It could be done with the passenger seat in place, but the four bolts to remove the seat were well worth the extra room that it provided.

I just dropped the steering column. There really is no need to remove it. I slid the dash back on the driver side and hung it from the passenger grab handle with a bungie cord.

I did listen to the advice to remove the turn signal and wiper stalks. After I had the dash set back, it shifted and it sure looks like one or both of them wouldn't have survived. Well worth the couple of minutes there.

The HVAC box had been out previously (evap core), and whoever did the job had already dealt with the extra fastener on the one firewall bolt hidden behind the head. There was zero drama with that bolt.

One of the AC fittings put up a fight. I had to remove the accumulator bracket so I could rotate it back and forth to break it free.

Open the windows before you disconnect the battery and yank the dash. It was a little warm in my garage and that extra airflow would have been nice.

Watch the ratchet handle when removing the top dash bolts. Even being very careful I tapped the windshield pretty good one time. Fortunately, no cracks.

The HVAC box came out and went in pretty easily working by myself. To put it back in, I held my right hand underneath where I could reach the AC drain. I used that as a guide for placement. I was expecting a fight, but it popped right in.

I removed the dash alone, but had my wife help me line up the studs to put it back in place. That made it super easy. Alone would have been more difficult.

I did not unplug the two large electrical plugs by the driver side kick panel. I did unplug the large gray one by the gas pedal, but nothing else on that side under the dash.

If I had to do it again, I might not remove the console. I'm on the fence there - I think reinstall of the HVAC box would be challenging with the console in place.

I had to loosen the e-brake cable (under the driver side) so that I could pull it up far enough to remove the console.

Don't forget new heater hose. I had to run out this evening because I thought I had some in the garage. I did, but it was a foot short.

I used a notebook and took notes as I disassembled. That gave me a checklist for reassembly. I put everything in zip lock bags and labelled them with sharpie. No confusion on reassembly.

I used the sharpie to code all of the electrical plugs that I removed. I just marked each end with a letter. I also labelled the colors for the vacuum lines on the HVAC box.

It took a couple of tries to get the two halves of the box lined up. I was just about to bend a piece of wire to reach in and guide the blend door into the hole in the top half of the box when it dropped into place. When you get it right, there's no need to force it at all.

That's about all I can think of. Again, it's really not difficult at all - just time consuming. Taking notes and bagging parts slowed me down, but I think it paid off during reassembly.