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[daggie]

errrm why did you just take one of the hoses of and loop it back 
much easier than all that bollocks 

[Brynjaminjones]

I did think about that, but I was worried they might kink so I just did the same as people in the States had done. Once I had them disconnected I did quickly try, and they didn't seem to like bending that much.

[Brynjaminjones]

I've finally got a new heater core, as my passengers aren't as fine with the cold as I am.
I now need to start getting things ready to replace it - are there any special tools that I need, or places that I might get stuck?


I know that I have to disconnect the AC lines, so do I need anything special for that? I've also heard mention of having to replace the foam around the heater box...

[Dave69]

try and leave the ac connected as its a different matrix to the heater core.

expect some scratched knuckles, but only move what you need to do the job

[bgbazz]

 ....put up with the scatched knuckles and save the cost of the aircon re-gas!

[Brynjaminjones]

Haha, the idea of working air con amuses me! I don't think it's blown cold in the last ten years...

[Dave69]

there will be gas still inside, all that has happened is that gas has escaped to the point where there isn't enough to create a cold condition when evaporating

[Brynjaminjones]

Sorry to keep asking the same stupid questions about this, but I'm looking to get this done this weekend, so I need some definitive advice!

• From everything I've read online, it's impossible to remove the heater core without also removing the evaporator. In this case I will need some disconnect tools for the AC lines - where can I find these?
• Apparently the foam around the heater box should be replaced, so that I don't encounter leaks in the future in the rain. What foam should I replace this with?
• Is there anyone that's actually done this job? I'm a bit nervous about it and all the write-ups I've found are of course for LHD. Are there any tips that would help me?

[Dave69]

there should be a block connector for the air con pipes that goes through the bulkhead, which creates a sandwich style joint. so break it there. looking at the manual it appears that the retaining nut is on the blower side of the block.

8mm multispline ring spanner might be the size but it will be tight on space. The splitter tools will not be of use since these joints are in the engine bay only.

[JamesH]

I haven't done it but have stripped most of the dash out before and would definitely allow loads of time and lots of pots and bags for all the screws and fixings, probably take pics too.

Expanding foam might be ok, I'm ready to be corrected on that though. I'd try and do it without disconnecting a/c because the lime green dye and slime goes everywhere and it is just more stuff to put back together, recharge etc.

Have you got the full workshop manual for the correct year? They usually have stages you can miss and still get the job done (like the a/c) and also list special tools that you don't always need. They are handy to have as a reference though.

[Dave69]

94yr manual implies it's a cartridge heater matrix. looks like you have a harder job now with the face lift cherry

[Jonny Jeep]

If it's like the TJ the whole dash is basically a mirror image of the LHD one. Saving the pics from a LHD write up and flipping them left-right might help as they'd look more like what you'd be looking at.

[Dave69]

if you need the tools to separate the lines i have a set but i doubt you will need them. but shout if you do.

if your braking the air con system do it from the engine bay in top gear style to save the lube going in the car.

But there again you shouldn't release the refrigerant into the air as it contributes to damaging the environment

[Brynjaminjones]

Cool, thanks Dave.


Is there likely to be any refrigerant in there? The AC hasn't blown cold in about 8 years...

[bgbazz]

It will be lurking...waiting for a chance to make a mess.

[Brynjaminjones]

That sounds about right!


As expected, didn't have a chance to get this sorted this weekend. Have done a couple of hundred miles though and the XJ is behaving perfectly (touch wood) 

[bgbazz]

 ....Good....keep a firm grip on that piece of wood!