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Jeep Cherokee XJ Heater Core Leaking

Q. Hi, I have a 1992 Jeep Cherokee XJ, 4X4, 4.0 liter engine and standard transmission. I think I have a leak in the heater core. I have air conditioning. I realize I will have to remove the refrigerant from the A/C system first. What I would like is a diagram of the heater core and surrounding area and some directions to remove the heater core.

I appreciate your help...

Jeep Cherokee XJ Heater Core Leaking


Here you go!
Jeep Cherokee XJ Heater Core Leaking
Figure 1
  1. Disconnect battery ground cable, then drain cooling system.
  2. Disconnect hoses from heater core.
  3. If equipped with A/C, remove evaporator/blower housing as follows:

    1. Discharge A/C system, then disconnect hoses from expansion valve.
    2. Disconnect electrical connector and vent tube from blower motor.
    3. Remove console, if equipped.
    4. Remove lower instrument panel attaching screws, then the lower panel.
    5. Disconnect electrical connections from A/C relay, blower motor resistors and A/C thermostat.
    6. Disconnect vacuum hose from vacuum motor.
    7. Cut evaporator/blower housing to heater core housing retaining strap, then disconnect heater control cable.
    8. Pry retaining clip from rear of blower housing flange, then remove the three retaining screws.
    9. Working from engine compartment, remove evaporator/blower housing attaching nuts, then the evaporator drain tube, Figure 1.
    10. Remove right kick panel, then the instrument panel support bolt.
    11. Pull right side of dash outward, then rotate housing downward and towards rear of vehicle until studs clear dash panel. Remove housing from vehicle.
  4. Remove heater core to housing retaining screws, then the heater core, Figure 2.
  5. Reverse procedure to install.
Jeep Cherokee XJ Heater Core Leaking
Figure 2

Personally, I'd pressure test the cooling system then look at the heater core to see if it leaks. It may just be a loose clamp or leaky hose.

Added 6/1/04

Sir, I read your instructions for replacing a heater core in a 1992 Jeep XJ 4.0. "Jeep Cherokee XJ Heater Core Leaking". Will you please advise if these are the same instructions for replacing the heater core in a 1995 XJ 4.0 w/ A/C?

Thank you,

Yes they are, Almost exactly the same.

Additional Information provided courtesy of AllDATA

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