Just did mine two weeks ago, yes it all has to come out. The heater core and all comes out as one unit. You'll probably want some "form-a-gasket" to replace the crappy foam seals around the various openings and insulation, or maybe even some "Great Stuff" (if you like that sort of thing). I cleaned the box pretty well with some anti-bacterial orange cleaner, usually some mold build up in here and this may help get rid of/prevent it from coming back so soon.
Also, you might want to put an additional screen (like window screen) in place of the cowling screen (the area below the windshield wipers). You can remove the cowling and place the screen under it so it looks nice). The standard screen in there is not sufficient for blocking debris from entering and collecting on the evaporator, which most likely contributes to the leaking evaporator.
When you're re-installing the dash and all of the connectors, it will be a good idea to leave everything loose while you verify everything functions correctly. Check everything out real good to make sure you didn't leave something disconnected that might be trapped behind a panel or something. Luckily I had nothing left undone, but I'm sure if I did button everything up I would.
Here is the official procedure, don't know if this helps or not:
1. Disconnect battery. This must be done to prevent accidental airbag deployment.
2. Using on A/C recovery unit, remove all R-134a refrigerant from the A/C system. See: Service and Repair
3. Remove the shift knob by pulling sharply upward.
4. Place the transfer case in low range. Pry the shift indicator bezel out of the console using a triin stick.
5. Apply the parking brake and place the transfer case in neutral. Remove the parking brake trim insert. Remove the console attaching screws. Lift the console up and disconnect the 4WD indicator lamp hamess. Remove the console.
6. Remove the passenger side knee blocker. Remove the single end screw. Remove the screws below the glove box. Remove the screw at the courtesy lamp. Remove the ash receiver and the screws behind it. Remove the instrument panel armature screw behind the ash receiver. Open the glove box and remove the screws behind it. Lower the panel and disconnect the lamp harnesses. For additional instrument panel service procedures to complete steps 6 thru 25, see Instrument Panel Service Procedures See: Instrument Panel, Gauges and Warning Indicators\Instrument Panel\Service and Repair
7. Remove the pod switch bezels on both sides of the steering column with a trim stick.
8. Remove the drive side knee blocker. Remove the end screw and screws located at the bottom of the knee blocker.
9. Remove the cowl top trim panel by prying it up with a trim stick. Remove the solar sensor if equipped.
10. Remove the "A" post trim panels.
11. Remove the remove the bolts that attach the lower instrument panel reinforcement to the instrument panel armature and remove the reinforcement.
12. Disconnect the park lamp switch.
13. Pull back the carpet at the transmission tunnel from the base of the instrument panel center bezel. Remove the nuts from the upper studs and bolts through the floor that secure the instrument panel center bracket.
14. Remove the bolts that secure the instrument panel center bracket to the drivers side of the transmission tunnel.
15. Remove the screws securing the Vehicle Information Center and remove it. Remove the screw fastening the mounting bracket.
16. Unplug the vacuum harness connector or vent tube on ATC equipped vehicles and the wire harness located under the passenger side of the instrument panel.
17. Remove the screws holding the passenger side kick panel, along with the screw from the kick panel shroud.
18. Unplug the antenna cable near the right cowl side panel.
19. Unplug the instrument panel wire harness connectors from the junction block at the right cowl side panel.
20. Remove the bolts that secure the instrument panel armature to the windshield fence.
21. Remove the nuts that secure the top if the instrument panel armature to the windshield fence.
22. Remove the bolts that secure the ends of the instrument panel to the cowl side panel.
23. Remove the nuts that secure the steering column to the brake pedal support and lower the steering column.
24. Remove the bolts that secure the instrument panel armature to the brake pedal support.
25. Place a protective cover on the seats. Lift the instrument panel off the windshield fence studs and maneuver the instrument panel out and lower it onto the seats.
26. Disconnect the refrigerant lines from the evaporator tubes. Make sure to install plugs or tape the ends of the lines and fittings to ensure that excessive amounts of moisture do not contaminate the A/C system.
27. Remove the vacuum line at the tee from the main vacuum supply harness. This line runs through the body with the upper refrigerant line. (if you have ATC there is no vacuum line, all doors are controlled by motors)
28. Disconnect the heater hoses from the heater core and clamp the ends closed to prevent coolant loss. See: Heater Core\Service and Repair
29. Remove the coolant overflow bottle.
30. Remove the Powertrain Control Module with connectors intact and set aside.
31. Remove the heater A/C housing mounting nuts from the studs on the engine compartment side of the dash.
32. Remove the heater A/C housing from the vehicle.
33. To Install the components, reverse the procedure stated above. Torque Specifications: Instrument panel center bracket to floor transmission tunnel fastener: 28 Nm (250 in. lbs.) Instrument panel to windshield fence bolts and nuts: 12 Nm (105 in. lbs.) Instrument panel to cowl side inner panel bolts: 12 Nm (105 in. lbs.) Instrument panel to steering column support bolts: 12 Nm (105 in. lbs.)
1994 Jeep Grand Cherokee Limited
5.2L all stock baby...
Last edited by wmchurch; 06-20-2005 at 01:01 PM..