First of all, the info i am providing is from my experience with a 2002 KJ (US model) your results may vary...i split this project up into two parts, the first tearing down the dash and stuff in the way under the hood. the second removing/installing the heater core, and re-assembling. this was accomplished in 3-5 hour work sessions, it is nice to have a helper but i did it all on my own.*WARNING* use caution when working on/around airbags, do so at your own risk, if you are not comfortable around them or are not sure they will be properly disabled, do not attempt.Also if you choose to discharge your air conditioning system for this, do it in the appropriate manner. it is illegal to discharge the Freon into the atmosphere, take it to the proper mechanic for this, or rent the tools to do it.Second, i have to give partial credit to Joejeeper420, he had some info that gave me the confidence to get startedfrom Joejeepers420"s thread on LOST:"I started by disconnecting the battery then removing the center console, then comes the A pillar handles; and everything *******/clipped into the dash... All of the trim around the steering wheel, the column switch, gauge cluster, as well as both kick panels come out... Then the stereo and all HVAC controls. then the passenger side airbag came out. once that is done you can remove the swing bolts that are located behind the kick panels, then i took out the center mounting bolts as well as the plate. I then unscrewed the fuse/junction box at this point, then disconnected the wire harness starting at the brake switch and working my way over I fished most of it through the opening for the steering wheel. Then I disconnected the vacuum line and electrical connectors on the passenger side that go to the blower motor and the resistor, etc and fished them out a bit. After that its the main bolts that go into the firewall... I never dropped the steering column... I only loosened the two 13mm? Bolts that go up and through the bottom of the mid column up, they protrude just enough that you can"t pull the dash towards you without backing them off till the ends are flush. Then there areTwo 10mm washer nuts on the bottom of the heater Box... And that just about finishes off the work in the cabin. Then ON to the engine bay! You have to move the coolant overflow out of the way to get to the one remaining washer bolt on the firewall and the input output hoses On the heater core... Evacuate the AC then disconnect evaporator... Back in the cabin you can pull the dash back enough to wiggle the old heater box out. Twist it back towards you so the heater core openings face up and pull it out. Jump around for joy at this point and look at your car in disbelief but be full of confidence because its not rocket science
When re installing take care to be easy and not Force it in... You can make enough space to get it in without forcing it. Also take care when handling your fuse/junction box... When I buttoned everything back up my gauge cluster was dead... I had to reseat the connectors and reset the battery... After that everything should be gravy. Enjoy the heat!"Third - thanks goes to Diggerfreek on LOST for info on taking out the center console, dash, and passenger side airbag/dash - NOTE those write ups were for a KK but very similar to a KJi will add to this, and pictures i took.reference the following threads/links:1) Link to Joejeeper420"s info: Jeep Liberty Forum - y2kcenter.org Country - View Single Post - Heater Core? What to check / costs?2) Center Console: LOST JEEPS • View topic - HOW TO: CENTER CONSOLE REMOVAL3) Dash: LOST JEEPS • View topic - HOW TO: DASH DISASSEMBLE4) Pass Dash and airbag: LOST JEEPS • View topic - Passenger side dash D&ATools:screwdriver - flat and phillips - electric ***** driver will help...3/8 drive ratchet, extensions, 10mm deep socket, 10mm regular socket, 13mm deep socket, 15mm deep and regular socket, 15mm ratcheting or regular end wrenchpliers for hose clampstrim removal tool or similar prying tool (i like a putty knife) for dash panelsT-20 screwdriver for the steering column clamshellParts: (this was for my 2002 KJ, check to see what YOU need for your jeep by make and model)Murray 93029 or equivalentmy steps (roughly) 1) disconnect the battery2) remove the center console (see above link) if you do this first you do not need the auto shifter in neutral to get the HVAC controls out3) remove the HVAC controls and radio (note there is a kind of hidden ***** that is in the pocket where the ash tray is) pry the surround out with putty knife. radio has 4 screws and 3 connectors on the back.
HVAC panel has multiple connectors on the back, take your time here.5) remove the cover panel up by the windshield, pry up at the edge closest to you as you sit in the seatdrivers side:-remove the knee bolster under the steering column, the trim on each side of the column etc. as well as the plastic cover panel above the pedals-remove the gauge cluster trim and the gauge cluster (phillips screws)-lower the steering column, (2) metric hex head bolts (13mm deep socket on extensions) loosen these bolts until they are not protruding through the aluminum bracket (circled in red below)