Chrysler Caravan/Voyager/Town n Country 1984-1995

Heater Core and Evaporator

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See Figures 1, 2, 3, 4, 5 and 6



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Fig. Fig. 1: Removing and installing the heater core assembly



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Fig. Fig. 2: Heater/evaporator assembly components



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Fig. Fig. 3: Removing or installing the actuator and linkage on the blower housing



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Fig. Fig. 4: Removing or installing the evaporator



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Fig. Fig. 5: Actuator assemblies



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Fig. Fig. 6: Instrument panel ventilation ducts and hoses

REMOVAL & INSTALLATION



1984-90 Models
  1. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable, then drain the cooling system.
  4.  
  5. Remove the lower steering column cover.
  6.  
  7. Remove the lower reinforcement under the steering column, right side cowl and sill trim. Remove the bolt holding the right side instrument panel to the right cowl.
  8.  
  9. Loosen the 2 brackets supporting the lower edge of the heater housing. Remove the instrument panel trim covering and reinforcement. Remove the retaining screws from the right side of the steering column.
  10.  
  11. Disconnect the vacuum lines at the brake booster and water valve.
  12.  
  13. Clamp off the heater hoses at the heater core and remove them from the heater core tubes. Plug the ends to prevent leakage.
  14.  
  15. Disconnect the H-valve at the water valve and remove it. Remove the retaining nuts at the package tray mounting studs. Remove the drain tube.
  16.  
  17. Disconnect the blower motor wiring and temperature control cable. Disconnect the vacuum harness at the top of the heater unit.
  18.  
  19. Remove the retaining nuts from the package mounting studs at the firewall. Disconnect the hanger strap from the package and rotate it aside.
  20.  
  21. Pull the right side of the instrument panel out as far as possible. Fold the carpeting and insulation back to provide a little more working room and to prevent spillage from staining the carpeting.
  22.  
  23. Remove the entire housing assembly from the dash panel and remove it from the vehicle.
  24.  
  25. To disassemble the housing assembly, remove the vacuum diaphragm and retaining screws from the cover and remove the cover.
  26.  
  27. Remove the retaining screw from the heater core and/or evaporator and remove from the housing assembly.
  28.  

To install:
  1. Remove the temperature control door from the unit and clean the unit out with solvent. Lubricate the lower pivot rod and its well and install. Wrap the heater core and/or evaporator with foam tape and place in position. Secure with the screws.
  2.  
  3. Assemble the unit, making sure all vacuum tubes are properly routed.
  4.  
  5. Install the assembly to the vehicle and connect the vacuum harness. Install the nuts to the firewall and install the condensation tube. Fold the carpeting back into position.
  6.  
  7. Connect the hanger strap from the package and rotate it aside. Install the 2 brackets supporting the lower edge of the heater housing. Connect the blower motor wiring, resistor wiring and the temperature control cable.
  8.  
  9. Install the retaining screws from the right side to the steering column. Install the instrument panel trim covering and reinforcement.
  10.  
  11. Install the bolt holding the right side instrument panel to the right cowl. Install the lower reinforcement under the steering column, right side cowl and sill trim.
  12.  
  13. Connect the vacuum lines at the brake booster and water valve.
  14.  
  15. Connect the heater hoses to the core tubes.
  16.  
  17. Using new gaskets, install the H-valve and connect the refrigerant lines. Install the condensation tube.
  18.  
  19. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment. Add 2 fl. oz. (59 ml) of refrigerant oil during the recharge. Fill the cooling system.
  20.  
  21. Connect the negative battery cable and check the entire climate control system for proper operation and leaks.
  22.  

1991-95 Models
  1. Disable the air bag system by disconnecting the negative battery cable.
  2.  
  3. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the steering column cover and left and right side under panel silencers.
  8.  
  9. Remove the center bezel by unclipping it from the instrument panel.
  10.  
  11. Remove the accessory switch carrier and the heater/air conditioning control head.
  12.  
  13. Remove storage bin and lower right instrument panel.
  14.  
  15. Disconnect the blower motor lead under the right side of the instrument panel.
  16.  
  17. Remove the right side 40-way connector wiring bracket.
  18.  
  19. Remove the lower right reinforcement, body computer bracket and mid-to-lower reinforcement as an assembly.
  20.  
  21. Disconnect the vacuum lines at the brake booster and water valve.
  22.  
  23. Clamp off the heater hoses near the heater core and remove the hoses from the core tubes. Plug the hose ends and the core tubes to prevent spillage of coolant.
  24.  
  25. If equipped with air conditioning, remove the H-valve and condensation tube.
  26.  
  27. Disconnect the temperature control cable and vacuum harness at the connection at the top of the unit.
  28.  
  29. Remove the retaining nuts from the package mounting studs at the firewall. Disconnect the hanger strap from the package and rotate it aside.
  30.  

To install:
  1. Remove the temperature control door from the unit and clean the unit out with solvent. Lubricate the lower pivot rod and its well and install. Wrap the heater core and/or evaporator with foam tape and place in position. Secure with the screws.
  2.  
  3. Assemble the unit, making sure all vacuum tubes are properly routed.
  4.  
  5. Install the assembly to the vehicle and connect the vacuum harness. Install the nuts to the firewall and install the condensation tube. Fold the carpeting back into position.
  6.  
  7. Connect the hanger strap from the package and rotate it aside. Install the 2 brackets supporting the lower edge of the heater housing. Connect the blower motor wiring, resistor wiring and the temperature control cable.
  8.  
  9. Install the retaining screws from the right side to the steering column. Install the instrument panel trim covering and reinforcement.
  10.  
  11. Assemble the unit, making sure all vacuum tubes are properly routed.
  12.  
  13. Install the assembly to the vehicle and connect the vacuum harness. Install the nuts to the firewall and install the condensation tube. Fold the carpeting back into position.
  14.  
  15. Connect the hanger strap from the package and rotate it aside. Connect the blower motor wiring and temperature control cable.
  16.  
  17. Install the lower right reinforcement, body computer bracket and mid-to-lower reinforcement as an assembly.
  18.  
  19. Install the right side 40-way connector wiring bracket.
  20.  
  21. Install the lower right instrument panel and storage bin.
  22.  
  23. Install the heater/air conditioning control head and accessory switch carrier.
  24.  
  25. Install the center bezel to the instrument panel.
  26.  
  27. Install the under panel silencers and steering column cover.
  28.  
  29. Install the vacuum lines at the brake booster and water valve.
  30.  
  31. Connect the heater hoses to the core tubes.
  32.  
  33. Using new gaskets, install the H-valve and connect the refrigerant lines. Install the condensation tube.
  34.  
  35. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment. Add 2 fl. oz. (59 ml) of refrigerant oil during the recharge. Fill the cooling system.
  36.  
  37. Perform the Air Bag System Check procedures outlined in this section before connecting the negative battery cable.
  38.  
  39. Connect the negative battery cable and check the entire climate control system for proper operation and leaks.
  40.  

 
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