Chrysler Caravan/Voyager/Town n Country 1984-1995

Heater/Evaporator Unit

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REMOVAL & INSTALLATION



1984-87 Models

See Figures 1, 2, 3, 4, 5, 6, 7 and 8



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Fig. Fig. 1: Removing the passenger side cowl and sill trim panel lower retaining screws-1987 Voyager shown



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Fig. Fig. 2: Remove the screw hole cover plugs from the upper cowl and sill trim panel



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Fig. Fig. 3: Remove the screws from the upper cowl and sill trim panel



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Fig. Fig. 4: Removing the passenger side cowl and sill trim panel



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Fig. Fig. 5: Slide out the trim strip to access the passenger side lower dash panel retaining screws



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Fig. Fig. 6: Removing the passenger side lower dash panel retaining screws



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Fig. Fig. 7: Removing the passenger side lower dash panel mounting bolt



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Fig. Fig. 8: Evaporator/heater assembly


CAUTION
The air conditioning system contains refrigerant under high pressure. Severe personal injury may result from improper service procedures. If the knowledge and necessary equipment are not on hand, have the system serviced by a qualified mechanic who will service the refrigerant system completely.

  1. Disconnect the negative battery cable. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine.
  2.  
  3. Block the vehicle wheels and apply the parking brake.
  4.  
  5. Drain the cooling system.
  6.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the passenger side lower instrument panel.
  2.  
  3. Remove the steering column lower cover.
  4.  
  5. Remove the right side cowl and sill trim.
  6.  
  7. Remove the mounting bolt from the right side instrument panel to the right cowl.
  8.  
  9. Loosen the (2) brackets supporting the lower edge to air conditioning and heater unit housing.
  10.  
  11. Remove the mid-reinforcement instrument panel trim molding.
  12.  
  13. Remove the attaching screws from the right side to center of the steering column.
  14.  
  15. From the engine compartment, disconnect the vacuum line at brake booster and water valve.
  16.  
  17. Remove the hoses from the heater core. Plug the heater tubes.
  18.  
  19. Disconnect the air conditioning plumbing at the H-valve.
  20.  
  21. Remove the (4) nuts from engine compartment package mounting studs.
  22.  
  23. From the passenger compartment, pull the right side of lower instrument panel rearward until it reaches the passenger seat. Disengage the electrical connectors and temperature control cable.
  24.  
  25. Remove the hangar strap from the unit assembly and bend rearward.
  26.  
  27. Carefully remove the unit assembly from the vehicle.
  28.  
  29. Place the heater/evaporator unit assembly on a work bench.
  30.  
  31. Remove the vacuum harness attaching screw and remove the harness through the access hole in the cover.
  32.  
  33. Remove the (13) attaching screws from the cover and remove the cover. The temperature control door will come out with the cover.
  34.  
  35. Remove the retaining bracket screws and the remove heater core assembly.
  36.  
  37. Remove the evaporator core assembly.
  38.  
  39. Disconnect the actuator linkage from the recirculation door and remove the vacuum line. Remove the actuator retaining screws and remove the actuator.
  40.  
  41. Remove the (4) attaching screws from the recirculation door cover to evaporator/heater assembly. Lift the cover from the unit and remove the recirculation door from its housing.
  42.  
  43. Remove the (5) attaching screws from the blower assembly sound helmet.
  44.  
  45. Remove the retaining clamp from the blower wheel hub and slide the blower wheel from the blower motor shaft.
  46.  
  47. Remove the blower motor (3) mounting screws from the helmet and remove the blower motor assembly.
  48.  

To install:
  1. Install the blower wheel to the blower motor shaft and secure it with the retaining clamp.
  2.  
  3. Feed the blower motor electrical wires through the access hole in the sound helmet and lower the blower motor into helmet.
  4.  
  5. Secure the blower motor with the (3) mounting screws.
  6.  
  7. Install the blower assembly and helmet into the fan scroll and secure it with (5) retaining screws.
  8.  
  9. Install the recirculation door into its housing. Place the recirculation door cover onto the unit and secure with the (4) retaining screws.
  10.  
  11. Install the actuator shaft onto the recirculation door and slide the actuator into its bracket. Secure the actuator assembly with (2) nuts.
  12.  
  13. Install the evaporator core into the unit.
  14.  
  15. Install the heater core into the unit and secure the core tube retaining bracket with attaching screws.
  16.  
  17. Install the unit cover and secure with (13) attaching screws.
  18.  
  19. Install the vacuum harness through the access hole in the cover and secure the vacuum harness.
  20.  
  21. Place the heater/evaporator assembly into the vehicle and position it against the dash panel.
  22.  
  23. Install the hangar strap.
  24.  
  25. Connect the temperature control cable, vacuum and electrical connectors.
  26.  
  27. Install the (4) retaining nuts to the unit mounting studs from the engine compartment.
  28.  
  29. Connect the air conditioning plumbing to the H-valve.
  30.  
  31. Connect the vacuum line at the brake booster and water valve.
  32.  
  33. Install the attaching screws from the right side to the center of the steering column.
  34.  
  35. Install the mid-reinforcement instrument panel trim molding.
  36.  
  37. Tighten the (2) brackets supporting the lower edge to the heater/evaporator unit housing.
  38.  
  39. Install the mounting bolt from the right side of the instrument panel to the right cowl.
  40.  
  41. Install the right side cowl and sill trim.
  42.  
  43. Install the steering column lower cover.
  44.  
  45. Install the passenger side lower instrument panel
  46.  
  47. Connect the heater hoses to heater core in the engine compartment.
  48.  
  49. Connect the negative battery cable.
  50.  
  51. Fill the cooling system.
  52.  
  53. Have the system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  54.  

 
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