Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

Heater-A/C Unit Assembly and Core

Print

REMOVAL & INSTALLATION



1981-84 Models
WITHOUT AIR CONDITIONING

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Locations of the heater assembly mounting fasteners and blower motor resistor block

  1. Disconnect the negative battery cable and drain the radiator.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the 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. Detach the blower motor wiring connector.
  2.  
  3. Reach under the unit, depress the tab on the mode door and temperature control cables, pull the flags from the receivers, and remove the self-adjust clip from the crank arm.
  4.  
  5. Remove the glove box assembly.
  6.  
  7. Disconnect the heater hoses to the unit on the engine side and seal the heater core tube openings and hoses.
  8.  
  9. Through the glove box opening, remove the screw attaching the hanger strap to the heater assembly.
  10.  
  11. Remove the nut attaching the hanger strap to the dash panel and remove the hanger strap.
  12.  
  13. Remove the two nuts attaching the heater assembly to the dash panel. The nuts are on the engine side.
  14.  
  15. Pull out the bottom of the instrument panel and slide out the heater assembly.
  16.  
  17. Remove the padding from around the heater core outlets and remove the upper core mounting screws.
  18.  
  19. Pry loose the retaining snaps from around the outer edge of the housing cover.
  20.  

If a retaining snap should break, the housing cover has provisions for mounting screws.

  1. Remove the housing top cover.
  2.  
  3. Remove the bottom heater core mounting screw.
  4.  
  5. Slide the heater core out of the housing.
  6.  

To install:
  1. Slide the heater core into the housing.
  2.  
  3. Install the bottom heater core mounting screw until secure.
  4.  
  5. Install the housing top cover and engage the retaining snaps around the outer perimeter of the housing. If the snaps were damaged during removal, install mounting screws.
  6.  
  7. Installation is the reverse of removal.
  8.  

WITH AIR CONDITIONING

Removal of the Heater-Evaporator Unit is required for heater core removal. Two people will be required to perform the operation.

It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. Have the A/C system discharged, as described in Routine Maintenance .
  2.  
  3. Disconnect the negative battery ground.
  4.  
  5. Drain the engine coolant, as described in Routine Maintenance .
  6.  


CAUTION
When draining 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. Disconnect the temperature door cable from the heater-evaporator unit.
  2.  
  3. Disconnect the temperature door cable from the retaining clips.
  4.  
  5. Remove the glove box.
  6.  
  7. Detach the vacuum harness from the control head.
  8.  
  9. Disconnect the blower motor lead and anti-diesel relay wire.
  10.  
  11. Remove the seven screws fastening the right trim bezel to the instrument panel. Starting at the right side, swing the bezel clear and remove it.
  12.  
  13. Remove the three screws on the bottom of the center distribution duct cover and slide the cover rearward and remove it.
  14.  
  15. Remove the center distribution duct.
  16.  
  17. Remove the defroster duct adaptor.
  18.  
  19. Remove the H-type expansion valve, located on the right side of the fire wall:
    1. Remove the 5 / 8 in. bolt in the center of the plumbing sealing plate.
    2.  
    3. Carefully pull the refrigerant lines toward the front of the car, taking care to avoid scratching the valve sealing surfaces.
    4.  
    5. Remove the two Allen head capscrews and remove the valve.
    6.  

  20.  
  21. Cap the pipe openings at once. Wrap the valve in a plastic bag.
  22.  
  23. Disconnect the hoses from the core tubes.
  24.  
  25. Disconnect the vacuum lines at the intake manifold and water valve.
  26.  
  27. Remove the unit-to-firewall retaining nuts.
  28.  
  29. Remove the panel support bracket.
  30.  
  31. Remove the right cowl lower panel.
  32.  
  33. Remove the instrument panel pivot bracket screw from the right side.
  34.  
  35. Remove the screws securing the lower instrument panel at the steering column.
  36.  
  37. Pull back the carpet from under the unit as far as possible.
  38.  
  39. Remove the nut from the evaporator-heater unit-to-plenum mounting brace and blower motor ground cable. While supporting the unit, remove the brace from its stud.
  40.  
  41. Lift the unit, pulling it rearward to allow clearance. These operations may require two people.
  42.  
  43. Slowly lower the unit taking care to keep the studs from hanging-up on the insulation.
  44.  
  45. When the unit reaches the floor, slide it rearward until it is out from under the instrument panel.
  46.  
  47. Remove the unit from the car.
  48.  
  49. Place the unit on a workbench. On the inside-the-car-side, remove the nut from the mode door actuator on the top cover and the two retaining clips from the front edge of the cover. To remove the mode door actuator, remove the two screws securing it to the cover.
  50.  
  51. Remove the screws attaching the cover to the assembly and lift off the cover. Lift the mode door out of the unit.
  52.  
  53. Remove the screw from the core retaining bracket and lift out the core.
  54.  

To install:
  1. Place the core in the unit and install the bracket.
  2.  
  3. Install the actuator arm.
  4.  

When installing the unit in the car, care must be taken that the vacuum lines to the engine compartment do not hang-up on the accelerator or become trapped between the unit and the fire wall. If this happens, kinked lines will result and the unit will have to be removed to free them. Proper routing of these lines will require two people. The portion of the vacuum harness which is routed through the steering column support MUST be positioned BEFORE the distribution housing is installed. The harness MUST be routed ABOVE the temperature control cable.

  1. Place the unit on the floor as far under the panel as possible.
  2.  
  3. Raise the unit carefully, at the same time pull the lower instrument panel rearward as far as possible.
  4.  
  5. Position the unit in place and attach the brace to the stud.
  6.  
  7. Install the lower ground cable and attach the nut.
  8.  
  9. Install and tighten the unit-to-firewall nuts.
  10.  
  11. Reposition the carpet and install, but do not tighten the right instrument panel pivot bracket screw.
  12.  
  13. Place a piece of sheet metal or thin cardboard against the evaporator-heater assembly to center the assembly duct seal.
  14.  
  15. Position the center distributor duct in place making sure that the upper left tab comes in through the left center air conditioning outlet opening and that each air take-off is properly inserted in its respective outlet.
  16.  

Make sure that the radio wiring connector does not interfere with the duct.

  1. Install and tighten the screw securing the upper left tab of the center air distribution duct to the instrument panel.
  2.  
  3. Remove the sheet metal or cardboard from between the unit and the duct.
  4.  

Make sure that the unit seal is properly aligned with the duct opening.

  1. Install and tighten the two lower screws fastening the center distribution duct to the instrument panel.
  2.  
  3. Install and tighten the screws securing the lower instrument panel at the steering column.
  4.  
  5. Install and tighten the nut securing the instrument panel to the support bracket.
  6.  
  7. Make sure that the seal on the unit is properly aligned and seated against the distribution duct assembly.
  8.  
  9. Tighten the instrument panel pivot bracket screw and install the right cowl lower trim.
  10.  
  11. Slide the distributor duct cover assembly onto the center distribution duct so that the notches lock into the tabs and the tabs slide over the rear and side ledges of the center duct assembly.
  12.  
  13. Install the three screws securing the ducting.
  14.  
  15. Install the right trim bezel.
  16.  
  17. Connect the vacuum harness to the control head.
  18.  
  19. Connect the blower lead and the anti-diesel wire.
  20.  
  21. Install the glove box.
  22.  
  23. Connect the temperature door cable.
  24.  
  25. Install new O-rings on the evaporator plate and the plumbing plate. Coat the new O-rings with clean refrigerant oil.
  26.  
  27. Place the H-valve against the evaporator sealing plate surface and install the two through-bolts. Tighten to 6-10 ft. lb.
  28.  
  29. Carefully hold the refrigerant line connector against the valve and install the bolt. Tighten the bolt to 14-20 ft. lb. (19-27 Nm).
  30.  
  31. Install the heater hoses at the core tubes.
  32.  
  33. Connect the vacuum lines at the manifold and water valve.
  34.  
  35. Install the condensate drain tube.
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Have the A/C system evacuated, recharged and leak tested by a reputable automotive technician utilizing a recovery/recycling apparatus.
  40.  

1985-86 Models

Modify the service steps as necessary for vehicles not equipped with air conditioning.

It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. Have the air conditioning system discharged, as described in Routine Maintenance .
  2.  
  3. Drain the engine cooling system, as described in Routine Maintenance .
  4.  
  5. Disconnect the heater hoses at the core and plug the core openings with a cork or cap.
  6.  


CAUTION
When draining 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. Label, then detach the vacuum lines for the heater/air conditioning system at the intake manifold and water valve.
  2.  
  3. Remove the right side scuff plate and the cowl side trim panel.
  4.  
  5. Remove the glove box.
  6.  
  7. Remove the air conditioning control head, as described later in this section.
  8.  
  9. If the car has a console, remove it.
  10.  
  11. Remove the two bolts and two screws which fasten the forward console mounting bracket to the body and remove it.
  12.  
  13. Remove the center distribution duct.
  14.  
  15. Remove the side window demister adapter on those models so-equipped. Pull the defroster adapter from the bottom of the defroster duct.
  16.  
  17. Remove the drain tube clamp, then remove the L-shaped condensate drain tube. Disengage the heater/air conditioning unit from the wiring harness at the connector.
  18.  
  19. Disconnect the control cable at the receiver, located near the evaporator assembly. To do this, depress the tab on the red flag and pull the flag out of the receiver.
  20.  
  21. Remove the right side cowl-to-plenum brace. Pull the carpet out from under the unit and fold it back.
  22.  
  23. Remove the screw holding the hanger strap to the unit, then remove the 4 mounting nuts for the unit which are located on the engine compartment side of the cowl. Finally, pull the unit toward the rear of the car until the studs clear the dash liner. Allow it to drop down until it rests on the catalytic converter tunnel.
  24.  
  25. Turn the unit so as to clear the lower instrument panel reinforcement without moving it too far to either side, then remove the unit from the car and place it on a workbench, standing behind it just as a front seat passenger would.
  26.  
  27. Disconnect the actuator arm at the mounting shaft by squeezing it with a pair of pliers to release it. Be careful to avoid prying the mounting clips, as they can easily be broken. When the arm is free, remove the retaining clips from the front edge of the cover.
  28.  
  29. Remove the two screws mounting the mode door actuator to the cover and remove it.
  30.  
  31. Remove the 15 screws attaching the cover to the housing and remove it, then lift the mode door out.
  32.  
  33. Remove the screw from the heater core tube retaining bracket and lift the core out of the unit.
  34.  

To install:
  1. Slide the new heater core into position and then install the screw into the retaining bracket.
  2.  
  3. Install the mode door. Install the cover to the heater/air conditioning housing and install the 15 attaching screws.
  4.  
  5. Install the mode door actuator and its two attaching screws.
  6.  
  7. Connect the actuator arm at the mounting shaft by squeezing it with a pair of pliers to permit it to be installed over the shaft (again be careful not to squeeze the mounting clips). Install the retaining clips on the front edge of the cover.
  8.  
  9. Install the unit back into the car, working it around the instrument panel reinforcement. Raise it until the mounting studs line up with the holes in the cowl and position it so the studs pass through the cowl. Install the four mounting nuts from the engine compartment side.
  10.  
  11. Install the screw attaching the hanger strap to the unit. Work the carpet back into position under the unit. Install the right side cowl-to-plenum brace.
  12.  
  13. Connect the control cable at the receiver. Install the L-shaped condensate drain tube. Attach the heater/air conditioning unit wiring harness connector.
  14.  
  15. Install the defroster adapter onto the bottom of the defroster duct. Install the side window demister adapter on those models so-equipped.
  16.  
  17. Install the center distribution duct.
  18.  
  19. Install the forward console mounting bracket. Install the console.
  20.  
  21. Install the air conditioning control head, as described later in this section.
  22.  
  23. Install the glove box. Install the right side scuff plate and the cowl side trim panel.
  24.  
  25. Connect the vacuum lines for the heater/air conditioning system at the manifold and water valve. Remove the plugs and reconnect the heater hoses at the core. Refill the cooling system.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Fill the engine cooling system, as described in Routine Maintenance .
  30.  
  31. Start the engine and check for coolant leaks. Refill the cooling system after the engine has reached operating temperature and cooled back off.
  32.  
  33. Have the A/C system evacuated, recharged and leak tested by a reputable automotive technician using a recovery/recycling machine.
  34.  

1987 Models

Modify the service steps as necessary on vehicles not equipped with air conditioning. To complete this procedure, make sure to have suitable caps or plastic sheeting and tape to cover and seal open refrigerant lines. Also needed are caps or plugs for the heater core tubes.

It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. Have the air conditioning system discharged, as described in Routine Maintenance .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine cooling system.
  6.  
  7. Remove the right side cowl cover. Remove the trim panel from the door opening scuff plate.
  8.  


CAUTION
When draining 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. There is a roll down bolt located behind the instrument panel to the right of the glove box. Loosen this bolt so that the instrument panel can be shifted later on in the procedure.
  2.  
  3. Remove the four instrument cluster center bezel attaching screws, open the glove box door and remove the bezel.
  4.  
  5. Remove the lower instrument panel module cover, if so equipped.
  6.  
  7. Remove the center console assembly. Position the accessory wiring harness so it will be out of the way when removing the heater/air conditioning unit.
  8.  
  9. Remove the instrument panel center support braces and brackets.
  10.  
  11. Remove the radio, as described later in this section.
  12.  
  13. Remove the ash tray, then remove its mounting bracket.
  14.  
  15. Remove the cigarette lighter and socket. Remove the glove box.
  16.  
  17. Remove the heater/air conditioning control, as described later in this section.
  18.  
  19. Disconnect the temperature cable attaching flag and vacuum harness from the control assembly.
  20.  
  21. Remove the two attaching screws and remove the center air duct.
  22.  
  23. Disconnect the blower motor relay module and wiring lead from the harness and position both so the heater/air conditioning unit can be removed later.
  24.  
  25. The defroster duct adapter is located between the heater/air conditioning unit and the defroster duct. Pull it downward from its installed position and remove it.
  26.  
  27. Remove the attaching nut and 4 screws from the heater/air conditioning unit support bracket and remove it.
  28.  
  29. Remove the 3 attaching screws from the heat outlet duct (located under the unit) and remove the duct.
  30.  
  31. Slide the front passenger's seat as far to the rear as it will go, then roll the carpet out from under the unit.
  32.  
  33. Disconnect the lines from the refrigerant expansion H-valve, and immediately and tightly cover the openings.
  34.  
  35. Disconnect both heater hoses and plug the core tubes.
  36.  
  37. Remove the condensate drain tube.
  38.  
  39. Remove the four heater/air conditioning unit attaching nuts from the engine compartment side of the cowl. Remove the heater/air conditioning unit support brace lower attaching bolt, then swing the brace out of the way to the left and behind the dash panel.
  40.  
  41. Pull the unit directly away from the dash panel (do not twist or turn it, so as to avoid damaging the seals). Once the studs clear both the dash panel and liner, allow it to drop down until it rests on the floor tunnel.
  42.  
  43. Remove the demister adapter duct from the top of the unit to provide working clearance.
  44.  
  45. Then, keeping the unit upright, slide it from under the instrument panel and out the right side door opening.
  46.  
  47. Place the unit on a workbench or in some similar spot where you can work on it effectively. Remove the retaining nut from the blend-air door pivot shaft, then position a pair of pliers so that the upper jaw rests against the top of the pivot shaft and the lower jaw will tend to pry the crank lever upward. Gently pry the crank lever off the pivot shaft.
  48.  
  49. Disconnect the vacuum lines from the defrost mode and panel mode vacuum actuators and position them out of the way.
  50.  
  51. Remove the two heater/air conditioning unit cover attaching screws located above the cover in the air inlet plenum. Remove the 11 heater/air conditioning unit cover attaching screws located downward from the cover in the housing. Lift the cover off the heater/air conditioning unit.
  52.  
  53. Remove the heater core-to-dash panel seal from the tubes of the core, then pull the core out of the unit.
  54.  

To install:
  1. Slide the core into the unit and install the seal. Then install the unit cover and all 13 attaching screws.
  2.  
  3. Connect the vacuum lines going to the defrost and panel vacuum actuators. Reinstall the blend air door crank lever onto the pivot shaft.
  4.  
  5. Put the unit back into the car. Install the demister adapter duct, then raise the unit until the mounting studs are lined up with the holes in the cowl and work the studs through the holes. Install the support brace and attaching bolt. Install the mounting nuts from the other side of the cowl.
  6.  
  7. Install the condensate drain tube. Install the heater hoses.
  8.  
  9. Reinstall the expansion H-valve. Uncap the openings and immediately reconnect the refrigerant lines.
  10.  
  11. Install the carpet back under the unit, then install the heat outlet duct and the 3 attaching screws.
  12.  
  13. Put the heater/air conditioning unit support bracket into position and then install the attaching nut and 4 screws.
  14.  
  15. Put the defroster duct adapter into position between the heater/air conditioning unit and the defroster duct.
  16.  
  17. Connect the blower motor relay module and wiring lead to the harness.
  18.  
  19. Install the center air duct and install the two attaching screws.
  20.  
  21. Connect the temperature cable attaching flag and vacuum harness to the control assembly. Install the heater/air conditioning control as described later in this section.
  22.  
  23. Install the glove box. Install the cigarette lighter and socket.
  24.  
  25. Install the ash tray and its mounting bracket. Install the radio as described later in this section.
  26.  
  27. Install the instrument panel center support braces and brackets.
  28.  
  29. Reposition the accessory wiring harness to its original location. Install the center console assembly.
  30.  
  31. Install the lower instrument panel module cover, if the car has one.
  32.  
  33. Install the instrument cluster bezel and its four attaching screws.
  34.  
  35. Tighten the roll down bolt located behind the instrument panel to the right of the glove box.
  36.  
  37. Install the trim panel onto the door opening scuff plate. Install the right side cowl cover. Refill the engine cooling system.
  38.  
  39. Connect the battery negative cable. Charge the air conditioning system, utilizing the procedures in Routine Maintenance . Operate the engine and check for leaks. After the engine has reached operating temperature and then has cooled back off, bring the coolant level back up to where it belongs.
  40.  

1988 Models
EXCEPT PREMIER

Modify the service steps as necessary on vehicles not equipped with air conditioning. To complete this procedure, make sure to have suitable caps or plastic sheeting and tape to cover and seal open refrigerant lines. Also needed are caps or plugs for the heater core tubes.

It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. Have the A/C system discharged, as described in Routine Maintenance .
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Drain the engine cooling system. Disconnect the heater hoses at the core and plug the openings.
  6.  


CAUTION
When draining 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 air conditioner condensate drain. Label and then detach the vacuum lines running from the car body to various components on the heater/air conditioning unit.
  2.  
  3. Disconnect/remove the following items, according to the body style of the car:
    1. On LeBaron (AK body) models, remove the right upper and lower silencers from under the instrument panel.
    2.  
    3. On LeBaron (AK body) models with passive restraints, remove the right side lower trim panel from under the dashboard.
    4.  
    5. On Sundance and Shadow models, remove the steering column cover.
    6.  
    7. On Daytona and LeBaron (AJ body) models with passive restraints, remove the inner steering column cover.
    8.  

  4.  
  5. Put the bench seat or right individual seat all the way to the rear, then, on Sundance models, remove the right pillar trim.
  6.  
  7. On all cars, remove the right cowl side trim (note that on the LeBaron, this requires pulling the lower end of the right side A-pillar trim outward).
  8.  
  9. Remove the glove box, then perform each of the following procedures on the models indicated:
    1. On Daytona, LeBaron and New Yorker with passive restraints, and on Lancer and LeBaron GTS, remove the right instrument panel reinforcement.
    2.  
    3. On Sundance and Shadow, Caravelle, 600 and New Yorker Turbo, remove the right instrument panel roll-up screw.
    4.  
    5. On Daytona, LeBaron and New Yorker, remove the forward console bezel, side trim, and lower carpet panels, then loosen the floor console and move it to the rear. Remove the forward console. If the car has passive restraints, remove the instrument panel-to-floor reinforcement.
    6.  
    7. On the Sundance and Shadow, remove the center dashboard bezel, lower center module cover, floor console, and instrument support brace (this brace runs from the steering column opening to the right cowl side at the bottom of the instrument panel). Also remove the bracket linking the instrument panel and its support, located under the glove box. Remove the ashtray. Remove the radio as described later. Remove the instrument panel top cover. Finally, remove the 3 right side panel-to-lower windshield panel attaching screws.
    8.  
    9. On the Caravelle, 600 and New Yorker Turbo, remove the forward console and its mounting bracket.
    10.  
    11. On the Aries, Reliant, LeBaron, New Yorker, and Town & Country, remove the floor console.
    12.  
    13. On the Lancer, remove both front and rear consoles.
    14.  
    15. On the Sundance and Shadow, Aries, Reliant, LeBaron, New Yorker, Town & Country, Caravelle, 600, and New Yorker Turbo pull the right lower side of the instrument panel to the rear.
    16.  

  10.  
  11. On all models, remove the center distribution and defroster adapter ducts, then perform each of the following procedures on the model indicated:
    1. On the Sundance, Shadow and Lancer, remove and detach the relay module.
    2.  
    3. On the Sundance and Shadow, remove the bracket linking the air conditioning unit and instrument panel, then on these models, remove the lower air distribution duct.
    4.  
    5. On the Aries, Reliant, LeBaron, New Yorker, Town & Country, Caravelle, 600 and New Yorker Turbo, remove the audible message center, then on these models, remove the right side cowl-to-plenum brace.
    6.  

  12.  
  13. On all models, detach the blower motor wire connector, then detach the demister hoses at the top of the heater/air conditioning unit.
  14.  
  15. If the car is equipped with a manual control, rather than the Automatic Temperature Control (ATC), perform the following:
    1. Disconnect the temperature control cable flag from the bottom of the heater/air conditioning unit and unclip the cable from the left side of the heat distribution duct, then swing the cable out of the way and to the left.
    2.  
    3. Label, then detach the vacuum lines at the unit.
    4.  

  16.  
  17. On vehicles equipped with the ATC, detach the instrument panel wiring from the rear face of the ATC unit.
  18.  
  19. On the Lancer, disengage the right side 25-way connector bracket and fuse block from the panel.
  20.  
  21. Remove the antenna cable from the clip on the top or rear face of the unit, where it is so-routed.
  22.  
  23. On all models but the Lancer, fold the carpeting back on the right side.
  24.  
  25. Remove the four attaching nuts for the unit from the engine compartment side of the cowl.
  26.  
  27. Remove the lower screw from the unit's hanging strap and then rotate the strap out of the way.
  28.  
  29. Pull the unit to the rear until its studs clear the cowl and liner and then lower it. On the Sundance and Shadow, remove the demister adapter from the top of the unit, then pull the lower right section of the instrument panel rearward and hold it for clearance as you slide the unit out of the car in an upright position. On the other models, rotate the unit as necessary for clearance as it is pulled out from under the instrument panel.
  30.  

To install:
  1. Reverse the step above to get the heater assembly into position under the dash. On the Sundance and Shadow, install the demister adapter, then raise it, line up the four mounting studs with the holes in the cowl, and work the studs through the cowl.
  2.  
  3. Install the four retaining nuts from the engine compartment side of the cowl.
  4.  
  5. Rotate the hanging strap back into position and install the attaching bolt.
  6.  
  7. Reposition the carpeting, if it was moved.
  8.  
  9. Reclip the antenna cable, if it is clipped to the heater/air conditioning unit.
  10.  
  11. On the Lancer, reattach the right side 25-way connector bracket and fuse block to the panel.
  12.  
  13. If the vehicle is equipped with ATC, reconnect the instrument panel wiring. Otherwise, reconnect the vacuum lines according to the labels, then reattach and remount the temperature control cable.
  14.  
  15. Reattach the demister hoses and the blower motor wiring connector.
  16.  
  17. On Aries, Reliant, LeBaron, New Yorker, Town & Country, Caravelle, 600 and New Yorker Turbo models, install the right side cowl-to-plenum brace. Then install the audible message center.
  18.  
  19. On Sundance, Shadow and Lancer models, connect the relay module.
  20.  
  21. On Sundance and Shadow models, install the lower air distribution duct, then install the bracket linking the air conditioning unit and instrument panel.
  22.  
  23. On all models, install the center distribution and defroster adapter ducts.
  24.  
  25. Perform each of the following procedures on the models indicated:
    1. On Daytona, LeBaron and New Yorker with passive restraints, and on Lancer and LeBaron GTS, install the right instrument panel reinforcement.
    2.  
    3. On Sundance and Shadow, Caravelle, 600 and New Yorker Turbo, install the right instrument panel roll-up screw.
    4.  
    5. On Daytona, LeBaron and New Yorker, install the forward console bezel, side trim, and lower carpet panels. Install the console assemblies. If the car has passive restraints, install the instrument panel-to-floor reinforcement.
    6.  
    7. On Sundance and Shadow, install the 3 right side panel-to-lower windshield panel attaching screws. Install the instrument panel top cover. Install the radio as described later. Install the ashtray. Install the bracket linking the instrument panel and its support, located under the glove box. Install the instrument panel support brace, floor console, lower center module cover, and center dashboard bezel.
    8.  
    9. On Caravelle, 600 and New Yorker Turbo models, install the forward console and its mounting bracket.
    10.  
    11. On Aries, Reliant, LeBaron, New Yorker, and Town & Country models, install the floor console.
    12.  
    13. On the Lancer, install both front and rear consoles.
    14.  
    15. On the Sundance and Shadow, Aries, Reliant, LeBaron, New Yorker, Town & Country, Caravelle, 600, and New Yorker Turbo, push the right lower side of the instrument panel forward and back into its normal position.
    16.  

  26.  
  27. Install the glove box. Install the right pillar trim on the Sundance and right side cowl side trim on all cars.
  28.  
  29. Install/connect the following, according to the model of the car:
    1. On LeBaron (AK body), install the right upper and lower silencers under the panel.
    2.  
    3. On LeBaron (AK body) with passive restraints, install the right side lower trim panel under the dashboard.
    4.  
    5. On Sundance and Shadow, install the steering column cover.
    6.  
    7. On Daytona and LeBaron (AJ body), with passive restraints, install the inner steering column cover.
    8.  

  30.  
  31. Connect the vacuum lines running from the car body to various components on the heater/air conditioning unit, according to the labeling done during removal. Install the air conditioner condensate drain.
  32.  
  33. Unplug the heater core openings and connect the heater hoses at the core.
  34.  
  35. Refill the cooling system, as described in Routine Maintenance .
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Start the engine and check for coolant leaks. Refill the cooling system once the vehicle has reached normal operating temperate and allowed to cool back down.
  40.  
  41. Have the air conditioning system evacuated, recharged and leak tested by a reputable automotive technician using a recovery/recycling machine.utilizing the procedures in Routine Maintenance . Operate the engine and check for leaks.
  42.  

PREMIER

See Figures 2 and 3

Click image to see an enlarged view

Fig. Fig. 2: Evaporator core and lower A/C housing components-Premier



Click image to see an enlarged view

Fig. Fig. 3: Heater core and upper A/C housing components-Premier

It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. Have the air conditioning system discharged by a qualified professional mechanic using an approved recovery/recycling machine, if equipped.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the engine coolant, as described in Routine Maintenance .
  6.  


CAUTION
When draining 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 instrument panel lower trim cover, which is retained by 3 screws.
  2.  
  3. Remove the instrument panel support rod. Remove the screw attaching the steering column wiring harness bulkhead connector.
  4.  
  5. Disconnect the automatic transaxle shift cable from the lever:
    1. Compress the cable retainer tangs with pliers and slide the cable from the column mounting bracket.
    2.  
    3. Loosen the screw that holds the anchoring bracket in place, then move the bracket to the keyhole position and remove it from its mounting bracket.
    4.  

  6.  
  7. Lift the indicator wire off of the pulley.
  8.  
  9. Pull the plastic sleeve down to expose the steering column universal joint.
  10.  
  11. Make a reference mark on the steering column shaft and intermediate shaft.
  12.  
  13. Remove the bolt from the intermediate shaft.
  14.  
  15. Remove the 4 bolts and nuts that hold the steering column to the instrument panel and carefully lower to the vehicle floor.
  16.  
  17. Separate the steering column shaft from the intermediate shaft and remove the steering column assembly from the vehicle.
  18.  
  19. Remove the defroster grille from the top of the instrument panel.
  20.  
  21. Loosen, but do not remove, the nut located near the parking brake release handle and the nut which is located on the passenger side kick panel.
  22.  
  23. Remove the screws and lower the parking brake release handle.
  24.  
  25. Remove the ashtray.
  26.  
  27. Detach the cigarette lighter connectors.
  28.  
  29. Remove the screw from the ashtray cavity.
  30.  
  31. Detach all electrical connections.
  32.  
  33. Remove the bolts that hold the instrument panel to the center floor bracket.
  34.  
  35. Disconnect the interior temperature sensor.
  36.  
  37. Remove the floor duct extension.
  38.  

The heater core inlet and outlet tubes are made of plastic and may break if too much pressure is applied.

  1. Remove the heater hoses from the heater core spouts.
  2.  
  3. Detach the coolant level switch connector.
  4.  
  5. Remove the coolant reservoir.
  6.  
  7. Detach the blower motor connector.
  8.  
  9. Disconnect the vacuum hoses.
  10.  
  11. Disconnect the refrigerant lines at the dash panel, if equipped.
  12.  
  13. Remove the retaining nuts from inside and outside the vehicle, and carefully pull the heater/air conditioning housing rearward to remove it.
  14.  
  15. Release the plastic tabs and remove the heater core from the housing.
  16.  

To install:
  1. Carefully insert the heater core into the housing and push until it snaps in place.
  2.  
  3. Before installing the housing, make sure the housing seals are in place and in good condition.
  4.  
  5. Position the heater/air conditioning housing to the dash panel. Make sure the drain tube extends through its opening in the upper floor, and that the blower motor connector and vacuum line extend through the dash panel. Ensure that the ECU connectors are to the right of the drain tube.
  6.  
  7. Install new housing retaining nuts. Install the floor duct extension.
  8.  
  9. Install new O-rings on the refrigerant lines and lubricate with clean refrigerant oil. Press each line into its connector until it snaps into place.
  10.  
  11. Connect the vacuum hose and the blower electrical connector.
  12.  
  13. Install the coolant reservoir bracket and reservoir.
  14.  
  15. Reattach the coolant level switch connector.
  16.  
  17. Carefully reconnect the heater hoses to the core.
  18.  
  19. Place the instrument panel into position so the mounting brackets engage the studs on the kick panels. Make sure the wiring harness is behind the center mounting bracket and fasten all electrical connections.
  20.  
  21. Install the bolt to the brake support.
  22.  
  23. Install the screw into the ashtray cavity.
  24.  
  25. Install the 2 bolts to the center support bracket.
  26.  
  27. Fasten the cigarette lighter connectors and the ashtray.
  28.  
  29. Tighten the nut located near the parking brake release handle and the nut located on the passenger side kick panel.
  30.  
  31. Install the parking brake release handle.
  32.  
  33. Install the bolts under the defroster grille, then install the grille.
  34.  
  35. Position and install the steering column shaft in the intermediate steering shaft U-joint. Align the 2 shafts using the reference marks made during removal. Install, but do not tighten, the U-joint bolt.
  36.  
  37. Attach the steering column to the instrument panel and tighten the bolts/nuts to 35 ft. lbs. (48 Nm).
  38.  
  39. Tighten the bolt in the intermediate steering shaft U-joint and move the plastic sleeve into position.
  40.  
  41. Snap the shift cable into the mounting bracket.
  42.  
  43. Snap the shift cable head onto the mounting ball in the shift arm.
  44.  
  45. Loop the shift indicator wire over the pulley. Position the anchoring bracket over the screw.
  46.  
  47. Move the gearshift lever into N and check the position of the shift indicator. If the pointer is not aligned with the N mark on the display, slide the bracket forward/rearward to align the indicator. Tighten the screw.
  48.  
  49. Install the bulkhead connector and fasten the connector attaching screw.
  50.  
  51. Install the instrument panel support rod securely.
  52.  
  53. Install the instrument panel lower trim cover.
  54.  
  55. Have the air conditioning system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  56.  
  57. Connect the negative battery cable and check the entire climate control system for proper operation. Check the system for leaks.
  58.  

1989-95 Models
EXCEPT DYNASTY AND PREMIER

The following procedure can be used on all specified 1989-95 models. Slight variations may occur due to extra connections, etc., but the basic procedure should cover all models. Modify the service steps as necessary. Refer to the supplemental restraint system disarming procedure as necessary.

It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. If the vehicle is equipped with air conditioning, have the A/C system discharged by a qualified professional mechanic, using an approved recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable. Drain the cooling system.
  4.  


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. 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.
  2.  
  3. Disconnect the H-valve connection at the valve and remove the H-valve. Remove the condensation tube.
  4.  
  5. Remove the glove box, right side kick and sill panels, and all modules, relay panels and computer components in the vicinity of the heater housing.
  6.  
  7. Remove the lower instrument panel silencers and reinforcements. Remove the radio and other dashboard-mounted optional equipment, as required.
  8.  
  9. Remove the floor console, if equipped. Remove the floor and defroster distribution ducts.
  10.  
  11. Remove the bolt holding the right side instrument panel to the right cowl.
  12.  
  13. Disconnect the blower motor wiring, antenna, resistor wiring and the temperature control cable.
  14.  
  15. On 1990-95 Daytona and LeBaron models, using a suitable cutting device, cut the instrument panel along the indented line on the padded cover to the right of the glove box opening. Cut only plastic, not metal. Remove the reinforcement and the piece of instrument panel that is riveted to it.
  16.  
  17. Disconnect the demister hoses from the top of the housing, if equipped.
  18.  
  19. Disconnect the hanger strap from the package and rotate it aside.
  20.  
  21. Remove the retaining nuts from the package mounting studs at the fire wall.
  22.  
  23. Fold the carpeting and insulation back to provide a little more working room and to prevent spillage from staining the carpeting. Pull the right side of the instrument panel out as far as possible.
  24.  
  25. Remove the heater housing from the dash panel and remove it from the passenger compartment. If the passenger seat is preventing removal, remove it.
  26.  
  27. To disassemble the housing assembly, remove the retaining screws from the cover and remove the cover.
  28.  
  29. Remove the retaining screw from the heater core and remove the core from the housing assembly.
  30.  

To install:
  1. Remove the temperature control door from the housing and clean the unit out with solvent. Lubricate the lower pivot rod and its well, then install. Wrap the heater core with foam tape and place it in position. Secure it with its screw.
  2.  
  3. Assemble the housing, making sure all cover screws were used.
  4.  
  5. Connect the demister hoses. Install the nuts to the fire wall and connect the hanger strap inside the passenger compartment.
  6.  
  7. Fold the carpeting back into position.
  8.  
  9. Install the bolt that attaches the right side of the instrument panel to the cowl.
  10.  
  11. Connect the blower motor wiring, antenna, resistor wiring and the temperature control cable.
  12.  
  13. Install the air distribution ducts.
  14.  
  15. Install the floor console, if equipped.
  16.  
  17. Install the radio and all other dashboard-mounted items that were removed during the disassembly procedure.
  18.  
  19. Install the lower instrument panel reinforcements and silencers.
  20.  
  21. Install all modules, relay panels and computer components that were removed during the disassembly procedure.
  22.  
  23. Install the glove box, and right side kick and sill panels. Install the passenger seat.
  24.  
  25. Connect the heater hoses.
  26.  
  27. Connect the vacuum lines at the brake booster and water valve.
  28.  
  29. Using new gaskets, install the H-valve and condensation tube.
  30.  
  31. Have the air conditioning system evacuated and recharged by a qualified professional mechanic utilizing the proper equipment.
  32.  
  33. Fill the cooling system.
  34.  
  35. Connect the negative battery cable and check the entire climate control system for proper operation and leakage.
  36.  

1989-93 DYNASTY



It is vital to have the A/C system discharged by a reputable automotive technician utilizing a recovery/recycling machine before detaching the A/C system. Refer to the A/C system precautions presented in Routine Maintenance .

  1. Have the air conditioning system discharged by a qualified professional mechanic using an approved recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable. Refer to the supplemental restraint system disarming service procedure as necessary.
  4.  


CAUTION
When draining 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. 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.
  2.  
  3. Disconnect the H-valve connection at the valve and remove the H-valve. Remove the condensation tube.
  4.  
  5. Disconnect the vacuum lines at the brake booster and water valve, if equipped.
  6.  
  7. Remove the right upper and lower under-panel silencers.
  8.  
  9. Remove the steering column cover and the ashtray.
  10.  
  11. Remove the left side under-panel silencer.
  12.  
  13. Remove the right side cowl trim piece.
  14.  
  15. Remove the glove box assembly and the right side instrument panel reinforcement.
  16.  
  17. Remove the center distribution and defroster adaptor ducts.
  18.  
  19. Detach the relay module, blower motor wiring, 25-way connector bracket and fuse block from the panel.
  20.  
  21. Disconnect the demister hoses from the top of the package.
  22.  
  23. Disconnect the temperature control cable and vacuum harness, if equipped. If equipped with Automatic Temperature Control (ATC), detach the instrument panel wiring from the rear of the ATC unit.
  24.  
  25. Disconnect the hanger strap from the package and rotate it out of the way.
  26.  
  27. Remove the retaining nuts from the package mounting studs at the fire wall.
  28.  
  29. Fold the carpeting and insulation back to provide a little more working room and to prevent spillage from staining the carpeting.
  30.  
  31. Move the package rearward to clear the mounting studs and lower.
  32.  
  33. Pull the right side of the instrument panel out as far as possible. Rotate the package while removing it from under the instrument panel.
  34.  
  35. To disassemble the housing assembly, remove the vacuum diaphragm, if equipped, then remove the retaining screws from the cover and remove the cover.
  36.  
  37. Remove the retaining screw from the heater core and remove the core from the housing assembly.
  38.  

To install:
  1. Remove the temperature control door from the housing and clean the unit out with solvent. Lubricate the lower pivot rod and its well, then install. Wrap the heater core with foam tape and place it in position. Secure it with its screw.
  2.  
  3. Assemble the package, making sure all vacuum tubing is properly routed.
  4.  
  5. If equipped, feed the vacuum lines through the hole in the fire wall and install the assembly to the vehicle. Connect the vacuum harness and demister hoses. Install the nuts to the fire wall and fasten the hanger strap inside the passenger compartment.
  6.  
  7. Fold the carpeting back into position.
  8.  
  9. Connect the wiring to the ATC unit, if equipped.
  10.  
  11. Install the fuse block. Attach the 25-way connector, relay module and blower motor wiring.
  12.  
  13. Install the center distribution and defroster adaptor ducts.
  14.  
  15. Install the right side instrument panel reinforcement and the glove box assembly.
  16.  
  17. Install the right side cowl trim piece, left side under-panel silencer, steering column cover, ashtray and right side under-panel silencers.
  18.  
  19. Connect the vacuum lines at the brake booster and water valve.
  20.  
  21. Using new gaskets, install the H-valve and condensation tube.
  22.  
  23. Connect the heater hoses.
  24.  
  25. Fill the cooling system, as described in Routine Maintenance .
  26.  
  27. Connect the negative battery cable and check the entire climate control system for proper operation and leakage.
  28.  
  29. Have the air conditioning system evacuated and recharged by a qualified professional mechanic utilizing the proper equipment.
  30.  

MONACO

For the procedure applicable for 1989 Premier models, refer to the 1988 Premier procedure earlier in this section.

 
label.common.footer.alt.autozoneLogo