Chrysler Full-Size Vans 1967-1988 Repair Guide

Evaporator Core

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REMOVAL & INSTALLATION



1970-79 Models

  1. Discharge the system. Refer to General Information And Maintenance .
  2.  
  3. Disconnect the battery ground.
  4.  
  5. Drain the cooling system.
  6.  


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. Remove the grille.
  2.  
  3. Remove the condenser.
  4.  
  5. Remove the radiator. Refer to Engine And Engine Overhaul .
  6.  
  7. Cover the alternator with a plastic bag.
  8.  
  9. Disconnect the heater hoses at the core tubes.
  10.  
  11. Using a back-up wrench on the fittings, disconnect the refrigerant lines at the case. Cap all openings at once!
  12.  
  13. Remove the glove box.
  14.  
  15. Remove the spot cooler bezel and appearance shield.
  16.  
  17. Working through the glove box, remove the evaporator housing-to-dash panel attaching screws and nuts.
  18.  
  19. Remove the windshield wiper motor.
  20.  
  21. Tag and disconnect all wiring and hoses at the evaporator case.
  22.  
  23. Disconnect the blower motor cooler hose and drain hoses.
  24.  
  25. Remove the two 2 1 / 4 " bolts from the crossbar and the four screws from the sealplate on the front of the housing.
  26.  
  27. Separate the evaporator housing from the blower motor housing and carefully remove it from the van.
  28.  
  29. Remove the receiver-drier, using a back-up wrench on the fittings, and cap all openings at once!
  30.  
  31. Carefully pry the heater core from the housing. Don't remove the seal unless it is damaged and is being replaced.
  32.  
  33. Remove the 6 evaporator core mounting screws from the housing; 3 on each side.
  34.  
  35. Remove the 19 sheet metal screws joining the top and bottom of the housing.
  36.  
  37. Lift the evaporator core from the housing.
  38.  

To install:
  1. Install the evaporator in the housing.
  2.  
  3. Install the 19 sheet metal screws joining the top and bottom of the housing.
  4.  
  5. Install the 6 evaporator core mounting screws in the housing.
  6.  
  7. Install the evaporator housing on the blower motor housing.
  8.  
  9. Install the two 2 1 / 4 " bolts in the crossbar and the four screws in the sealplate on the front of the housing.
  10.  
  11. Connect the blower motor cooler hose and drain hoses.
  12.  
  13. Connect all wiring and hoses at the evaporator case.
  14.  
  15. Install the windshield wiper motor.
  16.  
  17. Working through the glove box, install the evaporator housing-to-dash panel attaching screws and nuts.
  18.  
  19. Install the spot cooler bezel and appearance shield.
  20.  
  21. Install the glove box.
  22.  
  23. Using a back-up wrench on the fittings, connect the refrigerant lines at the case.
  24.  
  25. Connect the heater hoses at the core tubes.
  26.  
  27. Uncover the alternator.
  28.  
  29. Install the radiator. Refer to Engine And Engine Overhaul .
  30.  
  31. Install the condenser.
  32.  
  33. Install the grille.
  34.  
  35. Fill the cooling system.
  36.  
  37. Connect the battery ground.
  38.  
  39. Evacuate, charge and leak test the system. Refer to General Information And Maintenance .
  40.  

1980-88 Models

  1. Discharge the system. Refer to General Information And Maintenance .
  2.  
  3. Disconnect the battery ground.
  4.  
  5. Drain the cooling system.
  6.  


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. Cover the alternator with a plastic bag.
  2.  
  3. Disconnect the heater hoses at the core tubes.
  4.  
  5. Using a back-up wrench on the fittings, disconnect the refrigerant lines at the H-valve. Cap all openings at once!
  6.  
  7. Remove the 2 screws from the filter-drier bracket and swing the piping out of the way, towards the center of the van. Cap all openings at once!
  8.  
  9. Remove the temperature control cable from the case cover.
  10.  
  11. Remove the glove box.
  12.  
  13. Remove the spot cooler bezel and appearance shield.
  14.  
  15. Working through the glove box, remove the evaporator housing-to-dash panel attaching screws and nuts.
  16.  
  17. Remove the 2 screws from the flange connection at the blower housing. Separate the evaporator housing from the blower motor housing and carefully remove it from the van.
  18.  
  19. Remove the cover from the housing.
  20.  
  21. Remove 1 screw from the strap on the heater core tubes and pull the core from the housing.
  22.  
  23. Remove the attaching screw from under the plumbing attachment plate and pull the evaporator core from the housing.
  24.  

To install:
  1. Put the evaporator core in the housing. Install the attaching screw under the plumbing attachment plate.
  2.  
  3. Put the heater core in the housing. Install 1 screw in the strap on the heater core tubes.
  4.  
  5. Install the cover on the housing.
  6.  
  7. Join the evaporator housing to the blower motor housing. Install the 2 screws in the flange connection at the blower housing.
  8.  
  9. Working through the glove box, install the evaporator housing-to-dash panel attaching screws and nuts.
  10.  
  11. Install the spot cooler bezel and appearance shield.
  12.  
  13. Install the glove box.
  14.  
  15. Install the temperature control cable on the case cover.
  16.  
  17. Install the 2 screws from the filter-drier bracket.
  18.  
  19. Connect the refrigerant lines at the H-valve.
  20.  
  21. Connect the heater hoses at the core tubes.
  22.  
  23. Uncover the alternator.
  24.  
  25. Fill the cooling system.
  26.  
  27. Connect the battery ground.
  28.  
  29. Evacuate, charge and leak test the system. Refer to General Information And Maintenance .
  30.  

 
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