Chrysler Full-Size Vans 1967-1988 Repair Guide

Heater Core

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REMOVAL & INSTALLATION



1967-69 Models

See Figures 1 and 2

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Fig. Fig. 1: Heater assembly details for 1967-69 vehicles



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Fig. Fig. 2: Heater and auxiliary heater hose connections for 1967-69 vehicles

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  


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. Working through the grille, disconnect the heater hoses from the core tubes.
  2.  
  3. Remove the 2 screws that attach the heater control assembly to the instrument panel and allow the bezel to drop.
  4.  
  5. Disconnect the heater control switch wire at the fuse panel.
  6.  
  7. Remove the 7 screws that attach the fresh air inlet to the dash panel.
  8.  
  9. Remove the 2 screws from the small heater mounting bracket at the top right corner of the heater.
  10.  
  11. Remove the 2 screws that mount the heater support bracket to the floor pan. Loosen the 2 adjusting screws on the heater support bracket.
  12.  
  13. Remove the 2 nuts that attach the heater assembly to the dash panel mounting studs.
  14.  
  15. Pull the heater assembly off the mounting studs, lower the heater assembly and disconnect the defroster hoses.
  16.  
  17. Remove the 7 screws that attach the cover to the heater and pry off the cover.
  18.  
  19. Disconnect the inlet hose coupling at the core.
  20.  
  21. Remove the core.
  22.  
  23. Replace any damaged sealing material.
  24.  

To install:
  1. Install the core.
  2.  
  3. Connect the inlet hose coupling at the core.
  4.  
  5. Install the cover on the heater.
  6.  
  7. Connect the defroster hoses. Position the heater assembly on the mounting studs.
  8.  
  9. Install the 2 nuts that attach the heater assembly to the dash panel mounting studs.
  10.  
  11. Install the 2 screws that mount the heater support bracket to the floor pan. Tighten the 2 adjusting screws on the heater support bracket.
  12.  
  13. Install the 2 screws in the small heater mounting bracket at the top right corner of the heater.
  14.  
  15. Install the 7 screws that attach the fresh air inlet to the dash panel.
  16.  
  17. Connect the heater control switch wire at the fuse panel.
  18.  
  19. Install the 2 screws that attach the heater control assembly to the instrument panel.
  20.  
  21. Working through the grille, connect the heater hoses to the core tubes.
  22.  
  23. Fill the cooling system.
  24.  
  25. Connect the battery ground cable.
  26.  

1970-77 Models

See Figures 3 and 4

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Fig. Fig. 3: Heater assembly details for 1970-77 vehicles



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Fig. Fig. 4: Heater control assembly mounting for 1970-77 vehicles

WITHOUT AIR CONDITIONING
  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  


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 wiring at the blower.
  4.  
  5. Disconnect the hoses at the core tubes.
  6.  
  7. Disconnect the control cables at the case.
  8.  
  9. Unbolt the water valve and move it aside without disconnecting the hoses.
  10.  
  11. Remove the blower motor cooling tube.
  12.  
  13. Remove the 3 housing retaining nuts and tip the unit out through the hood opening.
  14.  
  15. Remove the 3 nuts and lift the blower motor from the case.
  16.  
  17. Remove the 4 cover nuts and lift the cover off.
  18.  
  19. Remove the 4 core retaining screws and lift out the core.
  20.  
  21. Replace any damaged sealing material.
  22.  
  23. Install the core in the case.
  24.  
  25. Install the 4 core retaining screws.
  26.  
  27. Install the cover.
  28.  
  29. Install the blower motor in the case.
  30.  
  31. Install the housing.
  32.  
  33. Install the blower motor cooling tube.
  34.  
  35. Install the water valve.
  36.  
  37. Connect the control cables at the case.
  38.  
  39. Connect the hoses at the core tubes.
  40.  
  41. Connect the wiring at the blower.
  42.  
  43. Uncover the alternator.
  44.  
  45. Fill the cooling system.
  46.  
  47. Connect the battery ground cable.
  48.  

WITH AIR CONDITIONING

See Figures 5, 6, 7 and 8

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Fig. Fig. 5: Heating/air conditioning control unit and schematic for 1970-75 vehicles



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Fig. Fig. 6: Heating/air conditioning assembly mounting for 1970-75 vehicles



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Fig. Fig. 7: Heating/air conditioning control unit and schematic for 1976-77 vehicles



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Fig. Fig. 8: Heating/air conditioning assembly details for 1976-77 vehicles

  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. Refer to the applicable procedure in this section.
  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 and cap all openings at once!
  30.  
  31. Carefully pry the heater core from the housing. Don't remove the air seal from the front of the core unless it is damaged.
  32.  

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

1978-79 Models
WITHOUT AIR CONDITIONING

See Figure 9

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Fig. Fig. 9: Heater assembly for 1978-79 vehicles

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  


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. Disconnect the heater hoses at the core tubes.
  2.  
  3. Disconnect the temperature control cable at the heater core cover and air door crank.
  4.  
  5. Disconnect the wiring at the blower resistor.
  6.  
  7. Remove the coolant overflow tank.
  8.  
  9. Remove the heater case mounting nuts and remove the heater case from the van.
  10.  
  11. Remove the heater core cover.
  12.  
  13. Remove the 2 heater core retaining screws and lift the core from the case.
  14.  
  15. Replace any damaged sealing material.
  16.  
  17. Lower the core into the case and install the 2 heater core retaining screws.
  18.  
  19. Install the heater core cover.
  20.  
  21. Install the heater case in the van and install the 5 heater case mounting nuts.
  22.  
  23. Install the coolant overflow tank.
  24.  
  25. Connect the wiring at the blower resistor.
  26.  
  27. Connect the temperature control cable at the heater core cover and air door crank.
  28.  
  29. Connect the heater hoses at the core tubes.
  30.  
  31. Fill the cooling system.
  32.  
  33. Connect the battery ground cable.
  34.  

WITH AIR CONDITIONING

See Figures 10 through 21

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Fig. Fig. 10: Heating/air conditioning control unit and schematic for 1978-79 vehicles



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Fig. Fig. 11: Heating/air conditioning assembly for 1978-79 vehicles



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Fig. Fig. 12: To remove the heater core, drain the cooling system and loosen the heater hose clamps ...



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Fig. Fig. 13: ... then disconnect the hoses from the heater box



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Fig. Fig. 14: Disconnect the temperature control cable from the air door crank ...



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Fig. Fig. 15: ... and unsnap the cable housing from the heater box



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Fig. Fig. 16: Unplug any electrical connections to the heater box, then remove the box retaining nuts



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Fig. Fig. 17: Pull the heater box assembly out of the vehicle



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Fig. Fig. 18: Remove the heater box cover retaining screws (arrows) ...



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Fig. Fig. 19: ... and remove the cover from the heater box



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Fig. Fig. 20: Remove the two heater core retaining screws (A & B; A is visible, B is behind the box opening) ...



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Fig. Fig. 21: ... and lift the heater core out of the box

  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. Refer to the applicable procedure in this section.
  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 and cap all openings at once!
  30.  
  31. Carefully pry the heater core from the housing. Don't remove the air seal from the front of the core unless it is damaged.
  32.  

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

1980-88 Models
WITHOUT AIR CONDITIONING

See Figure 12

Click image to see an enlarged view

Fig. Fig. 22: Heater assembly details for 1980-88 vehicles

  1. Disconnect the battery ground cable.
  2.  
  3. Drain the cooling system.
  4.  


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. Disconnect the heater hoses at the core tubes.
  2.  
  3. Disconnect the temperature control cable at the heater core cover and air door crank.
  4.  
  5. Disconnect the wiring at the blower resistor.
  6.  
  7. Remove the coolant overflow tank.
  8.  
  9. Remove the 5 heater case mounting nuts and remove the heater case from the van.
  10.  
  11. Remove the heater core cover.
  12.  
  13. Remove the 2 heater core retaining screws and lift the core from the case.
  14.  
  15. Replace any damaged sealing material.
  16.  
  17. Lower the core into the case and install the 2 heater core retaining screws.
  18.  
  19. Install the heater core cover.
  20.  
  21. Install the heater case in the van and install the 5 heater case mounting nuts.
  22.  
  23. Install the coolant overflow tank.
  24.  
  25. Connect the wiring at the blower resistor.
  26.  
  27. Connect the temperature control cable at the heater core cover and air door crank.
  28.  
  29. Connect the heater hoses at the core tubes.
  30.  
  31. Fill the cooling system.
  32.  
  33. Connect the battery ground cable.
  34.  

WITH AIR CONDITIONING

See Figures 13 and 24

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Fig. Fig. 23: Heating/air conditioning assembly for 1980-82 vehicles



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Fig. Fig. 24: Heating/air conditioning assembly for 1983-88 vehicles

  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.  

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

 
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