Chrysler Full-Size Vans 1989-1998 Repair Guide

Heater Core

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REMOVAL & INSTALLATION



Front Heater Core-Without Air Conditioning
  1. Disconnect the negative 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 connector at the blower motor.
  6.  
  7. Remove the heater case mounting nuts and bolts from the side cowl and firewall. Remove the heater case from the vehicle.
  8.  
  9. Remove the back plate from the heater assembly. Remove the heater core cover
  10.  
  11. Remove the heater core retaining screws and lift the core from the case.
  12.  

To install:
  1. Replace any damaged sealing material.
  2.  
  3. Lower the core into the case and install the core retaining screws.
  4.  
  5. Install the heater core cover and backing plate.
  6.  
  7. Install the heater case in the van and install the heater case mounting nuts and bolts.
  8.  
  9. Connect the wiring at the blower resistor.
  10.  
  11. Connect the temperature control cable at the heater core cover and air door crank.
  12.  
  13. Connect the heater hoses at the core tubes.
  14.  
  15. Fill and bleed the cooling system.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Check the heating system operation.
  20.  

Front Heater Core-With Air Conditioning

See Figure 1

  1. Have the vehicle's air conditioning system discharged by a certified MVAC technician.
  2.  
  3. Disconnect the negative battery ground cable.
  4.  
  5. Drain the cooling system. Disconnect the freeze control connector from the wiring harness at the H-expansion valve (years equipped).
  6.  


CAUTION
Never open, service or drain the radiator or cooling system when hot; serious burns can occur from the steam and hot coolant. Also, when draining engine coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze and could drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantities. Always drain coolant into a sealable container. Coolant should be reused unless it is contaminated or is 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 mounting 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 mounting 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 the 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 the screw in the strap on the heater core tubes.
  2.  
  3. Install the cover on the housing. Place the housing into position in the van.
  4.  
  5. Join the evaporator housing to the blower motor housing. Install the mounting 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 mounting 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 and bleed the cooling system.
  24.  
  25. Connect the freeze control wiring harness.
  26.  
  27. Connect the negative battery cable.
  28.  
  29. Have a certified MVAC service technician evacuate, charge and leak test the A/C system.
  30.  



Click image to see an enlarged view

Fig. Fig. 1: The heater core is mounted adjacent to the evaporator coil

Auxiliary Heater Core

See Figures 2, 3 and 4

The rear heater core and evaporator core are one unit and are serviced as a single unit, called a combination coil.

  1. Have the system discharged by a certified MVAC technician.
  2.  
  3. Disconnect the negative battery ground cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the expansion valve from the combination coil.
  10.  
  11. Disconnect the rear heater hoses and the A/C lines from the combination coil and plug or cover the combination coil tubes.
  12.  
  13. Remove the cover from the auxiliary heater-A/C unit.
  14.  
  15. Remove the vertical duct from the auxiliary heater-A/C unit.
  16.  
  17. Remove the horizontal duct from the auxiliary heater-A/C unit.
  18.  
  19. Remove the upper housing from the auxiliary heater-A/C unit.
  20.  
  21. Remove the combination coil from the auxiliary heater-A/C unit lower housing.
  22.  

To install:
  1. Install the combination coil into the auxiliary heater-A/C unit lower housing.
  2.  
  3. Install the upper housing on the auxiliary heater-A/C unit.
  4.  
  5. Install the horizontal duct on the auxiliary heater-A/C unit.
  6.  
  7. Install the vertical duct on the auxiliary heater-A/C unit.
  8.  
  9. Install the cover on the auxiliary heater-A/C unit.
  10.  
  11. Remove the plugs and connect the heater hoses and A/C lines to the combination coil.
  12.  
  13. Install the expansion valve on the combination coil.
  14.  
  15. Lower the vehicle.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Have a certified MVAC service technician evacuate, charge and leak test the system.
  22.  



Click image to see an enlarged view

Fig. Fig. 2: View of the auxiliary heater-A/C unit with its cover installed



Click image to see an enlarged view

Fig. Fig. 3: Unfasten the retainers and remove the unit's cover



Click image to see an enlarged view

Fig. Fig. 4: The auxiliary heater water control valve

 
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