Chrysler Neon 1995-1999 Repair Guide

Heater Core

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REMOVAL & INSTALLATION



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

In order to remove the heater core, you must first remove the HVAC unit housing, then disassemble the unit to remove the core.

  1. If equipped with A/C, 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 General Information & Maintenance .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the instrument panel from the vehicle, as outlined in Chassis Electrical of this guide.
  6.  
  7. Drain the cooling system into a suitable container, then disconnect the heater hoses from the dash panel. Plug the heater core outlets to prevent coolant from spilling during unit housing removal.
  8.  
  9. If equipped with A/C, perform the following:
    1. Remove the suction line from the expansion valve. Place a piece of tap over the open refrigerant line to prevent the system from being contaminated.
    2.  
    3. Remove the expansion valve from the evaporator. Place a piece of tap over the open evaporator fitting to prevent dirt and/or moisture from entering the evaporator.
    4.  
    5. Disconnect the rubber drain tube extension from the condensation drain tube.
    6.  

  10.  
  11. Remove the 3 retaining nuts located in the engine compartment on the dash panel.
  12.  



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Fig. Fig. 1: Location of the 3 dash panel retaining studs

  1. Unfasten the right side retaining screw.
  2.  
  3. Remove the remaining nut located on the dash panel stud.
  4.  



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Fig. Fig. 2: Unit housing retaining screw location

  1. Detach the blue 1-way connector from the plenum. The module wiring harness must be removed with the module.
  2.  
  3. Remove the unit housing from the vehicle.
  4.  

For right-hand drive vehicles, the unit housing does not separate. It is a one piece unit and must be replaced as an assembly.

  1. Remove the clips and screws that secure the air distribution module to the evaporator/blower module. Then, separate the 2 units.
  2.  



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Fig. Fig. 3: You must remove the retainers, then separate the air distribution module from the evaporator/blower module

  1. Remove the panel opening foam seal, demister opening foam seal, and heater core tube foam seals from the unit.
  2.  
  3. Unfasten the retaining clips and screws that hold the upper and lower housings together.
  4.  



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Fig. Fig. 4: Remove the upper-to-lower housing retaining clips and screws ...

  1. Place the unit in the upside down position, then separate the two halves of the module.
  2.  



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Fig. Fig. 5: ... then separate the two halves of the module

  1. Lift the heater core up and out of the case.
  2.  



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Fig. Fig. 6: Remove the heater core from the case

To install:
  1. Place the heater core in the case.
  2.  
  3. Position the upper and lower halves of the module together, then secure with the retaining screws and clips.
  4.  
  5. Install the heater core tube foam seals, demister opening foam seal and the panel opening foam seal into the unit.
  6.  
  7. Position the air distribution module to the evaporator/blower module. Then, secure with the retaining screws and clips.
  8.  
  9. Install the unit housing in the vehicle.
  10.  
  11. Attach the blue 1-way connector to the plenum.
  12.  
  13. Install the nut located on the dash panel stud and the right side retaining screw.
  14.  
  15. Install the 3 retaining nuts to the dash panel in the engine compartment.
  16.  
  17. The remainder of installation is the reverse of the removal procedure.
  18.  
  19. Instrument panel installation procedures can be found in Chassis Electrical of this guide.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Have the A/C system evacuated, recharged and leak tested by a reputable automotive technician utilizing a recovery/recycling apparatus.
  24.  

 
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