Dodge & Chrysler Heater Core Removal?

The complete step by step procedure to replace heater core.

The Details for Chrysler Aspen and Dodge Durango car/truck models.

The procedure for both Front and Rear Heater core removal is provided.

First the FRONT Heater Core Removal:----

1. Drain the engine cooling system.
2. Raise and support the vehicle.
3. Remove the right front wheelhouse splash shield.
4. Remove the heater hoses from the heater core tubes in the engine compartment.
5. Lower the vehicle.
   
   WARNING

   To avoid personal injury or death, on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, occupant classification system, seat belt tensioner, impact sensor, or Instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the Supplemental Restraint System (SRS). Failure to take the proper precautions could result in accidental airbag deployment.
6. Before proceeding with the following repair procedure, review all warnings and cautions at the beginning of this chapter.
7. Disconnect and isolate battery negative cable.
8. Using a trim stick C-4755 or equivalent, remove the left door sill trim cover.
9. Remove the screw and remove the left cowl trim cover.
10. Remove the left instrument panel end cap.
11. Remove the two screws and remove the steering column opening cover.
12. Remove the screws and position aside the hood release handle.
13. Remove the four screws and remove the steering column opening reinforcement.
14. Remove the steering column tilt lever.
15. Remove the upper and lower column shrouds.
16. Disconnect the wiring harness connectors to the column.
17. Remove the shift cable from the column shift lever actuator.
18. Release the shift cable from the column bracket and remove it from the bracket.
19. Remove the SKIM module in order to disconnect the electrical connector.
20. Remove the upper steering shaft coupler bolt and slide the shaft down.
21. Remove the brake light switch and discard.
22. Remove the four steering column mounting nuts.
23. Lower the column from the mounting studs.
24. Remove the steering column assembly from the vehicle.
25. Remove the pedal support bracket bolts.
26. Disengage the release rod from the arm on the pedal assembly.
27. Disconnect the electrical connectors from the fuse block.
28. Remove the bolt and remove the ground wire.
29. Open the trim covers in the drivers side a-pillar grab handle and remove the bolts.
30. Remove the a-pillar trim panel.
31. Remove the floor console.
32. Disconnect the two body wire harness connectors from the Occupant Restraint Controller (ORC) connector receptacles located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector.
33. Position the carpet aside and remove the center harness screws. Pull instrument panel wiring harness from under the carpet.
34. Remove the center support bolts.
35. Remove the driver-s seat.
36. Remove the drivers side floor duct.
37. Remove the drivers side support bolts.
38. Remove the right instrument panel end cap.
39. Remove the passenger side support bolts.
40. Using a trim stick C-4755 or equivalent, remove the right door sill trim cover.
41. Remove the screw and remove the right cowl trim cover.
42. Remove the bolts and remove the amplifier.
43. Disconnect the amplifier and antenna electrical connectors.
44. Remove the harness bolt and the ground wire bolt.
45. Remove the passenger side rear floor duct.
46. Open the trim covers in the passenger side a-pillar grab handle and remove the bolts.
47. Remove the a-pillar trim panel.
48. Using a trim stick C-4755 or equivalent, remove the instrument panel defroster grille.
49. Disconnect the sensor electrical connector.
50. Remove the four fenceline bolts.
51. Lift the instrument panel assembly off the side support pins and remove assembly through the driver-s door.
52. Remove the bolt that secures the HVAC housing bracket to the dash panel.
53. Remove the two screws that secure the HVAC housing bracket to the top of the HVAC housing.
54. Remove the HVAC housing bracket from the vehicle.
55. Remove the screw that secures the heater core tube retaining bracket to the top of the HVAC housing.
56. Remove the heater core tube retaining bracket from the HVAC housing.
57. Remove the screw that secures the heater core tubes to the heater core.
58. Remove the heater core tubes from the heater core and the dash panel. Remove the O-ring seals from the heater core tube fittings and discard.
59. Remove the two screws that secure the heater core retaining bracket to the top of the HVAC housing.
60. Remove the heater core retaining bracket from the top of the HVAC housing.
61. Carefully lift the heater core out of the HVAC housing. 
    
    
    
    Fig. Heater core and related components

To install:

1. Carefully install the heater core and the heater core retaining bracket to the top of the HVAC housing. Make sure that the heater core insulator is properly positioned.
2. Install the two screws that secure the heater core and retaining bracket to the HVAC housing. Tighten the screws to 20 inch lbs. (2.2 Nm).
3. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tube fittings. Use only the specified O-ring as it is made of a special material for the engine cooling system.
4. Install the heater core tubes through the dash panel and to the heater core.
5. Install the screw that secures the heater core tubes to the heater core. Tighten the screw securely.
6. Install the heater core tube retaining bracket to the top of the HVAC housing.
7. Install the screw that secures the heater core tube retaining bracket to the HVAC housing. Tighten the screw to 20 inch lbs. (2.2 Nm).
8. Install the HVAC housing bracket to the top of HVAC housing and to the dash panel.
9. Install the two screws that secure the HVAC housing bracket to the HVAC housing. Tighten the screws to 20 inch lbs. (2.2 Nm).
10. Install the bolt that secures the HVAC housing bracket to the dash panel. Tighten the bolt to 26 inch lbs. (3 Nm).
11. Position the instrument panel assembly into the vehicle through the driver-s side door and install onto the side support pins.
12. Install the four fenceline bolts and tighten to 70 inch lbs. (8 Nm).
13. Connect the sensor electrical connector.
14. Install the instrument panel defroster grille and seat fully.
15. Position the passenger side a-pillar trim panel into place and seat fully.
16. Install the bolts and tighten to 55 inch lbs. (6 Nm).
17. Install the passenger side rear floor duct.
18. Install the screws for the ground wire and passenger side wire harness.
19. Tighten the ground wire and harness bolts to 10 ft. lbs. (14 Nm).
20. Connect the amplifier and antenna electrical connectors.
21. Install the amplifier and install the bolts.
22. Tighten the bolts to 50 inch lbs. (6 Nm).
23. Install the right cowl trim cover and install the screw.
24. Install the right door sill trim cover.
25. Install the passenger side support bolts and tighten to 20 ft. lbs. (27 Nm).
26. Install the right instrument panel end cap.
27. Install the drivers side support bolts and tighten to 20 ft. lbs. (27 Nm).
28. Install the drivers side floor duct.
29. Install the driver-s seat.
30. Install the center support bolts and tighten to 95 inch lbs. (11 Nm).
31. Position the center instrument panel wiring harness under the carpet and install the bolts.
    
    CAUTION

    The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged.
32. Reconnect the two body wire harness connectors to the ORC connector receptacles located on the forward facing side of the module. Be certain that the latches on both connectors are each fully engaged.
33. Install the floor console.
34. Position the driver-s side a-pillar trim into place and seat the retaining clips fully.
35. Install the bolts and tighten to 55 inch lbs. (6 Nm).
36. Install the ground wire and install the bolt.
37. Tighten the ground wire bolts to 10 ft. lbs. (14 Nm).
38. Connect the electrical connectors at the fuse block.
39. Connect the brake release rod to the arm on the pedal assembly.
40. Install the pedal support bolts and tighten to 10 ft. lbs. (14 Nm).
    
    CAUTION

    All fasteners must be torqued to specification to ensure proper operation of the steering column.
41. Position the steering column on the dash panel support and loosely install the mounting nuts.
42. Firmly slide the steering column upward against the studs in dash panel and hand tighten the nuts.
43. Install the steering shaft coupler on the steering shaft and loosely install a new bolt.
44. Center steering column in dash opening and tighten mounting nuts to 21 ft. lbs. (28 Nm).
    
    NOTE

    Torque the upper left nut first then the lower right nut. Then torque the lower left nut then the upper right nut.
    
    
    
    NOTE

    A new bolt must be used for reinstallation.
45. Tighten the coupler bolt to 28 ft. lbs. (38 Nm).
46. Install a new brake light switch.
47. Install the shifter cable.
48. Connect the wiring harness to the column.
49. Install the SKIM module.
50. Install the upper and lower column shrouds and install the screws.
51. Install the column tilt lever.
52. Install the steering column opening reinforcement and install the four screws.
53. Install the hood release handle and install the screws.
54. Install the steering column opening cover and install the two screws.
55. Install the left instrument panel end cap.
56. Install the left cowl trim cover and install the screw.
57. Install the left door sill trim cover and seat fully.
58. Do not reconnect the battery negative cable at this time. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component.
59. Raise the vehicle and install the heater hoses to the heater core tubes in the engine compartment.
60. Install the right front wheelhouse splash shield.
61. Lower the vehicle.
62. Refill the engine cooling system.

NOW The REAR Heater Core Removal:---

1. Disconnect the negative battery cable.
2. Drain the engine cooling system into a clean container for reuse.
3. Recover the refrigerant from the refrigerant system.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Rear quarter trim panel, as necessary

   Right rear quarter trim panel

   A/C suction and discharge lines. Install plugs in, or tape over, the opened refrigerant line fittings.

   Heater hoses from the rear auxiliary heater core

   Electrical connectors, as necessary

   Drain valve

   Rear auxiliary heater assembly-to-chassis nuts and bolts

   Rear auxiliary heater assembly

   Blower motor from the heater assembly, if necessary

   Rear auxiliary heater assembly cover

   Heater core from the rear auxiliary assembly

   Installation is the reverse of removal.

These details will help.

Thanks.           

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Car repair guide?

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