How to replace Heater Core on Dodge and Chrysler?

In this chapter complete Heater core replacing procedure is provided.

Please Note that this Procedure Covers all U.S. and Canadian models of the Chrysler/Dodge Avenger, Chrysler Sebring Coupe and Dodge Stratus/ Stratus Coupe models for Year 1999 to 2005.

The Chapter provides heater core removal.Heater core installing procedure.
The Heater core location and removing diagrams.
Junction block location-Diagram For Cirrus, Stratus, Sebring convertible and Breeze.
Heater/air conditioning housing assembly Diagram.
HVAC housing Diagram.
Heater core Location under HVAC housing.
This all details are mentioned here.View complete procedure for all this details and helpful diagrams.

The procedure is as follows:---

1. Disconnect the negative battery cable. Properly drain the cooling system.
2. Disconnect the heater hoses from the heater core.
3. Remove the floor console by removing or disconnecting the following:
   
   
   Center console panel

   Shift knob

   Accessory box or ashtray

   Floor console panel assembly

   Shift lever cover assembly

   Floor console assembly
4. From under the steering wheel, remove the hood lock release handle, the driver-s side under cover and the lap cooler grille.
5. Remove the steering wheel by removing or disconnecting the following:
   
   
   Air bag module-to-steering wheel screws (rear of the steering wheel) and the air bag module

   Steering wheel-to-column nut and press the steering wheel from the column

   Lower steering column cover screws, the lower cover, the upper cover and the column pad
6. Remove the instrument panel by removing or disconnecting the following:
   
   
   Meter bezel and the combination meter

   Radio and tape player

   Console side cover

   Sunglass holder

   Glove box stopper and the glove box

   Passenger-s side air bag module

   Passenger-s side air bag module electrical connector

   Center air outlet assembly

   Instrument panel switch

   Instrument panel switch electrical connectors

   Right side instrument panel under cover

   Front speaker

   Instrument panel
7. Remove the attaching clip and nuts and remove the heater unit.
8. Remove the heater core from the heater unit. 
   
   CAUTION

   Do not let the heater core bump against the SRS-ECU or its components.
   
   
   
   
   Fig. Exploded view of the center console
   
   
   
   Fig. Exploded view of the ventilators and related components
   
   
   
   
   Fig. Exploded view of the steering column and related components
   
   
   
   
   Fig. Exploded view of the instrument panel and related components
   
   
   
   
   Fig. Exploded view of the heater core housing and related components
   
   
   
   Fig. Exploded view of the evaporator core housing and related components
   
   
   
   
   Fig. Exploded view of the manual control head and related components

To install:

1. Install or connect the following components:
   
   
   Heater core into the heater unit

   Heater unit and attach the nuts and clip

   Instrument panel by reversing the removal procedures

   Steering column pad, the upper cover, the lower cover and the lower steering column cover screws

   Steering wheel by reversing the removal procedure

   Lap cooler grille, the driver-s side under cover and the hood lock release handle

   Floor console by reversing the removal procedure

   Heater hoses to the heater core
2. Refill the cooling system.
3. Connect the negative battery cable. Check for leaks.

1. Disconnect the negative battery cable.
2. Drain the cooling system into a clean container for reuse.
3. From the center of the instrument panel, grasp and pull to remove the radio/control module bezel. 
   
   
   
   Fig. Exploded view of the instrument panel assembly
   
   
   
   

   Fig. Junction block location-Cirrus, Stratus, Sebring convertible and Breeze
4. At the right side of the instrument panel, remove the side trim. 
   
   
   

   Fig. Unlock the glove box door stoppers by pushing in the direction shown-Cirrus, Stratus, Sebring Convertible and Breeze
5. Remove or disconnect the following: 
   
   
   2 lower right side support beam screws

   Instrument panel support-to-A-pillar bolt

   On left side of the instrument panel, remove the side trim

   Upper instrument panel bezel

   Lower knee bolster

   Console-to-instrument panel screws

   Gearshift knob and the shifter bezel

   Rear console screws and the rear console half

   Front console screws and the front console half

   Right side instrument panel support strut

   Heater hoses from the heater core tubes

   Heater core cover-to-heater/air conditioning housing assembly screws and the cover

   Heater core from the heater/air conditioning housing assembly 
   
   

   

   Fig. View of the heater/air conditioning housing assembly-Cirrus, Stratus and Breeze

   
   
   
   

   Fig. View of the heater housing assembly and the heater core-Cirrus, Stratus and Breeze

To install:

1. Install or connect the following:
   
   
   Heater core to the heater/air conditioning housing assembly

   Heater core cover and the cover-to-heater/air conditioning housing assembly screws

   Heater hoses to the heater core tubes

   Right side instrument panel support strut

   Front console half and the front console screws

   Rear console half and the rear console screws

   Shifter bezel and the gearshift knob

   Console-to-instrument panel screws

   Lower knee bolster

   Upper instrument panel bezel

   On left side of the instrument panel, install the side trim

   Instrument panel support-to-A-pillar bolt

   2 lower right side support beam screws

   Right side of the instrument panel, install the side trim

   On center of the instrument panel, install the radio/control module bezel
2. Refill the cooling system.
3. Connect the negative battery cable.
4. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

============================================================
MORE HELP DETAILS AND PROCEDURE:------

NOTE

The instrument panel and HVAC housing are removed from the vehicle together as an assembly.

1. Recover the refrigerant from the refrigerant system.
2. Drain the engine cooling system.
3. Disconnect and isolate the negative battery cable.
4. Remove the one bolt retaining the A/C lines to the right strut tower.
5. Remove the two top HVAC housing retaining nuts in engine compartment.
6. Hoist vehicle and remove the lower HVAC housing retaining nut.
7. Lower vehicle from hoist.
8. Remove the driver-s and passenger-s seats:
   1. Position seat far enough forward to gain access to rear mount bolts on floor.
   2. Remove bolts holding rear of seat track to floor.
   3. Slide seat rearward.
   4. Remove bolts attaching front of the seat track to floor kick up.
   5. Disconnect negative battery cable, if electrical seat.
   6. Disconnect front seat wire harness connector from body harness connector.
      
      CAUTION

      Do not handle seat by adjuster release bar when removing spring loaded seat from vehicle.
   7. Remove front seat from vehicle.
9. Disconnect and isolate the battery negative remote cable.
10. Remove the one screw to shift knob and transmission range indicator bezel from floor console.
11. Remove the floor center console. Remove two mounting screws in the front and two mounting screws inside console storage bin.
12. Remove the amplifier retaining fasteners.
13. Disconnect the wire harness connector.
14. Remove the amplifier.
15. Using a trim stick or equivalent, gently pry out on the left and right rear floor heat ducts and remove.
16. Disconnect the console wiring connectors and unclip the push in fasteners.
17. Using a trim stick or equivalent, gently pry up on and remove the right sill plate.
18. Remove the two screws to the right cowl kick panel and remove from vehicle.
19. Using a trim stick or equivalent, gently pry out on the right end cover and remove from vehicle.
20. Using a trim stick or equivalent, gently pry out on the right A-pillar trim and remove from vehicle.
21. Open the glove box. Pinch in on the sides and drop to the floor. Pull down to disengage hinges.
22. Disconnect the right door harness connectors located within the A-pillar.
23. Remove the four right A-pillar instrument panel retainers.
24. Remove the right silencer.
25. Remove the one right side, center instrument panel support bolt.
26. Using a trim stick or equivalent, gently pry up on and remove the left sill plate.
27. Remove the two screws to the left cowl kick panel and remove from vehicle.
28. Using a trim stick or equivalent, gently pry out on the left end cover and remove from vehicle.
29. Using a trim stick or equivalent, gently pry out on the left A-pillar trim and remove from vehicle.
30. Disconnect the left door harness connectors located within the A-pillar.
31. Remove the four left A-pillar instrument panel retainers.
32. Remove the five screws and one wire connector to left lower instrument panel trim bezel.
33. Remove the left silencer.
34. Remove the one left side, center instrument panel support bolt.
35. Remove the one bolt to the left side support strut to bulkhead.
36. Disconnect the junction block wiring connectors.
37. Remove the two screws to the steering column shrouds and remove.
38. Disconnect all the column wiring and unclip the harness from the steering column.
39. Disconnect the transmission shift interlock and wire connector.
40. Remove the four steering column retaining bolts and drop column to floor.
41. Using a trim stick or equivalent, pry up on the rear of the top cover and pull rearward as you lift it off of instrument panel.
42. Remove the instrument panel pad.
43. Remove the seven bolts and five screws attaching instrument panel to fence line and cowl side.
44. With the help of an assistant, lift up instrument panel and move rearward to remove. Tilt the panel rearward to prevent the coolant from leaking out. If replacing the instrument panel, transfer all non-damaged parts and wiring harness to the new instrument panel assembly.
45. Disconnect HVAC wire harness from the instrument panel wire harness connector at the left side of the HVAC housing.
46. Remove the two nuts and two bolts that secure the HVAC housing to the instrument panel.
47. Separate the HVAC housing from the instrument panel.
48. Disconnect the HVAC wire harness connectors from the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
49. Remove the two screws that secure the HVAC harness connector to the HVAC housing and remove the HVAC wire harness.
50. Remove the screws that secure the blower motor to the HVAC housing and remove the blower motor.
51. Remove the screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove it from the housing.
52. Remove the screws that secure the air inlet housing to the HVAC housing and remove the air inlet housing.
53. Remove the three screws that secure the recirculation door actuator to the air inlet housing and remove the actuator.
54. Remove the screw that secures the recirculation door actuator gear to the air inlet housing and remove the gear.
55. Using a small screwdriver, depress the recirculation door gear release and remove the recirculation door gear from the recirculation door shaft.
    
    NOTE

    If the seals on the recirculation-air door is deformed or damaged, the air door must be replaced.
56. Tilt the gear end of the recirculation-air door up and pull the door out of the air inlet housing.
    
    NOTE

    If either foam seal is deformed or damaged, it must be replaced.
57. Carefully, remove the foam seals from the heater core and the evaporator tube mounting flange of the HVAC housing.
58. Remove the screws that secure the upper and lower HVAC housing halves together and separate the housing halves.
59. Using a flat blade pry tool, disengage the locking tab on the access plate of the evaporator temperature sensor. Turn the access plate clockwise one quarter turn and push the access plate inside of the HVAC housing, then orientate the plate in such a way that it can be removed from the housing.
60. Remove the evaporator temperature sensor probe from the A/C evaporator and remove the sensor.
61. Lift the A/C evaporator out of the bottom half of the HVAC housing.
62. Lift the heater core out of the bottom half of the HVAC housing. 
    
    
    
    Fig. HVAC housing
    
    
    
    

    Fig. Heater core

To install:

1. Install the heater core into the bottom half of the HVAC housing.
2. Align the blend and mode door shafts with the holes in the HVAC housing and install the top half of the housing to the bottom half of the housing.
3. Install the screws that secure the two halves of the HVAC housing together. Tighten the screws to 18 inch lbs. (2 Nm).
4. Install the foam seals on the heater core and evaporator coil tube mounting flange.
5. Install the recirculation-air door into the air inlet housing.
6. Install the recirculation door gear onto the recirculation door shaft.
   
   NOTE

   The recirculation door actuator gear and door gear must be properly aligned to operate correctly.
7. Align and install the recirculation door actuator gear with the door gear.
8. Install the screw that secure the recirculation door actuator gear to the air inlet housing. Tighten the screw to 18 inch lbs. (2 Nm).
9. Align the recirculation door actuator spline with the spline in the recirculation door gear and install the recirculation door actuator.
10. Install the three screws that secure the recirculation door actuator to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
11. Install the air inlet housing onto the HVAC housing.
12. Install the screws that secure the air inlet housing to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
13. If removed, install the blower motor resistor or power module (depending on application). Install and tighten the screws to 18 inch lbs. (2 Nm).
14. If removed, install the blower motor. Install and tighten the screws to 18 inch lbs. (2 Nm).
    
    NOTE

    Make sure that all HVAC wire harness leads are routed through all HVAC housing wiring retainers.
15. Install the HVAC wire harness onto the HVAC housing.
16. Install the two screws that secure the HVAC wire harness connector to the HVAC housing. Tighten the screws to 18 inch lbs. (2 Nm).
17. Connect the HVAC wire harness connectors to the blower motor, blower motor resistor or power module (depending on application), evaporator temperature sensor and each actuator.
18. Position the HVAC housing to the instrument panel. Make sure that all air ducts are properly aligned or connected.
19. Install the two nuts and bolts that secure the HVAC housing to the instrument panel. Tighten the nuts and bolts securely.
20. Connect the HVAC wire harness to the instrument panel wire harness connector.
    
    NOTE

    Verify that the evaporator drain tube and evaporator seals are properly seated to the HVAC housing before installing the instrument panel and HVAC Housing into the vehicle.
21. With the help of an assistant, place the instrument panel in the vehicle, carefully guiding the HVAC housing studs through the bulkhead and into position.
22. Install the seven bolts and five screws attaching instrument panel to fence line and cowl side.
23. Place instrument panel pad into position.
24. Place instrument panel top cover in position on vehicle.
25. Push top cover forward to engage hooks to hold front of top cover to instrument panel.
26. Engage clips to hold rear edge of top cover to instrument panel.
27. Pull top cover rearward as you firmly push down and snap into place.
28. Install the A-pillar trim.
29. Install the four steering column retaining bolts.
30. Connect the transmission shift interlock and wire connector.
31. Connect all the column wiring and clip the harness to the steering column.
32. Install the two screws to the steering column shrouds.
33. Connect the junction block wiring connectors.
34. Install the one bolt to the left side support strut to bulkhead.
35. Install the five screws and one wire connector to left lower instrument panel trim bezel.
36. Install the one left side, center instrument panel support bolt.
37. Install the left silencer.
38. Install the four left A-pillar instrument panel retainers.
39. Connect the right door harness connectors located within the A-pillar.
40. Install the left end cover.
41. Install the two screws to the left cowl trim panel.
42. Install the left door sill plate.
43. Install the one right side, center instrument panel support bolt.
44. Install the right silencer.
45. Install the four right A-pillar instrument panel retainers.
46. Connect the right door harness connectors located within the A-pillar.
47. Install the glove box.
48. Install the right A-pillar trim.
49. Install the right end cover.
50. Install the two screws to the right cowl trim panel.
51. Install the right door sill plate.
52. Connect the console wiring connectors and clip the push in fasteners in.
53. Install the left and right rear floor heat ducts.
54. Connect the two harness connectors to the amplifier.
55. Connect wire harness connector to amplifier.
56. Install the amplifier. Tighten the forward screw to 26.5 inch lbs. (3 Nm) and the rear nut to 18 inch lbs. (2 Nm).
57. Install the floor center console. Install the two mounting screws in the front and two mounting screws inside console storage bin.
58. Install the transmission range indicator bezel and one screw to shift knob.
59. Connect the battery negative remote cable.
    
    CAUTION

    Do not handle by seat adjuster release bar.
    
    
    
    NOTE

    Ensure that the seat tracks are rearward. Ensure the seat tracks on the right and left are in equal latch positions.
60. Place front seat in position in vehicle.
61. Connect front seat wire harness connector to body harness connector.
62. Install the bolts to attach front of seat track to the floor kick up. Tighten bolts to: 45 ft. lbs. (61 Nm).
63. Slide seat forward and install the bolts attaching rear of seat track to the floor. Tighten bolts to 45 ft. lbs. (61 Nm).
64. Verify front seat operation.
65. Hoist vehicle and install the lower HVAC housing retaining nut.
66. Lower vehicle from hoist.
67. Install the two top HVAC housing retaining nuts in engine compartment.
68. Install the one bolt retaining the A/C lines to the right strut tower.
69. Reconnect the negative battery cable.
70. If the heater core is being replaced, flush the cooling system.
71. Refill the engine cooling system.
72. Evacuate the refrigerant system.
73. Charge the refrigerant system.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html