Wednesday, June 1, 2011

How to remove heater core on dodge intrepid?

Removal & Installation


  1. Disconnect the negative battery cable from the remote battery post located near the right strut tower.
    CAUTION
    After disconnecting the negative battery cable, wait 2 minutes for the driver-s/passenger-s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument

  2. Remove the instrument panel by removing or disconnecting the following:
    NOTE
    On the LHS or 300M, remove the center bezel prior to the shifter bezel



    Shifter knob Allen screw
    Both instrument panel end covers

  3. Using a trim stick tool, gently pry upward on the shifter bezel; then, disconnect both wiring connectors and a light bulb socket connector; then, remove the socket.
  4. Remove the 2 lower instrument panel cover screws (outside end) and disconnect the deck lid release switch wiring connector. Pull the lower instrument panel cover rearward releasing the clips. Remove the cable-to-brake release handle. Pull the cover rearward and remove it.
  5. If equipped for 6 passengers, remove the lower floor bin.
  6. If equipped for 5 passengers, remove or disconnect the following items:

    Center bezel using the trim stick
    Heater/air conditioning housing assembly control switch and the traction control switch wiring harnesses
    Bezel from the vehicle
    Two left side console side cover screws, pull the cover outward and remove from the vehicle
    Lower glove box door; the 2 screws are located at the right console side cover, pull outward and remove it
    2 bracket screws and the 2 inside the console bin; then, remove the console
    2 center lower instrument panel nuts
    4 steel reinforcement-to-lower instrument panel cover bottom bolts
    16-way DLC from the reinforcement
    left floor duct/silencer pad screw and the pad
    Steering column shrouds
    Shift interlock cable at the ignition switch
    Column wiring
    The under column duct section
    Left panel air conditioning outlet duct
    The 4 brake pedal support bracket-to-column mounting bolts
    Lower the steering column
    Heater/air conditioning housing and the Air bag Control Module (ACM) harness connectors then, the 2 ground eyelets from the floor tunnel near the bulkhead

  7. Using a trim stick, carefully, pry out on the left and right A-pillar trim moldings and slide them rearward to remove them.
  8. Using a trim stick, carefully pry upward on the instrument panel top cover, and remove it.
  9. From both sides, remove the scuff plate screw. Using a trim stick, carefully, pry out the scuff plates and remove them.
  10. Remove or disconnect the following:

    3 right side cowl panel screws and the panel
    3 left side cowl panel screws and the panel
    Remove the right side under dash silencer and pad
    2 right side radio antenna and amplifier harness connectors
    Left side junction block and Body Control Module (BCM) harness connectors
    8 instrument panel-to-chassis screws
    Pull the instrument panel rearward
    Instrument panel from the vehicle with the help of an assistant

  11. Discharge and recover the air conditioning system refrigerant.
  12. Drain the cooling system into a clean container for reuse.
  13. Place shop cloths in the interior to catch any excess coolant.
  14. Remove or disconnect the following:
    WARNING
    The air conditioning lubricant used in this system absorbs moisture readily. Do not leave any portion of the system open for any long period of time.



    Air cleaner hose and the air distribution duct
    Heater hoses-to-dash panel spring type fasteners and the heater hoses from the heater core. Plug the openings to prevent coolant spillage.
    Refrigerant lines-to-expansion valve nut and separate the refrigerant lines from the expansion valve. Plug the openings to prevent contamination.



    3 heater/air conditioning housing assembly-to-chassis nuts from the engine compartment
    2 defroster duct screws and the duct
    Heater/air conditioning housing assembly-to-dash panel nuts and screws
    4 rear seat heat duct nuts and the duct
    Rear seat heat duct elbow push-pin fastener
    Electrical connector from the heater/air conditioning housing assembly
    Pull the heater/air conditioning housing assembly rearward and remove it from the vehicle
    2 heater core-to-heater/air conditioning housing assembly screws
    Heater core from the heater/air conditioning housing assembly

    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Intrepid



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-Concorde



    Click image to see an enlarged view

    Fig. Exploded view of the instrument panel-LHS and 300M



    Click image to see an enlarged view

    Fig. View of the remote battery cable terminal-LHS, 300M, Concorde and Intrepid



    Click image to see an enlarged view

    Fig. View of the heater/air conditioning housing assembly-LHS, 300M, Concorde and Intrepid



To install:

  1. Install or connect the following:

    Heater core to the heater/air conditioning housing assembly
    2 heater core-to-heater/air conditioning housing assembly screws
    Push the heater/air conditioning housing assembly forward (carefully) and install it to the vehicle
    Electrical connector to the heater/air conditioning housing assembly
    Rear seat heat duct elbow push pin fastener
    Duct and the 4 rear seat heat duct nuts
    Heater/air conditioning housing assembly-to-dash panel nuts and screws
    2 defroster duct and the duct screws
    In the engine compartment, the 3 heater/air conditioning housing assembly-to-chassis nuts
    Refrigerant lines to the expansion valve
    Refrigerant lines-to-expansion valve nut
    Heater hoses to the heater core and the heater hoses-to-dash panel spring type fasteners
    Air cleaner hose and the air distribution duct

  2. Refill the cooling system.
  3. Evacuate, charge and leak-test the air conditioning system refrigerant.
  4. Install the instrument panel by installing or connecting the following:

    Instrument panel to the vehicle
    Push the instrument panel forward
    8 instrument panel-to-chassis screws
    Left side junction block and Body Control Module (BCM) harness connectors
    2 right side radio antenna and amplifier harness connectors
    Right side under dash silencer and pad
    Left side cowl panel and the 3 panel screws
    Right side cowl panel and the 3 panel screws
    Install the scuff plate and the screw (both sides)
    Instrument panel top cover
    Left and right A-pillar trim moldings
    Heater/air conditioning housing and the Air bag Control Module (ACM) harness connectors then, the 2 ground eyelets to the floor tunnel near the bulkhead
    Raise the steering column
    The 4 brake pedal support bracket-to-column mounting bolts
    Left panel air conditioning outlet duct
    The under column duct section
    Column wiring
    Shift interlock cable at the ignition switch
    Steering column shrouds
    Left floor duct/silencer pad and the pad screw
    4 steel reinforcement-to-lower instrument panel cover bottom bolts
    6-way Diagnostic Link Connector (DLC) to the reinforcement
    2 center lower instrument panel nuts
    The 2 bracket screws and the 2 inside the console bin; then, the console (5 passenger models only)
    2 screws are located at the right console side cover (5 passenger models only)
    Two left side console side cover screws (5 passenger models only)
    Bezel to the vehicle (5 passenger models only).
    Heater/air conditioning housing assembly control switch and the traction control switch wiring harnesses.
    Center bezel using the trim stick.
    Lower floor bin (6 passenger models only).
    2 lower instrument panel cover screws (outside end) and connect the deck lid release switch wiring connector. Install the cable-to-brake release handle
    Light bulb socket. Both wiring connectors and a light bulb socket connector
    Shifter bezel
    Center bezel prior to the shifter bezel (LHS or 300M models)
    Both instrument panel end covers
    Shifter knob Allen screw

  5. Connect the negative battery cable to the remote battery post located near the right strut tower.
  6. Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
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