Monday, July 4, 2011

how to remove heater core on 1994 Chrysler Concorde?

The heater core is inside the housing big job heres the procedure from my online manual
UNIT HOUSING
REMOVAL
Disconnect battery. This must be done to prevent accidental air bag deployment.

Using an A/C recovery unit, remove all R-134a refrigerant from the A/C system.

Remove air cleaner hose and air distribution duct from the engine.

Drain the engine cooling system.

Disconnect heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to prevent anti-freeze from spilling on the vehicle interior during removal. If an appropriate plug cannot be found pull back carpet and use caution when removing unit. Keep the heater tubes elevated to prevent spillage of coolant.

Remove both A/C lines from expansion valve. Use special tool 7193 to disconnect quick connectors on A/C lines. After removing lines cap the expansion valve openings and the A/C hose openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing
CAUTION: The lubricant used in this air conditioning system absorbs moisture readily (similar to brake fluid) Do not leave any portion of the system open for extended periods of time.


Remove the three retaining nuts from the studs. These studs project through the dash panel into the engine compartment.

Remove right and left instrument panel end caps. These caps are held in place by a series of clips.

Remove right and left interior door post kick panel.

Remove right side bezel from instrument panel Right Side Bezel Removal

Remove the radio center bezel which is held in place by six clips. This can be done by carefully prying the bezel from the instrument panel.

Remove the radio. Remove the heater A/C control head from the panel and place in a safe area.

Remove the center instrument panel
bezel Center Bezel Removal This bezel is held in place by four clips. It can be removed by carefully prying it from the instrument panel.
Remove center console from vehicle (if equipped)

If the vehicle is equipped with a right side air bag, the glove box must be lowered. The glove box assembly can be lowered by pressing in on the sides of the glove box. This will release the glove box and allow access to air bag mounting screws. There are four screws located behind the glove box. Remove these screws and then close the glove box.

Remove lower bolster retaining screws.

Carefully lower the bolster and disconnect the trunk release and glove box light wiring. Then remove the lower bolster from the vehicle.

Remove the instrument panel top cover Panel Top Cover It is held in place by retainer clips at both ends of the cover. To remove carefully pry upward at one end of the cover until the clip is disengaged. Proceed to the opposite side and gradually pry the rear edge of the top cover along the entire width of the panel.

Remove right and left windshield pillar trim covers.

Remove five bolts that hold instrument panel to the cowl. These bolts are located at the base of the windshield.

Disconnect the scan tool (DRB) connector from brace.

Remove instrument panel ground strap. This strap is located on the lower left side of the center console.

Remove left knee blocker support bracket. This will allow access to the 60 way wiring connector.

Remove under column duct and left floor duct.

Disconnect 60 way wiring connector. Then disconnect all related wiring connectors.

Disconnect fuse panel wiring connectors.

Disconnect the brake light switch connector.

Remove steering column covers from steering column.

Remove steering column retaining bolts and allow the steering column to lower to the floor. Do not completely remove the column from the vehicle.

Remove wiring from the steering column.

Remove air bag connectors.

Remove right side floor air duct.

Disconnect 10 way connector, blower module connector and blower motor connector.

Remove body controller from vehicle.

Disconnect right side connector and antenna connector.

Remove right and left side upper instrument panel mounting screws located in door jam.

Remove upper instrument panel from the vehicle. The upper instrument panel will be removed with all harnesses and gauges still in the panel. It is recommended that two people handle the upper panel while removing.

Remove air duct for rear heater vents. It is held in place by a bracket/push pin near the rear of the duct.

Remove the air bag module and brace from the vehicle.

Remove three attaching bolts which hold the heater housing to the dash panel.

Carefully roll the heater housing out of the vehicle.

After removing the heater housing, remove the drain tube from the heater housing. The drain tube should be installed from underneath the vehicle after the heater housing is reinstalled into the vehicle.

INSTALLATION
For installation, reverse the above procedures.

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More details read as follows:-----


  • Disconnect the negative (black) cable from the battery.

  • Drain the engine coolant into a drainpan that holds at least 9.4 qts. If you plan on re-using the coolant instead of adding new coolant, make sure the pan is clean. The drain plug is on the back side of the lower edge of the radiator.

  • Unsnap and remove the end caps from each end of the instrument panel.

  • Remove the hex-head screw that retains the shift lever. Remove the shifter bezel using tool C-4755. The bezel can be pried out with a flat-head screwdriver, but it is easily damaged, so be careful. Disconnect the revealed electrical connectors.

  • Remove the two screws from the lower panel on the driver's side. They are near the door. Unplug the electrical connector from the trunk release switch. Pull the panel towards you to release the clips, but do not remove it.

  • Remove the center storage bin if your Concorde is equipped with six-passenger seating. It is held in place by a screw and a pin.

  • Remove the center console, if your Concorde has one. Remove the bezel with tool C-4755 (or carefully with a flat-head screwdriver) and unplug the heater, A/C and traction control switches. Remove the screws from the left side cover of the console and pull it off. Open the glove compartment and remove the right cover the same way. Remove the four screws that hold the console in place and pull out the console.

  • Unscrew the nuts that retain the lower panel in the center. Unhook the diagnostic port from its reinforcement.

  • Disconnect the electrical connections for the heater, A/C housing and air bag module.

  • Pry off the covers on both A-pillars and pry up the rear end of the instrument panel to remove it.

  • Disconnect the heater hoses from the heater core, working from inside the car. Remove the defrost and rear seat vent lines by removing the retaining screws.

  • Unbolt and remove the cover over the heater core. Remove the screws holding the heater core in place and remove it.

  • Replace the heater core. Installation is the reverse of removal.

  • REMOVAL & INSTALLATION



    See Figures 1 and 2



    Click image to see an enlarged view

    Fig. Fig. 1: Release the retining clips for the heater core, then pull the core out of the housing



    Click image to see an enlarged view

    Fig. Fig. 2: Fasten the heater core to the housing with the screws provided with the new heater core

    The heater housing must be removed from the vehicle to service the heater core. This is a lengthy and time-consuming procedure requiring the removal of a number of interior trim pieces. Use care when working with plastic trim pieces. Most are held in place with clips of several different types. Use care not to break trim pieces during service. The air conditioning system must be discharged and the refrigerant recovered and recycled using the appropriate equipment. A DRB III scan tool or equivalent is required when performing this procedure.

    1. Disconnect negative battery cable. Disarm the air bag system using the recommended procedure.
    2. Have a qualified technician discharge the R-134A refrigerant from the air conditioning system.


    CAUTION
    Avoid breathing air conditioning refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved service equipment meeting SAE requirements to discharge R-134A system. If accidental system discharge occurs, ventilate the work area before resuming service. R-134A service equipment or the vehicle air conditioning system should not be pressure tested or leak tested with compressed air. Some mixtures or R-134A have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing personal injury or property damage.

    1. Remove the air cleaner hose and the air distribution duct from the engine.
    2. Place a drain pan under the radiator. Open the radiator drain cock located at the lower right side of the radiator. Do NOT use pliers to open the plastic drain fitting. Drain the cooling system.
    3. Disconnect the heater hoses at the dash panel. Plug the heater core inlet and outlet tubes to keep coolant from leaking inside of the vehicle during removal. If an appropriate plug cannot be found, pull back the carpet and use caution when removing the unit.
    4. Remove both air conditioning lines from the expansion valve, using tool 7193 or equivalent, to disengage the quick-connectors at the air conditioning lines. After removing the lines, cap (rubber plugs, duct tape, etc.) the expansion valve openings to prevent system contamination.

    The lubricant used in this air conditioning system absorbs moisture readily. Do not leave any portion of the system open to the atmosphere for any extended period of time.

    1. Remove the instrument panel.
    2. Remove the three attaching bolts which holds the heater housing to the dash panel. Carefully roll the heater housing out of the vehicle.
    3. Remove the drain tube from the heater housing. It will later be installed from underneath the vehicle after the heater housing is reinstalled.
    4. With the heater housing out of the vehicle, pull the heater core retainer clips back and pull the heater core from the case.

    To install:
    1. Install the heater core into the housing and install the retainer brackets. Secure using the screws supplied with the new heater core.
    2. Install the housing into the vehicle and secure using the three attaching bolts. Install the heater housing drain tube to the heater housing from underneath the vehicle.
    3. Install the instrument panel.
    4. Install both air conditioning lines to the expansion valve using new O-rings at the connections.

    The O-rings used in this system are made of a special type of rubber that is not affected by R-134A refrigerant or the special oil used with R-134A. Do not substitute an O-ring not manufactured for R-134A refrigerant type system or leakage will occur within a short period of time.

    1. Reconnect the heater hoses at the dash panel and refill the cooling system.
    2. Install the air cleaner hose and the air distribution duct to the engine.
    3. Enable the air bag system.
    4. Connect the negative battery cable. Evacuate and charge the refrigerant system.
    5. Add coolant as required and bleed the cooling system.
    6. Start and warm the engine to check heater system operation.

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    Instrument Cluster and Bezel


    REMOVAL & INSTALLATION



    See Figures 1, 2, 3, 4 and 5



    image

    Fig. Fig. 1: Exploded view of the instrument components-1994 shown



    Click image to see an enlarged view

    Fig. Fig. 2: Cluster bezel components-except LHS



    Click image to see an enlarged view

    Fig. Fig. 3: Cluster bezel components-LHS



    Click image to see an enlarged view

    Fig. Fig. 4: For removal of most instrument components, the side end caps must be removed



    Click image to see an enlarged view

    Fig. Fig. 5: Remove the upper center bezel on the instrument panel

    The instrument cluster must be removed from the instrument panel if servicing any instrument cluster component. The instrument cluster is an electro-mechanical module that gains most of its information from the Body or Timing Control Module by way of the CCD bus.

    1. Disconnect the negative battery cable. Disarm the air bag system using the recommended procedure.

    1. Remove the instrument panel left end cap and the headlight bezel.

    1. Remove the two headlight switch screws and move switch to allow clearance for the instrument panel cluster bezel and instrument cluster removal.
    2. Remove the instrument panel upper center bezel. Remove the hazard switch and the upper steering column shroud.

    1. Tilt the steering column down into the lowest position. On the LHS, remove the instrument panel cluster bezel. If the message center is integrated with the instrument cluster bezel, separate the wire connector. The message center lamps may be replaced at this point, if required.

    1. Remove the instrument cluster retainer screws and disengage the upper latch.
    2. Pull the instrument cluster forward slightly and disconnect the wire harness at the back of the unit. Remove the instrument cluster from the panel. Disconnecting the wiring harness from the back of the instrument cluster will require approximately 20 lbs. (9 kg) of force.

    To install:
    1. Connect the wire harness to the instrument cluster and install cluster into the instrument panel. Install the retainer screws.
    2. Attach the message center wire connector. Install the instrument panel cluster bezel and secure in position.
    3. Install the hazard switch and the steering column shroud.
    4. Install the instrument panel upper center bezel, headlight switch and headlight bezel to the instrument panel.
    5. Install the instrument panel end cap. Connect the negative battery cable and check for proper operation of the instrument cluster gauges.