I am replacing the front evaporator core on my 2007 Grand Caravan this weekend. Has anyone replaced the evaporator core on a 4th Gen? I found the thread that dealt with the 2nd and 3rd Gens. But I can find nothing on the 4th Gen. There do not seem to be major differences except for the steering column that I can see. Are there any other material differences to replace the evaporator?

Although time consuming, the job is relatively straight forward. But I have been unable to find step-by-step instructions for the 4th Gen that makes the job easier. Does anyone have any instructions or know where I can find some? I ordered the FSM yesterday and should have it tomorrow. That may or may not be helpful. There is nothing in the Haynes Manual about replacing the evaporator core or pulling the dash.

Thanks for your help.

 

pm me your email and I will send you the instructions

 

Thank you. On the way

 

sent, let me know if you don't get them.

 

OMG. What a delightful little job! The FSM misses a lot. First, it states to remove the nut and bolt on the inside holding the HVAC box. I also states that there are 3 nuts to remove on the engine side. It also states to take the steering colunm loose and lower it to the the floor. It states to take off the mirrors.

First, there is only 1 nut in the passenger side on the HVAC box. There are 4 nuts and 1 bolt to take off on the engine side. One of the studs holds the heater hose line. There is one nut holding the HVAC box and one holding the lines. There is 1 bolt behind the shock tower that is a bugger to get to. Unless you take the seats out, the column will rest on the driver's seat. Be sure to pad the top of the steering wheel to avoid marring it. You do not need to take off the mirrors. Just disconnect the plug and tape the wires up and to the A pillar.

The HVAC box itself is rather complicated. There is a boat load of little screws holding it together in all kinds of different places that must come off before you can split the box. The box is actually 2 halfs-1 is the heater core and the other is the A/C. They will come apart from one another. You only need to split the A/C half, but everything must be disassembled. Double check and check again every little thing before reinstallation.

This easily took me 15 hours to do -and I'm not a novice. I did both my 2nd and 3rd gen Rams in less time than it took me to do this one. IMO this is not for the weekend mechanic. It's a rough job. Half way through I was wondering what I stepped in. I have a 3.8 and there is very little room to work. But, once you jump off the building, you don't have much choice.

Tizzy, thanks for the information, it did help. My wife came out and looked at her van when I had it apart. I thought she was going to get sick. That was the high point. She seemed relieved to see it all together again.

Good luck guys.

 

Hard to believe I do these in just a couple of hours. Once you do one, piece of cake for the next one.

 

You're probably right. Thankfully, I'm all out of vehicles. This was the 3rd evaporator/heater core I replaced this month. Thanks again for your help.

 

Dont know if either of you all will see this but if you do could I get the instructions? My husband is gonna be tackling our 07 Dodge Grand Caravan. Also any tips and suggestions would be great!!!

 

Here are the instructions that I got from Tizzy a while ago. The pictures did not copy. These are straight from the FSM.

Step One:

24 - Heating and Air Conditioning/Distribution, Front/HOUSING, HVAC/Removal
HVAC HOUSING
Labor Operations: Click to display a list of Labor Operations associated with this procedure


WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (Refer to 24 - Heating and Air Conditioning/Plumbing - Warning) and (Refer to 24 - Heating and Air Conditioning/Plumbing - Caution) . Failure to follow the warnings and cautions could result in possible personal injury or death.


WARNING: On vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury or death.




NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the air inlet housing, air distribution housing and the A/C evaporator.

NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage while performing this procedure.

NOTE: LHD model shown in illustrations. RHD model similar.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system (Refer to 24 - Heating and Air Conditioning/Plumbing - Standard Procedure) .
3. Drain the engine cooling system (Refer to 07 - Cooling - Standard Procedure) .
4. Disconnect the A/C liquid and suction lines from the A/C expansion valve (Refer to 24 - Heating and Air Conditioning/Plumbing/LINE, A/C Liquid - Removal) .
5. Disconnect the heater hoses from the heater core (Refer to 24 - Heating and Air Conditioning/Plumbing/HOSE, Heater - Removal) and (Refer to 24 - Heating and Air Conditioning/Plumbing/HOSE, Heater - Removal) .

6. Remove the three nuts that secure the HVAC housing to the engine compartment side of the dash panel Figure 1.


Figure 1 - HVAC Housing-Engine Compartment
1 - NUT (3)
2 - HVAC HOUSING MOUNTING STUDS
3 - DASH PANEL

7. Remove the instrument panel from the passenger compartment (Refer to 23 - Body/Instrument Panel/PANEL, Instrument - Removal) .

8. Remove the nut and bolt that secure the HVAC housing to the passenger compartment side of the dash panel Figure 2.
9. Pull the HVAC housing rearward to clear the dash panel and remove the HVAC housing from the passenger compartment.
10. If required, disassemble the HVAC housing (Refer to 24 - Heating and Air Conditioning/Distribution/HOUSING, HVAC - Disassembly) .


Figure 2 - HVAC Housing-Passenger Compartment
1 - NUT
2 - BOLT
3 - HVAC HOUSING ASSEMBLY
4 - DASH PANEL

here is section 2, when I do one of these, I remove both front seats so I can just slide the instrument panel back and not remove it from the vehicle.


23 - Body / Instrument Panel / PANEL, Instrument/Removal
REMOVAL
Labor Operations: Click to display a list of Labor Operations associated with this procedure


Special Tools: Click to display a list of tools used in this procedure

Click here to launch the form to order any tools you need.

C-4755 - Trim Stick

Originally Shipped In Kit Number(s) 9299, 9299CC, 9299CC, 9300A-CAN.

WARNING: TO AVOID PERSONAL INJURY OR DEATH, ON VEHICLES EQUIPPED WITH AIRBAGS, DISABLE THE SUPPLEMENTAL RESTRAINT SYSTEM 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. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT.


WARNING: TO AVOID PERSONAL INJURY OR DEATH ON VEHICLES EQUIPPED WITH THE OCCUPANT CLASSIFICATION SYSTEM (OCS), ONLY THE OCCUPANT CLASSIFICATION MODULE (OCM) AND THE SEAT CUSHION TRIM MAY BE SERVICED SEPARATELY. ALL OTHER COMPONENTS OF THE PASSENGER SIDE FRONT SEAT CUSHION ASSEMBLY MUST BE SERVICED ONLY AS A COMPLETE FACTORY-CALIBRATED, ASSEMBLED AND TAMPER-EVIDENT SERVICE REPLACEMENT PACKAGE. THIS PACKAGE INCLUDES THE FRAME, SPRINGS, PAD, BLADDER, SENSOR, FOAM, WIRING AND A CALIBRATED OCM. WHEN INSTALLING THIS PACKAGE ALWAYS REPLACE ALL OF THE EXISTING COMPONENTS WITH THE NEW COMPONENTS AS A UNIT. DO NOT ATTEMPT TO SEPARATE OR DISCONNECT ANY OF THE NEW OCS COMPONENTS IN THE SERVICE REPLACEMENT PACKAGE FROM EACH OTHER, AND DO NOT ATTEMPT TO REUSE ANY OF THE REPLACED COMPONENTS IN THIS OR ANY OTHER VEHICLE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN FAILURE OF THE PASSENGER AIRBAG TO DEPLOY WHEN REQUIRED, OR IN PASSENGER AIRBAG DEPLOYMENT WHEN
NOT REQUIRED.


1. Disconnect and isolate the battery negative cable.
2. Remove the lower console:a. Remove five retaining screws.
b. Pull rearward and disconnect the auxiliary power outlet.
c. Remove lower console from vehicle.


3. Remove the bolts attaching the lower supports to the instrument panel frame Figure 1.


Figure 1 - FLOOR TO CENTER STACK BRACKETS
1 - DASH PANEL OCCUPANT BRACKET
2 - FLOOR BRACKET NUT
3 - FLOOR TO CENTER STACK BRACKET (RIGHT)
4 - BRACKET ATTACHING SCREW(S)
5 - FLOOR TO CENTER STACK BRACKET (LEFT)

4. Remove the bolts attaching the lower supports to the floor pan.
5. Remove the both left and right side A-pillar trim covers using a trim stick (special tool # C-4755 ) or equivalent gently pry out on the trim covers and remove.
6. Remove the instrument panel top cover. (Refer to 23 - Body/Instrument Panel/PAD, Instrument Panel - Removal) .
7. Disconnect the wire connectors from the Passenger Airbag.
8. Remove the two screws to each right and left cowl trim covers.

9. Remove screws attaching instrument panel frame to the dash panel below windshield opening Figure 2.


NOTE: Left hand drive shown. Right hand drive similar.


Figure 2 - INSTRUMENT PANEL REMOVAL
1 - INSTRUMENT PANEL
2 - SIX ATTACHING SCREWS
3 - 13 mm BOLT - TWO ON EACH SIDE
4 - ROLL DOWN BRACKET
5 - 10 mm BOLT - STARTING BOLT ONE EACH SIDE


10. Remove the glove box:a. Push in on sides of glove box bin and lower door.
b. Pivot glove box downward and disengage hinge hooks from instrument panel.
c. Remove glove box from vehicle.

11. Disconnect the antenna lead connector from behind the glove box.
12. Disconnect the right side wire connectors from the HVAC behind the glove box area and the two antenna connectors behind the glove box hinge.
13. Remove the right end cover by pulling outboard.

14. Remove the right side A-pillar retaining bolts Figure 3. There are two 13 mm bolts and one 10 mm bolt.
15. Loosen the right side cowl side roll down bolt.


Figure 3 - RIGHT SIDE INSTRUMENT PANEL ATTACHING SCREWS
1 - INSTRUMENT PANEL ATTACHING SCREWS
2 - INSTRUMENT PANEL TO COWL SIDE LOCATOR SCREW
3 - COWL SIDE COWL REINFORCEMENT
4 - COWL PANEL
5 - INSTRUMENT PANEL COWL SIDE ROLL DOWN BOLT

16. Remove over steering column cover. (Refer to 23 - Body/Instrument Panel/COVER, Steering Column Opening - Removal) .
17. Remove the cluster bezel. (Refer to 23 - Body/Instrument Panel/BEZEL, Instrument Cluster - Removal) .
18. Remove the lower steering column cover and end cap. (Refer to 23 - Body/Instrument Panel/COVER, Steering Column Opening - Removal)
19. Remove the inflatable knee blocker. (Refer to 23 - Body/Instrument Panel/KNEEBLOCKER - Removal)
20. Remove the two screws to the hood release handle.

21. Remove the two steering column fixed shroud retaining screws Figure 4.

22. Remove the four steering column shroud retaining screws. Separate the steering column bearing shroud and steering column shroud and remove from vehicle Figure 4.
23. Disconnect the left side wiring:a. Brake switch.
b. Main bulkhead connector.
c. Five harness connectors.
d. Driver airbag connector.



Figure 4 - STEERING COLUMN SHROUDS
1 - FIXED SHROUD
2 - ATTACHING SCREW(S)
3 - STEERING COLUMN BEARING SHROUD
4 - TRACTION CONTROL DISABLE SWITCH
5 - MULTI-FUNCTION SWITCH AND CLOCKSPRING HOUSING
6 - STEERING COLUMN SHROUD
7 - STEERING COLUMN

24. Disconnect the steering column wiring. There are seven connectors and then unclip the harness from the column.
25. Disconnect the Occupant Restraint Controller (ORC) harness connector.

26. Remove the three nuts retaining the steering column to the dash panel steering column mounting bracket and lower column to the floor Figure 5.
27. Remove the three nuts attaching the instrument panel to the brake pedal support bracket.

28. Remove six instrument panel steering column cover plate attaching screws and remove cover plate Figure 6.Remove the screws attaching the instrument panel reinforcement and remove Figure 7.


Figure 5 - STEERING COLUMN MOUNTING BRACKET
1 - DASH PANEL STEERING COLUMN MOUNTING BRACKET
2 - INSTRUMENT PANEL STEERING COLUMN BRACKET
3 - ATTACHING NUT(S)



Figure 6 - LEFT SIDE I/P ATTACHING SCREWS
1 - INSTRUMENT PANEL ATTACHING SCREWS
2 - INSTRUMENT PANEL
3 - COLUMN COVER PLATE ATTACHING SCREWS
4 - INSTRUMENT PANEL COLUMN COVER PLATE
5 - INSTRUMENT PANEL COWL SIDE ROLL DOWN SCREW
6 - COWL PANEL



Figure 7 - INSTRUMENT PANEL LOWER REINFORCEMENT
1 - LOWER RIGHT REINFORCEMENT
2 - STEERING WHEEL ASSEMBLY

29. Remove both the left and right power mirrors:a. Using a trim stick or equivalent, gently pry out on mirror trim cover.
b. Open door and remove the three torx retaining screws.
c. Disconnect the wire connector and remove mirror from the vehicle.

30. Feed power mirror wire harness inboard through the A-pillar.

31. Loosen the left side roll down bolt Figure 6.

32. Remove the left side A-pillar retaining bolts. There are two 13 mm bolts and one 10 mm bolt Figure 6.
33. With the help of an assistant remove the instrument panel from vehicle. Lift the instrument panel up off the HVAC so you won't damage the sealing surface of the distribution duct.
34. If the instrument panel is being replaced, transfer all parts to the new instrument panel assembly.

last one.


24 - Heating and Air Conditioning/Distribution, Front/HOUSING, HVAC/Disassembly
HVAC HOUSING
Labor Operations: Click to display a list of Labor Operations associated with this procedure




NOTE: The HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator.

NOTE: LHD model shown in illustrations. RHD model similar.
1. Remove the HVAC housing from the vehicle and place it on a workbench (Refer to 24 - Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal) .

2. Remove the air distribution housing from the HVAC housing Figure 1(Refer to 24 - Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal) .
3. Remove the air inlet housing from the HVAC housing (Refer to 24 - Heating and Air Conditioning/Distribution/HOUSING, HVAC - Removal) .


Figure 1 - HVAC Housing Assembly
1 - HVAC HOUSING
2 - AIR INLET HOUSING
3 - AIR DISTRIBUTION HOUSING

4. Remove the A/C expansion valve from the A/C evaporator (Refer to 24 - Heating and Air Conditioning/Plumbing/VALVE, A/C Expansion - Removal) .

5. Disconnect the HVAC wiring harness from the blower motor resistor or power module (depending on application) Figure 2.
6. On RS models, disconnect the HVAC wiring harness from the evaporator temperature sensor located on the top of the HVAC housing and remove the sensor from the housing.
7. Disengage the HVAC wire harness from the routing clips on the HVAC housing and remove the wire harness from the housing.
8. If required, remove three screws that secure the blower motor to the HVAC housing and remove the blower motor.
9. If required, remove two screws that secure the blower motor resistor or power module (depending on application) to the HVAC housing and remove the resistor or module.
10. If required, remove two screws that secure the support bracket to the HVAC housing and remove the bracket.
11. Remove the thirteen screws that secure the upper HVAC housing half to the lower half of the HVAC housing.
12. Separate the two halves of the HVAC housing.
13. Carefully lift the A/C evaporator and insulator out of the lower half of the HVAC housing.


Figure 2 - HVAC Housing
1 - LOWER HVAC HOUSING
2 - UPPER HVAC HOUSING
3 - BLOWER MOTOR
4 - BLOWER MOTOR RESISTOR/POWER MODULE
5 - A/C EVAPORATOR
6 - SUPPORT BRACKET

 

I did not remove the seats. I supported the dash on the passenger side with a ratchet strap to pull it up and out of the way:



Take your time. I started on Saturday and finished up on Sunday morning. Have fun!