Need help with instructions on how to replace front and rear evaporators. Yes my luck! Both front and rear are leaking refrigerant. If anyone has a manual or disc with these instructions and can provide instructions I’d greatly appreciate it. I’ve dyed system and I have dye running out of evap cond drains. I am a/c certified and have machine to recover and service system. I’ve never had to do a Caravan though.

 

I don't know how much work is involved to get to the front evaporator coil because I never had to but there's a video on how to get to rear one and replace it. You being an HVAC tech shouldn't have much trouble for the rear one the front one could be different simply because on how many things you might have to remove just to get to the coil.

 

The front evaporator can only be changed by removing the HVAC housing (holds evaporator, heater core, all doors and actuators, blower motor, etc) and removing the necessary case section (I think it’s screwed together in 3 or 4 pieces).

The HVAC housing can only be removed by removing the instrument panel carrier (the metal framework supporting the dash, steering column, and front air bags). There’s about 12 primary bolts that need to be removed to do this, as well as unhooking the steering column and some electrical connectors. This means removing almost all of the trim as well as the upper dash pad.

The instrument panel carrier can only be removed by removing the front seats and center floor console (if equipped).

All said and done it’s a 6-8 hour job (or longer) depending on how experienced you are with this type of work.

I will try to find some exploded views for you to give you a good idea what you’re looking for. I’d advise planning to replace the heater core as well while it’s out.

 

Just wanted to let you know that I’m not having much luck finding the diagrams I was hoping for to give you a complete picture on how the dash comes out. The process outlined in service information provides pictures of each area separately but nothing with an overall view, and I’m not super great with search engines so I didn’t find much there either.

To remove the carrier, there are bolts across the top against the firewall, on each end near the doors, and on either side of the center console. Trim panels that will have to be removed to expose all the bolts are the end panels (doors opened), center kick panels (may be part of the center console assembly), the upper dash pad, and both A pillar panels (allows removal of upper dash pad). You’ll also need to unhook the steering column and primary wiring harness connectors that are in the driver footwell area and behind the passenger side right kick panel.

You will definitely want a helper to move the carrier. It doesn’t have to come out completely, but as long as you can swing the passenger side away from the firewall far enough to remove the HVAC housing, that will be sufficient.