trying to get to my heater core I have everything out except the metal framing that supports the dash and can see the entire plastic assembly that houses the blower motor and vents but im stuck and cannot remove these can anyone help with suggestions or walkthrough.

 

heres a walkthrough for a sedan

1. Remove negative battery cable.
2. Recover refrigerant from A/C system with R134a refrigerant recovery machine.
3. Drain the engine cooling system.
4. Remove heater hoses from heater core. NOTE: Plug core tubes to prevent antifreeze from spilling on vehicle interior during removal.
5. Remove quick connect clips from A/C lines at the expansion valve.
6. Remove A/C lines from expansion valve.
7. Remove expansion valve mounting bolts and remove valve. NOTE: Cap the A/C lines and evaporator to prevent moisture from entering the refrigerant system.
8. Remove floor console.
9. Remove rear heat ducts.
10. Remove nuts securing HVAC housing to dash panel under the hood

INSTRUMENT PANEL ASSEMBLY

REMOVAL

The Instrument Panel and HVAC assemblies are removed together as one assembly. If service is required to the individual unit, separation might be required.

1. Recover the A/C refrigerant.
2. Partially drain the coolant.
3. Remove one bolt retaining the A/C lines to the right strut tower
4. Remove the two top HVAC housing retaining nuts in engine compartment (Fig. 2).
5. Hoist vehicle and remove the lower HVAC housing retaining nut.
6. Lower vehicle from hoist.
7. Remove the driver and passenger seats.
8. Disconnect and isolate the battery negative remote cable.
9. Remove one screw to shift **** and transmission range indicator bezel from floor console.
10. Remove floor center console. Remove two mounting screws in the front and two mounting screws inside console storage bin.
11. Remove the amplifier
12. Using a trim stick (special tool #C-4755) or equivalent, gently pry out on the left and right rear floor heat ducts and remove (Fig. 3).
13. Disconnect the console wiring connectors and unclip the push in fasteners.
14. Using a trim stick or equivalent, gently pry up on and remove the right sill plate.
15. Remove the two screws to the right cowl kick panel and remove from vehicle. Refer to Trim Panel.
16. Using a trim stick or equivalent, gently pry out on the right end cover and remove from vehicle.
17. Using a trim stick or equivalent, gently pry out on the right A-pillar trim and remove from vehicle, Refer to Trim Panel.
18. Open the glove box. Pinch in on the sides and drop to the floor. Pull down to disengage hinges.
19. Disconnect the right door harness connectors located within the A-pillar.
20. Remove the four right A-pillar instrument panel retainers.
21. Remove the right silencer.
22. Remove the one right side, center instrument panel support bolt.
23. Using a trim stick or equivalent, gently pry up on and remove the left sill plate, Refer to Trim Panel.
24. Remove the two screws to the left cowl kick panel and remove from vehicle.
25. Using a trim stick or equivalent, gently pry out on the left end cover and remove from vehicle.
26. Using a trim stick or equivalent, gently pry out on the left A-pillar trim and remove from vehicle. Refer to Trim Panel.
27. Disconnect the left door harness connectors located within the A-pillar.
28. Remove the four left A-pillar instrument panel retainers.
29. Remove five screws and one wire connector to left lower instrument panel trim bezel.
30. Remove the left silencer.
31. Remove the one left side, center instrument panel support bolt.
32. Remove one bolt to the left side support strut to bulkhead.
33. Disconnect the junction block wiring connectors.
34. Remove two screws to the steering column shrouds and remove.
35. Disconnect all the column wiring and unclip the harness from the steering column.
36. Disconnect the transmission shift interlock and wire connector.
37. Remove the four steering column retaining bolts and drop column to floor.
38. Using a trim stick or equivalent, pry up on the rear of the top cover and pull rearward as you lift off of instrument panel.
39. Remove instrument panel pad.
40. Remove seven bolts and five screws attaching instrument panel to fence line and cowl side.
41. 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

TO SEPARATE THE INSTRUMENT PANEL AND HVAC UNIT HOUSINGS

• Disconnect the HVAC wiring connector to the instrument panel wire harness.
• Remove the two bolts and two nuts holding the HVAC housing to the instrument panel.
• Lift the instrument panel off the HVAC housing to separate.

INSTALLATION

The Instrument Panel and HVAC assemblies are installed together as one assembly. They must be reconnected before installation.

TO CONNECT THE INSTRUMENT PANEL AND HVAC UNIT HOUSINGS

• Place the instrument panel on the HVAC housing.
• Install the two bolts and two nuts holding the HVAC housing to the instrument panel.
• Connect the HVAC wiring connector to the instrument panel wire harness.

If replacing the instrument panel, transfer all non damaged parts and wiring harness to the new instrument panel assembly.

1. 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
2. Install the seven bolts and five screws attaching instrument panel to fence line and cowl side (Fig. 4).
3. Place instrument panel pad into position.
4. Install the instrument panel top cover.
5. Install the four steering column retaining bolts.
6. Connect the transmission shift interlock and wire connector.
7. Connect all the column wiring and clip the harness to the steering column.
8. Install two screws to the steering column shrouds.
9. Connect the junction block wiring connectors.
10. Install one bolt to the left side support strut to bulkhead.
11. Install five screws and one wire connector to left lower instrument panel trim bezel.
12. Install the one left side, center instrument panel support bolt.
13. Install the left silencer.
14. Install the four left A-pillar instrument panel retainers.
15. Connect the right door harness connectors located within the A-pillar.
16. Install the right A-pillar trim.
17. Install the left end cover.
18. Install the two screws to the left cowl trim panel.
19. Install the left door sill plate.
20. Install the one right side, center instrument panel support bolt.
21. Install the right silencer.
22. Install the four right A-pillar instrument panel retainers.
23. Connect the right door harness connectors located within the A-pillar.
24. Install the glove box.
25. Install the right A-pillar trim.
26. Install the right end cover.
27. Install the two screws to the right cowl trim panel.
28. Install the right door sill plate.
29. Connect the console wiring connectors and clip the push in fasteners in.
30. Install the left and right rear floor heat ducts (Fig. 3).
31. Connect the two harness connectors to the amplifier.
32. Install the amplifier.
33. Install floor center console. Install two mounting screws in the front and two mounting screws inside console storage bin.
34. Install the transmission range indicator bezel and one screw to shift ****.
35. Connect the battery negative remote cable.
36. Install the driver and passenger seats.
37. Hoist vehicle and install the lower HVAC housing retaining nut.
38. Lower vehicle from hoist.
39. Install the two top HVAC housing retaining nuts in engine compartment (Fig. 2).
40. Install one bolt retaining the A/C lines to the right strut tower.
41. Top off the coolant.
42. Recharge the A/C refrigerant with specified amount. Refer to placard in engine compartment

 

Thanks Bill,

 

Bill you seem to know your studd so I thought I might ask a question also having to do with heater cores and hoses. My issue is I removed the heater hoses from my heater core some time ago and no can not recall which hose went where. I have searched hi and low for a diagram but to no avial. I have a 2002 Dodge Stratus with a 2.4 SOHC. Thank yuo in adviance for your assistance.

 

not that familiar with the 2.4 setup did the new heater core have an in and out marking on it ,what I would do is try cranking car and see which hose shoots antifreeze out and book that to the core in .