Calling all Chrysler mechanics!?

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bikinkawboy

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How do you remove the evaporator from under the dash on a 2002 Dodge Caravan? My Haynes manual is absolutely useless...they even have the drawing of the blower-evaporator housing upside down! I've replaced evaporators before and all manufacturers seem to enjoy making it nearly impossible to remove them without disassembling the entire dash.

I'd appreciate a basic procedure...you know, not like remove screw #1, screw #2, etc, but more basic like remove dash bezel, blower motor, 4 screws on the evaporator housing, that kind of stuff as well as any little tricks of the trade.

Incidently, the AC decided to conk out less than a week before the kids and I are to leave for Colorado. Firgures, doesn't it? Thanks!
 
The entire dash board assembly must be removed to gain access to the evaporator. Not a job for the inexperienced. If your going to try have access to a shop manual, you will need it.

You have to remove the whole dash from the van, remove the heater box and disassemble. It is a major job, even for a trained tech with all proper tools.

Recover the refrigerant from the refrigerant system.
Drain the engine cooling system.
Disconnect and isolate the battery negative cable.
Disconnect the liquid line and suction line from the expansion valve.
Remove the windshield wiper module from the vehicle.
Disconnect the heater hoses from the heater core tubes. .
Remove the four nuts that secure the heater-A/C unit housing studs to the engine compartment side of the dash panel .
Remove the instrument panel from the passenger compartment. .

Disconnect and isolate the battery negative cable.
Remove the lower console:
Remove six retaining screws.
Pull rearward and disconnect the auxiliary power outlet.
Remove lower console from vehicle.
Remove the bolts attaching the lower supports to the instrument panel frame
Remove the bolts attaching the lower supports to the floor pan.
Disconnect the wire connectors from the Passenger Airbag.
Remove the two screws to each right and left cowl trim covers.
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.
Remove the glove box:
Push in on sides of glove box bin and lower door.
Pivot glove box downward and disengage hinge hooks from instrument panel.
Remove glove box from vehicle.
Disconnect the antenna lead connector from behind the glove box.
Remove the four screws to the lower steering column cover.
Remove the eight screws to the steering column backing plate.
Unclip the Data Link Connector (DLC) from the steering column backing plate.
Remove two screws to the left side instrument panel silencer and remove .
Disconnect the left side wiring:
Brake switch.
Main bulkhead connector.
Five harness connectors.
Driver airbag connector.
Remove the two screws to the hood release handle.
Remove five screws to steering column backing plate and remove
Remove the two steering column shroud retaining screws. Separate the shrouds and remove from vehicle.
Remove the screws attaching the instrument panel reinforcement and remove
Disconnect the steering column wiring. There are seven connectors and then unclip the harness from the column.
Disconnect the Occupant Restraint Controller (ORC) harness connector.
Remove the four nuts retaining the steering column to the dash panel steering column mounting bracket and lower column to the floor
Remove the four nuts attaching the instrument panel to the brake pedal support bracket.
Loosen the left side roll down bolt.
Remove the left side A-pillar retaining bolts. There are two 13 mm bolts and one 10 mm bolt.
If equipped with a mechanical transmission range indicator:
Remove the indicator cable loop.
Remove the clip holding gear shift cable end to the gear selector adapter.
Pull the cable end from gear selector.
Disconnect the clip for the indicator cable and guide tube from the shift cable bracket and move out of the way.
Remove the instrument panel top cover. Using a trim stick or equivalent, gently pry up on the front edge of the top cover, pull rearward and remove from vehicle.
Disconnect the right side wire connectors from the HVAC behind the glove box area and the two antenna connectors behind the glove box hinge.
Remove the right end cover by pulling outboard.
Remove the right side A-pillar retaining bolts. There are two 13 mm bolts and one 10 mm bolt.
Loosen the right side roll down bolt.
Disconnect the two front window defroster grid wire connectors. One on each side of vehicle.
Remove both the left and right power mirrors:
Using a trim stick or equivalent, gently pry out on mirror trim cover.
Open door and remove the three torx retaining screws.
Disconnect the wire connector and remove mirror from the vehicle.
Feed power mirror wire harness inboard through the A-pillar.
Remove the bolts attaching the instrument panel frame to the dash panel below windshield opening.
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.


Remove the floor distribution duct from the heater-A/C unit housing
Remove the one screw that secures the heater-A/C unit housing bracket to the passenger compartment side of the dash panel
Pull the heater-A/C unit housing rearward far enough for the mounting studs to clear the dash panel and remove the unit from the passenger compartment.
Remove the heater core tubes from the heater core. .
Remove and discard the foam seal from the HVAC housing seal flange around the
 
http://dodgeforum.com/forum/dodge-caravan/195415-ac-evaporator-repair-instructions-with-pictures.html

Glad it's you doing it and not me!
 
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