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1Remove the dashboard. The heater core in S10s is behind the main dashboard, and it must be removed to access the core. The front dash panel can be removed by unbolting several screws at the bottom of the panel, then pulling the panel away from the dash. Once this front panel is off, the primary dash can be unbolted from the firewall with four large bolts below the windshield. Several accessories may need to be taken out to unbolt the dash from the firewall, such as the radio or 4WD switches.
Drain the coolant from the core. There is a drain plug at the bottom right of the primary radiator that will empty the coolant system when unscrewed. Some residual coolant might remain in the core, but it will come out when the core is taken out
Uncouple the core from the coolant lines. These hoses are directly behind the oil filler tube and will come loose when squeezed with pliers. They are of different sizes, and it won't be necessary to mark them for later re-attachment.
Unbolt the core from its mounts behind the removed dash panel. Several bolts might be difficult to reach, but once free from the mounts, the core assembly slides up and out toward the interior of the truck. Lay a towel down when removing the core, as come coolant might splash out.
Insert the new heater core and bolt it into the mounts. The openings will fit into the holes provided in the firewall.
Reconnect the heater core hoses, and re-attach the dashboard and front panel.
Fill the coolant system with a 50/50 mix of antifreeze and water. Tighten the drain plug on the radiator, then fill it. Crank the truck up with the heater system on its maximum setting and continue to pour coolant into the radiator until it will not take in any more.
Your job will be a long one, but not the worst one out there by far. You will need to unhook the battery, remove all of the lower trim from the driver and passenger sides under the dash. Remove the nuts that hold the steering column to the bottom of the dash and let is rest on the drivers seat. Remove the kick panel trim from both the drivers and passenger side foot well. There are 2 bolts on each the drivers and passenger side that hold the sides of the dash board to the vehicle, then there are I believe 6 bolts along the front edge of the dash along the windshield that need to be removed. This should let the dash be tilted back away from the windshield and rest atop the steering column. There will be an access door in the top of the heater box that will allow removal and replacement of the new heater core. You will still need to unhook the hoses under the hood, and you might need to unplug, or remove some ground wires hear and there, just make sure you take note of what you have to unplug or remove and make sure you put everything back like it was before you started.
Remove heater/evaporator case. Remove vacuum source line from heater core tube seal. Remove seal from heater core tubes. Remove heater core access cover screws. Remove access cover and seal from heater/evaporator case. Lift heater core and case seals out of heater/evaporator case. Installation If installing new heater core, transfer case seals to new core. Install heater core and seals into heater/evaporator case. Install heater core access cover on case. Install seal on heater core tubes. To complete installation, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.
HEATER/EVAPORATOR CASE Removal
Disconnect negative battery cable. Drain coolant from radiator. Gently pull instrument panel away from right side of dash panel.
Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect heater hoses from heater core. Plug heater core tubes or drain coolant by blowing coolant from heater core using low pressure compressed air. Disconnect vacuum supply hose from inside engine compartment.
Disconnect A/C lines from evaporator core. Plug A/C lines and evaporator core tubes. Remove instrument panel assembly brace to evaporator case bracket screw. Remove assembly brace.
Remove floor register and rear floor duct from bottom of heater/evaporator case. Remove nuts securing heater/evaporator case to firewall. Remove 2 screws securing support brackets to cowl top panel. Carefully pull heater/evaporator case away from firewall. Remove heater/evaporator case.
To install, reverse removal procedure. Evacuate and charge A/C system. Refill cooling system.
INSTRUMENT PANEL Removal & Installation
Position front wheels in straight-ahead position. Disable air bag system. See AIR BAG RESTRAINT SYSTEM article in ACCESSORIES/SAFETY EQUIPMENT section. Disconnect negative battery cable. Remove steering column trim shrouds.
Disconnect all electrical connections from steering column switches. Remove cover from under steering column. Remove 4 bolts and reinforcement from under steering column. Disconnect parking brake release control motor from parking brake and ignition switch connector.
Disengage insulator retainer. Remove insulator. Remove 4 nuts and reinforcement below steering column. Remove 4 nuts securing steering column to instrument panel and lower column to front seat. Disconnect PRNDL cable (A/T models).
Ensure ignition switch is locked to prevent steering column from turning. Remove 4 instrument cluster retaining screws. Disconnect speed control cable and vehicle speed sensor (if equipped). Disconnect electrical connectors and remove instrument cluster. At steering column opening, remove one bolt securing instrument panel to brace. Remove one instrument panel brace bolt (below radio area).
Remove sound insulator under glove box by removing 2 push nuts securing insulator to studs on climate control case. Remove glove box door and compartment. Remove air cleaner housing, battery and battery tray. Disconnect wires of main wire loom in engine compartment. Disengage rubber grommet from firewall. Feed wiring into passenger compartment through hole in firewall.
Remove right and left kick panels. Disconnect wires from instrument panel at right and left kick panel sides. Remove screws on left and right sides of instrument panel.
Pull up to unsnap right and left speaker opening covers. Remove speaker covers. Working through steering column and glove box openings, reach under instrument panel and disconnect electrical connectors, vacuum hoses, A/C-heater control panel cables, and radio antenna cable.
Support instrument panel. Remove 3 screws attaching top of instrument panel to cowl top. Disconnect remaining wires. Remove instrument panel. To install instrument panel, reverse removal procedure.
The 2001 Dodge caravan has 2 heater cores - front (the main one), and the rear. Removal of the rear heater core is a whole different procedure than the front.
Front Heater Core - Removal and Installation
Before servicing the vehicle, refer to the Precautions Section.
Align the wheels in the straight-ahead position.
Disconnect the negative battery cable.
Before working around the steering wheel or the instrument panel all 2 minutes to pass to allow the air bag module to discharge.
Drain the cooling system into a clean container for reuse.
Remove the steering column, by removing or disconnect the following:
Lower left side steering column coverParking brake release cable from the parking brake lever10 steering column cover liner-to-instrument panel bolts and the cover liner
Rotate the key to the LOCK position; then, rotate the steering wheel to the LOCKED position.
Gear selector cable and its mounting bracket as an assembly from the upper steering column mounting bracket2 instrument cluster trim bezel-to-instrument panel screws, retaining clips and bezel2 steering column shroud-to-steering column screws and the shroudSteering column-to-intermediate steering shaft coupler
Loosen but do not remove the 2 lower steering column mounting bracket nuts/washers.
2 upper steering column mounting bracket nuts/washersSteering column assembly from the vehicle
Remove or disconnect the following:
Instrument panel-to-chassis harness interconnect and bracketLower silencer boot, at the base of the steering shaft
Working in the engine compartment, pinch off the heater hoses.
Heater core cover. Position some towels under the heater core hoses.Heater core plate and the hoses
Depress the heater core retaining clips.
Lift the accelerator pedal and slide the heater core past it.
Depress the brake pedal and remove the heater core from the heater/air conditioning housing assembly.
Fig. View of the steering column assembly
Fig. View of the interconnect and bracket
Fig. View of the front heater core assembly
Depress the brake pedal and install the heater core into the heater/air conditioning housing assembly.
Lift the accelerator pedal and slide the heater core past it.
Install or connect the following:
Heater hoses (using new O-rings) and the heater core plateHeater core coverHeater hoses clamps, working in the engine compartmentLower silencer boot at the base of the steering shaftInstrument panel-to-chassis harness interconnect and bracket
Install the steering column assembly by installing or connect the following:
Steering column assembly, carefully into the vehicle.2 upper and 2 lower steering column mounting bracket nuts/washers. Torque the nuts to 105 inch lbs. (12 Nm).Steering column-to-intermediate steering shaft coupler and tighten the pinch bolt to 21 ft. lbs. (28 Nm)2 steering column shroud and the shroud-to-steering column screwsBezel, the retaining clips and the 2 instrument cluster trim bezel-to-instrument panel screwsGear selector cable and its mounting bracket as an assembly to the upper steering column mounting bracket10 steering column cover liner and the cover liner-to-instrument panel boltsParking brake release cable to the parking brake leverLower left side steering column cover.Lower left side steering column cover
Refill the cooling system.
Connect the negative battery cable.
Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
Disconnect the negative battery cable and wait at least one minute for the air bag system to lose power. Make sure the front wheels are straight ahead and lock the steering column.
Detach the air bag module by removing the bolts from underneath both sides of the steering wheel and the electrical connector. Remove the steering wheel bolt and press the wheel away from the steering column. Remove the lower steering column cover.
Insert a 1/8-inch wire or pin punch in the shroud hole under the ignition switch while it's in the "Run" position. Press on the pin and pull on the ignition switch lock cylinder to remove it.
Disassemble and remove the instrument panel from the Taurus' interior. This includes the radio and all panels, electrical connectors, harnesses and screws. You'll need an assistant to help you lift and remove the instrument panel.
Drain the engine coolant from the cooling system, using a clean container for reuse. Remove the heater hoses, actuator and metal cover from the heater. Disengage the spring from the heater core cover and the lever.
Depress the locking ramp and remove the lever from the secondary air temperature control (the lever is brittle, so don't bend it). Remove the primary air conditioning air temperature control door shaft from the pin.
Remove the heater core cover and seal from the heater/air conditioning housing assembly. Remove the heater core from the heater/air conditioning housing by pressing on the core tubes and assembly.
Install the replacement heater core to the heater/air conditioning housing. Install the core cover, seal, lever, spring, metal cover, actuator and heater hoses.
Replace and assemble the instrument panel with your assistant's help. Connect the steering wheel (use a new bolt to connect it to the column), air bag and negative battery cable.
Refill the cooling system with either the old coolant or new. Start the Taurus' engine and let it reach normal operating temperature. Watch the climate control operation and check for any leaks.
Here is an exploded view of the heating/air conditioning blower box. This contraption is located on the passengerside under the dash. I've changed heater cores on other cars but never worked on a caravan so not sure how difficult it'll be. You may need to remove a few cover panels to access this and the heater core #22 is located behind the distribution box #6 containing parts 7-18 and hopefully comes off as a unit. I wouldn't want to put it back together just looking at the pic. You may just need to remove the heater tube cover #4 to access the connections and slide out the core.....NAH couldn't be that simple!!! Hope this was of some help. Good luck.