This is a very involved procedure! I just changed the evaporator core ($83 with shipping from Ebay) on my 1999 Plymouth Grand Voyager and it took me 10 hours. The quote from the repair shop was $800 - $1000 for labor alone! Parts that must be changed also are the receiver/drier (next to the radiator). Other parts that should be changed are the expansion valve (on the firewall) and all the O-rings. The system should be flushed and must be vacuumed down and serviced. It's also a good idea to remove the compressor, drain the oil, and look for any signs of damage - such as bits of teflon or a gray-black sludge. Don't forget to add oil to the system or you'll be needing a new compressor in no time. The oil capacity is 9 oz. and 34 oz. of R-134a.
I found this posting of photos and instructions and couldn't have changed the evap
without them. Special thanks to the Dodge forum, Mr. Mahoney
and Dodge Tech. Here's the link:http://www.scsc.k12.in.us/mahoney/vanfix/
Some notes, as the instructions are somewhat ambiguos:
1. VERY IMPORTANT TIME SAVER: The steering column, instrument panel and dash all come out as a single unit! In the photos Mr. Mahoney
disassembled way more than he had to. The instructions may be interpreted incorrectly and you'd be tempted to separate the steering column from the dash, or remove the instrument bezel, or the hvac
controls. This is totally unnecessary
! Just take your time and look at everything and check and double-check what needs removed/disconnected. Also, the step where it says to remove the nuts from the steering column
at the die cast brake pedal support - those are the ones (4) that go forward to the bracket on the firewall, NOT the 4 nuts that go up to the dash! Again, the steering column comes out with the dash as a unit.
2. Some things left out of the steps: Disconnecting the parking brake light wire, disconnecting the blower fan wires, and removing the one hidden bolt from the bottom of the plenum. That bolt is near the floor, just the the left of center, and holds the bottom of the plenum to the firewall.
3. I found it much easier to get access to the engine side of the firewall by removing the alternator. This gives more room to get at the expansion valve and the 3 nuts that hold the plenum to the firewall.
4. Once you get the dash all the way out, and the plenum removed it's about 15 mins
to half an hour to change the evaporator. Isn't that ironic?
I hope I haven't left anything out, and that this helps you. Let me know if there's anything else I can help with.
1999 Plymouth Grand Voyager. 178,000 miles and goin' strong!