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Evap coil replacement

mm5900 on Mon July 12, 2010 7:30 PM User is offline

Year: 2001
Make: Dodge
Model: Van 2500
Engine Size: 5.2L
Refrigerant Type: R134a
Country of Origin: United States

Can the evap coil be replaced from the engine side or does the dash have to come out on this model? Help

HVargas on Tue July 13, 2010 1:27 PM User is offlineView users profile

Evaporator Removal & Installation

Remove front A/C-heater assembly. See A/C-HEATER ASSEMBLY . With front A/C-heater assembly removed, remove assembly cover. Remove heater core retaining screw and heater core. To remove evaporator core, remove fin sensor cycling clutch switch probe from evaporator. Remove expansion valve from evaporator. Remove bolt from below plumbing attachment plate. Remove evaporator core. To install, reverse removal procedure. If replacing evaporator core, add 2 ounces of refrigerant oil to evaporator before installation. Evacuate, charge, and leak test A/C system.

Heater Assembly Removal & Installation (Front)

Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Drain engine cooling system. In engine compartment, protect generator from coolant spillage, remove heater hoses from heater core tubes. Remove refrigerant lines from evaporator. Plug all openings. Remove grille, cowl grille support panel, right headlight assembly, and right radiator core support assembly. From inside vehicle, remove glove box bin. Through glove box opening and from under instrument panel, remove nuts and bolts attaching A/C-heater assembly to dash panel. Remove blower housing flange screws. Separate A/C-heater assembly from blower housing. Carefully remove A/C-heater assembly from vehicle. Place A/C-heater assembly on work bench. Remove nut securing lever to blend-air door pivot shaft. Disconnect blend-air door link boot from A/C-heater assembly housing rear mounting flange. Remove blend-air door link, boot and lever from A/C-heater assembly housing. Remove screw securing high speed blower motor relay mounting bracket, and remove blower motor relay and mounting bracket. Remove top cover securing screws. Remove top cover from A/C-heater assembly. To install, reverse removal procedure. Ensure A/C-heater housing top cover seal, firewall and side cowl seals are in good condition.


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MM9135 on Tue July 13, 2010 7:48 PM User is offline

Adam, thanks for the reply. Could you clarify it for me? I am having trouble following it. Do I need to perform both steps or is one from the engine side and one from the dash? Also See A/C-HEATER ASSEMBLY ??


Tennessee_Timmy on Tue July 13, 2010 8:29 PM User is offlineView users profile

i could be mistaken (often am) but believe that "See A/C-HEATER ASSEMBLY" in the first paragraph refers to the procedure in the 2nd.

pardon if you already knew that.

Good Luck 2 ya,

MM9135 on Tue July 13, 2010 9:14 PM User is offline

Ahhh I bet you are right TN Timmy. Thanks.

I was surprised that it was this involved. It looked like the fiberglass heater box from the engine side had a cover and the refrigerant lines when right into the vap coil.

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