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Randall C
Randall C, ASE Master Technician
Category: Dodge
Satisfied Customers: 11086
Experience:  ASE Master Tech, 32 years Diag/Electrical Specialist
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1999 dodge dakota: step by step instructions from start to finish..v6

Resolved Question:

looking for step by step instructions from start to finish on how to replace heatercore on a 1999 dodge dakota v6
Submitted: 3 years ago.
Category: Dodge
Expert:  Randall C replied 3 years ago.
Hello, the job as you know is quite involved in that the dash has to come out. there are just too many steps for me to explain each along the way. You have to start with dash removal. Once out, then the HVAC is removed from the firewall and then the cover to heater core. Below are the detailed instructions per the repair manual.I will then be sending on how to remove the case from the firewall

EMOVAL

NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position.

  1. Disconnect and isolate the battery negative cable.
  2. Remove the trim from the right and left door sills.
  3. Remove the trim from the left and right cowl side inner panels.
  4. Remove the steering column opening cover from the instrument panel.
  5. Remove the two screws that secure the inside hood latch release handle to the instrument panel lower reinforcement and lower the release handle to the floor.
  6. Disconnect the driver side airbag module wire harness connector from the instrument panel wire harness at the instrument panel lower reinforcement.
  7. If the vehicle is so equipped, disconnect the overdrive lockout switch wire harness connector from the instrument panel wire harness near the instrument panel lower reinforcement.
  8. Remove the steering column from the vehicle, but do not remove the driver side airbag module, the steering wheel, or the switches from the steering column. Be certain that the steering wheel is locked and secured from rotation to prevent the loss of clockspring centering.
  9. From under the driver side of the instrument panel, perform the following:
    1. Remove the screw from the center of the headlamp and dash to instrument panel bulkhead wire harness connector and disconnect the connector.
    2. Disconnect the two body wire harness connectors from the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector.
    3. Disconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) from the three junction block connector receptacles located closest to the dash panel.
    4. Unsnap the plastic retainer clip that secures the park brake release linkage rod to the lever on the back side of the park brake release handle and disengage the linkage rod end from the lever on the handle.
    5. Disconnect the instrument panel wire harness connector from the stop lamp switch connector receptacle.
    6. Disconnect the vacuum harness connector located near the left end of the heater-A/C housing.
  1. Remove the center support bracket from the instrument panel. s.
  2. Remove the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel.
  3. .Disconnect the instrument panel wire harness connector from the ACM connector receptacle.
  4. Remove the glove box from the instrument panel. Refer to Glove Box Replacement for the procedures.
  5. Reaching through the instrument panel glove box opening, perform the following:
    1. Disconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening.
    2. Disengage the antenna half of the radio antenna coaxial cable from the retainer clip near the outboard side of the lower instrument panel glove box opening.
    3. Disconnect the blower motor wire harness connector located near the heater-A/C housing support brace on the inboard side of the instrument panel glove box opening.
  1. From under the passenger side of the instrument panel, perform the following:
    1. If the vehicle is so equipped, disconnect the two instrument panel wire harness connectors from the Infinity speaker amplifier connector receptacles on the right cowl side inner panel.
    2. Remove the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel.

Instrument Panel Assembly Remove/Install

  1. Loosen the right and left instrument panel cowl side roll-down bracket screws about 6 mm (0.25 inch) .
  2. Remove the five screws that secure the top of the instrument panel to the top of the dash panel, removing the center screw last.

Roll-Down Bracket




  1. Pull the lower instrument panel rearward until the right and left cowl side roll-down bracket screws are in the roll-down slot position of both brackets.
  2. Roll down the instrument panel and install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 inches) from the dash panel.
  3. With the instrument panel supported in the roll-down position:
    1. Disconnect the two instrument panel wire harness connectors from the door jumper wire harness connectors located on a bracket near the right end of the instrument panel.
    2. Disconnect the instrument panel wire harness connector from the blower motor resistor connector receptacle on the dash panel.
    3. Disconnect the temperature control cable flag retainer from the top of the heater-A/C housing and pull the cable core adjuster clip off of the blend-air door lever.
    4. Disconnect the demister duct flexible hose from the adapter on the top of the heater-A/C housing.
  1. With the aid of an assistant, remove the temporary hook and lift the instrument panel assembly off of the roll-down bracket screws and remove it from the vehicle.

INSTALLATION

  1. With the aid of an assistant, install the instrument panel assembly onto the roll-down bracket screws in the vehicle. Install a temporary hook in the center hole on top of the instrument panel. Secure the other end of the hook to the center hole in the top of the dash panel. The hook should support the instrument panel in its rolled down position about 46 cm (18 inches) from the dash panel.
  2. With the instrument panel supported in the roll-down position:
    1. Reconnect the two instrument panel wire harness connectors to the door jumper wire harness connectors located on a bracket near the right end of the instrument panel.
    2. Reconnect the instrument panel wire harness connector to the blower motor resistor connector receptacle on the dash panel.
    3. Reconnect the temperature control cable flag retainer onto the top of the heater-A/C housing and push the cable core adjuster clip onto the blend-air door lever.
    4. Reconnect the demister duct flexible hose to the adapter on the top of the heater-A/C housing.
  1. Push the lower instrument panel forward until the right and left cowl side roll-down bracket screws are in the installed slot position of both brackets.
  2. Remove the temporary hook from the instrument panel and roll the instrument panel up to the installed position against the dash panel.
  3. Install and tighten the five screws that secure the top of the instrument panel to the top of the dash panel. Tighten the screws to 3.2 N.m (28 in. lbs.) .
  4. Tighten the right and left instrument panel cowl side roll-down bracket screws. Tighten the screws to 11.9 N.m (105 in. lbs.) .
  5. From under the passenger side of the instrument panel, perform the following:
    1. If the vehicle is so equipped, reconnect the two instrument panel wire harness connectors to the Infinity speaker amplifier connector receptacles on the right cowl side inner panel.
    2. Install and tighten the nut that secures the instrument panel wire harness radio ground eyelet to the stud on the right cowl side inner panel. Tighten the nut to 3.9 N.m (35 in. lbs.) .
  1. Reaching through the instrument panel glove box opening, perform the following:
    1. Reconnect the two halves of the radio antenna coaxial cable connector near the center of the lower instrument panel glove box opening.
    2. Engage the antenna half of the radio antenna coaxial cable into the retainer clip near the outboard side of the lower instrument panel glove box opening.
    3. Reconnect the blower motor wire harness connector located near the heater-A/C housing support brace on the inboard side of the instrument panel glove box opening.
  1. Install the glove box onto the instrument panel. Refer to Glove Box Replacement for the procedures.
  2. Install and tighten the screw that secures the instrument panel wire harness ground eyelets to the left side of the Airbag Control Module (ACM) mount on the floor panel transmission tunnel. Tighten the screw to 3.4 N.m (30 in. lbs.) .
  3. Reconnect the instrument panel wire harness connector to the ACM connector receptacle.
  4. Install the center support bracket onto the instrument panel. Refer to Instrument Panel Center Support Bracket Replacement for the procedures.
  5. From under the driver side of the instrument panel, perform the following:
    1. Reconnect the headlamp and dash to instrument panel bulkhead wire harness connector and tighten the screw in the center of the connector. Tighten the screw to 3.5 N.m (31 in. lbs.) .
    2. Reconnect the two body wire harness connectors to the two instrument panel wire harness connectors that are secured to the outboard side of the instrument panel bulkhead connector.
    3. Reconnect the three wire harness connectors (one from the body wire harness, and two from the headlamp and dash wire harness) to the three junction block connector receptacles located closest to the dash panel.
    4. Engage the linkage rod end into the lever on the back side of the park brake release handle and snap the plastic retainer clip over the linkage rod that secures it to the lever.
    5. Reconnect the instrument panel wire harness connector to the stop lamp switch connector receptacle.
    6. Reconnect the vacuum harness connector located near the left end of the heater-A/C housing.
  1. Install the steering column into the vehicle. Be certain that the steering wheel was locked and secured from rotation to prevent the loss of clock- spring centering.
  2. If the vehicle is so equipped, reconnect the overdrive lockout switch wire harness connector to the instrument panel wire harness near the instrument panel lower reinforcement.
  3. Reconnect the driver side airbag module wire harness connector to the instrument panel wire harness at the instrument panel lower reinforcement.
  4. Position the inside hood latch release handle to the instrument panel lower reinforcement.
  5. Install and tighten the two screws that secure the inside hood latch release handle to the instrument panel lower reinforcement. Tighten the screws to 2.8 N.m (25 in. lbs.) .
  6. Install the steering column opening cover onto the instrument panel. Refer to Steering Column Opening Cover Replacement for the procedures.
  7. Install the trim onto the left and right cowl side inner panels.
  8. Install the trim onto the right and left door sills.
  9. Reconnect the battery negative cable.


Randall C, ASE Master Technician
Category: Dodge
Satisfied Customers: 11086
Experience: ASE Master Tech, 32 years Diag/Electrical Specialist
Randall C and 8 other Dodge Specialists are ready to help you
Customer: replied 3 years ago.
hi , my steering column does not lock, its been this way for awhile. what should i do?
Expert:  Randall C replied 3 years ago.
You are just fine. Just try to keep the steering column/wheel in straight ahead position. maybe? you can tie a small string or rope around the wheel- co,umn to help hold it? this step is really so it makes it easier to line back up when you go back with it
Customer: replied 3 years ago.
hi. i got the dash out enough to go to the next step. can you send me the rest? thanks mark!!
Expert:  Randall C replied 3 years ago.
he heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors.

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY .

REMOVAL
  1. Disconnect and isolate the battery negative cable.
  2. Remove the instrument panel from the vehicle. Refer to: "Body and Frame : Interior Moulding/Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair
  3. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair
  4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings.
  5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings.
  6. Drain the engine cooling system. Refer to: "Engine, Cooling and Exhaust : Cooling System : Service and Repair" See: Engine, Cooling and Exhaust\Cooling System\Service and Repair
  7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes.

Heater - A/C Housing Remove/Install


  1. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel.
  2. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel.
  3. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes.
  4. Remove the heater-A/C housing from the vehicle.
DISASSEMBLY
  1. Place the heater-A/C housing on a work bench, with the heater-A/C housing cover facing down.
  2. Remove the two screws that secure the heater-A/C housing cover to the top of the blower motor housing cover.
  3. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator.
  4. Unplug the vacuum harness connector from the panel-defrost door actuator.
  5. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing and remove the duct from the housing.

Heater - A/C Housing Floor Outlet Screws


  1. Remove the two screws that secure the heater- A/C housing cover to the lower housing near the floor outlet.
  2. Turn the heater-A/C housing over on the work bench, with the heater-A/C housing cover facing up.
  3. Disengage the vacuum harness retainer from the hole near the left end of the heater-A/C housing cover.

Blend-Air Door Lever Remove/Install


  1. Remove the vacuum harness from the molded clips on the heater-A/C housing cover.
  2. Remove the thirteen screws that secure the perimeter of the housing cover to the heater-A/C housing.
  3. Remove the nut that secures the blend-air door lever to the blend-air door pivot shaft and remove the lever.
  4. Gently pry off the push nut that secures the heater-A/C housing cover to the heater-A/C housing post.

Panel-Defrost Door Lever Remove


  1. Using a trim stick or another suitable wide flat-bladed tool, gently pry the panel-defrost door lever off of the panel-defrost door pivot shaft.
  2. Pull up the perimeter edges of the heater-A/C housing cover far enough to separate the cover sealant from the heater-A/C housing.
  3. Remove the housing cover from the heater-A/C housing.
  4. If the vehicle is so equipped, remove the recirculation air door actuator from the blower motor housing cover. See Mode Door Vacuum Actuators in the Replacement for the procedures.

Blower Motor Housing Cover Remove/Install


  1. Remove the six screws that secure the blower motor housing cover to the heater-A/C housing.
  2. Remove the blower motor housing cover from the heater-A/C housing.
ASSEMBLY

Blower Motor Housing Cover Sealant


  1. Before installing the blower motor housing cover, be certain that the cover sealant is in place and in good condition.
  2. Position the blower motor housing cover to the heater-A/C housing.
  3. Install the six screws that secure the blower motor housing cover to the heater-A/C housing. Tighten the screws to 2.2 N.m (20 in. lbs.) .
  4. If the vehicle is so equipped, reinstall the recirculation air door actuator.

Heater - A/C Housing Cover Sealant


  1. Before installing the heater-A/C housing cover, be certain that the cover sealant is in place and in good condition.
  2. Position the heater-A/C housing cover on the heater-A/C housing. Be certain that the pivots for the floor-defrost, the panel-defrost, the blend-air, and the recirculation air (if the vehicle is so equipped) doors are properly positioned.
  3. Reinstall the push nut that secures the heater A/C housing cover to the heater-A/C housing post.
  4. Install the thirteen screws that secure the perimeter of the housing cover to the heater-A/C housing. Tighten the screws to 2.2 N.m (20 in. lbs.) .
  5. Snap the panel-defrost door lever onto the panel-defrost door pivot shaft.
  6. Install the blend-air door lever to the blend-air door pivot shaft and secure it to the shaft with the nut.
  7. Install the vacuum harness retainer into the hole near the left end of the heater-A/C housing cover.
  8. Route the vacuum harness through the molded clips on the heater-A/C housing cover.
  9. Turn the heater-A/C housing over on the work bench, with the heater-A/C housing cover facing down.
  10. Install the two screws that secure the heater-A/C housing cover to the lower housing near the floor outlet. Tighten the screws to 2.2 N.m (20 in. lbs.) .
  11. Position the floor duct to the bottom of the heater-A/C housing and secure with four screws. Tighten the screws to 2.2 N.m (20 in. lbs.) .
  12. Plug in the vacuum harness connector to the panel-defrost door actuator.
  13. If the vehicle is so equipped, plug in the two vacuum harness connectors to the recirculation air door actuator.
  14. Install the two screws that secure the heater- A/C housing cover to the top of the blower motor housing cover. Tighten the screws to 2.2 N.m (20 in. lbs.) .
  15. Reinstall the heater-A/C housing in the vehicle.

INSTALLATION

  1. Position the heater-A/C housing to the dash panel. Be certain that the evaporator condensate drain tube and the housing mounting studs are inserted into their correct mounting holes.
  2. Install the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. Tighten the nut to 11 N.m (95 in. lbs.) .
  3. Install and tighten the four nuts onto the heater-A/C housing mounting studs on the engine compartment side of the dash panel. Tighten the nuts to 7 N.m (60 in. lbs.) .
  4. Unplug or remove the tape from the heater core tubes. Connect the heater hoses to the heater core tubes and fill the engine cooling system.
  5. If the vehicle is not equipped with air conditioning, go to Step 9. If the vehicle is equipped with air conditioning, unplug or remove the tape from the accumulator inlet tube and the evaporator outlet tube fittings. Connect the accumulator inlet tube coupler to the evaporator outlet tube. See Refrigerant Line Coupler in the Replacement for the procedures.
  6. Unplug or remove the tape from the liquid line and the evaporator inlet tube fittings. Connect the liquid line coupler to the evaporator inlet tube. See Refrigerant Line Coupler in the Replacement for the procedures.
  7. Evacuate the refrigerant system.
  8. Charge the refrigerant system. Refer to: "Heating and Air Conditioning : Service and Repair" See: Service and Repair
  9. Reinstall the instrument panel in the vehicle. Refer to: "Body and Frame : Interior Moulding/Trim : Dashboard/Instrument Panel : Service and Repair" See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair
  10. Connect the battery negative cable.
  11. Start the engine and check for proper operation of the heating and air conditioning systems.



 

Customer: replied 3 years ago.
hi, just wanted to say thanks for info. it was very helpful !!
Expert:  Randall C replied 3 years ago.
well, I am glad you fixed it. Its a hard job for us to type and explain. If you need help agian, pls look me up. Thanks for letting me know

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