Technical Car Experts Answers everything you need: How to remove heater core on dodge intrepid?

Removal & Installation

Disconnect the negative battery cable from the remote battery post located near the right strut tower.
CAUTION
After disconnecting the negative battery cable, wait 2 minutes for the driver-s/passenger-s air bag system capacitor to discharge before attempting to do any work around the steering column or instrument

Remove the instrument panel by removing or disconnecting the following:
NOTE
On the LHS or 300M, remove the center bezel prior to the shifter bezel

Shifter knob Allen screw

Both instrument panel end covers

Using a trim stick tool, gently pry upward on the shifter bezel; then, disconnect both wiring connectors and a light bulb socket connector; then, remove the socket.

Remove the 2 lower instrument panel cover screws (outside end) and disconnect the deck lid release switch wiring connector. Pull the lower instrument panel cover rearward releasing the clips. Remove the cable-to-brake release handle. Pull the cover rearward and remove it.

If equipped for 6 passengers, remove the lower floor bin.

If equipped for 5 passengers, remove or disconnect the following items:

Center bezel using the trim stick

Heater/air conditioning housing assembly control switch and the traction control switch wiring harnesses

Bezel from the vehicle

Two left side console side cover screws, pull the cover outward and remove from the vehicle

Lower glove box door; the 2 screws are located at the right console side cover, pull outward and remove it

2 bracket screws and the 2 inside the console bin; then, remove the console

2 center lower instrument panel nuts

4 steel reinforcement-to-lower instrument panel cover bottom bolts

16-way DLC from the reinforcement

left floor duct/silencer pad screw and the pad

Steering column shrouds

Shift interlock cable at the ignition switch

Column wiring

The under column duct section

Left panel air conditioning outlet duct

The 4 brake pedal support bracket-to-column mounting bolts

Lower the steering column

Heater/air conditioning housing and the Air bag Control Module (ACM) harness connectors then, the 2 ground eyelets from the floor tunnel near the bulkhead

Using a trim stick, carefully, pry out on the left and right A-pillar trim moldings and slide them rearward to remove them.

Using a trim stick, carefully pry upward on the instrument panel top cover, and remove it.

From both sides, remove the scuff plate screw. Using a trim stick, carefully, pry out the scuff plates and remove them.

Remove or disconnect the following:

3 right side cowl panel screws and the panel

3 left side cowl panel screws and the panel

Remove the right side under dash silencer and pad

2 right side radio antenna and amplifier harness connectors

Left side junction block and Body Control Module (BCM) harness connectors

8 instrument panel-to-chassis screws

Pull the instrument panel rearward

Instrument panel from the vehicle with the help of an assistant

Discharge and recover the air conditioning system refrigerant.

Drain the cooling system into a clean container for reuse.

Place shop cloths in the interior to catch any excess coolant.

Remove or disconnect the following:
WARNING
The air conditioning lubricant used in this system absorbs moisture readily. Do not leave any portion of the system open for any long period of time.

Air cleaner hose and the air distribution duct

Heater hoses-to-dash panel spring type fasteners and the heater hoses from the heater core. Plug the openings to prevent coolant spillage.

Refrigerant lines-to-expansion valve nut and separate the refrigerant lines from the expansion valve. Plug the openings to prevent contamination.

3 heater/air conditioning housing assembly-to-chassis nuts from the engine compartment

2 defroster duct screws and the duct

Heater/air conditioning housing assembly-to-dash panel nuts and screws

4 rear seat heat duct nuts and the duct

Rear seat heat duct elbow push-pin fastener

Electrical connector from the heater/air conditioning housing assembly

Pull the heater/air conditioning housing assembly rearward and remove it from the vehicle

2 heater core-to-heater/air conditioning housing assembly screws

Heater core from the heater/air conditioning housing assembly

Fig. Exploded view of the instrument panel-Intrepid

Fig. Exploded view of the instrument panel-Concorde

Fig. Exploded view of the instrument panel-LHS and 300M

Fig. View of the remote battery cable terminal-LHS, 300M, Concorde and Intrepid

Fig. View of the heater/air conditioning housing assembly-LHS, 300M, Concorde and Intrepid

To install:

Install or connect the following:

Heater core to the heater/air conditioning housing assembly

2 heater core-to-heater/air conditioning housing assembly screws

Push the heater/air conditioning housing assembly forward (carefully) and install it to the vehicle

Electrical connector to the heater/air conditioning housing assembly

Rear seat heat duct elbow push pin fastener

Duct and the 4 rear seat heat duct nuts

Heater/air conditioning housing assembly-to-dash panel nuts and screws

2 defroster duct and the duct screws

In the engine compartment, the 3 heater/air conditioning housing assembly-to-chassis nuts

Refrigerant lines to the expansion valve

Refrigerant lines-to-expansion valve nut

Heater hoses to the heater core and the heater hoses-to-dash panel spring type fasteners

Air cleaner hose and the air distribution duct

Refill the cooling system.

Evacuate, charge and leak-test the air conditioning system refrigerant.

Install the instrument panel by installing or connecting the following:

Instrument panel to the vehicle

Push the instrument panel forward

8 instrument panel-to-chassis screws

Left side junction block and Body Control Module (BCM) harness connectors

2 right side radio antenna and amplifier harness connectors

Right side under dash silencer and pad

Left side cowl panel and the 3 panel screws

Right side cowl panel and the 3 panel screws

Install the scuff plate and the screw (both sides)

Instrument panel top cover

Left and right A-pillar trim moldings

Heater/air conditioning housing and the Air bag Control Module (ACM) harness connectors then, the 2 ground eyelets to the floor tunnel near the bulkhead

Raise the steering column

The 4 brake pedal support bracket-to-column mounting bolts

Left panel air conditioning outlet duct

The under column duct section

Column wiring

Shift interlock cable at the ignition switch

Steering column shrouds

Left floor duct/silencer pad and the pad screw

4 steel reinforcement-to-lower instrument panel cover bottom bolts

6-way Diagnostic Link Connector (DLC) to the reinforcement

2 center lower instrument panel nuts

The 2 bracket screws and the 2 inside the console bin; then, the console (5 passenger models only)

2 screws are located at the right console side cover (5 passenger models only)

Two left side console side cover screws (5 passenger models only)

Bezel to the vehicle (5 passenger models only).

Heater/air conditioning housing assembly control switch and the traction control switch wiring harnesses.

Center bezel using the trim stick.

Lower floor bin (6 passenger models only).

2 lower instrument panel cover screws (outside end) and connect the deck lid release switch wiring connector. Install the cable-to-brake release handle

Light bulb socket. Both wiring connectors and a light bulb socket connector

Shifter bezel

Center bezel prior to the shifter bezel (LHS or 300M models)

Both instrument panel end covers

Shifter knob Allen screw