How to Replace the Heater Core in a Dodge Caravan

The heater core is a smaller version of the radiator located underneath the dashboard of your Dodge Caravan. Sometimes this auto part can fail and cause the cooling system to malfunction. Replacing the heater core is a labor-intensive process that can save money on repair bills, if you possess mechanical skills and can remain patient.

Instructions

1

Move the Dodge Caravan onto a repair ramp or lift, if possible, as it will make working underneath the van much easier. Next, position a bucket under the radiator drain plug, which is on the driver's side bottom of the radiator. Then, open the drain plug to allow the coolant to drain from the radiator.

2

Remove the hoses that connect the heater core to the engine. You can access the hoses by getting underneath the Caravan and looking for two hoses that connect to the firewall, which is what separates the potentially dangerous engine parts from the driver. Use pliers to loosen the spring clamps and slide them down the heater core hose. Be careful when removing the hoses, as the coolant can remain even though you drained the system.

3

Use rags or something similar to plug these newly created openings in the coolant system, so that debris doesn't make its way into your cooling system.

4

Go to the inside of the Dodge Caravan and put down towels, blankets or newspapers over the interior of your Dodge Caravan to protect the floor and seats from coolant damage.

5

Grab a screwdriver to remove the foot well, kick panel, radio trim panel and access panel on the passenger's side. All the paneling underneath and to the left of the passenger's side needs removal. All the screws are noticeable when you lay down on the floorboard. There isn't a set order to remove the part, but it's usually easier to start outside and work inside.

6

Pull out the dashboard once you remove all the paneling. There may be at least one screw holding the dashboard in place that you'll need to remove before you pull it out. However, on most every model of the Dodge Caravan, you can simply pull the dashboard back from the windshield.

7

Employ the screwdriver once again to remove the four or five screws, depending on the model year, from the heater core cover. The cover is behind the glove compartment and is only accessible with the dashboard pulled back. The screw to the far right side of the cover may require a socket wrench for easier removal because of the limited space.

8

Unclasp the strap, which holds the heater core in place with a screwdriver. Then, remove the old heater core. Be careful with it, as coolant and other debris can spill out. One way to prevent spillage is to use covers from your new heater core to cover the tubes of the old heater core.

9

Install the new heater core in the same space as the old heater core. Be sure to cover the ends of the new core to prevent debris from entering. Then, get underneath the Dodge Caravan and connect the hoses to the new heater core with the spring clamps. You may need new spring clamps, as the old one may not be secure enough.

10

Put the radiator drain plug back in place and add fresh coolant to the radiator while watching the heater core for any leak. Then, put the strap screws back in place, along with the heater core cover. Next, put the dashboard back into position and replace the side foot well, kick, radio trim and access panels. Finally, turn on the engine and let it run for about 15 minutes with the heater on high to test the new heater core.