Fix It

The evaporator core, or heater core in a 2003 Dodge van is a radiator that contains hot coolant. The coolant circulates through the heater core when the heater is turned on, warming the interior of the van.

Instructions

1

Remove the negative battery cable with a socket wrench, and wait two minutes. This allows the capacitor in the airbag system to discharge, and prevents the airbag from deploying. Discharge the rigerant in the air conditioning system, and detach evaporators suction line jumper.

2

Remove the mounting screws that attach the heater to the air conditioning unit with a socket wrench. Push the mounting bracket and rigerant lines out of the way to gain access to the heater.

3

Detach the wiring harnesses for the fin sensing cycling clutch switch, blower motor resistor and blower motor relay. Cover the alternator with a shop cloth to prevent coolant from spilling on it. Drain the coolant in the radiator into a clean container for later use.

4

Disconnect the coolant hoses from the heater with a socket wrench. Remove the right headlight assembly, support assembly for the right radiator core, support panel for the right cowl grille and the grille panel. Disconnect the screws that attach the heater housing to the blower motor housing.

5

Disconnect the door motor link from the distribution duct in the passenger compartment. Use a socket wrench to remove the nuts in the glove compartment that fasten the heater to the dashboard.

6

Remove the stamped nut in the engine compartment that connects the heater housing to the dashboard with a socket wrench. Detach the heater housing from the housing for the blower motor. Pull the heater housing from the dashboard so that the door link clears the hole in the dash panel. Remove the heater housing from the vehicle.

7

Remove the pivot shaft nut from the blend-air door of the heater housing with a socket wrench. Pivot shaft nut. Detach the mounting flange boot and lever from the blend-air door. Disconnect the motor relay and its mounting bracket from the high-speed blower motor on the heater housing. Disconnect the screws from the top cover of the heater housing with a socket wrench, and remove the cover.

8

Remove the screw that fastens the tube support bracket for the heater core to the mounting boss. Remove the heater core from its housing.

9

Place the new heater core into its housing, and fasten its support bracket to the mounting boss with the retaining screw. Tighten the screw to 20 inch-pounds with a torque wrench.

10

Complete the installation of the new heater core by performing steps two through seven in reverse order. Attach the suction line jumper for the evaporator, and charge the air conditioner with rigerant. Connect the cable for the negative battery terminal with a socket wrench.

The heater core in your Saturn converts cool air into warm air by utilizing already heated coolant. The heater core has fins for air to pass through. It also has water tubes to let warm coolant cycle in and out. This process causes the air to heat as it blows into the passenger compartment. When replacing your Saturns heater core with a new one, look for the correct specifications in depth, height, width, and diameters to the inlet and outlet ducts.

Instructions

Removing The Heater Core

1

Disconnect the negative cable from the Saturns battery.

2

Drain the coolant mix out of the cooling system. If the coolant mix is still good, save it for when it is time to ill the system. Otherwise dispose of it properly.

3

Remove the heater hose coming out of the thermostat housing behind the engine block on the 4-cylinder engine. This hose is connected to the heater core pump on V-6 engines. Drain any additional coolant mix.

4

Remove both heater hoses from the firewall-heater/air conditioner housing by squeezing the tabs on the locking couplers and pulling.

5

Take out the right console extension inside the passenger compartment by sliding it back.

6

Use your flathead screwdriver to pry the tabs on the heater pipe clamps. Remove the clamps from the couplers, then remove the pipes from the heater core.

7

Unscrew the heater core strap-mounting screw. Move the strap to the side.

8

Firmly grasp the heater core and pull it out of its housing.

Installing The New Heater Core

9

Install the new heater core into the housing.

10

Position the heater core strap and tighten the mounting screw.

11

Place the new rubber O-rings on the pipes. Fit the pipes back into the cores appropriate inlet and outlet tubes. Install the clamps on the couplers.

12

Slide back the right console extension.

13

Install both heater hoses back onto the firewall-heater/air conditioner housing.

14

Refit the heater hose back onto the thermostat housing behind the engine block for 4-cylinder engines. For V-6 engines, it the heater hose back onto the heater core pump.

15

Refill the coolant system with the coolant mix.

16

Re-connect the negative cable on the battery.

17

Turn on your car and test the heater.

When buying an alternator, or other car part, many consumers are surprised to learn that they are charged a core deposit. However, the deposit is returned when the old alternator is returned to the parts store.

How it Works

When buying a new alternator, the buyer pays the price of the alternator plus a deposit. After the new alternator is put onto the car, the buyer can exchange the old alternator for the deposit.

Conditions

The conditions for the old alternator to be accepted will vary depending on store policy. Information on the core return should be given at the time of purchase and is often included on the receipt. Most cores must be returned in rebuildable condition, within a set amount of time and in the box that the new part was sold in.

Core Deposit Purpose

The reason parts stores want the old alternator is that it will be sent to be remanufactured and resold. Parts stores charge the core deposit to assure that they receive the old part.

There are few things more uncomfortable than getting into your Blazer on a cold winter morning and realizing that you have no heat. Because you have to remove the dashboard to replace the heater core, it is often a costly repair. If you have time and patience, you can replace the heater core in your Chevy Blazer in an afternoon.

Instructions

1

Disconnect the negative terminal of the battery prior to starting any work. You need to do this before performing any repairs on your Blazer to reduce the risk of shock or electrical shorts while you work.

2

Locate the heater core on the engine compartment side of the firewall. Disconnect the inlet and outlet heater hoses from the heater core and plug the open end of the hoses to prevent debris from entering the hoses while you are working.

3

Remove the lower dashboard panels from both the left and right sides by turning the retaining screws counterclockwise to remove them and then depress the clips to release the panels.

4

Locate the pivot bracket under the dashboard at both ends of the dash. Turn the bolts on the pivot bracket counterclockwise to remove them from the dash assembly. Turn the Torx screws on the pivot brackets counterclockwise to remove them from the bracket.

5

Lower the steering column from the dashboard by turning the four nuts counterclockwise to remove them from the firewall bracing.

6

Find the steel rod brace located just to the right of center at the bottom of the dashboard. Turn the bolt at the end of this brace counterclockwise using the appropriate socket to remove it from the dashboard.

7

Use a flat screwdriver to pry the speaker grilles and the defrost outlet out of the dashboard. This will expose a series of bolts that are hidden behind the grilles. Turn each of these bolts counterclockwise to remove them from the dash.

8

Hold the dashboard and allow it to tilt towards the passenger compartment of the vehicle. Disconnect the main electrical plug and the radio antenna.

9

Remove the steel rod brace from the heater core. Once this brace has been removed, use the Phillips screwdriver to remove the six screws that secure the heater core cover to the housing.

10

Remove the screws at the top and bottom of the straps attaching the heater core to the passenger compartment side of the firewall counterclockwise to remove the support straps.

11

Remove the screw from the center of the strap covering the tubes leading to the engine compartment. This is located at the top-left of the heater core. Once this screw is removed, you will be able to pull the faulty heater core from the firewall and install the new one.

12

Reverse all steps to install the new heater core.