Dodge R1500 1999 Service Manual page 832

removal procedure.
HEATER ASSEMBLY
Removal (Dakota & Durango)
1) Disconnect negative battery cable. Drain cooling system.
Remove instrument panel. See INSTRUMENT PANEL.
2) In engine compartment, disconnect heater hoses and plug
all openings. Remove 4 heater assembly nuts from engine compartment
firewall. Inside vehicle, remove heater assembly support brace screw,
and swing support brace out of way. Move passenger seat rearward.
3) Carefully pull heater assembly rearward until studs and
heater core tubes clear firewall. Lower heater assembly and rotate
assembly until studs are facing downward. Remove heater assembly from
vehicle.
4) Place heater assembly on work bench with assembly housing
cover facing down. Remove 2 bolts securing heater assembly housing
cover to blower motor housing cover. Unplug vacuum harness connector
from panel/defrost door actuator.
5) Remove floor duct from heater assembly housing. Remove 2
bolts securing heater assembly housing cover to lower housing near
floor outlet. Turn assembly over. Disengage vacuum harness retainer
and vacuum harness. Remove 13 screws securing housing cover.
6) Remove blend-air door lever. Gently pry panel-defrost door
lever off. Pull up on heater assembly housing cover far enough to
separate cover sealant and remove cover.
Installation
Ensure blower motor housing cover sealant is in place and in
good condition. To complete installation, reverse removal procedure.
Removal (Ram Pickup)
1) Disconnect negative battery cable. Drain cooling system.
In engine compartment, remove coolant hoses from heater core tubes.
Plug all openings. Remove coolant overflow bottle. Remove instrument
panel. See INSTRUMENT PANEL. Remove Powertrain Control Module (PCM)
and position aside. DO NOT disconnect 60-pin connector from PCM.
2) Remove attaching nuts from studs on engine compartment
side of dash panel. Remove defrost duct. Disconnect electrical
connectors. Remove attaching nuts from studs in passenger compartment
side of dash panel. Remove heater assembly from vehicle.
3) Place heater assembly upside-down on work bench. Remove
screw securing floor duct to bottom of heater assembly and slide floor
duct off of center heat duct adapter. Unsnap center heat duct adapter
from bottom of heater assembly housing. Remove screw hidden behind
adapter. Remove remaining screws and separate heater assembly.
Installation
Ensure mode door pivot pins are properly inserted in holes.
To complete installation, reverse removal procedure.
Removal & Installation (Ram Van/Wagon)
1) Disconnect negative battery cable. Drain engine cooling
system. In engine compartment, protect generator from coolant
spillage. Remove heater hoses from heater core tubes. Plug all
openings. Remove grille, cowl grille support panel, right headlight
assembly, and right radiator core support assembly. See Fig. 7.
2) From inside vehicle, remove glove box bin. Through glove
box opening and from under instrument panel, remove nuts and bolts
attaching heater assembly to dash panel.
3) Remove blower housing flange screws. Separate heater
assembly from blower housing. See Fig. 6. Carefully remove heater
assembly from vehicle.