Heater System: Removal & Installation Dodge Ram Van B2500

REMOVAL & INSTALLATION

Removal & Installation (Ram Pickup)

Remove heater assembly. See HEATER ASSEMBLY . Remove blend air door servo motor electrical connector and mounting bolts. Remove blend air door servo motor. Ensure blend air door operates properly without restriction or binding. To install, reverse removal procedure.

Removal & Installation (Ram Van/Wagon)

Disconnect negative battery cable. Remove glove box. Disconnect wire harness connector from blend air door motor. Disconnect blend air door motor lever and remove link from retainer. Remove 3 mounting bolts and remove blend air door motor.

Removal (Dakota & Durango)

1. Disconnect negative battery cable. Remove and disassemble heater assembly. See «HEATER ASSEMBLY»(ref-196-S38470903062000030800000) . Disconnect blower motor lead at bottom of housing. Remove 6 bolts and blower motor housing cover.
2. Remove blower motor and fan assembly. Place reference marks on blower motor and fan for installation reference. Remove blower fan retainer clip. Pull blower motor fan off blower motor shaft.

Installation (Dakota & Durango)

Align reference marks made during removal. Press blower fan hub onto blower motor shaft. Ensure retainer clip ears are indexed over flats of blower motor shaft and fan hub. To complete installation, reverse removal procedure.

Removal (Ram Pickup)

1. Blower motor is located under glove box and can be removed from passenger compartment. (Scheme 5) Disconnect negative battery cable. Disconnect blower motor cooling tube. Remove blower motor electrical connector from retainer. Disconnect electrical connector.
2. Remove blower motor and fan assembly mounting bolts. Remove blower motor and fan assembly. Place reference marks on blower motor and fan for installation reference. Remove blower motor fan retainer clip. Pull blower motor fan off blower motor shaft.

Installation (Ram Pickup)

Align reference marks made during removal. Press blower fan hub onto blower motor shaft. Ensure retainer clip ears are indexed over flats of blower motor shaft and fan hub. Ensure blower motor seal is installed on housing. To complete installation, reverse removal procedure.

Removal (Ram Van/Wagon)

1. Disconnect negative battery cable. Remove top half of radiator shroud. At right side of engine compartment, disconnect blower motor wiring connector and motor cooling tube. Remove nuts and washers from blower motor backing plate to heater housing studs. (Scheme 6)
2. Remove blower motor assembly. Place reference marks on blower motor and fan for installation reference. Remove blower motor fan retainer clip. Pull blower motor fan off blower motor shaft. Inspect backing plate seal for breaks and adhesion.

Installation (Ram Van/Wagon)

Align reference marks made during removal. Press blower fan hub onto blower motor shaft. Ensure retainer clip ears are indexed over flats of blower motor shaft and fan hub. Apply a small bead of rubber sealant to blower motor side of rubber seal. To complete installation, reverse removal procedure.

Scheme 5

Scheme 6

Removal

1. Disconnect and isolate the battery negative cable.
2. Remove the cowl plenum cover/grille panel from the cowl top. See Vacuum Reservoir in the Removal and Installation section of this group for the procedures.
3. Reach through the cowl plenum access hole to remove the two hex screws that secure the front blower motor resistor to the cowl plenum panel. (Scheme 7)
4. Pull the front blower motor resistor and its wire harness out of the plenum panel and through the cowl plenum access hole far enough to access the wire harness connector.
5. Unplug the front blower motor resistor from the wire harness connector.
6. Remove the front blower motor resistor from the cowl plenum.

Scheme 7

Scheme 8

Installation

1. Plug the front blower motor resistor into the wire harness connector.
2. Install the front blower motor resistor to the cowl plenum panel by feeding the resistor and wire harness back through the cowl plenum access hole.
3. Install and tighten the two screws that secure the front blower motor resistor to the cowl plenum panel. Tighten the mounting screws to 2.2 Nm (20 in. lbs.)
4. Reinstall the cowl plenum cover/grille panel to the cowl top. See Vacuum Reservoir in the Removal and Installation section of this group for the procedures.
5. Connect the battery negative cable.

Blower motor resistor is located under glove box, attached to blower motor housing. (Scheme 5) Disconnect negative battery cable. Remove blower motor resistor connector. Remove resistor retaining bolts. Remove blower motor resistor. To install, reverse removal procedure.

Blower motor resistor is located behind glove box, attached to dash plenum panel. Disconnect negative battery cable. Remove glove box bin. Disconnect blower motor resistor connector. Remove resistor retaining bolts. Remove blower motor resistor. To install, reverse removal procedure.

1. Disconnect negative battery cable. Drain cooling system. Remove instrument panel. See «INSTRUMENT PANEL»(ref-196-S04136689132000030800000) .
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.

Ensure blower motor housing cover sealant is in place and in good condition. To complete installation, reverse removal procedure.

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»(ref-196-S04136689132000030800000) . 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.

Ensure mode door pivot pins are properly inserted in holes. To complete installation, reverse removal procedure.

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. (Scheme 9)
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. (Scheme 6) Carefully remove heater assembly from vehicle.
4. To install, reverse removal procedure. Ensure heater housing top cover seal, firewall and side cowl seals are in good condition.

Scheme 9

Removal & Installation (Dakota & Durango)

1. Disconnect negative battery cable. On models equipped with A/T, unlock ignition switch. Set parking brake and place gear selector lever in "L" position. If equipped, set tilt steering column in lowest position.
2. On all models, carefully pry bezel away from instrument panel to disengage clips. Unplug connectors from cigarette lighter and auxiliary power outlet. Disconnect fog light switch (if equipped). Remove 4 heater control panel bolts.
3. Pull control panel outward enough to disconnect wiring connector, vacuum harness and temperature control cable. Remove heater control panel. To install, reverse removal procedure. Adjust temperature control cable. See «TEMPERATURE CONTROL CABLE»(ref-196-S01017033242000030800000) under ADJUSTMENTS.

1. Disconnect negative battery cable. Reach under driver's side of instrument panel, near transmission tunnel, and unplug heater control panel-to-heater assembly vacuum harness connector. Disconnect vacuum harness from center air duct.
2. On models equipped with A/T, unlock ignition switch. Set parking brake and place gear selector lever in "L" position. If equipped, set tilt steering column in lowest position.
3. On all models, remove screw securing cluster bezel to instrument panel. (Scheme 10) Carefully pry bezel away from instrument panel to disengage clips. Unplug connectors from cigarette lighter and auxiliary power outlet.
4. Remove 4 bolts attaching heater control panel. Pull control panel outward enough to disconnect wiring connector and vacuum harness. Remove heater control panel. To install, reverse removal procedure.

Scheme 10

1. Disconnect negative battery cable. Remove engine cover from passenger compartment. Reach between upper dash panel engine housing extension and bottom of instrument panel. Disconnect vacuum harness connector located near left defroster outlet of distribution duct.
2. On models equipped with A/T, unlock ignition switch. Set parking brake and place gear selector lever in "L" position. If equipped, set tilt steering column in lowest position. Carefully pry bezel away from instrument panel to disengage clips. Pull bezel away far enough to clear trip odometer reset button. Remove bezel.
3. Remove 3 bolts from heater control panel. Pull heater control panel outward enough to disconnect electrical connectors and vacuum connector. Remove heater control panel. To install, reverse removal procedure.

Remove heater assembly from vehicle. See HEATER ASSEMBLY . Disable heater assembly and remove heater core.

1. Disconnect negative battery cable. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Place front wheels in straight-ahead position. Remove sill trim from both doorways. Remove kick panel covers from both sides of vehicle. Remove mounting bolts for hood release handle.
2. Remove steering column trim panel and support bracket. If equipped, remove tilt steering column lever. Remove upper and lower shrouds from steering column. Remove knee bolster. Unplug driver's side air bag module. Loosen multifunction switch wiring harness connector screw and disconnect from switch. Screw will remain in connector.
3. Disconnect PRNDL cable. Disconnect shift cable from steering column. Remove steering coupler lock pin. Remove toe plate retaining bolts. Remove steering column mounting bolts and remove steering column from vehicle.
4. Remove screw from bulkhead wiring harness connector and disconnect. Disconnect 2 body wiring harness connectors located next to bulkhead connector. Disconnect 3 wiring harness connectors located nearest to dash panel from junction block. Disconnect brake light switch. If equipped, disconnect Rear Wheel Anti-Lock (RWAL) brake module, located near steering column support brackets.
5. Disconnect plastic retainer clip from parking brake linkage rod, located at back of parking brake release handle. Remove rod end from parking brake handle. Remove instrument panel center support bracket. Unplug vacuum harness connector located at left end of heater assembly housing. Disconnect Air Bag Control Module (ACM) connector.
6. Remove glove box. Reach through glove box opening and disconnect antenna coaxial cable. Disconnect blower motor connector located above glove box opening, near support brace for heater assembly housing. Disconnect radio ground strap. Loosen instrument panel roll-own bracket bolts about 2 turns (bolts are located at lower corners, on both sides of instrument panel). Remove 5 bolts across top of dash panel, at base of windshield, removing center screw last.
7. Roll down instrument panel and install a temporary support hook that is about 18" (457 mm) in length. Install hook from center hole in instrument panel to center hole of dash panel. Pull lower instrument panel outward until both roll-down bracket bolts are in slotted roll-down position. Instrument panel should now be supported and away from firewall.
8. Disconnect 2 body wiring harness connectors, located on a bracket near right end of instrument panel. Disconnect blower motor resistor. Disconnect temperature control cable from heater assembly housing and remove from housing. Disconnect defrost duct flexible hose from heater assembly housing.
9. Ensure all electrical and vacuum connectors are disconnected and instrument panel is free and clear for removal. With the aid of an assistant, remove temporary support hook. Lift instrument panel off of roll-down bracket bolts and remove from vehicle.
10. To install, reverse removal procedure. Ensure all wiring and hoses are clear and not pinched. Adjusting temperature control cable. See «TEMPERATURE CONTROL CABLE»(ref-196-S01017033242000030800000) under ADJUSTMENTS. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-196-S21504385012000030800000) . Enable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING.

1. Disconnect negative battery cable. Ensure front wheels are in a straight-ahead position and steering wheel is in LOCKED position. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Remove Air Bag Control Module (ACM) and bracket from floor panel transmission tunnel. Drain cooling system.
2. Remove left and right cowl side inner trim panels. Remove knee bolster/steering column cover. Remove hood release and parking brake release handle bolts from lower instrument panel support.
3. Disconnect driver's side air bag connector at lower left corner of instrument panel. If equipped, disconnect overdrive lock-out switch wiring harness connector from instrument panel wire harness near instrument panel lower reinforcement.
4. Pull PRNDL cable and twist to remove from position arm. Push tab on bottom of cable retainer upward, then squeeze sides to remove retainer from column. If equipped, remove tilt lever. Remove both upper and lower shrouds from column. Remove lower fixed column shroud. Loosen multifunction switch connector screw. Screw will remain in connector.
5. Ensure steering wheel is in LOCKED position. Remove remaining steering column electrical connectors. Remove air bag wiring harness from steering column wiring trough. Remove wiring trough from steering column. Remove steering column as an assembly from vehicle.
6. From driver's side of instrument panel, disengage parking brake release linkage rod from parking brake mechanism. Disconnect instrument panel wiring harness from parking brake mechanism. Disconnect 3 wiring harness bulkhead connectors located closest to dash panel.
7. Disconnect instrument panel left side wiring harness connectors. Remove screw from center of headlight and dash-to-instrument panel (bulkhead) connector, and disconnect connector. Disconnect instrument panel-to-door wiring harness. Disconnect instrument panel to stoplight switch connector. Disconnect vacuum harness for heater system.
8. If equipped with an Infinity sound system, disconnect Infinity wiring harness connector from instrument panel harness connector that is secured to bulkhead connector.
9. From passenger's side of instrument panel, disconnect radio antenna coaxial cable connector. Loosen right and left instrument panel roll-down bracket bolts about.50" (13 mm). Removing center screw last, remove 5 bolts holding top of instrument panel to top of dash panel.
10. Roll instrument panel downward and install a temporary support hook to center hole of dash panel. Support hook should support instrument panel in rolled-down position, about 18" (457 mm) away from dash panel. Disconnect remaining wiring harness connectors. With the aid of an assistant, remove temporary hook and lift instrument panel from vehicle.
11. To install, reverse removal procedure. Ensure all wiring and hoses are clear and not pinched. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(ref-196-S21504385012000030800000) . Enable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING.

Disconnect negative battery cable. Disconnect but DO NOT remove instrument panel. See INSTRUMENT PANEL. Disconnect temperature control cable from heater control panel. Disconnect temperature control cable from flag retainer located at top of heater assembly housing. (Scheme 11) Remove temperature control cable self-adjuster clip and temperature control cable.

1. Before installing temperature control cable, ensure that self-adjuster clip is positioned as indicated. (Scheme 12) Measurements must be made with cable end bottomed against flag retainer on heater control panel end of cable housing.
2. Measure distance between center of self-adjusting clip and end of cable flag retainer. If distance is not as specified, adjust self-adjuster clip. To complete installation, reverse removal procedure.

Scheme 11

Scheme 12

Removal (Dakota, Durango & Ram Pickup)

1. Vacuum reservoir is located in engine compartment, under cowl plenum cover. Disconnect negative battery cable. With hood open, unsnap and remove wiper arm pivot cover. Remove wiper arm nut. Mark wiper arm and pivot for installation reference. Using battery terminal puller, remove wiper arms.
2. Remove weatherstrip along front edge of cowl plenum cover and cowl plenum panel. Remove plastic nuts, plastic rivets, and plastic push-in retainers from cowl plenum cover. Unsnap slotted center hole from adhesive backed snap fastener. Ensure not to remove fastener from cowl side panel.
3. Lift cowl plenum cover enough to access windshield washer nozzle and vacuum plumbing. Disconnect vacuum supply hose from vacuum reservoir. Remove cowl plenum cover. Remove bolts and vacuum reservoir.

Installation (Dakota, Durango & Ram Pickup)

To install, reverse removal procedure. Ensure all hoses are clear and not pinched. Tighten wiper arm nuts to specification. See TORQUE SPECIFICATIONS .