How to Replace a Dodge Caravan Evaporator

The evaporator, or the accumulator-drier, is a crucial part of a vehicle's air conditioner. Its task is to take the liquid refrigerant and reduce its pressure to turn it into a gas. Replacing the evaporator for your Dodge Caravan's air conditioner can be dangerous due to the pressure the system is under. The process varies depending on your van's year, but the evaporator is generally mounted to a shock tower and connected to the system through metal lines.

Instructions

Removal

1

Take the van to an automotive repair shop that has an air conditioning specialist who can discharge and recover the refrigerant from the air conditioner. This must not be attempted by an amateur.

2

Disconnect the electrical connector for the air filter's intake duct and the temperature sensor, then loosen the clamps for the hose with a screwdriver and disconnect the hose from the air filter housing.

3

Remove the single mounting bolt for the air filter housing with a wrench, then lift the housing up and detach the grommets underneath the housing from the upper and lower locator pins.

4

Unscrew and remove the line fittings on the evaporator; the bolts/screws usually require a screwdriver or Torx wrench.

5

Remove the mounting fasteners for the evaporator's mounting bracket, which is usually mounted on the shock tower, using a wrench or screwdriver. Check the position of the ground strap if one is equipped and remove the evaporator.

Installation

6

Pour 25 milliliters of refrigerant oil into the replacement evaporator; the oil must be compliant with R134a refrigerant unless the Caravan is an old model.

7

Install the replacement evaporator within the engine compartment using its mounting bracket and fasteners.

8

Connect the line fittings to the evaporator using new O-rings that are designed for air conditioning systems and lightly coated with refrigerant oil.

9

Reinstall the air filter housing, making sure the grommets seat within the locator pins, tightening the mounting bolt and reconnecting the intake duct.

10

Return the van to the shop for the same technician to evacuate and recharge the air conditioning system.