How do you replace evaporator core 1999 Dodge intrepid?

Answer 1

Open hood and disconnect the negative battery cable remote terminal from the remote battery post.
Remove one alien screw to shifter knob.
Remove left and right instrument panel end covers.
Using a trim stick (special tool #C-4755) gently pry up on shifter bezel, disconnect two wire connectors , one illumination bulb socket and remove.
Remove two screws from lower instrument panel cover (outside end) and disconnect decklid release switch wiring connector. Pull reaward on lower instrument panel cover releasing clips. Remove cable to brake release handle. Pull rearward and remove cover from vehicle.
On five passenger vehicles, use trim stick to gently remove center bezel. Disconnect wire harnesses connected to HVAC control and track on control switch.
Remove bezel from vehicle.
Remove two screws to left console side cover, pull outboard and remove from vehicle.
Lower glove box door. Remove two screws to right console side cover, pull outboard and remove from vehicle
Remove two front bracket screws and two screws inside console bin to remove console.
Remove two nuts attaching center lower instrument panel.
Remove four bolts to steel reinforcement from bottom of lower instrument panel cover and disconnect l6-way Diagnostic Link Connector (DLC) from steel reinforcement,
Remove steering column from vehicle.
Remove under column duct section from vehicle.
Remove one screw to left floor duct/silencer pad and remove from vehicle.
Disconnect two harness connectors to the HVAC housing, the Airbag Control Module (ACM) and three ground eyelets left of the floor tunnel near the bulkhead.
Using a trim stick, gently pry out on the left and right A-pillar trim moldings.
Using a trim stick, gently pry up on the instrument panel top cover and remove toward the rear of vehicle.
Using a trim stick, gently pry out on left and right scuff plates and remove from vehicle.
Remove three screws to right side cowl panel and remove from vehicle.
Remove three screws to left side cowl panel and remove from vehicle.
Remove right side under dash silencer/pad.
Disconnect the two right side harness connectors to radio antenna and amplifier DIN cable.
Disconnect the left side harness connectors to junction block and Body Control Module (BCM).
Disconnect the front 'viper defrost grid wire connector.
Remove one instrument panel retaining screw behind glove box.
Remove twelve instrument panel retaining screws
Pull rearward on instrument panel.
Make sure that all harnesses are free and clear from snagging.
With the help of an assistant, remove instrument panel from vehicle and place on bench.
If replacing instrument panel and pad assembly, transfer all parts to new assembly
Using an A/C recovery unit, remove all R-134a refrigerant from the A/C system. Refer to: Heating and Air Conditioning, Service and Repair, Refrigerant System Evacuate, See: Service and Repair\Refrigerant System Evacuate
Drain the engine cooling system.
Remove air cleaner hose and air distribution duct from the engine.
Remove spring type fasteners to heater hoses at the dash panel and remove hoses from heater core. Plug the heater core inlet and outlet tubes to prevent anti-freeze from spilling on the vehicle interior during removal. If an appropriate plug cannot be found pull back carpet and use caution when removing unit. Keep the heater tubes elevated to prevent spillage of coolant.
Remove one nut at expansion valve retaining both A/C lines to expansion valve. After removing lines cap the expansion valve openings and the A/C hose openings. This will prevent any dirt or moisture from entering the refrigerant system during servicing. CAUTION: The lubricant used in this air conditioning system absorbs moisture readily (similar to brake fluid). Do not leave any portion of the system open for extended periods of time.
Remove the three retaining nuts from the studs. These studs project through the dash panel into the engine compartment.
Remove two screws to defrost duct and remove.
Remove two nuts, two screws attaching HVAC housing to dash panel.
Remove four nuts retaining rear seat heat duct and remove.
Remove rear seat heat duct elbow push pin fastener.
Disconnect HVAC harness connector.
Gently pull HVAC unit housing rearward from dash panel, being careful not to spill any coolant into passenger compartment.
Remove recirculation door actuator.
Remove recirculation door and housing.
Remove upper housing retaining screws.
Remove upper half of heater housing.
Lift evaporator out of lower housing.
Transfer evaporator probe. Place the evaporator probe in the same location as on the previous

With the refridgerant removed,

Disconnect the negative battery cable from the remote battery post located near the right strut tower.
CAUTION After disconnecting the negative battery cable, wait 2 minutes for the driver's/passenger's air bag system capacitor to discharge before attempting to do any work around the steering column or instrument
Remove the instrument panel by removing or disconnecting the following:
Shifter knob Allen screw
Both instrument panel end covers
NOTE On the LHS or 300M, remove the center bezel prior to the shifter bezel
Using a trim stick tool, gently pry upward on the shifter bezel; then, disconnect both wiring connectors and a light bulb socket connector; then, remove the socket.
Remove the 2 lower instrument panel cover screws (outside end) and disconnect the deck lid release switch wiring connector. Pull the lower instrument panel cover rearward releasing the clips. Remove the cable-to-brake release handle. Pull the cover rearward and remove it.
If equipped for 6 passengers, remove the lower floor bin.
If equipped for 5 passengers, remove or disconnect the following items:
Center bezel using the trim stick
Heater/air conditioning housing assembly control switch and the traction control switch wiring harnesses
Bezel from the vehicle
Two left side console side cover screws, pull the cover outward and remove from the vehicle
Lower glove box door; the 2 screws are located at the right console side cover, pull outward and remove it
2 bracket screws and the 2 inside the console bin; then, remove the console
2 center lower instrument panel nuts
4 steel reinforcement-to-lower instrument panel cover bottom bolts
16-way DLC from the reinforcement
left floor duct/silencer pad screw and the pad
Steering column shrouds
Shift interlock cable at the ignition switch
Column wiring
The under column duct section
Left panel air conditioning outlet duct
The 4 brake pedal support bracket-to-column mounting bolts
Lower the steering column
Heater/air conditioning housing and the Air bag Control Module (ACM) harness connectors then, the 2 ground eyelets from the floor tunnel near the bulkhead
Using a trim stick, carefully, pry out on the left and right A-pillar trim moldings and slide them rearward to remove them.
Using a trim stick, carefully pry upward on the instrument panel top cover, and remove it.
From both sides, remove the scuff plate screw. Using a trim stick, carefully, pry out the scuff plates and remove them.
Remove or disconnect the following:
3 right side cowl panel screws and the panel
3 left side cowl panel screws and the panel
Remove the right side under dash silencer and pad
2 right side radio antenna and amplifier harness connectors
Left side junction block and Body Control Module (BCM) harness connectors
8 instrument panel-to-chassis screws
Pull the instrument panel rearward
Instrument panel from the vehicle with the help of an assistant
Discharge and recover the air conditioning system refrigerant.
Drain the cooling system into a clean container for reuse.
Place shop cloths in the interior to catch any excess coolant.
Remove or disconnect the following:
Air cleaner hose and the air distribution duct
Heater hoses-to-dash panel spring type fasteners and the heater hoses from the heater core. Plug the openings to prevent coolant spillage.
Refrigerant lines-to-expansion valve nut and separate the refrigerant lines from the expansion valve. Plug the openings to prevent contamination.
WARNING The air conditioning lubricant used in this system absorbs moisture readily. Do not leave any portion of the system open for any long period of time.

3 heater/air conditioning housing assembly-to-chassis nuts from the engine compartment
2 defroster duct screws and the duct
Heater/air conditioning housing assembly-to-dash panel nuts and screws
4 rear seat heat duct nuts and the duct
Rear seat heat duct elbow push-pin fastener
Electrical connector from the heater/air conditioning housing assembly
Pull the heater/air conditioning housing assembly rearward and remove it from the vehicle
2 heater core-to-heater/air conditioning housing assembly screws
Heater core from the heater/air conditioning housing assembly
Exploded view of the instrument panel-Intrepid Exploded view of the instrument panel-Concorde Exploded view of the instrument panel-LHS and 300M View of the remote battery cable terminal-LHS, 300M, Concorde and Intrepid View of the heater/air conditioning housing assembly-LHS, 300M, Concorde and Intrepid
To install:

Install or connect the following:
Heater core to the heater/air conditioning housing assembly
2 heater core-to-heater/air conditioning housing assembly screws
Push the heater/air conditioning housing assembly forward (carefully) and install it to the vehicle
Electrical connector to the heater/air conditioning housing assembly
Rear seat heat duct elbow push pin fastener
Duct and the 4 rear seat heat duct nuts
Heater/air conditioning housing assembly-to-dash panel nuts and screws
2 defroster duct and the duct screws
In the engine compartment, the 3 heater/air conditioning housing assembly-to-chassis nuts
Refrigerant lines to the expansion valve
Refrigerant lines-to-expansion valve nut
Heater hoses to the heater core and the heater hoses-to-dash panel spring type fasteners
Air cleaner hose and the air distribution duct
Refill the cooling system.
Evacuate, charge and leak-test the air conditioning system refrigerant.
Install the instrument panel by installing or connecting the following:
Instrument panel to the vehicle
Push the instrument panel forward
8 instrument panel-to-chassis screws
Left side junction block and Body Control Module (BCM) harness connectors
2 right side radio antenna and amplifier harness connectors
Right side under dash silencer and pad
Left side cowl panel and the 3 panel screws
Right side cowl panel and the 3 panel screws
Install the scuff plate and the screw (both sides)
Instrument panel top cover
Left and right A-pillar trim moldings
Heater/air conditioning housing and the Air bag Control Module (ACM) harness connectors then, the 2 ground eyelets to the floor tunnel near the bulkhead
Raise the steering column
The 4 brake pedal support bracket-to-column mounting bolts
Left panel air conditioning outlet duct
The under column duct section
Column wiring
Shift interlock cable at the ignition switch
Steering column shrouds
Left floor duct/silencer pad and the pad screw
4 steel reinforcement-to-lower instrument panel cover bottom bolts
6-way Diagnostic Link Connector (DLC) to the reinforcement
2 center lower instrument panel nuts
The 2 bracket screws and the 2 inside the console bin; then, the console (5 passenger models only)
2 screws are located at the right console side cover (5 passenger models only)
Two left side console side cover screws (5 passenger models only)
Bezel to the vehicle (5 passenger models only).
Heater/air conditioning housing assembly control switch and the traction control switch wiring harnesses.
Center bezel using the trim stick.
Lower floor bin (6 passenger models only).
2 lower instrument panel cover screws (outside end) and connect the deck lid release switch wiring connector. Install the cable-to-brake release handle
Light bulb socket. Both wiring connectors and a light bulb socket connector
Shifter bezel
Center bezel prior to the shifter bezel (LHS or 300M models)
Both instrument panel end covers
Shifter knob Allen screw
Connect the negative battery cable to the remote battery post located near the right strut tower.
Operate the engine to normal operating temperatures; then, check the climate control operation and check for leaks.

Item 3
Have the refridgerant refilled at an EPA authorized facility