The 2003 Dodge Caravan has two heater cores: one for the front vents and one for the rear. Replacing the front heater core is a large project that requires removing the steering column. The rear heater core is simpler to change, but you must still remove several body panels to access it. Be prepared to spend a few hours performing the swap.
Turn the steering wheel so that the wheels point straight forward.
Disconnect the negative (black) battery cable.
Drain the coolant by twisting open the valve at the bottom of the radiator. Use a clean container that holds at least 10.5 quarts. You will reuse the coolant later.
Remove the panel on the lower left side of the steering column and disconnect the parking brake cable with a pair of pliers.
Unscrew the 10 bolts that connect the steering column cover liner to the instrument panel and remove the cover.
Turn the key to the LOCK position and turn the steering wheel to the LOCKED position.
Unhook the gear shift cable and remove its mounting bracket.
Unscrew the two screws that connect the bezel to the instrument panel and remove the retaining clips. Remove the bezel.
Remove the two screws that connect the steering column shroud to the column and remove the shroud.
Remove the coupler from the steering column and intermediate steering shaft.
Loosen the nuts that connect the lower steering column mounting bracket, but do not remove them. Completely remove the two nuts and washers from the upper bracket.
Pull out the steering column.
Remove the interconnect and bracket that connects the instrument panel to the chassis wiring.
Remove the boot from the bottom of the steering shaft.
Use locking pliers to pinch off the heater hoses in the engine compartment. Remove the plate covering the heater core (the hoses run through it) and disconnect the hoses.
Unclip the connectors that hold in the heater core. Lift the accelerator pedal to enable you to slide the heater core out part way. Press the brake pedal to make room to completely remove the heater core.
Replace the heater core. Installation is the reverse of removal. The nuts on the steering column mounting bracket should be torqued to 105 ft. lbs. Torque the pinch bolt on the coupler to 21 ft. lbs.
Remove the first and second row of seats on the right side.
Remove the trim panel from the sliding door sill. Remove the C and D-pillar trim panels.
Remove the seat belt anchors from the right side of the first and second rows.
Unscrew the screws that connect the quarter trim to the quarter panel. Remove the screws from the bracket on the rear side of the quarter trim.
Use a flathead screwdriver to disconnect the hidden clips behind the sliding door and remove the quarter trim.
Unplug the connector from the rear power plug if your van is equipped with one.
Slide the seat belts through the slots in the trim panel and completely remove the panel.
Loosen the clamps from the hoses on the exposed heater core and disconnect the hoses. Remove the screws holding the heater core in place and extract the core.
Replace the heater core. Installation is the reverse of removal.
