1. Preparation:
* Consult a Shop Manual: This is crucial. A factory service manual will give you precise instructions, diagrams, and torque specifications. This is not something you should attempt without one.
* Gather Tools: You'll need a variety of tools, including various screwdrivers (Phillips and flathead), sockets (metric and possibly SAE), wrenches, pliers, a good set of needle-nose pliers, possibly a tubing cutter or flare nut wrench, and possibly a small pipe wrench. A good quality drain pan is essential to catch coolant.
* Safety First: Wear safety glasses, gloves, and old clothes. Coolant is corrosive and can stain. Disconnect the negative battery terminal to prevent electrical shorts.
* Drain the Cooling System: Completely drain the coolant from the engine and radiator.
2. Dashboard Disassembly:
* This is the most labor-intensive part. You'll need to carefully remove the dashboard, steering column (possibly), and any other components obstructing access to the heater core. This will involve removing screws, nuts, bolts, and possibly various trim pieces. Take pictures as you go to aid reassembly.
* Be gentle! Many of these components are fragile and can easily break. Work methodically, carefully noting the location and order of removal for each part.
3. Heater Core Access:
* Once the dashboard is removed (partially or fully, depending on your car's design), you should be able to see the heater core housing. This is usually located behind the dashboard, often near the firewall.
* Locate the heater core hoses: These will be connected to the heater core. Prepare to catch any remaining coolant.
4. Heater Core Removal:
* Disconnect the heater hoses: Carefully disconnect the heater hoses from the heater core. Use a drain pan. These connections may be difficult to access and may require special tools to loosen and disconnect them.
* Remove the heater core housing: This usually involves removing screws or bolts securing the housing. The housing itself may be somewhat fragile.
* Remove the heater core: Once the housing is off, the heater core should be accessible. It will likely be held in place by clips or brackets. Carefully remove the heater core, paying attention to its orientation to make replacement easier.
5. Installation (Reverse of Removal):
* Install the new heater core. Ensure it's properly seated and all connections are secure.
* Reassemble the heater core housing and reconnect the hoses.
* Reinstall the dashboard and other components in the reverse order of removal.
6. Refill and Bleed the Cooling System:
* Once everything is reassembled, carefully refill the cooling system with the correct coolant mixture (check your owner's manual).
* Bleed the cooling system to remove any air pockets. This process varies by vehicle; consult your shop manual.
Important Considerations:
* Rust and Corrosion: On a car this age, rust and corrosion are likely. Be prepared for broken parts and difficult-to-remove fasteners. Penetrating oil can be a lifesaver.
* Fragile Parts: The dashboard and other interior components are often brittle after decades of age. Take your time and be extremely careful.
* Professional Help: If you're not comfortable with this level of automotive repair, consider taking your Charger to a professional mechanic specializing in classic cars. The cost of a damaged part due to inexperience may far exceed the cost of professional labor.
This is a complex procedure. Again, obtaining and thoroughly studying a factory service manual is absolutely essential. Improper removal or reinstallation can lead to leaks, damage to other components, and a frustrating experience. Remember to take your time, work carefully, and document each step.
