Dodge Durango (HB). Manual — part 1561
1. Recover the refrigerant from the refrigerant system
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING FRONT - STANDARD PROCEDURE -
REFRIGERANT SYSTEM RECOVERY).
2. Disconnect and isolate the negative battery cable.
3. Remove the push-pin retainers (1) and the upper
condenser/radiator seal (2).
4. Disconnect the wire harness connectors from the
condenser cooling fan motor (9) and the A/C pres-
sure transducer (10).
5. Remove the two wire harness retainers (2) from
the condenser fan shroud (4) and position the wire
harness out of the way.
6. Remove the nuts (1 and 8) that secure the A/C dis-
charge line (5) and A/C liquid line (7) to the A/C
condenser (6).
7. Disconnect the A/C discharge and liquid lines from
the A/C condenser and remove and discard the
O-ring seals and gaskets.
8. Remove the A/C discharge line from the retainer
(3) located on the condenser fan shroud (4).
9. Install plugs in, or tape over the opened discharge
and liquid line fitting and condenser ports.
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PLUMBING - FRONT
24 - 437
10. Remove the three bolts (1) that secure the upper
radiator support (2) to the upper front crossmem-
ber (5).
11. Remove the upper radiator support and position
the radiator overflow hose (3) out of the way.
12. Remove the bolt that secures the condenser/cool-
ing fan assembly (4) to the upper left fender rail.
13. Carefully push back the radiator (6) for clearance
and remove the condenser/cooling fan assembly
from the engine compartment.
14. Place the condenser/cooling fan assembly on a
workbench and remove the two screws (1) that
secure the A/C condenser (2) to the condenser
fan shroud (3).
15. Remove the A/C condenser from the condenser
fan shroud.
INSTALLATION
NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
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PLUMBING - FRONT
HB
1. Position the A/C condenser (2) into the condenser
fan shroud (3).
2. Install the two bolts (1) that secure the A/C con-
denser to the condenser fan shroud. Tighten the
bolts to 5 N·m (45 in. lbs.).
3. Carefully push back the radiator (6) for clearance
and install the condenser/cooling fan assembly (4).
Insert the two lower condenser fan shroud mount-
ing tabs into the holes in the lower front crossmem-
ber.
4. Install the bolt that secures the condenser/cooling
fan assembly to the upper left fender rail. Tighten
the bolt to 5 N·m (45 in. lbs.).
5. Position the radiator overflow hose (3) to it’s
installed location
6. Align the upper mounting tab of the condenser/
cooling fan assembly to the hole in the upper radi-
ator support (2) and install the upper radiator
support.
7. Install the three bolts (1) that secure the upper
radiator support to the upper front crossmember
(5). Tighten the bolts to 23 N·m (17 ft. lbs.).
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PLUMBING - FRONT
24 - 439
8. Remove the tape or plugs from the discharge and
liquid line fittings and condenser ports.
9. Lubricate new rubber O-ring seals with clean refrig-
erant oil and install them and new gaskets onto the
discharge and liquid line fittings. Use only the spec-
ified O-rings as they are made of a special material
for the R-134a system. Use only refrigerant oil of
the type recommended for the A/C compressor in
the vehicle.
10. Connect the A/C discharge line (5) and the A/C
liquid line (7) to the A/C condenser (6).
11. Install the nuts (1 and 8) that secure the A/C dis-
charge and liquid lines to the A/C condenser.
Tighten the nuts to 22 N·m (16 ft. lbs.).
12. Install the A/C discharge line into the retainer (3)
located on the condenser fan shroud.
13. Install the wire harness and the two wire harness
retainers (2) to the condenser fan shroud (4).
14. Connect the wire harness connectors to the condenser cooling fan motor (9) and the A/C pressure transducer
(10).
15. Position the upper condenser/radiator seal and
install the push-pin retainers.
16. Reconnect the negative battery cable.
17. Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM EVACUATE).
18. Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM CHARGE).
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PLUMBING - FRONT
HB
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