Dodge Durango (DN). Manual — part 199

(2) Connect the temperature control cable housing

flag retainer to the receptacle on the back of the
heater-A/C control.

(3) Plug in the vacuum harness connector and

install the two stamped nuts to secure the connector
to the back of the heater-A/C control.

(4) Plug the wire harness connector into the back

of the heater-A/C control.

(5) Reinstall the wire harness retainer to the side

of the heater-A/C control.

(6) Position the heater-A/C control in the instru-

ment panel and secure it with four screws. Tighten
the screws to 2.2 N·m (20 in. lbs.).

(7) Reinstall the cluster bezel to the instrument

panel. Refer to Cluster Bezel in the Removal and
Installation section of Group 8E - Instrument Panel
Systems for the procedures.

(8) Connect the battery negative cable.
(9) Adjust the temperature control cable. See Tem-

perature Control Cable in the Adjustments section of
this group for the procedures.

HEATER-A/C HOUSING

The heater-A/C housing assembly must be removed

from the vehicle and disassembled for service access
of the blower motor, blower motor wheel, heater core,
evaporator coil, blend-air door, and each of the vari-
ous mode control doors.

WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE PER-
FORMING THE FOLLOWING OPERATION.

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,

REFER

TO

GROUP

8M

-

PASSIVE

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING

WHEEL,

STEERING

COLUMN,

OR

INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel from the vehicle.

Refer to Instrument Panel Assembly in the Removal
and Installation section of Group 8E - Instrument
Panel Systems for the procedures.

(3) Recover the refrigerant from the refrigerant

system. See Refrigerant Recovery in the Service Pro-
cedures section of this group.

(4) Remove the front expansion valve from the

evaporator tube mounting flange. See Expansion
Valve in the Removal and Installation section of this
group for the procedures. Install plugs in, or tape
over all of the opened refrigerant line fittings.

(5) Drain the engine cooling system. Refer to

Group 7 - Cooling System for the procedures.

(6) Disconnect the heater hoses from the heater

core tubes. Refer to Group 7 - Cooling System for the
procedures. Install plugs in, or tape over the opened
heater core tubes.

(7) Remove the four nuts from the heater-A/C

housing mounting studs on the engine compartment
side of the dash panel (Fig. 61).

(8) Disengage the front floor panel transmission

tunnel duct from the adapter on the heater-A/C hous-
ing.

(9) Remove the nut that secures the heater-A/C

housing mounting brace to the stud on the passenger
compartment side of the dash panel.

(10) Pull the heater-A/C housing rearward far

enough for the mounting studs and the evaporator
condensate drain tube to clear the dash panel holes.

(11) Remove the heater-A/C housing from the vehi-

cle.

DISASSEMBLY

(1) Place the heater-A/C housing on a work bench,

with the heater-A/C housing cover facing down.

(2) Remove the two screws that secure the heater-

A/C housing cover to the top of the blower motor
housing cover.

(3) If the vehicle is so equipped, unplug the two

vacuum harness connectors from the recirculation air
door actuator.

(4) Unplug the vacuum harness connector from the

panel-defrost door actuator.

(5) Remove the four screws that secure the floor

duct to the bottom of the heater-A/C housing and
remove the duct from the housing.

(6) Remove the two screws that secure the heater-

A/C housing cover to the lower housing near the floor
outlet (Fig. 62).

(7) Turn the heater-A/C housing over on the work

bench, with the heater-A/C housing cover facing up.

(8) Disengage the vacuum harness retainer from

the hole near the left end of the heater-A/C housing
cover.

(9) Remove the vacuum harness from the molded

clips on the heater-A/C housing cover (Fig. 63).

(10) Remove the thirteen screws that secure the

perimeter of the housing cover to the heater-A/C
housing.

(11) Remove the nut that secures the blend-air

door lever to the blend-air door pivot shaft and
remove the lever.

24 - 54

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

Fig. 61 Heater-A/C Housing Remove/Install

1 – STUD
2 – BRACE
3 – HEATER-A/C HOUSING

4 – NUT
5 – NUT

Fig. 62 Heater-A/C Housing Floor Outlet Screws

1 – HEATER-A/C HOUSING FLOOR OUTLET
2 – FLOOR-DEFROST DOOR ACTUATOR
3 – SCREWS

Fig. 63 Blend-Air Door Lever Remove/Install

1 – CLIP
2 – PUSH NUT
3 – BLEND-AIR DOOR LEVER
4 – VACUUM HARNESS

DN

HEATING AND AIR CONDITIONING

24 - 55

REMOVAL AND INSTALLATION (Continued)

(12) Gently pry off the push nut that secures the

heater-A/C housing cover to the heater-A/C housing
post.

(13) Using a trim stick or another suitable wide

flat-bladed tool, gently pry the panel-defrost door
lever off of the panel-defrost door pivot shaft (Fig.
64).

(14) Pull up the perimeter edges of the heater-A/C

housing cover far enough to separate the cover seal-
ant from the heater-A/C housing.

(15) Remove the housing cover from the heater-

A/C housing.

(16) If the vehicle is so equipped, remove the recir-

culation air door actuator from the blower motor
housing cover. See Mode Door Vacuum Actuators in
the Removal and Installation section of this group for
the procedures.

(17) Remove the six screws that secure the blower

motor housing cover to the heater-A/C housing (Fig.
65).

(18) Remove the blower motor housing cover from

the heater-A/C housing.

ASSEMBLY

(1) Before installing the blower motor housing

cover, be certain that the cover sealant is in place
and in good condition (Fig. 66).

(2) Position the blower motor housing cover to the

heater-A/C housing.

(3) Install the six screws that secure the blower

motor housing cover to the heater-A/C housing.
Tighten the screws to 2.2 N·m (20 in. lbs.).

(4) If the vehicle is so equipped, reinstall the recir-

culation air door actuator. See Mode Door Vacuum
Actuators in the Removal and Installation section of
this group for the procedures.

(5) Before installing the heater-A/C housing cover,

be certain that the cover sealant is in place and in
good condition (Fig. 67).

(6) Position the heater-A/C housing cover on the

heater-A/C housing. Be certain that the pivots for the

Fig. 64 Panel-Defrost Door Lever Remove

1 – PANEL-DEFROST DOOR ACTUATOR LINK
2 – PANEL-DEFROST DOOR LEVER
3 – HEATER-A/C HOUSING TOP COVER
4 – DOOR PIVOT SHAFT

Fig. 65 Blower Motor Housing Cover Remove/Install

1 – SCREWS
2 – BLOWER MOTOR HOUSING COVER

Fig. 66 Blower Motor Housing Cover Sealant

1 – BLOWER MOTOR HOUSING COVER
2 – SEALANT

24 - 56

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

floor-defrost, the panel-defrost, the blend-air, and the
recirculation air (if the vehicle is so equipped) doors
are properly positioned.

(7) Reinstall the push nut that secures the heater-

A/C housing cover to the heater-A/C housing post.

(8) Install the thirteen screws that secure the

perimeter of the housing cover to the heater-A/C
housing. Tighten the screws to 2.2 N·m (20 in. lbs.).

(9) Snap the panel-defrost door lever onto the pan-

el-defrost door pivot shaft.

(10) Install the blend-air door lever to the blend-

air door pivot shaft and secure it to the shaft with
the nut.

(11) Install the vacuum harness retainer into the

hole near the left end of the heater-A/C housing
cover.

(12) Route

the

vacuum

harness

through

the

molded clips on the heater-A/C housing cover.

(13) Turn the heater-A/C housing over on the work

bench, with the heater-A/C housing cover facing
down.

(14) Install the two screws that secure the heater-

A/C housing cover to the lower housing near the floor
outlet. Tighten the screws to 2.2 N·m (20 in. lbs.).

(15) Position the floor duct to the bottom of the

heater-A/C housing and secure with four screws.
Tighten the screws to 2.2 N·m (20 in. lbs.).

(16) Plug in the vacuum harness connector to the

panel-defrost door actuator.

(17) If the vehicle is so equipped, plug in the two

vacuum harness connectors to the recirculation air
door actuator.

(18) Install the two screws that secure the heater-

A/C housing cover to the top of the blower motor
housing cover. Tighten the screws to 2.2 N·m (20 in.
lbs.).

(19) Reinstall the heater-A/C housing in the vehi-

cle.

INSTALLATION

(1) Position the heater-A/C housing to the dash

panel. Be certain that the evaporator condensate

drain tube and the housing mounting studs are
inserted into their correct mounting holes.

(2) Install the nut that secures the heater-A/C

housing mounting brace to the stud on the passenger
compartment side of the dash panel. Tighten the nut
to 11 N·m (95 in. lbs.).

(3) Engage the front floor panel transmission tun-

nel duct with the adapter on the heater-A/C housing.

(4) Install and tighten the four nuts onto the heat-

er-A/C housing mounting studs on the engine com-
partment side of the dash panel. Tighten the nuts to
7 N·m (60 in. lbs.).

(5) Unplug or remove the tape from the heater

core tubes. Connect the heater hoses to the heater
core tubes and fill the engine cooling system. Refer to
Group 7 - Cooling System for the procedures.

(6) Reinstall the front expansion valve to the evap-

orator tube mounting flange. See Expansion Valve in
the Removal and Installation section of this group for
the procedures.

(7) Evacuate the refrigerant system. See Refriger-

ant System Evacuate in the Service Procedures sec-
tion of this group.

(8) Charge the refrigerant system. See Refrigerant

System Charge in the Service Procedures section of
this group.

(9) Reinstall the instrument panel in the vehicle.

Refer to Instrument Panel Assembly in the Removal
and Installation section of Group 8E - Instrument
Panel Systems for the procedures.

(10) Connect the battery negative cable.
(11) Start the engine and check for proper opera-

tion of the heating and air conditioning systems.

HEATER-A/C HOUSING DOOR

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,

REFER

TO

GROUP

8M

-

PASSIVE

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING

WHEEL,

STEERING

COLUMN,

OR

INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

BLEND-AIR DOOR

(1) Remove the heater-A/C housing from the vehi-

cle, and remove the housing cover. See Heater-A/C
Housing in the Removal and Installation section of
this group for the procedures.

(2) Lift the blend-air door pivot shaft out of the

pivot hole in the bottom of the heater-A/C housing
(Fig. 68).

(3) Reverse the removal procedures to install.

Fig. 67 Heater-A/C Housing Cover Sealant

1 – HEATER-A/C HOUSING COVER
2 – SEALANT

DN

HEATING AND AIR CONDITIONING

24 - 57

REMOVAL AND INSTALLATION (Continued)