Dodge Durango (DN). Manual — part 203

three places. Tighten the mounting screws to 2.2 N·m
(20 in. lbs.).

(2) Remove the tape or plugs from the refrigerant

line fittings at the rear of the underbody liquid and
suction lines and at the B-pillar liquid and suction
lines. Connect the underbody refrigerant lines to the
B-pillar refrigerant lines. See Refrigerant Line Cou-
pler in the Removal and Installation section of this
group for the procedures.

(3) Lower the vehicle.
(4) From the engine compartment, remove the tape

or plugs from the refrigerant line fittings at the front
of the underbody liquid and suction lines and at the
liquid line extension and the suction line jumper.
Connect the underbody refrigerant lines to the
engine compartment refrigerant lines. See Refriger-
ant Line Coupler in the Removal and Installation
section of this group for the procedures.

(5) Connect the battery negative cable.
(6) Evacuate the refrigerant system. See Refriger-

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

(7) Charge the refrigerant system. See Refrigerant

System Charge in the Service Procedures section of
this group.

VACUUM CHECK VALVE

(1) Unplug the vacuum supply line connector at

the vacuum check valve (Fig. 88).

(2) Note the orientation of the check valve in the

vacuum supply line for correct reinstallation.

(3) Unplug the vacuum check valve from the vac-

uum supply line fittings.

(4) Reverse the removal procedures to install.

VACUUM RESERVOIR

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the wiper arms from the wiper pivots.

Refer to Wiper Arm in the Removal and Installation
section of Group 8K - Wiper and Washer Systems for
the procedures.

Fig. 87 Underbody Refrigerant Line Remove/Install

1 – SUCTION LINE JUMPER
2 – FRONT EXPANSION VALVE
3 – LIQUID LINE EXTENSION
4 – UNDERBODY LIQUID LINE
5 – SCREWS
6 – REAR EXPANSION VALVE
7 – SCREW

8 – CLIP
9 – B-PILLAR REFRIGERANT LINES
10 – CLIP
11 – CLAMPS
12 – UNDERBODY SUCTION LINE
13 – CLIPS

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HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

(3) Remove the weatherstrip along the front edge

of the cowl plenum cover/grille panel and the cowl
plenum panel (Fig. 89).

(4) Remove the four plastic nuts that secure the

cowl plenum cover/grille panel to the studs on the

cowl top panel near the base of the windshield (Fig.
90).

(5) Remove the one plastic rivet that secures the

front corner on each side of the cowl plenum cover/
grille panel to the cowl plenum panel.

(6) Remove the one plastic push-in retainer that

secures the rear corner on each side of the cowl ple-
num cover/grille panel to the windshield reveal mold-
ing.

(7) Unsnap the slotted center hole on each side of

the cowl plenum cover/grille panel from the adhesive-
backed snap fastener. (If equipped: This feature
may not be on all models).

(8) Lift the cowl plenum cover/grille panel from the

cowl top far enough to access the windshield washer
nozzle and vacuum plumbing near the right end of
the cowl plenum.

(9) Disconnect the windshield washer supply hose

at the in-line connector.

(10) Disconnect the vacuum supply hose from the

vacuum reservoir, which is secured to the underside
of the right end of the cowl plenum cover/grille panel
(Fig. 91).

Fig. 88 Vacuum Supply

1 – VACUUM CHECK VALVE
2 – CLIP
3 – TO HEATER-AC CONTROLS

4 – VACUUM SUPPLY LINE
5 – TO SPEED CONTROL SERVO
6 – GROMMET

Fig. 89 Cowl Plenum Cover/Grille Panel

Weatherstrip

1 – COWL GRILLE
2 – WEATHERSTRIP

DN

HEATING AND AIR CONDITIONING

24 - 71

REMOVAL AND INSTALLATION (Continued)

(11) Remove the cowl plenum cover/grille panel

from the vehicle.

(12) Remove the three screws that secure the vac-

uum reservoir to the underside of the cowl plenum
cover/grille panel.

(13) Remove the vacuum reservoir from the cowl

plenum cover/grille panel.

(14) Reverse the removal procedures to install.

Tighten the vacuum reservoir mounting screws to 2.2
N·m (20 in. lbs.).

ADJUSTMENTS

TEMPERATURE CONTROL CABLE

Any time the heater-A/C control or the tempera-

ture control cable are removed and/or replaced, the
following procedure must be performed.

(1) The temperature control cable housing and core

must be installed at both the heater-A/C control and
the heater-A/C housing ends, and the heater-A/C con-
trol must be installed in the instrument panel. See
Heater-A/C Control and Temperature Control Cable

Fig. 90 Cowl Plenum Cover/Grille Panel Remove/Install

1 – IN-LINE WASHER SUPPLY HOSE CONNECTOR
2 – STUD
3 – PUSH-IN PLASTIC RETAINER
4 – PLASTIC NUT

5 – COWL PLENUM COVER/GRILLE PANEL
6 – PLASTIC RIVET
7 – ADHESIVE-BACKED SNAP FASTENER

Fig. 91 Vacuum Reservoir

1 – VACUUM SUPPLY CONNECTOR
2 – COWL PLENUM COVER/GRILLE PANEL
3 – VACUUM RESERVOIR
4 – SCREWS

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HEATING AND AIR CONDITIONING

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REMOVAL AND INSTALLATION (Continued)

in the Removal and Installation section of this group
for the procedures.

(2) Rotate the temperature control knob on the

heater-A/C control so that the knob pointer is in the
12 o’clock position.

(3) Pull the temperature control knob straight out

from the heater-A/C control base until the perimeter
of the knob (not the knob pointer) protrudes about 6
millimeters (0.25 inch) from the face of the control
base.

(4) Rotate the temperature control knob to the 1

o’clock position. Push in on the knob slightly and con-
tinue rotating the knob to its full clockwise stop. The
knob pointer should be aimed at a position about 8
millimeters (0.315 inch) beyond the end of the grad-
uated red strobe temperature control graphic on the
face of the heater-A/C control base. If the knob is not
pointed to the correct position, go back to Step 2 and
repeat the adjustment procedure.

(5) Rotate the temperature control knob counter-

clockwise until the knob pointer is in the 12 o’clock
position again.

(6) Push the temperature control knob straight in

towards the heater-A/C control base until the perim-
eter of the knob (not the knob pointer) is flush with
the face of the heater-A/C control base.

(7) Rotate the knob to its full clockwise stop again.

The knob pointer should be aimed at the end of the
graduated red strobe temperature control graphic on
the face of the heater-A/C control base. If OK, go to
Step 8. If not OK, go back to Step 2.

(8) Rotate the knob to its full counterclockwise

stop and release the knob. If the knob springs back
from the counterclockwise stop, the self-adjuster clip
that secures the temperature control cable to the
blend-air door lever is improperly installed. See Tem-
perature Control Cable in the Removal and Installa-
tion section of this group for the procedures. If the
knob does not spring back, the temperature control
cable adjustment is complete.

SPECIFICATIONS

A/C APPLICATION TABLE

Item

Description

Notes

VEHICLE

Durango

SYSTEM

R134a
w/expansion
valve

Optional - Rear
A/C

Evaporator in
roof, Rear
blower switch in
headliner

COMPRESSOR

Sanden
SD7H15

SP-20 PAG oil

Freeze–up
Control

Electronic
Clutch Cycling
Switch (ECCS)

mounted on
expansion valve

Low psi Control

opens < 7-13
psi - resets >
15-28 psi

mounted on
suction line
jumper

High psi Control

opens >
450-490 psi -
resets <
270-330 psi

mounted on
discharge line

CONTROL
HEAD

manual type

Mode Door

vacuum

Blend Air Door

cable

Fresh/Recirc
door

vacuum

Blower Motor

hardwired to
control head

resistor block

COOLING
FANS

viscous
clutch/electric
fan cooling
module

CLUTCH

Control

relay

PCM

Draw

2.0 - 3.9 amps
@ 12 V

6

0.5V @ 70° F

Gap

0.016” - 0.031

9

DRB III

T

Reads

TPS, RPM, A/C
switch

Actuators

clutch

DN

HEATING AND AIR CONDITIONING

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ADJUSTMENTS (Continued)