Dodge Durango (DN). Manual — part 197

(4) Disconnect the flexible demister duct hose from

the demister duct adapter on the top of the heater-
A/C housing.

(5) Remove the demister duct hose from the demis-

ter duct tee near the underside of the instrument
panel top cover.

(6) Reverse the removal procedures to install.

Tighten the hose mounting screw to 2.2 N·m (20 in.
lbs.).

DEMISTER DUCTS AND OUTLETS

(1) Remove the instrument panel top cover from

the instrument panel. Refer to Instrument Panel Top
Cover in the Removal and Installation section of
Group 8E - Instrument Panel Systems for the proce-
dures.

(2) Remove the screws (two - left side, three - right

side) that secure the demister ducts to the instru-
ment panel top cover (Fig. 46).

(3) Using a trim stick or another suitable wide

flat-bladed tool, gently pry between the end of the
demister duct and the demister outlet flange to
release the duct from the outlet.

(4) Remove the demister ducts and the tee from

the instrument panel top cover.

(5) Squeeze the demister outlet flange from the

underside of the instrument panel top cover and
push it out through the top.

Fig. 44 Rear Seat Floor Ducts Remove/Install - Bucket Seat

1 – RETAINER
2 – FRONT TUNNEL DUCT
3 – REAR SEAT FLOOR DUCT

4 – RETAINER
5 – CENTER SEAT FLOOR DUCT

Fig. 45 Demister Duct Adapter Remove/Install

1 – HEATER-A/C HOUSING
2 – SCREW
3 – ADAPTER

24 - 46

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

(6) Using a trim stick or another suitable wide

flat-bladed tool, gently pry between the end of the
demister duct and the demister outlet flange to
release the duct from the outlet.

(7) Remove the demister ducts and the tee from

the instrument panel top cover.

(8) Squeeze the demister outlet flange from the

underside of the instrument panel top cover and
push it out through the top.

(9) Reverse the removal procedures to install.

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

HEATER-A/C HOUSING PLENUM ADAPTER

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

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

(2) Slide the heater-A/C housing plenum adapter

(Fig. 47) all the way to one side of the plenum open-
ing.

(3) Pull downwards sharply and firmly on the

opposite side of the plenum adapter to disengage the
snap feature from the plenum opening.

(4) Remove the plenum adapter from the plenum

panel.

(5) When reinstalling the heater-A/C housing ple-

num adapter to the plenum panel opening, be certain
that the snap features on each side of the adapter
are fully engaged with the sides of the plenum panel
opening. This must be a water tight connection to
prevent leaks.

(6) Reverse the remaining removal procedures to

complete the installation.

REAR OVERHEAD A/C OUTLET BEZEL

The rear overhead A/C outlet bezel is used only on

models with the optional rear overhead A/C unit. The
outlet barrels located in the bezel are only serviced
as a unit with the rear overhead A/C outlet bezel.

(1) Using a trim stick or another suitable wide

flat-bladed tool, gently pry between both ends of the
rear overhead A/C outlet bezel and the headliner to
release the two snap clip retainers that secure the
bezel to the rear overhead A/C unit housing (Fig. 48).

Fig. 46 Demister Ducts Remove/Install

1 – DEMISTER DUCT TEE
2 – INSTRUMENT PANEL TOP COVER
3 – LEFT DEMISTER DUCT
4 – DEMISTER HOSE
5 – PASSENGER SIDE AIRBAG MODULE
6 – RIGHT DEMISTER DUCT

Fig. 47 Heater-A/C Housing Plenum Adapter

Remove/Install

1 – PLENUM PANEL
2 – PLENUM ADAPTER
3 – DASH PANEL

Fig. 48 Rear Overhead A/C Outlet Bezel Remove/

Install

1 – RETAINER
2 – OUTLET BEZEL
3 – HEADLINER
4 – REAR BLOWER MOTOR SWITCH

DN

HEATING AND AIR CONDITIONING

24 - 47

REMOVAL AND INSTALLATION (Continued)

(2) Remove the rear overhead A/C outlet bezel

from the headliner mounting hole.

(3) Reverse the removal procedures to install.

ELECTRONIC CYCLING CLUTCH SWITCH

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Unplug the wire harness connector from the

electronic cycling clutch switch near the expansion
valve (Fig. 49).

(3) Remove and discard the fastener that secures

the electronic cycling clutch switch to the outboard
side of the expansion valve.

(4) Pull the electronic cycling clutch switch away

from the side of the expansion valve far enough for
the thermistor probe capillary tube to clear the well
in the expansion valve. The washer bottle may have
to be removed.

NOTE: The capillary tube well in the expansion
valve is filled with a special thermally-conductive
grease. This grease should be removed from the
old parts and reused on the new parts whenever
the electronic cycling clutch switch or the expan-
sion valve are replaced.

INSTALLATION

(1) Insert the thermistor probe capillary tube of

the electronic cycling clutch switch into the well on
the outboard side of the expansion valve.

(2) Install the electronic cycling clutch switch to

the expansion valve and secure it with a new fas-
tener.

(3) Plug the wire harness connector into the elec-

tronic cycling clutch switch.

(4) Connect the battery negative cable.

EVAPORATOR COIL

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.

FRONT

REMOVAL

(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 front evaporator coil out of the heater-

A/C housing (Fig. 50).

Fig. 49 Electronic Cycling Clutch Switch Remove/

Install

1 – ELECTRONIC CYCLING CLUTCH SWITCH
2 – WIRE HARNESS CONNECTOR
3 – EXPANSION VALVE
4 – FASTENER

Fig. 50 Evaporator Coil Remove/Install

1 – EVAPORATOR COIL
2 – HEATER-A/C HOUSING

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HEATING AND AIR CONDITIONING

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REMOVAL AND INSTALLATION (Continued)

INSTALLATION

(1) Insert the front evaporator coil into the bottom

of the heater-A/C housing.

(2) Reassemble and reinstall the heater-A/C hous-

ing in the vehicle. See Heater-A/C Housing in the
Removal and Installation section of this group for the
procedures.

NOTE: If the front evaporator coil is replaced, add
60 milliliters (2 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.

REAR

The rear evaporator coil is used only on models

with the optional rear overhead A/C unit.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Recover the refrigerant from the refrigerant

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

(3) Remove the headliner from the passenger com-

partment of the vehicle. Refer to Group 23 - Body for
the procedures.

(4) From the passenger compartment, remove the

nuts that secure the block fittings at the top of the
B-pillar refrigerant lines to the studs on the rear
overhead A/C unit, and disengage the fittings (Fig.
51). Install plugs in, or tape over all of the opened
refrigerant line fittings.

(5) Disconnect the B-pillar drain hoses from the

wye fittings on each side of the rear overhead A/C
unit (Fig. 52).

(6) Remove the nine screws that secure the lower

housing cover to the rear overhead A/C unit.

(7) Release the lower housing cover snap retainer

near the center of the outlet side (rear) of the rear
overhead A/C unit (Fig. 53).

(8) Feed the rear blower motor switch wire har-

ness and connector through the hole in the right end
of the rear overhead A/C unit lower housing cover
while removing the cover from the unit.

(9) Remove the screw that secures the rear over-

head A/C refrigerant tube and block fitting retaining
strap to the right side of the upper housing cover
(Fig. 54).

(10) Remove the two screws that secure the rear

evaporator coil to the rear overhead A/C unit upper
housing cover (Fig. 55).

(11) Remove the rear evaporator coil from the rear

overhead A/C unit.

Fig. 51 Rear Overhead A/C Unit Refrigerant Line

Remove/Install

1 – B-PILLAR SUCTION LINE
2 – B-PILLAR LIQUID LINE
3 – OVERHEAD AIR CONDITIONING UNIT
4 – NUT
5 – STUD
6 – BOLT
7 – NUT

Fig. 52 Rear Overhead A/C Drain Hose Remove/

Install

1 – REAR OVERHEAD A/C UNIT
2 – WYE FITTING
3 – CLIP
4 – GROMMET
5 – DRAIN HOSE

DN

HEATING AND AIR CONDITIONING

24 - 49

REMOVAL AND INSTALLATION (Continued)